Master Lock MGY5000C User's Manual
Contents
1. PORTABLE DIESEL GENERATOR OWNER S OPERATION AND INSTALLATION MANUAL Generator Model MGY5000C IMPORTANT Read and understand this manual before operating or servicing generator Improper use of generator can cause serious injury Keep this manual for future reference SAFETY INFORMATION A WARNINGS IMPORTANT Read this owner s manual and the engine owner s manual carefully Become famil iar with this generator before try ing to operate or service it Know its uses limitations and any haz ards involved Improper use of generator can cause severe in jury or death from explosion fire burns electrical shock or car bon monoxide poisoning A DANGER Carbon monoxide poisoning may lead to death Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death Use only in well vented areas Make sure area has plenty of free moving fresh outside air Never run generator in an enclosed or confined area Never run generator inside occupied building Carbon Monoxide Poisoning Early signs of carbon monoxide poisoning resemble the flu with headaches dizziness and nausea If you have these signs get fresh air at once Some people are more affected by carbon monoxide than others These in clude pregnant women persons with heart or lung disease or anemia those under the influence of alcohol and those at high alti tudes Make certa2. Relay 10 32 Hex locknut Adhesive backed PVC foam Connector 6 32 x 1 2 Hex tapping screw 6 Internal tooth lockwasher Available from your local hardware store t Includes reference numbers 1 through 23 KEY PART QTY NO NUMBER DESCRIPTION QTY 1 13 26509000 26002006 15020000 WP 3C 26499000 26490000 26494000 26492000 101038 01 101036 01 101035 01 101103 01 Full bridge 8 32 x 3 8 Screw Grommet 10 Flat washer 10 32 x 3 4 Hex head screw Solenoid M4 x 8 Hex head screw M3 x 8 Hex head screw Control Box Cover Cable Conduit Switch Control Box Assembly PARTS AVAILABLE NOT SHOWN 107359 OWNER S MANUAL WARRANTY INFORMATION KEEP THIS WARRANTY Model Serial No Date Purchased Always specify model and serial numbers when communicating with the factory We reserve the right to amend these specifications at any time without notice The only warranty applicable is our standard written warranty We make no other warranty expressed or implied Note The five year limited warranty below covers all non engine parts of this generator including the alternator Honda warrants the engine See engine owner s manual for engine warranty information FIVE YEAR LIMITED WARRANTY PORTABLE GENERATORS DESA Power Tools warrants each alternator generator or electric product of its manufacture to be free from defects in material and workmanship f
3. Voltage is less than normal voltage with no electrical load Voltmeter reading more than 10 high with no electrical load Voltmeter reading correct with no electrical load but more than 10 low when electri cal load is added A CAUTION Shut off generator before performing maintenance IMPORTANT Keep generator level when servicing Never turn generator upside down or stand it on end to service Note We supply the engine owner s manual with generator Refer to that manual for questions concerning engine maintenance and repairs Non engine parts require little maintenance Keep generator clean Use a damp cloth to clean outside surfaces Never use water to clean generator Water can cause damage to internal parts Use vacuum to clean air inlet and outlet louvers of alternator STORAGE AX WARNING Remove all fuel from fuel tank before storing gen erator Store fuel in approved con tainer Store fuel in a well vented area free of open flames or sparks AX WARNING The muffler be comes very hot during operation The muffler remains hot for a while after shutdown Let engine cool before storing IMPORTANT Keep generator level while in storage Never store generator upside down or standing on end Note We supply the engine owner s manual with generator Refer to that manual for questions concerning engine storage Cover and store generator in a clean dry place Do not expose generator to extreme high
4. 252 446 4203 East Coast Energy 10 East Route 36 West Long Branch NJ 07764 1501 1 800 755 8809 Laportes 2444 N 5th Street Hartsville SC 29550 7704 843 332 0191 MTA Distributors 555 Hickory Hills Blvd Nashville TN 37189 9244 615 299 8777 1 800 264 0225 Industrial Hardware 4109 Bainbridge Blvd Chesapeake VA 23324 1403 804 543 2232 1 800 788 0008 catatem erols com Mills Lawn and Garden 928 Commonwealth Place Virginia Beach VA 23464 757 361 9293 www mills parts com Tuco Industrial Products 5223 180th Street SW Suite 4A 1 Lynnwood WA 98037 4506 425 743 9533 1 800 735 1268 www tucoheat com 107359 ILLUSTRATED PARTS LIST ALTERNATOR ASSEMBLY This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 14 of this manual Part not available by itself Must purchase Alternator Assembly 107359 099723 02 099844 01 099701 01 099760 01 099863 01 099863 02 17587000 M11084 26 099847 02 WLE 5 099843 01 27005003S 27003002 27003015S 27001010S 270030135 099842 02 27003003 270030125 27003008 101839 01 26322004 WLE 6 099892 01 Alternator Assembly End Cover Screw M5 x 10mm Bushing Terminal Block 4 block Terminal Block 2 block Ground Lug Screw 10 16 x 3 8 Stator Bolt Lock Washer 5 16 Bearing Housing Capacitor Stator Fan Bracket Screw M8 x 20 Rotor Nut Was
5. Keep them tightly secured e The muffler becomes very hot dur ing operation The muffler remains hot for a while after shutdown Do not touch muffler while it is hot Do not let muffler touch anything flam mable Let engine cool before trans porting or storing Have standby installation to home or building performed by a licensed electrician Do not let anyone else wire into a utility circuit Personal injury equipment damage or damage to home could occur Never connect generator to any exist ing electrical circuits The generator output will back feed into the utility power line This may electrocute a power company line repair person Also if generator is powering electri cal circuits the chance of an electrical fire exists Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking or running Only service or use battery in a well vented area Battery contains sulfuric acid Battery acid is poisonous if swallowed Con tact with skin or eyes may cause severe burns Do not tilt generator with bat tery installed Tilting could cause bat tery acid to spill Wear protective cloth ing and face shield when servicing Keep out of children s reach 107359 SAFETY INFORMATION Continued g 10 11 2 13 14 Only a qualified electrical service per son should service and repair generator Generator produces hi
6. or running Only service or use battery in a well vented area A WARNING Battery contains sulfuric acid Contact with skin or eyes may cause severe burns Do not tilt generator with battery in stalled Tilting could cause battery acid to spill Wear protective cloth ing and face shield when servic ing Keep out of children s reach e If battery acid gets on your skin wash with water e Ifbattery acid gets in your eyes flush with water at least 15 min utes Call a doctor at once Battery acid is poisonous e If swallowed drink large amounts of water or milk Fol low with milk of magnesia or vegetable oil Call a doctor at once AX CAUTION If you remove bat tery insulate the red positive battery cable terminal Insu late with electrical tape Ex posed terminal may spark when generator runs IMPORTANT Make sure battery con nections are the correct polarity This gen erators uses negative ground 12 volt DC starting system This generator has and electric starter A battery is not supplied with generator You must provide a 12 volt 32 amp hour bat tery The positive and negative battery cables are supplied with generator You must in stall these cables before mounting battery Always wear safety glasses when working with battery Make sure battery terminals are clean Make sure cable connections are tight Always shut down engine before removing or attaching battery cables Always rem
7. 800 Volt Connect T2 green and T3 black Measure resistance between T1 red and T4 yellow A Resistance between brown and white leads t Remove diodes to check resistance WIRING DIAGRAMS Green Yellow Circuit Breaker 25A Circuit p Breaker 25A 5 D a PE 120V 15A Receptacle 120 240V 20A Receptacle 120V 15A Receptacle 120V 30A Receptacle Circuit Breaker 20A Circuit Breaker 20A Ti Selector Switch Auxiliary Phase Stator T4 Rotor Stator T1 T2 T3 T4 110 120V 110 120V Charge Shutdown Solenoid Yellow Bridge LS Figure 22 Engine Wiring Diagram Continued Low Oil Pressure Lamp 107359 13 MASTER PORTABLE DIESEL GENERATOR TECHNICAL SERVICE You may have further questions about as sembling operating or maintaining this product If so you can visit our Technical Service web site at www desatech com or contact our Technical Service Department at 1 800 858 8501 English Only You may also write to DESA Power Tools P O Box 90004 Bowling Green KY 42102 9004 ATTN Technical Service Power Tools When contacting DESA Power Tools have ready e Your Name e Your Address e Your Phone Number e Model Number of Product e Date of Purchase Include copy of receipt for written requests SERVICING THE ENGINE For Yanmar engine replacement parts con tact Parts Company of Americ
8. air to bleed from line When fuel exits fuel line in a steady stream reat tach fuel line to engine 4 Add spilled fuel back into fuel tank STARTING A CAUTION You must always run the engine at full speed Do not run engine at lower speeds At full speed the engine runs at 3600 RPM under load The en gine must maintain 3600 RPM for generator to create correct volt age Running engine at lower speeds will damage generator and powered items A WARNING Never use gaso line paint thinner or any other flammable liquid as a starting aid An explosion may occur IMPORTANT Never start generator with electrical loads connected Start engine be fore adding electrical loads 1 Make sure fuel tank is full See Fuel page 6 for fuel information 2 Move fuel valve lever to the O open position see Figure 15 3 Move engine run lever to RUN posi tion see Figure 16 Fuel Valve Lever Figure 15 Fuel Valve Lever in O open Position Engine Run Lever Figure 16 Engine Run Lever in RUN Position 4 Start the engine A Electric Starter I Push decompression lever all the way down see Figure 17 page 11 Decompression lever will stay in this positon until you turn starting key Il Turn the starting key clockwise to START positon see Figure 18 page 11 Hold it there until engine starts III When engine starts release key IMPORTANT Do not use electric star
9. ONLY This position sends full power to the 120V receptacles only 240V power is not available Use this position when powering 120V items only 120 240 VOLT This position sends full power to the 120 240V receptacle It also powers the 120V receptacles at reduced wattage capacity Full Power 120V 120 Only 240V Selector ENM 0000000 HOURS 1 10 Ne A 120 VOLT ONLY Position m Full Power 120 240V Selector 120V Only ENM 0000000 HOURS 1 10 C p 120 240 VOLT Position Figure 3 Full Power Selector Switch IMPORTANT Do not move the full power selector switch while powering electrical items Unplug all items before moving switch Failure to do so can damage switch GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE This generator has a 120 volt ground fault circuit interrupter GFCI receptacle The GFCI receptacle is on the control panel The GFCI protects you against hazardous electri cal shock caused when your body becomes a path through which electricity travels to reach ground This could happen when you touchan appliance or cord that is live through faulty mechanism damp or worn insulation etc 107359 OWNER S MANUAL When protected by the GFCI you may still feel a shock but the GFCI should cut it off quickly A person in normal health should not receive serious injury Not
10. Service Center You must show proof of purchase If faulty materi als or workmanship caused damage we will repair orreplace product without charge Note Normal wear misuse abuse neglect or acci dental damage is not covered under warranty NON WARRANTY SERVICE If product requires service return it to near est Authorized Service Center Repairs will be billed to you at regular repair list prices For additional Service Center or warranty information call 1 800 858 8501 or visit our Technical Service web site at www desatech com PARTS CENTRALS These Parts Centrals are privately owned businesses They have agreed to support our customer s needs by providing original re placement parts and accessories Tool amp Equipment 5 Manila Drive Hamden CT 06514 0322 203 248 7553 1 800 397 7553 Grainger Parts Operations 1657 Shermer Road Northbrook IL 60062 5362 708 498 5900 1 800 323 0620 www grainger com Portable Heater Parts 342 North County Road 400 East Valparaiso IN 46383 9704 219 462 7441 1 800 362 6951 www portableheaterparts com sales portableheaterparts com techservice portableheaterparts com FBD 1349 Adams Street Bowling Green KY 42103 3414 270 846 1199 1 800 654 8534 franktalk aol com Master Part Distributors 1251 Mound Avenue NW Grand Rapids MI 49504 2672 616 791 0505 1 800 446 1446 www masterparts net Bowden Electric Motor Service 1681 S Wesleyan Blvd Rocky Mount NC 27803
11. TROL PANEL This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 14 of this manual 103349 02 22616009 099833 01 100445 01 099956 01 22616011 099834 01 101350 01 099760 01 24306006 100149 01 22261000 WLI 2BL 099997 01 099836 01 103348 02 Control Panel Circuit Breaker 20 Amp 120V 30A Twist Lock Receptacle 120V 15A Duplex GFCI Receptacle Full Power Selector Switch Circuit Breaker 25 Amp 120 240V 20A Twist Lock Receptacle Hour Meter Bushing Screw 8 18 x 1 2 Control Box Speed Nut 8 Lock Washer 8 Switch Plug 120V 15A Duplex Receptacle Control Panel Assembly PARTS AVAILABLE NOT SHOWN a A Oo A NMM NV a 100177 07 Panel Schematic Decal Includes fastening hardware Tt Includes reference numbers 1 through 15 107359 17 MASTER PORTABLE DIESEL GENERATOR ILLUSTRATED PARTS LIST SWITCH CONTROL BOX This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 14 of this manual PART NUMBER DESCRIPTION 101037 01 22721000 099936 01 Switch control box Low oil light Key switch lamp and harness assembly 1 4 28 Keps Nut Strain relief bushing 1 4 20 x 5 8 Hex Head Sems 101039 01 099760 01 101040 01 26498000 NTF 3C RN12000100
12. a at 1 800 323 0620 Yanmar engine servicing should be handled by your nearest authorized Yanmar engine service firm Contact Yanmar at 1 714 630 9415 for nearest au thorized Yanmar engine service firm REPLACEMENT PARTS AND ACCESSORIES For original replacement parts and accesso ries contact your nearest Authorized Dealer or Authorized Service Center for this prod uct If they can not supply the part or acces sory contact your nearest Parts Central listed on pages 14 and 15 Each Authorized Dealer Authorized Service Center and Parts Cen tral is independently owned and operated See pages 15 through 18 for an Illustrated Parts List If you need additional referral information contact our Technical Service Department see Technical Service page 14 In Canada call 1 800 561 3372 for parts information Heavy Duty Wheel Kit PA2000 Wheelbarrow style wheel kit Makes gen erator easy for one person to move This kit includes e Large 12 inch wheels for easy rolling e Plated tubing and hardware for long life e Long handles with thick grips for greater comfort and control Complete installation instructions included REPAIR SERVICE Note Only use original replacement parts This will protect your warranty coverage for parts replaced under warranty Each Authorized Service Center is indepen dently owned and operated WARRANTY SERVICE If product requires warranty service return it to nearest Authorized
13. acle e NEMA L5 30P plug e Three wire 30 amp cord 120 240V 20 amp twist lock receptacle e NEMA L14 20P 20 amp plug e Four wire 20 amp cord 120 Volt 30 Amp L5 30P Ground Plug Green w Lj Neutral 120 240 Volt 20 Amp Neutral 120V 120V oe L14 20P Plug Ground utral Figure 14 Cord and Plug Configurations PRESTART Operate generator on a firm dry and clean surface The surface must be level Protect generator from heavy dust sand dirt rain or snow Do not locate generator near standing water and snow Make sure area is well vented AX WARNING Only responsible adults should use generator Never let anyone operate genera tor without proper instructions Note If oil level is too low oil alert system will keep engine from starting see Oil Alert System page 4 Make sure oil level is full before starting See Engine Oil page 6 Before starting the engine disconnect all electric loads from generator You may need to bleed fuel line to remove trapped air e if starting engine for first time e if starting engine after allowing generator to run out of fuel Follow the directions below to bleed fuel line BLEEDING FUEL LINE 1 Loosen fuel line clamp and remove fuel line from engine Place open end of fuel line over a clean container to catch any fuel spilled in step 3 below 2 Move fuel valve lever to the O open position see Figure 15 3 Allow
14. ames or sparks Guard against fire hazard Keep opera tion area well vented Keep generator at least three feet away from any ob ject Do not place flammable objects near generator e Do not use generator where flam mable vapors are present Some va pors are heavier than air These va pors settle in low lying places e Do not use generator in enclosed spaces This includes motor home or RV generator compartments Guard against electric shock Generator produces high voltage This high voltage can cause severe electric shock Only re sponsible adults should use generator e Properly ground generator before starting e Never let anyone operate or service generator without proper instructions e Avoid contact with live terminals or bare wires e Do not use generator outdoors in rain or snow e Do not use generator near standing water or snow e Donotuse if generator is wet or damp e Do not use generator in highly con ductive areas These areas include metal decking and steelwork e Only use grounded extension cords e Do not use any worn or damaged electric cords Electric shock or dam age to generator may result e Do not wear damp clothing or wet shoes when using generator Guard against burns Hot engine parts can cause severe injury Use caution and remain alert when using generator e Keep children and animals away from generator while it is running or hot e Keep all covers and shields in place
15. e Infants and very small children may still be affected Test Procedure Check the GFCI receptacle every month This insures it is working right 1 Push black TEST button Red RESET button should pop out This should trip GFCI resulting in no electrical power at receptacle Verify this by plugging test lamp with good bulb into recep tacle If lamp does not work GFCI re ceptacle is good AX WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a quali fied electrician for repairs 2 Ifthe GFCI receptacle tests okay restore power by pushing the RESET button back in The test lamp should work at this time IMPORTANT You must press the RESET button firmly and fully It should lock into place If the GFCI does not lock into place do not use receptacle Contact a qualified electrician for repairs Figure 4 GFCI Receptacle ELECTRIC START This model has an electric starter A battery is not supplied with generator You must pro vide a 12 volt 45 amp hour battery For more battery information see Battery page 6 RECEPTACLE CIRCUIT BREAKER The circuit breakers protect the receptacles and alternator Overloading generator will trip circuit breaker A short circuit in item being powered will also trip breaker If this occurs unplug electrical load from recep tacle Let circuit breaker cool down Push circuit breaker button to reset Electric motors need higher starting curr
16. electrical loads does not 5 000 watts Elec tric motors present a special problem when figuring load Read step 3 carefully 1 Make two lists of items you want pow ered by generator List all motors and motor powered appliances in one List all lights small appliances etc in the other For standby service to home or building only include items you must power 2 Enter running watts of each item ex cept motors The light bulb or appli ance nameplate lists its wattage Re member 1 KW 1000 watts Note The nameplate may not list wattage It may only list volts and amps The formula for finding wattage is Volts x Amps Watts For example An appliance nameplate states 3 amps at 120 volts 3 amps x 120 volts 360 watts 3 Electric motors present a special problem They require up to three times their rated wattage to start Chart 2 page 9 shows starting watts for different size motors For ex ample an electric motor nameplate states 5 amps at 120 volts 5 amps x 120 volts 600 watts running Mul tiply this figure by 3 This will show the starting watts needed 600 watts x 3 1800 watts to start When fig uring the generator load for motors you must use the starting watts fig ure Do not use the running watts fig ure Note Some motors require nearly the same wattage to run as to Start These items include saws drills hair dryers and food mixers See Chart 1 page 9 for typical ap pliance wattage exampl
17. ely dusty or dirty conditions This will severely affect its life Keep generator clean Do not allow dust dirt rain or snow to collect on it Protect generator from outdoor elements HIGH AND LOW TEMPERATURE OPERATION Air temperature affects generator output Output drops 1 for each 10 temperature rise above 60 F Very low temperatures may make the engine hard to start See engine owner s manual for more information GENERATOR FEATURES OIL ALERT SYSTEM The oil alert system protects the engine from low oil damage This system automatically shuts down the engine and prevents engine restarting if the oil level falls too low If this system shuts down the engine the engine will not start until you add oil Add oil to engine see Engine Oil page 6 See engine owner s manual for more information BATTERY DISCHARGE LAMP The battery discharge lamp see Figure 2 will light if battery charger is not operating while engine is running If this happens the battery will not charge and will eventually run down Have battery charging circuit repaired by authorized service person Oil Alert ov Lamp ee of yee Battery Discharge Lamp Figure 2 Battery Discharge Lamp and Oil Alert Lamp Location 107359 GENERATOR FEATURES Continued FULL POWER SELECTOR SWITCH The full power selector switch is on the control panel The switch has two positions 120 VOLT ONLY and 120 240 VOLT 120 VOLT
18. ent They require up to three times their rated wattage to start The starting current needed may be too high This can cause nuisance circuit breaker tripping To help prevent this start electric motors first Connect ad ditional items to generator after starting motors If this continues to happen reduce the total generator load a Normal Tripped Figure 5 Receptacle Circuit Breaker Button SPARK ARRESTER We ship a spark arrester with this generator You must install spark arrester to muffler see figure 6 A spark arrester is required if using genera tor in a national forest and other designated state and local areas Check local codes The spark arrester needs periodic cleaning A dirty spark arrester reduces engine output and increases fuel consumption It also makes starting difficult See engine owner s manual for cleaning instructions Muffler Arrester Figure 6 Installing Spark Arrester MASTER PORTABLE DIESEL GENERATOR ENGINE OIL We ship the generator without oil in the engine crankcase You must add oil before starting engine See engine owner s manual for specific oil type CHECKING OIL LEVEL AND ADDING OIL Follow steps below to check oil level Make sure engine is level and stopped 1 Remove dipstick see Figure 7 Wipe dipstick clean 2 Insert dipstick into oil filler neck Do not screw it in Oil level should be at top of filler neck Oil should cove
19. es Add watts and starting watts of all items This total must not be larger than 5 000 watts It is a good idea to have up to 25 extra capacity for future needs or extra equipment 107359 OWNER S MANUAL DETERMINING OPERATION ELECTRICAL LOAD GENERAL INFORMATION FOR GENERATOR This generator is not large enough to power Continued your entire home Do not connect generator to any existing electrical circuits Plug items Chart 1 Typical Electric Appliance Wattages directly into generator receptacles Do not Chart to be used as reference Data may vary wiht size make and or model exceed amperage rating of receptacles Only use grounded cords AX DANGER Use only in well vented areas Make sure area has plenty of free moving fresh out side air Never run generator in an enclosed or confined area Never run generator inside occu pied building Engine exhaust contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death Running Starting Running Starting Watts Watts Watts Watts Light bulb 100W 1 2 Drill Radio Toaster Fan Coffee maker Television Skillet Furnace fan 1 3 hp 14 Chain saw Vacuum cleaner Water well pump Sump pump 1 3 hp 1 2 hp Refrigerator freezer Hot plate range 6 Circular saw per burner Floodlight 10 Table saw Water heater AX WARNING Never connect generator to any existing electri cal circuits The generator out put will bac
20. ge of generator Overloading may shorten generator life It could also cause internal damage to genera tor Overloading will trip circuit breaker IMPORTANT Keep full power selector switch in the 120 VOLT ONLY position if onlyu powering 120V items Only move switch to 120 240 VOLT position if power ing 240V items 1 Check items to be powered Their nameplate lists their wattage ratings Note The wattage ratings for some electrcal motors are misleading They may require up to 3 times their rated wattage to start You must figure total electrical load wattage Make sure to tal wattage of all electrical loads does not exceed rated wattage of generator See Determining Electrical Load For Generator pages 8 and 9 Start engine Let engine reach full speed 3 Connect electrical loads one at a time If the load consists of electric motors start them first Always start the larg est first Start each motor individually DISCONNECTING ELECTRICAL LOADS Remove electrical loads one at a time Re move voltage sensitive items first Voltage Sensitive items include TVs VCRs and other home electronic items STOPPING ENGINE Follow the steps below to stop engine 1 Remove all electrical loads from gen erator see Disconnecting Electrical Loads above Remove electrical loads one at a time 2 Let engine run for two or three min utes after removing electrical loads This lets engine cool slightly 3 Push down engi
21. gh voltage Use extreme caution when working on electrical parts When working on generator avoid hot muffler exhaust manifold and engine parts Severe burns may occur Do not work on generator when tired Use only factory approved replace ment parts Store generator in a well vented area Make sure fuel tank is empty Never store with fuel in tank Never operate generator if engine speed changes greatly if engine misfires often if powered items overheat if electrical output drops if it is sparking if it produces smoke or flames if it vibrates at high levels if it has a damaged receptacle Keep generator and nearby areas clean Keep generator free of oil mud and other foreign matter Remove anything that creates slip pery areas around generator Remove oily rags and other items that create fire hazards Keep a fire extinguisher nearby Make sure it is rated ABC by the NFPA They are good for all uses Consult your local fire department Keep fire extinguisher well main tained Be familiar with its use Know how to stop engine quickly Know how to use all controls Prolonged exposure to loud noise can cause hearing loss When working around generator wear approved hearing protection Remember neighbors when using generator 107359 OWNER S MANUAL PRODUCT IDENTIFICATION Full Power Selector Switch Roll Cage IA Control Panel Engine Run Lever 120 Volt Receptacle En
22. gine 120 Volt aS Wer Stop e 3 Lever Z py Receptacle oll Gas GFCIl IA 120 Volt Receptacle P ee Duplex an Fuel Valve Hour Meter 120 240 Volt Circuit Alternator Receptacle Breaker Electric Start Battery Oil Alert Switch Discharge Lamp Lamp Fuel Gage i 2 Fuel Cap Decompression a NS Fuel Tank Lever NX SS a Ground Starter Grip Lug Spark Arrester Muffler Figure 1 Portable Generator Oil Dipstick 3 MASTER PORTABLE DIESEL GENERATOR GENERAL INFORMATION This portable generator is rugged and com pact It provides dependable trouble free service The alternator is brushless with revolving fields Yanmar diesel engine pro vides long life under heavy use This engine is governed to maintain engine speed of 3600 RPM under load 3600 RPM engine speed provides 120 240V 60 Hz power Additional Features e Circuit breaker protection e Spark arresting muffler e Large fuel tank e Oil alert system e Electric starter e Pressurized lubrication system e 15 Amp ground fault circuit interrupter GFCI receptacle SPECIFICATIONS MODEL MGY5000C Electrical Rated Wattage 5000 Rated Amperage 120 V 41 7 240 V 20 8 Receptacle 120 V 15 A Duplex Yes 120 V 15 A GFCI Yes 120 V 30 A Twist Lock Yes 120 240 V 20 A Twist Lock Yes 120 V Full Power Switch Yes General Yanmar Engine H P 10 Yanmar Engine Model L100 Fuel Type Diesel Fuel Tank Capacity 4 2 Gallons Oil Alert Sy
23. her Draw Bolt Bearing Diode Rotor Fan Engine Flange Bolt 3 8 16 x 5 8 Lock Washer 3 8 Foam Pad 15 OWNER S MANUAL r i 6 1 1 1 1 1 4 4 i i i i 4 i i i i 2 i i 4 4 i MASTER PORTABLE DIESEL GENERATOR ILLUSTRATED PARTS LIST FUEL TANK AND ROLL CAGE This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 14 of this manual ta 11 SSE DN 8 9 gt 8 7 ASS A b o g KEY PART KEY PART NO NUMBER DESCRIPTION QTY NO NUMBER DESCRIPTION QTY 1 16 1 099935 01 Fuel Tank Assembly 099749 01 Battery Bracket HC4 6C Screw 1 4 20 x 3 4 17 099750 01 Hook Bolt WP 4C Washer 1 4 18 14138000 Ground Strap 103880 01 Nut 1 4 20 19 M10908 74 Screw 1 4 20 x 1 2 099943 01 Roll Cage 20 100410 01 Screw 8 10 x 1 2 099945 01 Spreader PARTS AVAILABLE NOT SHOWN A 1 2 ales pall TORE te 099947 01 Safety Information WP 5C Washer 5 16 Decal NEC 5C Nut 5 16 18 099948 01 Operation Decal 26302006 Screw 1 2 20 x 1 099873 01 Battery Cable WLI 8 Lockwasher 1 2 Positive 17529000 Shock Mounts 099873 02 Battery Cable 26007004 Bolt 5 16 18 x 3 4 Negative WLE 5 Washer 5 16 099954 01 Spark Arrestor 103289 01 Shock Mount aN AR A 2 3 4 5 6 T 8 O U A NND 16 107359 OWNER S MANUAL ILLUSTRATED PARTS LIST CON
24. in you read and under stand all warnings Keep this manual for reference Itis your guide to safe and proper operation of this generator Safety information appears throughout these instructions Pay close attention to them Below are definitions for the safety infor mation listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substantial property damage if you ignore warning WARNING indicates ahazard whichcancause severe personal injury death or substantial property damage if you ignore warning CAUTION indicates a hazard which will or can cause minor personal injury or property damage if you ignore warning MASTER PORTABLE DIESEL GENERATOR Diesel fuel presents a hazard of fire Diesel fuel is flammable e Keep fuel out of children s reach e Refuel generator in a well vented area Do not fill fuel tank in the dark Do not refuel while engine is run ning Unhook all electrical loads and shut off engine before refueling e Do not overfill fuel tank Always al low room for fuel to expand If you overfill tank fuel can overflow onto hot generator This can cause fire After refueling tightly close fuel tank cap e Do not spill fuel If fuel spills make sure area is dry before starting engine e Never smoke in refueling area Never allow open flames or sparks in area e Store fuel in approved container Store fuel in a well vented area free of open fl
25. k feed into the utility power line This may electrocute a power company line repair per son Also if generator is power ing electrical circuits the chance of an electrical fire exists Chart 2 Approximate Starting Watts Approximate Universal Repulsion Running Motors Induction Capacitor Watts small appliance Motors Motors Note We supply the engine owner s manual with generator Refer to that manual for questions concerning engine operation USING RECEPTACLE Note Do not exceed amperage rating of receptacles Exceeding rating will trip re ceptacle circuit breaker Always use starting watts not running watts when figuring correct electrical load x Motors of higher horsepower are not generally used Use receptacles properly Improper use could damage generator Use only grounded exten sion cords Power only grounded or double insulated items Do not overload receptacles This generator has the following receptacles see Figure 13 e 120V 15 amp duplex receptacle e 120V 15 amp GFCI duplex receptacle e 120V 30 amp twist lock receptacle 120 240V 20 amp twist lock receptacle Continued 107359 9 MASTER PORTABLE DIESEL GENERATOR OPERATION Continued 120V 15 Amp GFCI Duplex 120V 15 Amp Duplex 120 240V 20 Amp Twist Lock 120V 30 Amp Twist Lock Figure 13 Receptacle Locations POWER CORD AND PLUG REQUIREMENTS 120V 30 amp twist lock recept
26. ne stop lever see Fig ure 19 This releases engine run lever and stops engine Do not stop engine with the decompression lever Turn the starter key to the OFF position 5 Turn fuel valve lever off Do this by moving valve lever to the S position see Figure 20 6 Slowly pull starter rope until you feel strong resistance Gently return starter rope to engine This action closes the in take and exhaust valves This prevents rust from forming while not using engine Engine Stop Lever Figure 19 Pushing Down Engine Stop Lever Fuel Valve Lever Figure 20 Fuel Valve Lever In S Position MASTER PORTABLE DIESEL GENERATOR MAINTENANCE AND REPAIRS AX WARNING Only a qualified electrical service person should service and repair the alternator on this generator Use only fac tory approved replacement parts Ad CAUTION You must always run the engine at full speed Do not run engine at lower speeds At full speed the engine runs at 3600 RPM under load The en gine must maintain 3600 RPM for generator to create correct volt age Running engine at lower speeds will damage generator and powered items TROUBLESHOOTING Note For additional help visit DESA International s technical service web site at www desatech com Note See engine owner s manual for en gine troubleshooting OBSERVED PROBLEM No voltage when starting generator with no electrical load
27. of Load Cord in Feet 18 18 18 STANDBY INSTALLATION TO HOME OR BUILDING AX WARNING Have standby in stallation performed by a skilled licensed electrician Do not let anyone else wire into a utility circuit Personal injury equip ment damage or damageto home could occur IMPORTANT This generator will not power your entire home Most home utility electric service 1s more than 60 amps This will exceed generator output Only power needed items during a power outage Make sure total wattage of electrical load does not exceed rated wattage of generator You may need to use this generator as a standby power source During a power out age the generator will power selected items in a building Have generator and additional wiring installed by a skilled licensed elec trician This is not a do it yourself job Fol low all local codes MASTER PORTABLE DIESEL GENERATOR AX WARNING The electrician must installa double throw trans fer switch This isolates existing electrical circuits from the utility power line If not isolated gen erator output will back feed into utility power line This may elec trocute a power company line repair person DETERMINING ELECTRICAL LOAD FOR GENERATOR You must decide what electrical load your generator can power Do this before using generator Use the following four step method It will help you select a load that is not too large Make sure total wattage of all
28. or five years from the date of first purchase from an authorized dealer provided that the product has been properly installed maintained and operated in accordance with all applicable instructions The bill of sale or proof of purchase must be presented at the time a claim is made under this warranty This warranty is extended only to the original retail purchaser This warranty covers only the parts and labor required to restore this unit to its proper operating condition Warranty parts must be obtained through factory authorized dealers and service centers for this product These dealers and service centers will provide original factory replace ment parts Failure to use original factory replacement parts voids this warranty This warranty does not apply to parts that are not in original condition because of normal wear and tear or parts that fail or become damaged as a result of misuse abuse negligence accident lack of proper maintenance alteration modification tampering contaminated fuels repair using improper parts or repair by anyone other than an authorized dealer or service center Routine maintenance is the responsibility of the owner Travel handling transportation and incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of the owner DESA Power Tools makes no warranty with respect to the engine and engine components not of its manufacture They are subject to
29. or low temperatures during storage A WARNING Only a qualified electrical service person should service and repair generator Use only factory approved replacement parts POSSIBLE CAUSE 1 Defective capacitor 2 Winding short circuit or loose connections 3 Defective rotor diode 4 Loss of residual magnetism 1 Engine speed too low 2 Clogged spark arrester 3 Defective rotor diode 4 Partial short circuit in winding 5 Defective capacitor 1 Engine speed too high pd Defective rotor diode Electrical load too high 3 Engine not running properly www desatech com 12 REMEDY 1 Replace capacitor 2 Check resistance of coils see Electri cal Component Specifications page 13 3 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor ter minals for 2 3 seconds 1 Set engine speed to 3720 RPM 62 Hz with no load 2 Clean arrester See engine owner s manual 3 Replace both diodes on rotor 4 Check resistance of coils see Electri cal Component Specifications page 13 5 Replace capacitor 1 Set engine speed to 3720 RPM 62 Hz with no load Replace both diodes on rotor Do not overload generator 3 Contact an authorized engine service center N me 107359 OWNER S MANUAL ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Capacitor Main Auxiliary Primary Secondary MFD Diodes 2 Winding Winding A Winding t Winding t 450 Volt
30. ove the negative cable first Always attach negative cable last 107359 BATTERY Continued INSTALLING BATTERY CABLES TO ENGINE 1 Attach the red positive battery cable to the starter solenoid on engine see Figure 8 2 Attach the black negative battery cable to the engine block Use the bolt nut and two washers provided with the battery cables Attach cable as shown in Figure 9 M gm Saera IOE Red Positive Battery Cable Figure 8 Connecting Red Positive Battery Cable to Starter Solenoid on Engine i Negative _ Battery Cable Figure 9 Connecting Black Negative Battery Cable to Engine Block 107359 OWNER S MANUAL MOUNTING BATTERY TO GENERATOR 1 Secure battery to generator by battery hold down system This system consists of the battery mounting bracket hook bolts and nuts see Figure 10 2 Locate the red positive battery cable from starter solenoid Connect it to the positive battery terminal see Figure 11 3 Locate the black negative battery cable attached to engine block Connect it to the negative battery terminal see Figure 11 4 Check battery before starting engine Make sure fluid levels are full Make sure battery is charged See engine owner s manual for more information Battery Mounting Bracket Bolt Figure 10 Battery Hold Down System Red Positive Cable From S
31. r most of dipstick 3 If level is low fill to top of oil filler neck see Figure 7 Only use oil rec ommended in engine owner s manual Note If oil level is too low oil alert system will shutdown engine and prevent engine from restarting Oil Level At Top Of Filler Neck a Figure 7 Checking Oil Level FUEL AX WARNING Diesel fuel pre sents a hazard of fire Diesel fuel is flammable e Keep fuel out of children s reach Refuel generator in a well vented area Do not fill fuel tank in the dark Do not refuel while engine is running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Al ways allow room for fuel to ex pand If you overfill tank fuel can overflow onto hot engine This can cause fire After refu eling tightly close fuel tank cap Do not spill fuel If fuel spills make sure area is dry before starting engine Never smoke in refueling area Never allow open flames or sparks in area Store fuel in approved con tainer Store fuel in a well vented area free of open flames or sparks Use clean fresh diesel fuel Use diesel fuel with cetane rating of 45 or higher Avoid getting dirt dust or water in fuel tank See engine owner s manual for more information BATTERY AX WARNING Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking
32. stem Yes Electric Start Yes Weight pounds 241 Single phase 1 0 power factor UNPACKING 1 Remove generator from carton 2 Remove any protective packaging ap plied to generator for shipment 3 Check for loose or missing parts Check for shipping damage If any parts are missing or damaged promptly inform dealer where you bought generator 4 Battery cables are in a separate bag in side generator carton You must install these cables to engine See Battery page 6 for installation instructions VENTILATION AX DANGER Use only in well vented areas Make sure area has plenty of free moving fresh out side air Never run generator in an enclosed or confined area Never run generator inside occu pied building Engine exhaust contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death This generator needs cooling air to run prop erly Never block free flowing cooling air to generator Overheating will occur with out cooling air This will damage the gen erator Keep generator at least three feet away from any object DUST DIRT RAIN AND SNOW A WARNING Do not use gen erator outdoors in rain or snow Do not use generator near stand ing water or snow Do not use if generator is wet or damp Oper ating generator in these condi tions increases the risk of elec trocution Severe injury or death can occur Do not use generator in extrem
33. tarter Solenoid l E Black Negative Cable From Engine Block Figure 11 Connecting Positive and Negative Cables to Battery 7 GENERATOR GROUNDING A WARNING You must prop erly earth ground generator be fore starting This will help guard against deadly electric shock Only use grounded plugs with generator Only use grounded ex tension cords Only use three wire or double insulated power tools Grounding generator helps prevent electric shock from a ground fault condition Locate ground lug on end of generator housing see Figure 12 Attach a 10 stranded copper ground wire to ground lug Drive grounding point into ground Grounding point can be a stake grounding rod or pipe Grounding point should be copper or brass Attach ground wire to grounding point You must supply the ground wire and grounding point These do not come with generator Follow the National Electrical Code and all state and local codes Consult your power com pany or a licensed electrician AX WARNING For a grounding point do not use metal pipe be ing used to carry combustible materials or gases Copper or Brass Grounding Point Alternator Ground Wire Figure 12 Grounding Generator EXTENSION CORDS Only use grounded extension cords Be sure to use extension cord with proper wire gauge size See chart below Recommended Minimum Wire Gauges AWG for Extension Cords Ampere AWG for Length
34. ter more than ten seconds Starter motor damage may occur If engine fails to start release the key and wait 15 seconds Af ter 15 seconds try starting again 107359 OPERATION Continued B Recoil Starter I Slowly pull starter rope until you feel strong resistance Gently re turn starter rope to engine II Push decompression lever all the way down see Figure 17 Decom pression lever will stay in this po sition until you pull starter rope II Firmly grasp starter grip with both hands Remove slack from starter rope by lightly pulling starter grip IV To start engine pull starter rope briskly You must pull the starter rope all the way out If not the engine will not start IMPORTANT Do not let starter grip snap back against engine Return it gen tly This will prevent damage to starter A WARNING Never use gaso line paint thinner or any other flammable liquid as a starting aid An explosion may occur If engine does not start repeat steps under B Recoil Starter Decompression Lever Figure 17 Decompression Lever Starting Key Figure 18 Starting Key 107359 OWNER S MANUAL HIGH ALTITUDE OPERATION This generator will not perform well at high altitudes without proper adjustment Contact a Yanmar dealer for adjustment information ADDING ELECTRICAL LOADS IMPORTANT Do not overload generator Make sure total wattage of all electrical loads does not exceed rated watta
35. warranties of their manufacturers To the full extent allowed by the law of the jurisdiction that governs the sale of the product this express warranty excludes any and all other expressed warranties and limits the duration of any and all implied warranties including warranties of merchantability and fitness for a particular purpose to five years from the date of first purchase and DESA Power Tools liability is hereby limited to the purchase price of the product and DESA Power Tools shall not be liable for any other damages whatsoever including indirect incidental or consequential damages Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental or consequential damages so the above limitation of damages may not apply to you This warranty provides the original purchaser with specific rights For information regarding those rights please consult the applicable state laws DESA POWER TOOLS P O Box 90004 Bowling Green KY 42102 9004 107359 01 www desatech com REV C 06 04
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