Master MGR2900, MGR4500I, MGR6000I Owner'S Operation And Installation Manual Download Page 2

2

114716

PORTABLE GASOLINE GENERATORS

R

CAUTION:

 indicates a hazard which will or 

can cause minor personal injury or property 

damage if you ignore warning.
1.  Gasoline presents a hazard of fire or 

explosion. Gasoline is flammable. Its 

vapor is explosive.

•  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 run-

ning. Unhook all electrical loads and 

shut off engine before refueling.

•  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 or 

explosion. After  refueling,  tightly 

close fuel tank cap.

•  Do not spill fuel. Fuel or fuel vapor 

may ignite. 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  container. 

Store fuel in a well-vented area free 

of open flames or sparks.

2.  Guard against fire hazard. Keep opera-

tion area well-vented. Keep generator at 

least three feet away from any object. 

Do not place flammable objects near 

generator.

•  Do  not  use  generator  where  flam-

mable  vapors  are  present.  Some 

vapors  are  heavier  than  air. These 

vapors settle in low-lying places. 

•  Do  not  use  generator  in  enclosed 

spaces. This includes motor home or 

RV generator compartments.

3.  Guard against electric shock. Generator 

produces high voltage. This high voltage 

can cause severe electric shock. Only 

responsible adults should use generator.

•  Properly  ground  generator  before 

starting.

•  Never let anyone operate or service 

generator  without  proper  instruc-

tions.

•  Avoid contact with live terminals or 

bare wires. 

•  Do not use generator outdoors in rain 

or snow.

•  Do not use generator near standing 

water or snow.

•  Do  not  use  if  generator  is  wet  or 

damp.

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 re-

semble 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 include pregnant women, persons 

with  heart  or  lung  disease  or  anemia, 

those under the influence of alcohol, and 

those  at  high  altitudes.  Make  certain 

you read and understand all warnings. 

Keep this manual for reference. It is 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 informa-

tion 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 a hazard which can 

cause  severe  personal  injury,  death,  or 

substantial property damage if you ignore 

warning.

SAFETY 

INFORMATION

•  Do not use generator in highly con-

ductive  areas. These  areas  include 

metal decking and steelwork.

•  Only use grounded extension cords.

•  Do  not  use  any  worn  or  damaged 

electric cords. Electric shock or dam-

age to generator may result.

•  Do not wear damp clothing or wet 

shoes when using generator.

4.  Guard against burns. Hot engine parts 

can cause severe injury. Use caution 

and remain alert when using genera-

tor.

•  Keep children and animals away from 

generator while it is running or hot.

•  Keep all covers and shields in place. 

Keep them tightly secured.

•  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 

flammable. Let engine cool before 

transporting or storing.

5.  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. 

6.  Never connect generator to any existing 

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 electrical circuits, the chance 

of an electrical fire exists.

7.  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.

8.  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.

 WARNINGS

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.

 DANGER: Carbon monoxide 

poisoning may lead to death!

Summary of Contents for MGR2900, MGR4500I, MGR6000I

Page 1: ...N AND INSTALLATION MANUAL R IMPORTANT Read and understand this manual before operating or servic ing generator Improper use of generator can cause serious injury Keep this manual for future reference Generator Models MGR2900 MGR4500I and MGR6000I ...

Page 2: ... and understand all warnings Keep this manual for reference It is your guide to safe and proper operation of this generator Safetyinformationappearsthroughoutthese instructions Pay close attention to them Belowaredefinitionsforthesafetyinforma tion listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substantial property damage if you ignore warni...

Page 3: ...al output drops if it is sparking if it produces smoke or flames if it vibrates at high levels if it has a damaged receptacle 12 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 b...

Page 4: ...ssing parts Check for shipping damage If any parts are missing or damaged please contact our Technical Service Department at 1 800 858 8501 English Only Thisgeneratorneedscoolingairtorunprop erly Never block free flowing cooling air togenerator Overheatingwilloccurwithout cooling air This will damage the generator Keepgeneratoratleastthreefeetawayfrom any object DANGER Use only in well vented areas...

Page 5: ...ock 20 Amp 30 Amp 120 V Voltage Selector Switch Yes Yes General Robin Engine H P 6 9 11 5 Robin Model EX170 D52010 EX270 0638T EH360 0644T Fuel Type Gasoline Gasoline Gasoline Fuel Tank Capacity 3 9 qt 8 gal 8 gal Oil Alert System Yes Yes Yes Start Method Recoil Recoil Recoil Weight pounds 85 5 135 165 Single phase 1 0 power factor Note Ratings apply to SAE standard conditions Reduce ratings 3 1 2...

Page 6: ...shuts down the engine the engine will not start until you add oil Add oil to engine see Engine Oil page 7 Note Operate generator on a level surface If not level the oil may flow away from the oil level sensing device This will cause the oil alert system to shut down engine See engine owner s manual for more information Figure 2 Engine Switch Location ENGINE SW ON OFF 120 240 VOLT Position 120 VOLT ...

Page 7: ...ould cover most of dipstick 3 If level is low fill to top of oil filler neck see Figure 6 Only use oil recom mended in engine owner s manual Note If oil level is too low oil alert system will shutdown engine and prevent engine from restarting Figure 6 Checking Oil Level Model MGR4500I Shown FUEL Oil Level At Top Of Filler Neck Dipstick Oil GENERATOR FEATURES Continued Use clean fresh unleaded gasoli...

Page 8: ... 12 12 10 20 10 10 8 GENERATOR GROUNDING Ground Wire Alternator Copper or Brass Grounding Point Figure 7 Grounding Generator Model MGR4500I Shown EXTENSION CORDS Only use grounded extensioncords Be sure touseextensioncordwithproperwiregauge size See chart below Recommended Minimum Wire Gauges AWG for Extension Cords WARNING For a grounding point do not use metal pipe be ing used to carry combustib...

Page 9: ...e of generator For rated wattage of your generator see Specifications page 5 Electric 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 motorpoweredappliancesinone Listall lights small appliances etc in the other For standby service to home or building only include items you must power 2 Enter runnin...

Page 10: ...DANGER Neverconnectgen erator to any existing electrical circuits Thegeneratoroutputwill back feed into the utility power line Thismayelectrocuteapower companylinerepairperson Also ifgeneratorispoweringelectrical circuits the chance of an electri cal fire exists DANGER Use only in well vented areas Make sure area has plenty of free moving fresh outside air Never run generator in an enclosed or confi...

Page 11: ...GR6000I see Figure 11 This closes the choke Note You may not need to close choke if engine is warm or air temperature is high WARNING Only responsible adults should use generator Neverletanyoneoperategenera tor without proper instructions 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 genera...

Page 12: ...00I IMPORTANT Adjust the idle speed only If the idle speed becomes too high If the engine idle speed will not regulate enginewants to hunt or speeds up and slows down repeatedly 1 Turn Auto Idle switch OFF Start en gine Allow engine to warm up with no load for five minutes Figure 15 Control Panel Auto Idle Switch 2 Loosen the two m10 bolts mounting the solenoid to the engine see Figures 16 and 17 3...

Page 13: ...s one at a time Re move voltage sensitive items first Voltage sensitive items include TVs VCRs and other home electronic items STOPPING ENGINE IMPORTANT The engine speed is preset The throttle is locked in preset position Do not adjust throttle Follow the steps below to stop engine 1 Remove all electrical loads from genera tor seeDisconnectingElectricalLoads Remove electrical loads one at a time 2 ...

Page 14: ...l service web site at www desatech com www desatech com Note See engine owner s manual for engine troubleshooting SERVICING THE ENGINE Robin parts and services should be handled by your nearest authorized engine service firm Visit www robinamerica com or call Robin direct 1 800 277 6246 IMPORTANT Keepgeneratorlevelwhilein storage Never store generator upside down or standing on end Note Wesupplythe...

Page 15: ... 0 835 1 852 4 91 40 8 Amp MGR6000I 0 741 1 582 5 55 40 8 Amp ELECTRICAL COMPONENT SPECIFICATIONS 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 T2 Stator 110 120V T1 T3 T2 T4 L2 L1 Rotor Stator White Brown Auxiliary Phase Green Red Black Yellow Main Windings T1 T3 T4 L1 L2 L2 L1 20A Circuit B...

Page 16: ...Ylw Grn Ylw Green Yellow Green Yellow To Alternator Ground To Solenoid Green Yellow To Roll Cage Yellow White White Blue Red Black Black Black Blk Blk Black Black Black Red Red Red Red Red Green 120 240V 20A 30A Receptacle 120V 30A Receptacle 120V 15A Receptacle 120V 20A Receptacle White White Wht Wht Wht Wht Wht White White White White Auto Idle Stator 110 120V T1 T2 T3 T4 L2 L1 110 120V 220 240V...

Page 17: ...ted under Replacement Parts on page 23 of this manual Includes fastening hardware Includes reference numbers 1 through 22 Parts not available Included in alternator assembly Available at any hardware store KEY PART NO NUMBER DESCRIPTION QTY 099722 02 Alternator Assembly 1 100074 01 Top Cover 1 2 100445 01 120V 15A Duplex GFCI Receptacle 1 3 22616009 Circuit Breaker 20 Amp 1 4 27002002S Capacitor 1...

Page 18: ...9 115308 01 115308 01 Hex Head Taptite 8mm Screw 4 10 WLE 5 WLE 5 Lock Washer 5 16 4 11 115315 01 115315 01 Bearing 1 12 115316 01 115316 01 Diode 2 13 Rotor Alternator 1 14 115317 01 115317 01 Fan 1 15 Bolt 3 8 16 x 5 8 4 16 Lock Washer 3 8 4 17 115242 01 115242 01 Flange Alternator 1 1 2 3 6 5 4 8 9 10 7 11 12 15 16 17 13 14 ILLUSTRATED PARTS LIST For Models MGR4500I and MGR6000I Alternator Asse...

Page 19: ...olt 5 16 18 x 1 2 1 5 WLE 5 Lock Washer 5 16 1 6 115388 01 Grounding Strap 1 ILLUSTRATED PARTS LIST For Model MGR2900 Roll Cage This list contains replaceable parts used in yourgenerator Whenorderingparts follow the instructions listed under Replacement Parts on page 23 of this manual 3 2 2 4 5 3 2 2 3 2 6 3 1 Available at any hardware store ...

Page 20: ...UTO ID LE RESET RESET RESET RESET OFF ON SELE CTO R 12 0 ONLY 12 0 24 0 RE SE T TE ST EN M 00 00 00 05 HO UR S 1 1 0 E F F U E L Un leaded Gasoline Only SAFETY INFORMATION 14 9 8 16 10 11 13 12 12 13 17 15 16 17 18 15 16 1 2 15 3 10 4 6 5 7 15 ILLUSTRATED PARTS LIST For Models MGR4500I and MGR6000I Fuel Tank and Roll Cage ...

Page 21: ... 11 114685 01 114685 01 Spacer 1 12 Bolt 5 16 18 x 1 2 2 13 WLE 5 WLE 5 Lock Washer 5 16 2 14 103289 01 103289 01 Shock Mount 1 15 NEC 5C NEC 5C Lock Nut 5 16 18 4 16 WP 5C WP 5C Flat Washer 5 16 3 17 103289 02 103289 02 Shock Mounts 2 18 114721 01 114721 02 Control Panel 1 PARTS AVAILABLE NOT SHOWN 100003 06 100003 06 Operation Decal 1 5 16 18 x 1 2 Grounding Bolt 1 5 16 Flat Washer 1 5 16 SEMS N...

Page 22: ... 099760 02 Bushing 1 11 114722 01 114722 01 Enclosure 1 12 116475 01 116475 01 Plastite Pan Head Screw 6 13 100366 01 100366 01 Rocker Switch 1 14 115404 01 115404 01 Auto Idle Control Board Kit 1 114721 01 114721 02 Control Panel Assembly 1 114963 01 114963 01 Panel Schematic Decal 1 ILLUSTRATED PARTS LIST For Models MGR4500I and MGR6000I Control Panel This list contains replaceable parts used in...

Page 23: ...S AND ACCESSORIES For original replacement parts and acces sories contact your nearest Authorized DealerorAuthorizedServiceCenterforthis product If they can not supply the part or accessory contactyournearestPartsCentral listed below Each Authorized Dealer Au thorizedServiceCenter andPartsCentralis independently owned and operated See pages 17 through 22 for an Illustrated Parts List If you need a...

Page 24: ...on 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 To the full extent allowed by the law...

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