Master MGY5000 - Manuals - manualsarea.com

Page 2 - CONTENTS

2 SECTION PAGE Safety Information ........................................................................... 3Product Identification ...................................................................... 6General Information ........................................................................ 7...

Page 3 - WARNINGS; DANGER; DANGER

3 SAFETY INFORMATION ! WARNING ICON G 001 WARNINGS IMPORTANT: Read this owner’s manual and the engine owner’smanual carefully. Become familiar with this generator before trying tooperate or service it. Know its uses, limitations, and any hazardsinvolved. Improper use of generator can cause severe in...

Page 6 - PRODUCT; Figure 1 - Portable Generator

6 E F RUN STOP E F RESET TEST RESET 120 VOLTS FULL POWER SELECTOR 120 ONLY 120 240V 120/240 VOLTS RESET RESET PRODUCT IDENTIFICATION Figure 1 - Portable Generator ControlPanel Roll Cage Alternator EngineRun Lever Electric StartSwitch Fuel Valve(under fueltank) EngineStop Lever CircuitBreaker Decompr...

Page 7 - Additional Features; GENERAL; SPECIFICATIONS; MODEL; UNPACKING

7 This portable generator is rugged and compact. It provides dependable, trouble-freeservice. The alternator is brushless with revolving fields. Yanmar diesel engineprovides long life under heavy use. This engine is governed to maintain enginespeed of 3600 RPM under load. 3600 RPM engine speed provi...

Page 8 - ture rise above 60; OIL ALERT SYSTEM; See engine owner’s manual for more information.

8 WARNING ICON G 001 DANGER Use only in well-vented areas. Make sure area hasplenty of free-moving, fresh, outside air. Never rungenerator in an enclosed or confined area. Never rungenerator inside occupied building. Engine exhaustcontains poisonous carbon monoxide gas.Overexposure will cause loss o...

Page 9 - Figure 2 - Battery Discharge Lamp and Oil Alert Lamp Location; GENERATOR; FULL POWER SELECTOR SWITCH; This position sends full power to the 120V receptacles only.; BATTERY DISCHARGE LAMP; Figure 3 - Full Power Selector Switch

9 CHARGE OFF OIL BatteryDischargeLamp Oil AlertLamp Figure 2 - Battery Discharge Lamp and Oil Alert Lamp Location Continued GENERATOR FEATURES Continued FULL POWER SELECTOR SWITCH The full power selector switch is on the control panel. The switch has two posi-tions: 120 VOLT ONLY, and 120/240 VOLT. ...

Page 10 - Infants and very small children may still be affected.; Test Procedure; WARNING; back in. The test lamp should work at this time.; ELECTRIC START; Figure 4 - GFCI Receptacle

10 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 againsthazardous electrical shock caused when your body becomes a path throu...

Page 11 - Figure 5 - Receptacle Circuit Breaker Button; Figure 6 - Installing Spark Arrester

11 RECEPTACLE CIRCUIT BREAKER The circuit breakers protect the receptacles and alternator. Overloading generatorwill trip circuit breaker. A short circuit in item being powered will also tripbreaker. If this occurs, unplug electrical load from receptacle. Let circuit breakercool down. Push circuit b...

Page 12 - CHECKING OIL LEVEL AND ADDING OIL; of filler neck. Oil should cover most of dipstick.; ENGINE OIL; Figure 7 - Checking Oil Level

12 We ship the generator without oil in the engine crankcase. You must add oil beforestarting 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 either dipstick (see Figure...

Page 13 - FUEL; BATTERY

13 FUEL WARNING ICON G 001 WARNING Diesel fuel presents a hazard of fire. Diesel fuel isflammable. • 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 isrunning. Unhook all electrical loads and shut offengine be...

Page 14 - CAUTION; to Starter Solenoid on Engine; Make sure battery connections are the correct polarity. This; INSTALLING BATTERY CABLES TO ENGINE

14 WARNING ICON G 001 CAUTION If you remove battery, insulate the red, positive (+)battery cable terminal. Insulate with electrical tape.Exposed terminal may spark when generator runs. StarterSolenoid Figure 8 - Connecting Red, Positive (+) Battery Cable to Starter Solenoid on Engine BATTERY Continu...

Page 15 - Figure 11 - Connecting Positive and Negative Cables to Battery; MOUNTING BATTERY TO GENERATOR

15 BATTERY Continued Nut Battery BatteryMountingBracket HookBolt Red, PositiveCable FromStarter Solenoid Black, Negative Cable From Engine Block Figure 10 - Battery Hold-Down System Figure 11 - Connecting Positive and Negative Cables to Battery MOUNTING BATTERY TO GENERATOR 1. Secure battery to gene...

Page 16 - Figure 12 - Grounding Generator

16 GENERATOR GROUNDING WARNING ICON G 001 CAUTION You must properly earth-ground generator beforestarting. This will help guard against deadly electricshock. Only use grounded plugs with generator. Onlyuse grounded extension cords. Only use three-wireor double-insulated power tools. Grounding genera...

Page 17 - This generator will not power your entire home. Most home utility

17 EXTENSION CORDS Only use grounded extension cords. Be sure to use extension cord with proper wiregauge size. See chart below. Ampere AWG for Length of Cord in Feet Load 50' 100' 150' 2 18 18 18 3 18 18 18 4 16 16 16 5 16 16 16 6 16 16 14 8 16 14 12 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 ...

Page 18 - Some motors require nearly the; Chart 2

18 DETERMINING ELECTRICAL LOAD FOR GENERATOR You must decide what electrical load your generator can power. Do this beforeusing generator. Use the following four-step method. It will help you select a loadthat is not too large. Make sure total wattage of all electrical loads does not exceed5000 watt...

Page 19 - GENERAL INFORMATION; OPERATION; for questions concerning engine operation.; Figure 13 - Receptacle Locations

19 GENERAL INFORMATION This generator is not large enough to power your entire home. Do not connectgenerator to any existing electrical circuits. Plug items directly into generatorreceptacles. Do not exceed amperage rating of receptacles. Only use groundedcords. OPERATION WARNING ICON G 001 DANGER U...

Page 20 - POWER CORD AND PLUG REQUIREMENTS; Ground

20 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 w G Y X Ground X (Hot) W (Neutral) Y (Hot) Ground (Green) L14-20PPlug 120...

Page 21 - PRESTART; You may need to bleed fuel line to remove trapped air; BLEEDING FUEL LINE; reattach fuel line to engine.; STARTING

21 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-tor near standing water and snow. Make sure area is well-vented. OPERATION Continued Note: If oil level is too low, oil alert ...

Page 22 - Figure 16 - Engine Run Lever In RUN Position; Hold it there until engine starts.; Figure 18 - Starting Key; before adding electrical loads.

22 OPERATION Continued O S Fuel ValveLever Figure 15 - Fuel Valve Lever In “O” (open) Position RUN STOP EngineRun 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). Decompres-sion lever will stay i...

Page 23 - Figure 20 - Decompression Lever; sion lever will stay in this position until you pull starter rope.

23 OIL OIL In cold weather, your engine may be hard to start. If so, remove the rubberplug on the rocker arm cover (see Figure 19). Add 2 cc of engine oil in hole.Replace rubber plug. Repeat starting procedure. WARNING ICON G 001 WARNING Never use gasoline, paint thinner, or any otherflammable liqui...

Page 24 - HIGH ALTITUDE OPERATION; Keep full power selector switch in the 120 VOLT ONLY position

24 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 e...

Page 25 - Figure 21 - Pushing Down Engine Stop Lever; DISCONNECTING ELECTRIC LOADS; lets engine cool slightly.

25 RUN STOP EngineStopLever Figure 21 - Pushing Down Engine Stop Lever Figure 22 - Fuel Valve Lever In “S” Position O S Fuel ValveLever DISCONNECTING ELECTRIC LOADS Remove electrical loads one at a time. Remove voltage sensitive items first.Voltage sensitive items include TVs, VCRs, and other home e...

Page 26 - Shut off generator before performing maintenance.; Keep generator level when servicing. Never turn generator upside; STORAGE; down or standing on end.

26 MAINTENANCE AND REPAIRS WARNING ICON G 001 WARNING Only a qualified electrical service person shouldservice and repair the alternator on this generator.Use only factory approved replacement parts. WARNING ICON G 001 CAUTION You must always run the engine at full speed. Donot run engine at lower s...

Page 27 - SHOOTING; See engine owner’s manual for engine troubleshooting.; REMEDY; ELECTRICAL

27 TROUBLE- SHOOTING Note: See engine owner’s manual for engine troubleshooting. WARNING ICON G 001 WARNING Only a qualified electrical service person shouldservice and repair generator. Use only factoryapproved replacement parts. POSSIBLECAUSE 1. Defective capacitor 2. Winding short circuit or loos...

Page 28 - Figure 24 - Engine Wiring Diagram; WIRING; Figure 23 - Alternator Wiring Diagram

28 Figure 24 - Engine Wiring Diagram WIRING DIAGRAMS Figure 23 - Alternator Wiring Diagram Starter Motor/ Solenoid White Red Battery Red Black + - Charge Regulator White Yellow Green 2 3 4 1 Green Green White Red Yellow Key Switch Charge Lamp Black Green/White Green/White Charge Coil Bridge Red Red ...

Page 29 - age for parts replaced under warranty.; Parts Under Warranty; Parts Not Under Warranty; When calling DESA International, have ready; Heavy-Duty Wheel Kit – PA2000; Complete installation instructions included.

29 TECHNICAL SERVICE You may have further questions about installation, operation, or troubleshooting.If so, contact DESA International’s Technical Service Department at 1-800-323-5190. SERVICING THE ENGINE For Yanmar engine replacement parts, contact Parts Company of America at 1-800-323-0620. Yanm...

Page 30 - Alternator Assembly; KEY

30 1 6 2 10 12 15 16 17 13 14 18 19 20 21 22 9 24 23 3 9 8 4 7 5 11 25 ILLUSTRATED PARTS LIST Alternator Assembly KEY PART NO. NUMBER DESCRIPTION QTY. 099723-02 Alternator Assembly 1 1 099844-01 End Cover 1 2 099701-01 Screw, M5 x 13 6 3 099760-01 Bushing 1 4 099863-01 Terminal Block (4-block) 1 5 0...

Page 31 - Fuel Tank and Roll Cage

31 ILLUSTRATED PARTS LIST Fuel Tank and Roll Cage KEY PART NO. NUMBER DESCRIPTION QTY. 1 099935-01 Fuel Tank Assembly 1 2 HC4-6C Screw, 1/4-20 x 3/4" 4 3 WP-4C Washer, 1/4" 4 4 NTC-4C Nut, 1/4-20 4 5 099943-01 Roll Cage 1 6 099945-01 Spreader 1 7 04110002 Bolt, 5/16-18 x 1 1/2" 2 8 WP-5C...

Page 32 - Control Panel

32 ILLUSTRATED PARTS LIST Control Panel RESET FULL POWER SELECTOR 120/240 VOLTS RESET RESET 1 2 3 4 5 7 6 6 9 10 11 12 12 13 120 ONLY 120 240V 120 VOLTS 8 RESET TEST 14 KEY PART NO. NUMBER DESCRIPTION QTY. 1 100148-05 Control Panel 1 2 22616009 Circuit Breaker, 20 Amp * 1 3 099833-01 120V, 30A Twist...

Page 33 - Switch Control Box

33 ILLUSTRATED PARTS LIST Switch Control Box KEY PART NO. NUMBER DESCRIPTION QTY. 1 100131-01 Switch Control Box 1 2 22721000 Low Oil Light 1 3 099936-01 Key Switch, Lamp, and Harness Assy. 1 4 24306006 Hex-Head Screw, #8-18 x 1/2" 4 5 WLI-2BL Lock Washer, #8 4 6 22261000 Speed Nut, #8 4 7 26498...

Page 35 - NOTES

Page 36 - KEEP THIS WARRANTY; WARRANTY INFORMATION; TWO-YEAR LIMITED WARRANTY; INTERNATIONAL

36 KEEP THIS WARRANTY WARRANTY INFORMATION TWO-YEAR LIMITED WARRANTY PORTABLE GENERATORS DESA International warrants each alternator, generator, or electric product of its manufacture, to be free from defectsin material and workmanship for two years from the date of first purchase from an authorized...