Master MGY5000C Owner'S Operation And Installation Manual Download

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PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

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.

Generator Model: MGY5000C

120 ONLY

FULL POWER

120/240V

SELECTOR

RUN

STOP

120/240 VOLTS

RESET

TEST

120 VOLTS

ENM

00000005

S 1/10

Summary of Contents for MGY5000C

Page 1: ...al before operating or servicing generator Improper use of generator can cause serious injury Keep this manual for future reference Generator Model MGY5000C 12 0 ON LY FU LL PO WER 12 0 2 40 V SE LE CT OR RU N ST OP E F 12 0 24 0 VO LT S RE SE T RE SE T RE SE T TE ST 12 0 VO LT S EN M 00 00 00 05 HO UR S 1 1 0 ...

Page 2: ...mining Electrical Load For Generator 18 Operation 19 General Information 19 Using Receptacle 19 Power Cord and Plug Requirements 20 Prestart 21 Bleeding Fuel Line 21 Starting 21 High Altitude Operation 24 Adding Electrical Loads 24 Disconnecting Electrical Loads 25 Stopping Engine 25 Maintenance and Repairs 26 Storage 26 Troubleshooting 27 Electrical Component Specifications 27 Wiring Diagrams 28 ...

Page 3: ...rnings 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 information listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substantial property damage if you ignore warning WARNING i...

Page 4: ...ctric shock or damage to generator may result Do not wear damp clothing or wet shoes when using generator 4 WARNING Guard against burns Hot engine parts can cause severe injury Use caution and remain alert when using generator 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 during o...

Page 5: ...tank is empty Never store with fuel in tank 11 CAUTION 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 12 CAUTION Keep generator and nearby areas clean Keep generator free of oil mud and other foreign mat...

Page 6: ...ompression Lever Starter Grip Fuel Gage Fuel Cap Fuel Tank Ground Lug Spark Arrester Muffler Oil Dipstick Engine Engine Run Lever Engine Stop Lever Oil Alert Lamp Battery Discharge Lamp Electric Start Switch Fuel Valve under fuel tank Alternator 120 240 Volt Receptacle Circuit Breaker Control Panel Roll Cage Full Power Selector Switch 120 Volt Receptacle 120 Volt Receptacle GFCI 120 Volt Receptacl...

Page 7: ...0 Rated Amperage 120 Volt 41 7 240 Volt 20 8 Receptacle Specifications 120 Volt 15 Amp Duplex Yes 120 Volt 15 Amp GFCI Yes 120 Volt 30 Amp Twist Lock Yes 120 240 Volt 20 Amp Twist lock Yes 120 Volt Full Power Switch Yes General Specifications Yanmar Engine H P 9 Yanmar Engine Model L90 Fuel Type Diesel Fuel Tank Capacity 4 2 Gallons Oil Alert System Yes Electric Start Yes Weight pounds 241 Single ...

Page 8: ...ns increases the risk of electrocution Severe injury or death can occur DUST DIRT RAIN AND SNOW Do not use generator in extremely 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 Air temperature affects generator output Output drops 1 for each 10 tempera ture rise above 60 ...

Page 9: ... 120 240 VOLT This position sends full power to the 120 240V receptacle It also powers the 120V receptacles at reduced wattage capacity 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 BATTERY DISCHARGE LAMP The battery discharge lamp see Figure 2 above will light if battery charger is not ...

Page 10: ...nth This insures it is working right 1 PushblackTESTbutton RedRESETbuttonshouldpopout ThisshouldtripGFCI resulting in no electrical power at receptacle Verify this by plugging test lamp with good bulb into receptacle If lamp does not work GFCI receptacle is good WARNING ICON G 001 WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a qualified electrician for repairs 2 ...

Page 11: ...t electric motors first Connect additional items to generator after starting motors If this continues to happen reduce the total generator load 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 generator in a national forest and other desig nated state and local areas Check local codes The spark...

Page 12: ...ther 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 cover most of dipstick 3 If level is low fill to top of oil filler neck see Figure 7 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 ENGI...

Page 13: ...1 WARNING Battery contains sulfuric acid 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 If battery acid gets on your skin wash with water If battery acid gets in your eyes flush with water at least 15 minutes Call a doctor at ...

Page 14: ...ve battery cables are supplied with generator You must install these cables before mounting battery Always wear safety glasses when working with battery Make sure battery termi nals are clean Make sure cable connections are tight Always shut down engine before removing or attaching battery cables Always remove the negative cable first Always attach negative cable last INSTALLING BATTERY CABLES TO ...

Page 15: ...or 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 engin...

Page 16: ...h 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 They do not come with generator Follow the National Electrical Code and all state and local codes Consult your power company or a li...

Page 17: ...RTANT 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 Make sure total wattage of electrical load does not exceed rated wattage of generator You can use this generator as a standby power source During a power outage the generator will power selected items in a build...

Page 18: ...g the generator load for motors you must use the starting watts figure Do not use the running watts figure 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 for typical appliance wattage examples 4 Addwattsandstartingwattsofallitems Thistotalmustnotbelargerthan5000watts Itisagoodideatohaveupto25 extracapacity...

Page 19: ... 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 electri cal fire exists 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 ...

Page 20: ...ug Three wire 30 amp cord 120 240V 20 amp twist lock receptacle NEMA L14 20P 20 amp plug Four wire 20 amp cord w G Y X Ground X Hot W Neutral Y Hot Ground Green L14 20P Plug 120V 120V Neutral 120 240 Volt 20 Amp Figure 14 Cord and Plug Configurations W Neutral X Hot Ground Green 120 Volt 30 Amp G W X L5 30P Plug ...

Page 21: ...s 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 page 22 3 Allow air to bleed from line When fuel exits fuel line in a steady stream reattach fuel line to engine 4 Add spilled fuel back into ...

Page 22: ...ntil engine starts III When engine starts release key IMPORTANT Do not use electric starter more than ten seconds Starter motor damage may occur If engine fails to start release the key and wait 15 seconds After 15 seconds try starting again OIL OIL Figure 18 Starting Key Starting Key Decompression Lever Figure 17 Decompression Lever IMPORTANT Never start generator with electrical loads connected ...

Page 23: ...TION Keep rubber plug on rocker arm in place when not adding oil for starting Rain dirt and other debris may enter the engine This can damage the engine Rubber Plug Engine Starting Oil Hole Figure 20 Decompression Lever Figure 19 Rubber Plug On Rocker Arm Cover B Recoil Starter I Slowly pull starter rope until you feel strong resistance Gently return starter rope to engine II Push decompression le...

Page 24: ...roper 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 wattage of generator Overloading may shorten generator life It could also cause internal damage to generator Overloading will trip circuit breaker IMPORTANT Keep full power selector switch in the 120 VO...

Page 25: ...oads above Remove electrical loads one at a time 2 Let engine run for two or three minutes after removing electrical loads This lets engine cool slightly 3 Push down engine stop lever see Figure 21 This releases engine run lever and stops engine Do not stop engine with the decompression lever 4 Turn the starter key to the OFF position 5 Turn fuel valve lever off Do this by moving valve lever to th...

Page 26: ...uestions 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 WARNING ICON G 001 WARNING Remove all fuel from fuel tank before storing generator Store fuel ...

Page 27: ...cal load but more than 10 low when electrical load is added REMEDY 1 Replace capacitor 2 Checkresistanceofcoils see Electrical Component Speci fications below 3 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor terminals 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 Checkresistanceofcoil...

Page 28: ...ed White Fuse Oil Pressure Switch Circuit Breaker 25A 120 240V 20A Receptacle T4 120V 15A Receptacle 120V 30A Receptacle White White Green Black Red Black Red Black White T3 Red Green Stator 110 120V T1 T2 T3 T4 L2 L1 110 120V 220 240V Rotor Stator White Brown Auxiliary Phase Diode T2 Green Red Black Yellow Main Windings T1 T3 T4 T1 T1 T2 T3 T4 Green Yellow Yellow Red Black Green Diode Capacitor W...

Page 29: ...l s Parts Department at 1 800 323 5190 for information You can also write to the address listed on the back page of this manual When calling DESA International have ready your name your address model number of your generator how generator is malfunctioning purchase date Usually we will ask you to return the defective part to the factory Parts Not Under Warranty Contact authorized dealers of this p...

Page 30: ...87000 Ground Lug 1 7 M11084 26 Screw 10 16 x 3 8 1 8 099847 02 Stator Bolt 4 9 WLE 5 Lock Washer 5 16 4 10 099843 01 Bearing Housing 1 11 27005003S Capacitor 1 12 Stator 1 13 27003002 Fan Bracket 1 14 27003015S Screw M8 x 20 4 15 27001010S Rotor Nut 1 16 27003013S Washer 1 17 099842 02 Draw Bolt 1 18 27003003 Bearing 1 19 27003012S Diode 2 20 Rotor 1 21 27003008 Fan 1 22 101839 01 Engine Flange 1 ...

Page 31: ...ckwasher 1 2 2 12 17529000 Shock Mounts 2 13 26007004 Bolt 5 16 18 x 3 4 4 14 WLE 5 Washer 5 16 3 15 103289 01 Shock Mount 1 KEY PART NO NUMBER DESCRIPTION QTY E F 3 1 2 4 5 18 19 14 19 14 15 9 9 17 8 10 11 13 12 6 9 20 14 8 9 8 7 9 16 16 099749 01 Battery Bracket 1 17 099750 01 Hook Bolt 2 18 14138000 Ground Strap 1 19 M10908 74 Screw 1 4 20 x 1 2 2 20 100410 01 Screw 8 10 x 1 2 4 PARTS AVAILABLE...

Page 32: ...16011 Circuit Breaker 25 Amp 2 7 099834 01 120 240V 20A Twist Lock Receptacle 1 8 101350 01 Hour Meter 1 9 099760 01 Bushing 1 10 24306006 Screw 8 18 x 1 2 4 11 100149 01 Control Box 1 12 22261000 Speed Nut 8 8 13 WLI 2BL Lock Washer 8 4 14 099997 01 Switch Plug 1 15 099836 01 120V 15A Duplex Receptacle 1 103348 02 Control Panel Assembly 1 PARTS AVAILABLE NOT SHOWN 100177 07 Panel Schematic Decal ...

Page 33: ... screw 1 12 6 Internal tooth lockwasher 5 KEY PART NO NUMBER DESCRIPTION QTY 13 26509000 Full bridge 1 14 26002006 8 32 x 3 8 Screw 4 15 15020000 Grommet 1 16 WP 3C 10 Flat washer 1 17 26499000 10 32 x 3 4 Hex head screw 1 18 26490000 Solenoid 1 19 26494000 M4 x 8 Hex head screw 2 20 26492000 M3 x 8 Hex head screw 4 21 101038 01 Control Box Cover 1 22 101036 01 Cable 1 23 101035 01 Conduit 1 10110...

Page 34: ...204 1 800 264 0225 615 726 2225 Tuco Industrial Products P O box 5076 Lynwood WA 98046 206 743 9533 1 800 735 1268 Parts Department Baltimore Electric 1348 Dixwell Avenue Hamden CT 06514 1 800 397 7553 203 248 7553 Marvin Baltimore Parts Company of America 1657 Shermer Road Northbrook IL 60062 1 800 323 0620 708 498 5900 Parts Department Portable Heater Parts 342 N County Road 400 East Valparaiso ...

Page 35: ...35 102206 NOTES ...

Page 36: ... warranty and are the responsibility of the owner DESA International makes no warranty with respect to the engine and engine components not of its manufacture They are subject to 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 duratio...

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