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Summary of Contents for Master MGY5000
- Page 1 PORTABLE DIESEL GENERATOR OWNER’S OPERATION AND INSTALLATION MANUAL Generator Model: MGY5000 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.
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Page 2: Table Of Contents
CONTENTS SECTION Safety Information ... 3 Product Identification ... 6 General Information ... 7 Specifications ... 7 Unpacking ... 7 Ventilation ... 8 Dust, Dirt, Rain, and Snow ... 8 High and Low Temperature Operation ... 8 Generator Features ... 8 Oil Alert System ... -
Page 3: Safety Information
SAFETY INFORMATION IMPORTANT: Read this owner’s manual and the engine owner’s manual carefully. Become familiar with this generator before trying to operate or service it. Know its uses, limitations, and any hazards involved. Improper use of generator can cause severe injury or death from explosion, fire, burns, electrical shock, or carbon monoxide poisoning. - Page 4 SAFETY INFORMATION Continued WARNING Guard against fire hazard. Keep operation area well-vented. Keep generator at least three feet away from any object. Do not place flam- mable objects near generator. • Do not use generator where flammable vapors are present. Some vapors are heavier than air.
- Page 5 SAFETY INFORMATION Continued WARNING Battery contains sulfuric acid. Battery acid is poisonous if swallowed. Contact with skin or eyes may cause severe burns. Do not tilt generator with battery installed. Tilting could cause battery acid to spill. Wear protective clothing and face shield when servicing. Keep out of children’s reach.
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Page 6: Product Identification
120 Volt Receptacle (GFCI) Full Power Selector Switch 120/240 Volt Circuit Breaker Receptacle Decompression Lever Starter Grip Engine Figure 1 - Portable Generator Engine Run Lever Engine Stop Lever Oil Alert Lamp Battery Discharge Lamp Electric Start Switch Fuel Valve... -
Page 7: General Information
INFORMATION SPECIFICATIONS UNPACKING This portable generator is rugged and compact. It provides dependable, trouble-free service. The alternator is brushless with revolving fields. Yanmar diesel engine provides 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. -
Page 8: Ventilation
VENTILATION DUST, DIRT, RAIN, AND SNOW HIGH AND LOW TEMPERATURE OPERATION GENERATOR FEATURES WARNING ICON G 001 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. -
Page 9: Battery Discharge Lamp
GENERATOR FEATURES Continued BATTERY DISCHARGE LAMP The battery discharge lamp (see Figure 2, above) 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. -
Page 10: Ground Fault Circuit Interrupter Receptacle
GENERATOR FEATURES Continued 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 electrical shock caused when your body becomes a path through which electricity travels to reach ground. -
Page 11: Receptacle Circuit Breaker
RECEPTACLE CIRCUIT BREAKER GENERATOR The circuit breakers protect the receptacles and alternator. Overloading generator FEATURES will trip circuit breaker. A short circuit in item being powered will also trip breaker. If this occurs, unplug electrical load from receptacle. Let circuit breaker Continued cool down. -
Page 12: Engine Oil
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. -
Page 13: Fuel
FUEL Diesel fuel presents a hazard of fire. Diesel fuel is flammable. • Keep fuel out of children’s reach. • Refuel generator in a well-vented area. Do not fill • Do not overfill fuel tank. Always allow room for • Do not spill fuel. If fuel spills, make sure area is •... - Page 14 BATTERY Continued WARNING ICON G 001 If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when generator runs. IMPORTANT: Make sure battery connections are the correct polarity. This generator use negative ground, 12-volt DC starting system. This generator has an electric starter.
- Page 15 MOUNTING BATTERY TO GENERATOR BATTERY 1. Secure battery to generator by battery hold-down system. This system consists Continued 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).
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Page 16: Generator Grounding
GENERATOR GROUNDING WARNING ICON G 001 You must properly earth-ground generator before starting. This will help guard against deadly electric shock. Only use grounded plugs with generator. Only use grounded extension 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). -
Page 17: Extension Cords
Only use grounded extension cords. Be sure to use extension cord with proper wire EXTENSION gauge size. See chart below. CORDS STANDBY INSTALLATION TO HOME OR BUILDING IMPORTANT: This generator will not power your entire home. Most home utility electric service is more than 60 amps. This will exceed generator output. Only power needed items during a power outage. -
Page 18: Determining Electrical Load For Generator
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 electrical loads does not exceed 5000 watts. -
Page 19: Operation
GENERAL INFORMATION OPERATION This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles. Only use grounded cords. Note: We supply the engine owner’s manual with generator. -
Page 20: Power Cord And Plug Requirements
OPERATION Continued POWER CORD AND PLUG REQUIREMENTS 120V, 30-amp twist-lock receptacle • NEMA L5-30P plug • Three-wire, 30-amp cord 120/240V, 20-amp twist-lock receptacle • NEMA L14-20P (20-amp) plug • Four-wire, 20-amp cord 120 Volt 30 Amp Ground (Green) (Neutral) 120/240 Volt 20 Amp Ground (Green) -
Page 21: Prestart
PRESTART OPERATION Operate generator on a firm, dry, and clean surface. The surface must be level. Continued Protect generator from heavy dust, sand, dirt, rain, or snow. Do not locate genera- tor near standing water and snow. Make sure area is well-vented. Note: If oil level is too low, oil alert system will keep engine from starting (see Oil Alert System, page 8). - Page 22 OPERATION Continued IMPORTANT: Never start generator with electrical loads connected. Start engine before adding electrical loads. 1. Make sure fuel tank is full. See Fuel, page 13 for fuel information. 2. Move fuel valve lever to the “O” (open) position (see Figure 15). 3.
- Page 23 In cold weather, your engine may be hard to start. If so, remove the rubber OPERATION plug on the rocker arm cover (see Figure 19). Add 2 cc of engine oil in hole. Continued Replace rubber plug. Repeat starting procedure. B.
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Page 24: High Altitude Operation
OPERATION Continued III. 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. -
Page 25: Disconnecting Electrical Loads
DISCONNECTING ELECTRIC LOADS OPERATION Remove electrical loads one at a time. Remove voltage sensitive items first. Continued 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 generator (see Disconnecting Electrical Loads, above). -
Page 26: Maintenance And Repairs
MAINTENANCE AND REPAIRS STORAGE WARNING ICON G 001 Only a qualified electrical service person should service and repair the alternator on this generator. Use only factory approved replacement parts. WARNING ICON G 001 You must always run the engine at full speed. Do not run engine at lower speeds. -
Page 27: Troubleshooting
10% low when electrical load is added ELECTRICAL COMPONENT SPECIFICA- Model MGY5000 TIONS * Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow). Resistance between brown and white leads. † Remove diodes to check resistance. WARNING... -
Page 28: Wiring Diagrams
WIRING DIAGRAMS Green/Yellow 120/240V 20A Circuit Breaker Circuit Breaker Yellow Black Black Capacitor White White Green/White Charge Coil Green/White Green/White Black Receptacle Light Black White Full Pwr Selector Black Switch Black White Black Green Main Windings Rotor Green Diode Black Yellow Figure 23 - Alternator Wiring Diagram Green... -
Page 29: Technical Service
TECHNICAL SERVICE SERVICING THE ENGINE REPLACEMENT PARTS ACCESSORY You may have further questions about installation, operation, or troubleshooting. If so, contact DESA International’s Technical Service Department at 1-800-323- 5190. For Yanmar engine replacement parts, contact Parts Company of America at 1- 800-323-0620. -
Page 30: Illustrated Parts Lists
ILLUSTRATED PARTS LIST Alternator Assembly PART NUMBER 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 27003013S 099842-02 27003003 27003012S 27003008 101839-01 26322004 WLE-6 099892-01 * - Part not available by itself. Must purchase Alternator Assembly. DESCRIPTION Alternator Assembly End Cover... -
Page 31: Parts List
ILLUSTRATED PARTS LIST Fuel Tank and Roll Cage PART NUMBER DESCRIPTION 099935-01 Fuel Tank Assembly HC4-6C Screw, 1/4-20 x 3/4" WP-4C Washer, 1/4" NTC-4C Nut, 1/4-20 099943-01 Roll Cage 099945-01 Spreader 04110002 Bolt, 5/16-18 x 1 1/2" WP-5C Washer, 5/16" NEC-5C Nut, 5/16-18 26302006... -
Page 32: Illustrated Parts List
ILLUSTRATED PARTS LIST Control Panel PART NUMBER 100148-05 22616009 099833-01 100445-01 099956-01 22616011 099834-01 099804-01 099760-01 24306006 100149-01 22261000 WLI-2BL 099997-01 100177-01 * Includes fastening hardware DESCRIPTION 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 *... -
Page 33: Illustrated Parts Lists
ILLUSTRATED PARTS LIST Switch Control Box PART NUMBER DESCRIPTION 100131-01 Switch Control Box 22721000 Low Oil Light 099936-01 Key Switch, Lamp, and Harness Assy. 24306006 Hex-Head Screw, #8-18 x 1/2" WLI-2BL Lock Washer, #8 22261000 Speed Nut, #8 26498000 Relay NTF-3C Hex Lock Nut, #10-32 RN12000100 Adhesive-Backed PVC... -
Page 34: Parts Centrals
PARTS CENTRALS These Parts Centrals are privately owned businesses. They have agreed to support our customer’s needs by providing original replacement parts and accessories. Master Service Center Baltimore Electric 1184 Wilson NW 1348 Dixwell Avenue Hamden, CT 06514 Walker, MI 49504 1-800-397-7553 1-800-446-1446 616-791-4760... - Page 35 NOTES...
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Page 36: Warranty Information
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 two-year limited warranty below covers all non-engine parts of this generator including the alternator.
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