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TROUBLE-

SHOOTING

Note:

See engine owner’s manual for engine troubleshooting.

WARNING ICON

G 001

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

1. Defective rotor diode

2. Electrical load too high

3. Engine not running

properly

OBSERVED
PROBLEM

No voltage when
starting generator
with no electrical
load

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 electrical load
is added

REMEDY

1. Replace capacitor

2. Check resistance of coils (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. Check resistance of coils (see

Electrical Component Speci-
fications, below)

5. Replace capacitor

1. Set engine speed to 3720

RPM (62 Hz) with no load

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized

engine service center

Resistance in Ohms

Stator

Rotor

Capacitor,

Main

Auxiliary

Primary

Secondary

MFD

Diodes (2)

Model

Winding * Winding

∆

Winding † Winding †

450 Volt

800 Volt

MGY5000

0.54

1.38

0.61

2.29

70 Amp

ELECTRICAL

COMPONENT

SPECIFICA-

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.

Содержание MGY5000

Страница 1: ...nd this manual before operating or servicing generator Improper use of generator can cause serious injury Keep this manual for future reference Generator Model MGY5000 RU N ST OP E F RE SE T TE ST RE SE T 12 0 VO LT S FU LL PO WER SE LE CT OR 12 0 ON LY 12 0 24 0V 12 0 24 0 VO LT S RE SE T RE SE T ...

Страница 2: ...ator Grounding 16 Extension Cords 17 Standby Installation To Home or Building 17 Determining 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 St...

Страница 3: ...gs 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 indic...

Страница 4: ...c 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 opera...

Страница 5: ... 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 matter ...

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

Страница 7: ...attage 5000 Rated Amperage 120 Volt 41 7 240 Volt 20 8 Receptacle Specifications 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 phase 1 0 power f...

Страница 8: ...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 F L...

Страница 9: ...r 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 operating while engine is running If this h...

Страница 10: ... 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 If ...

Страница 11: ...lectric 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 ar...

Страница 12: ... 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 ENGINE O...

Страница 13: ...RNING 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 once...

Страница 14: ...attery 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 ENGI...

Страница 15: ...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 M...

Страница 16: ...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 licens...

Страница 17: ...NT 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 building...

Страница 18: ... 1800 watts to start When figuring 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 Itisag...

Страница 19: ...lity 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 amperage rating of receptacles Exceeding rating will trip receptacle circuit break...

Страница 20: ...hree 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 ...

Страница 21: ...elow 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 fue...

Страница 22: ... 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 CHARGE OFF OIL OIL OIL Figure 18 Starting Key Starting Key Decompression Lever Figure 17 Decompression Lever IMPORTANT Never start generator with electrical loads connected Sta...

Страница 23: ... 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 lever ...

Страница 24: ...r 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 VOLT O...

Страница 25: ...s 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 the S...

Страница 26: ...tions 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 in ...

Страница 27: ...ith no electrical 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 Checkre...

Страница 28: ...ck P Shutdown Solenoid Yellow Red White Fuse Oil Pressure Switch Circuit Breaker 25A 120 240V 20A Receptacle T4 Full Pwr Selector Switch 120V 15A Receptacle T2 120V 30A Receptacle White White Green Black Red Red Black Black Red Black White T3 Black Red Green Red 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 Winding...

Страница 29: ...t s call DESA International s Technical Service Department at 1 800 323 5190 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 product If they can t supply original replacement pa...

Страница 30: ... 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 23 26...

Страница 31: ...WLI 8 Lockwasher 1 2 2 12 17529000 Shock Mounts 2 13 26007004 Bolt 5 16 18 x 3 4 5 14 WLE 5 Washer 5 16 3 KEY PART NO NUMBER DESCRIPTION QTY E F 3 1 2 4 5 18 19 14 19 14 15 9 9 16 17 8 10 11 13 12 6 9 20 14 13 8 9 8 7 15 26020000 Shock Mount 1 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 A...

Страница 32: ...3 01 120V 30A Twist Lock Receptacle 1 4 100445 01 120V 15A Duplex GFCI Receptacle 1 5 099956 01 Full Power Selector Switch 1 6 22616011 Circuit Breaker 25 Amp 2 7 099834 01 120 240V 20A Twist Lock Receptacle 1 8 099804 01 Lamp 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 PARTS AVAIL...

Страница 33: ...tor 1 12 M10908 3 Hex Tapping Screw 6 32 x 1 2 1 13 WLI 1C Internal Tooth Lock Washer 6 6 KEY PART NO NUMBER DESCRIPTION QTY 19 20 5 4 6 13 21 23 13 15 22 13 12 14 11 24 18 17 16 10 6 9 7 8 3 3 1 2 4 5 3 14 26509000 Full Bridge 1 15 M10908 27 Hex Tapping Screw 10 32 x 1 2 1 16 15020000 Grommet 1 17 WP 3C Flat Washer 10 1 18 26499000 Hex Head Screw 10 32 x 3 4 1 19 26490000 Solenoid 1 20 26494000 H...

Страница 34: ...0 Parts Department Portable Heater Parts 342 N County Rd 400 East Valparaiso IN 46383 All States 1 800 362 6951 219 462 7441 FBD 601 Hope Street Bowling Green KY 42101 1 800 654 8534 502 796 8406 Master Service Center 1184 Wilson NW Walker MI 49504 1 800 446 1446 616 791 4760 LA Porte s Parts Service 2444 North 5th Street Hartsville SC 29550 803 332 0191 Parts Department MTA Distributors 2940 Fost...

Страница 35: ...35 NOTES ...

Страница 36: ...ranty 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 duration of...

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