Master Lock Portable Generator MGY5000C User Manual

PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

120 VOLTS

RESET

TEST

120/240 VOLTS

ENM

00000005

RESET

Generator Model: MGY5000C

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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OWNER’S MANUAL

SAFETY

PRODUCT

INFORMATION

IDENTIFICATION

Continued

Full Power Selector

9. Only a qualified electrical service per-

son should service and repair generator.

• Generator produces high voltage.

Use extreme caution when working

on electrical parts.

Switch

Roll Cage

Engine Run

Lever

Control

Panel

•

When working on generator, avoid hot

muffler, exhaust manifold, and engine

parts. Severe burns may occur.

120 Volt

Receptacle

• Do not work on generator when tired.

• Use only factory approved replace-

ment parts.

Engine

Stop

Lever

120

TES

120 Volt

Receptacle

(GFCI)

120

/240

10. Store generator in a well-vented area.

Make sure fuel tank is empty. Never

store with fuel in tank.

ENM

00000

005

11. Never operate generator

• if engine speed changes greatly

• if engine misfires often

120 Volt

Receptacle

(Duplex)

Fuel Valve

(under fuel tank)

• if powered items overheat

• if electrical output drops

• if it is sparking

Hour Meter

• if it produces smoke or flames

• if it vibrates at high levels

• if it has a damaged receptacle

Alternator

Circuit

Breaker

120/240 Volt

Receptacle

Electric Start

Switch

Battery

Discharge

Lamp

Oil Alert

Lamp

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.

Fuel Gage

• Remove oily rags and other items

that create fire hazards.

Fuel Cap

Decompression

Lever

Fuel Tank

• Keep a fire extinguisher nearby.

Make sure it is rated ABC by the

NFPA. They are good for all uses.

Consult your local fire department.

• Keep fire extinguisher well main-

tained. Be familiar with its use.

13. Know how to stop engine quickly.

Know how to use all controls.

Ground

Lug

Starter Grip

14. Prolonged exposure to loud noise can

cause hearing loss.

• When working around generator,

wear approved hearing protection.

• Remember neighbors when using

generator.

Spark

Arrester

Muffler

Engine

Oil Dipstick

Figure 1 - Portable Generator

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PORTABLE DIESEL GENERATOR

GENERAL

UNPACKING

HIGH AND LOW

TEMPERATURE

OPERATION

Air temperature affects generator output.

Output drops 1% for each 10° temperature

rise above 60° F. Very low temperatures may

make the engine hard to start. See engine

owner’s manual for more information.

1. Remove generator from carton.

INFORMATION

2. Remove any protective packaging ap-

plied to generator for shipment.

This portable generator is rugged and com-

pact. It provides dependable, trouble-free

service. The alternator is brushless with

revolving fields. Yanmar diesel engine pro-

vides 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.

3. Check for loose or missing parts. Check

for shipping damage. If any parts are

missing or damaged, promptly inform

dealer where you bought generator.

4. Battery cables are in a separate bag in-

side generator carton. You must install

these cables to engine. See Battery,

page 6, for installation instructions.

GENERATOR

FEATURES

Additional Features

• Circuit breaker protection

• Spark-arresting muffler

• Large fuel tank

OIL ALERT SYSTEM

VENTILATION

Theoilalertsystemprotectstheenginefrom

low oil damage. This system automatically

shuts down the engine and prevents engine

restarting if the oil level falls too low.

DANGER: Use only in well-

ventedareas.Makesureareahas

plenty of free-moving, fresh, out-

side air. Never run generator in

an enclosed or confined area.

Never run generator inside occu-

pied building. Engine exhaust

containspoisonouscarbonmon-

oxide gas. Overexposure will

causelossofconsciousnessand

will lead to death.

• Oil alert system

• Electric starter

• Pressurized lubrication system

If this system shuts down the engine, the

engine will not start until you add oil. Add

oil to engine (see Engine Oil, page 6).

• 15-Amp ground fault circuit interrupter

(GFCI) receptacle

See engine owner’s manual for more

information.

SPECIFICATIONS

MODEL

MGY5000C

BATTERY DISCHARGE LAMP

Electrical

The battery discharge lamp (see Figure 2)

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.

Rated Wattage*

5000

Thisgeneratorneedscoolingairtorunprop-

erly. Never block free-flowing, cooling air

to generator. Overheating will occur with-

out cooling air. This will damage the gen-

erator. Keep generator at least three feet

away from any object.

Rated Amperage

120 V

41.7

20.8

240 V

Receptacle

120-V,15-A Duplex

120-V, 15-A GFCI

Yes

Oil Alert

120-V, 30-A Twist-Lock

120/240-V, 20-A Twist-Lock

120-V Full-Power Switch

Lamp

OIL

DUST, DIRT, RAIN,

AND SNOW

CHARGE

OFF

General

WARNING: Do not use gen-

erator outdoors in rain or snow.

Do not use generator near stand-

ing water or snow. Do not use if

generator is wet or damp. Oper-

ating generator in these condi-

tions increases the risk of elec-

trocution. Severe injury or death

can occur.

Battery

Discharge

Lamp

Yanmar Engine H.P.

Yanmar Engine Model

Fuel Type

L100

Diesel

4.2 Gallons

Yes

Fuel Tank Capacity

Oil Alert System

Electric Start

Yes

Weight (pounds)

241

* Single-phase, 1.0 power factor

Do not use generator in extremely dusty or

dirtyconditions. Thiswillseverelyaffectits

life. Keep generator clean. Do not allow

dust, dirt, rain, or snow to collect on it.

Protect generator from outdoor elements.

Figure 2- Battery Discharge Lamp and Oil

Alert Lamp Location

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OWNER’S MANUAL

When protected by the GFCI, you may still

RECEPTACLE CIRCUIT

BREAKER

GENERATOR

feel a shock, but the GFCI should cut it off

quickly. A person in normal health should

notreceiveseriousinjury. Note:Infantsand

very small children may still be affected.

FEATURES

The circuit breakers protect the receptacles

and alternator. Overloading generator will

trip circuit breaker. A short circuit in item

being powered will also trip breaker. If this

occurs, unplug electrical load from recep-

tacle. Let circuit breaker cool down. Push

circuit breaker button to reset.

Continued

FULL POWER SELECTOR

SWITCH

Test Procedure

Check the GFCI receptacle every month.

This insures it is working right.

The full power selector switch is on the

controlpanel. Theswitchhastwopositions:

120 VOLT ONLY, and 120/240 VOLT.

1. Push black TEST button. Red RESET

button should pop out. This should trip

GFCI, resulting in no electrical power

at receptacle. Verify this by plugging

test lamp with good bulb into recep-

tacle. If lamp does not work, GFCI re-

ceptacle is good.

Electricmotorsneedhigherstartingcurrent.

They require up to three-times their rated

wattage to start. The starting current needed

may be too high. This can cause nuisance

circuit breaker tripping. To help prevent

this, start electric motors first. Connect ad-

ditional items to generator after starting

motors. If this continues to happen, reduce

the total generator load.

120 VOLT ONLY: This position sends full

power to the 120V receptacles only. 240V

power is not available. Use this position

when powering 120V items only.

120/240 VOLT: This position sends full

power to the 120/240V receptacle. It also

powers the 120V receptacles at reduced

wattage capacity.

WARNING: If RESET button

does not pop out, do not use the

GFCI receptacle. Contact a quali-

fied electrician for repairs.

2. If the GFCI receptacle tests okay, restore

power by pushing the RESET button

back in. The test lamp should work at

this time. IMPORTANT:You must press

the RESET button firmly and fully. It

should lock into place. If the GFCI does

not lock into place, do not use receptacle.

Normal

Tripped

Figure 5 - Receptacle Circuit Breaker

Button

SPARK ARRESTER

120 VOLT ONLY Position

Contact a qualified electrician for repairs. 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 genera-

tor in a national forest and other designated

state and local areas. Check local codes.

RESET

TEST

The spark arrester needs periodic cleaning.

A dirty spark arrester reduces engine output

andincreasesfuelconsumption.Italsomakes

startingdifficult.Seeengineowner’smanual

120/240 VOLT Position

Figure 3 - Full Power Selector Switch

IMPORTANT: Do not move the full power

selector switch while powering electrical

items.Unplugallitemsbeforemovingswitch.

Failure to do so can damage switch.

for cleaning instructions.

Figure 4 - GFCI Receptacle

Muffler

ELECTRIC START

This model has an electric starter. A battery is

not supplied with generator. You must pro-

videa12-volt,45-amp-hourbattery.Formore

battery information, see Battery, page 6.

Clamp

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 electri-

cal shock caused when your body becomes a

paththroughwhichelectricitytravelstoreach

ground.Thiscouldhappenwhenyoutouchan

appliance or cord that is ‘live’ through faulty

mechanism, damp or worn insulation, etc.

Spark

Arrester

Figure 6 - Installing Spark Arrester

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PORTABLE DIESEL GENERATOR

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.

FUEL

WARNING: Diesel fuel pre-

sents a hazard of fire. Diesel fuel

is flammable.

• Keep fuel out of children’s

reach.

WARNING: Battery contains

sulfuric acid. Contact with skin or

eyes may cause severe burns. Do

not tilt generator with battery in-

stalled. Tiltingcouldcausebattery

acidtospill.Wearprotectivecloth-

ing and face shield when servic-

ing. Keep out of children’s reach.

• If battery acid gets on your

skin, wash with water.

CHECKING OIL LEVEL AND

ADDING OIL

•

Refuel generator in a well-

ventedarea.Donotfillfueltank

in the dark. Do not refuel while

engine is running. Unhook all

electrical loads and shut off

engine before refueling.

Follow steps below to check oil level. Make

sure engine is level and stopped.

• Ifbatteryacidgetsinyoureyes,

flushwithwateratleast15min-

utes. Call a doctor at once.

1. Remove dipstick (see Figure 7). Wipe

dipstick clean.

• Do not overfill fuel tank. Al-

ways allow room for fuel to ex-

pand. If you overfill tank, fuel

can overflow onto hot engine.

This can cause fire. After refu-

eling,tightlyclosefueltankcap.

• Do not spill fuel. 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 con-

tainer. Store fuel in a well-

ventedareafreeofopenflames

or sparks.

Battery acid is poisonous.

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.

• If swallowed, drink large

amounts of water or milk. Fol-

low with milk of magnesia or

vegetable oil. Call a doctor

at once.

3. If level is low, fill to top of oil filler

neck (see Figure 7). Only use oil rec-

ommended in engine owner’s manual.

CAUTION: If you remove bat-

tery, insulate the red, positive

(+) battery cable terminal. Insu-

late with electrical tape. Ex-

posed terminal may spark when

generator runs.

Note: If oil level is too low, oil alert system

will shutdown engine and prevent engine

from restarting.

Oil Level

At Top Of

Filler Neck

IMPORTANT: Make sure battery con-

nections are the correct polarity. This gen-

erators uses negative ground, 12-volt DC

starting system.

Use clean, fresh, diesel fuel. Use diesel fuel

with cetane rating of 45 or higher. Avoid

getting dirt, dust, or water in fuel tank.

This generator has and electric starter. A

battery is not supplied with generator. You

must provide a 12-volt, 32-amp-hour bat-

tery.Thepositiveandnegativebatterycables

are supplied with generator. You must in-

stall these cables before mounting battery.

See engine owner’s manual for more

information.

Dipstick

Always wear safety glasses when working

with battery. Make sure battery terminals are

clean. Make sure cable connections are tight.

Oil

BATTERY

Figure 7 - Checking Oil Level

WARNING: 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.

Always shut down engine before removing

or attaching battery cables. Always remove

the negative (–) cable first. Always attach

negative (–) cable last.

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OWNER’S MANUAL

MOUNTING BATTERY TO

GENERATOR

1. Secure battery to generator by battery

hold-down system. This system consists

of the battery mounting bracket, hook

bolts, and nuts (see Figure 10).

BATTERY

GENERATOR

GROUNDING

Continued

INSTALLING BATTERY

CABLES TO ENGINE

1. Attach the red, positive (+) battery

cable to the starter solenoid on engine

(see Figure 8).

WARNING: You must prop-

erly earth-ground generator be-

fore starting. This will help guard

against deadly electric shock.

Only use grounded plugs with

generator. Onlyusegroundedex-

tensioncords.Onlyusethree-wire

or double-insulated power tools.

2. Locate the red, positive (+) battery

cable from starter solenoid. Connect

it to the positive (+) battery terminal

(see Figure 11).

2. Attach the black, negative (–) battery

cable to the engine block. Use the

bolt, nut, and two washers provided

with the battery cables. Attach cable

as shown in Figure 9.

3. Locate the black, negative (–) battery

cable attached to engine block. Connect

it to the negative (–) battery terminal

(see Figure 11).

Grounding generator helps prevent electric

shock from a ground fault condition. Locate

ground lug on end of generator housing (see

Figure 12). Attach 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

supplythegroundwireandgroundingpoint.

These do not come with generator. Follow

the National Electrical Code and all state

and local codes. Consult your power com-

pany or a licensed electrician.

4. Check battery before starting engine.

Make sure fluid levels are full. Make

sure battery is charged.

Starter

Solenoid

See engine owner’s manual for more

information.

Battery Mounting Bracket

Nut

Red, Positive (+)

Battery Cable

WARNING: For a grounding

point, do not use metal pipe be-

ing used to carry combustible

materials or gases.

Figure 8 - Connecting Red, Positive (+)

BatteryCabletoStarterSolenoidonEngine

Battery

Hook

Bolt

Figure 10 - Battery Hold-Down System

Ground Lug

Black,

Negative (–)

Battery Cable

Red, Positive

Cable From

Starter Solenoid

Copper or Brass

Grounding Point

Figure 9 - Connecting Black, Negative (-)

Battery Cable to Engine Block

Ground Wire

Alternator

Figure 12 - Grounding Generator

Black, Negative

Cable From

Engine Block

Figure 11 - Connecting Positive and

Negative Cables to Battery

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PORTABLE DIESEL GENERATOR

problem. They require up to three-

times their rated wattage to start.

Chart 2, page 9, shows starting watts

for different size motors. For ex-

ample: an electric motor nameplate

states 5 amps at 120 volts. 5 amps x

120 volts = 600 watts running. Mul-

tiply this figure by 3. This will show

the starting watts needed. 600 watts

x 3 = 1800 watts to start. When fig-

uring the generator load for motors,

you must use the starting watts fig-

ure. Do not use the running watts fig-

ure. 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, page 9, for typical ap-

pliance wattage examples.

EXTENSION

WARNING: The electrician

mustinstalladouble-throwtrans-

CORDS

fer switch. This isolates existing

Only use grounded extension cords. Be sure

touseextensioncordwithproperwiregauge

size. See chart below.

electrical circuits from the utility

power line. If not isolated, gen-

erator output will back-feed into

utility power line. This may elec-

trocute a power company line

repair person.

Recommended Minimum Wire

Gauges (AWG) for Extension

Cords

Ampere

Load

AWG for Length of

Cord in Feet

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 5,000 watts. Elec-

tric motors present a special problem when

figuring load. Read step 3 carefully.

50'

100'

150'

4. Add watts and starting watts of all

items. This total must not be larger

than 5,000 watts. It is a good idea to

have up to 25% extra capacity for

future needs or extra equipment.

1. Make two lists of items you want pow-

ered by generator. List all motors and

motor powered appliances in one. List all

lights, small appliances, etc. in the other.

For standby service to home or building,

only include items you must power.

STANDBY

INSTALLATION TO

HOME OR

2. Enter running watts of each item ex-

cept motors. The light bulb or appli-

ance nameplate lists its wattage. Re-

member, 1KW = 1000 watts. Note:The

nameplate may not list wattage. It may

only list volts and amps. The formula

for finding wattage is: Volts x Amps =

Watts. For example: An appliance

nameplate states 3 amps at 120 volts. 3

amps x 120 volts = 360 watts.

BUILDING

WARNING: Have standby in-

stallation performed by a skilled,

licensed electrician. Do not let

anyone else wire into a utility

circuit. Personal injury, equip-

mentdamage,ordamagetohome

could occur.

3. Electric motors present a special

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. Make

sure total wattage of electrical load does not

exceed rated wattage of generator.

You may need to use this generator as a

standby power source. During a power out-

age, the generator will power selected items

in a building. Have generator and additional

wiring installed by a skilled, licensed elec-

trician. This is not a do-it-yourself job. Fol-

low all local codes.

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OWNER’S MANUAL

DETERMINING

OPERATION

GENERAL INFORMATION

This generator is not large enough to power

your entire home. Do not connect generator

toanyexistingelectricalcircuits.Plugitems

directly into generator receptacles. Do not

exceedamperageratingofreceptacles.Only

use grounded cords.

ELECTRICAL LOAD

FOR GENERATOR

Continued

Chart 1 - Typical Electric Appliance Wattages

Chart to be used as reference. Data may vary wiht size, make, and/or model.

Running Starting

Equipment

Watts

Watts Equipment

Watts

DANGER: Use only in well-

ventedareas.Makesureareahas

plenty of free-moving, fresh, out-

side air. Never run generator in

an enclosed or confined area.

Never run generator inside occu-

pied building. Engine exhaust

containspoisonouscarbonmon-

oxide gas. Overexposure will

causelossofconsciousnessand

will lead to death.

Light bulb (100W)

Radio

Fan

100

150

200

400

600

700

800

1000

100

150

1/2" Drill

Toaster

1000

1200

1250

1200

1500

600

400

Coffee maker

Skillet

Television

Furnace fan (1/3 hp)

Vacuum cleaner

Sump pump (1/3 hp)

Refrigerator/freezer

6" Circular saw

Floodlight

1800

750

2100

2400

1000

14" Chain saw

Water well pump

(1/2 hp)

Hot plate/range

(per burner)

10" Table saw

Water heater

1000

3000

1500

2000

5000

1500

6000

5000

WARNING: Never connect

generatortoanyexistingelectri-

cal circuits. The generator out-

put will back-feed into the utility

power line. This may electrocute

apowercompanylinerepairper-

son. Also, if generator is power-

ingelectricalcircuits,thechance

of an electrical fire exists.

Chart 2

Approximate Starting Watts*

Repulsion

Motor

Rating

Approximate

Running

Watts

Universal

Motors

Split

Phase

Motors

Induction

Motors

Capacitor

Motors

(small appliance)

1/8

1/4

1/3

1/2

3/4

500

700

800

1100

1400

1700

2100

2450

625

875

1100

1550

1750

2400

3100

3750

4620

5400

1500

2100

2400

3300

4200

5100

6300

2250

3150

3600

4950

1000

1375

1750

2125

2625

3075

Note:Wesupplytheengineowner’smanual

with generator. Refer to that manual for

questions concerning engine operation.

1 ¹/2

USING RECEPTACLE

Note: Do not exceed amperage rating of

receptacles. Exceeding rating will trip re-

ceptacle circuit breaker.

* – Always use starting watts, not running watts, when figuring correct electrical load.

x – Motors of higher horsepower are not generally used.

Usereceptaclesproperly.Improperusecould

damagegenerator.Useonlygroundedexten-

sion cords. Power only grounded or double-

insulateditems.Donotoverloadreceptacles.

This generator has the following receptacles

(see Figure 13):

• 120V, 15-amp duplex receptacle

• 120V, 15-amp GFCI duplex receptacle

• 120V, 30-amp twist-lock receptacle

• 120/240V, 20-amp twist-lock receptacle

Continued

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PORTABLE DIESEL GENERATOR

PRESTART

OPERATION

WARNING: Never use gaso-

line, paint thinner, or any other

flammableliquidasastartingaid.

An explosion may occur.

Continued

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 generator

near standing water and snow. Make sure

area is well-vented.

120V, 15-Amp GFCI Duplex

120V, 15-Amp Duplex

IMPORTANT: Never start generator with

electrical loads connected. Start engine be-

fore adding electrical loads.

120/240V, 20-Amp

120

LTS

Twist-Lock

WARNING: Only responsible

adults should use generator.

Neverletanyoneoperategenera-

tor without proper instructions.

1. Make sure fuel tank is full. See Fuel,

page 6, for fuel information.

FULL POWER

120 ONLY

2. Move fuel valve lever to the "O" (open)

position. (see Figure 15).

SELECTOR

120/240V

ENM

00000005

HOURS

1/10

3. Move engine run lever to RUN posi-

tion (see Figure 16).

Note: If oil level is too low, oil alert system

will keep engine from starting (see Oil Alert

System, page 4). Make sure oil level is full

before starting. See Engine Oil, page 6.

120V, 30-Amp

Twist-Lock

Before starting the engine, disconnect all

electric loads from generator.

You may need to bleed fuel line to remove

trapped air

Figure 13 - Receptacle Locations

Fuel Valve

Lever

POWER CORD AND PLUG

REQUIREMENTS

• if starting engine for first time

• if starting engine after allowing generator

to run out of fuel

Figure 15 - Fuel Valve Lever in "O"

(open) Position

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

Follow the directions below to bleed fuel line.

• Three-wire, 30-amp cord

BLEEDING FUEL LINE

Engine Run

Lever

120/240V, 20-amp twist-lock receptacle

• NEMA L14-20P (20-amp) plug

• Four-wire, 20-amp cord

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.

RUN

STOP

2. Move fuel valve lever to the "O" (open)

position (see Figure 15).

3. Allow air to bleed from line. When fuel

exits fuel line in a steady stream, reat-

tach fuel line to engine.

Figure 16 - Engine Run Lever in RUN

Position

4. Add spilled fuel back into fuel tank.

4. Start the engine.

A. Electric Starter

STARTING

I. Push decompression lever all the

way down (see Figure 17, page 11).

Decompression lever will stay in this

positon until you turn starting key.

CAUTION: You must always

run the engine at full speed. Do

not run engine at lower speeds.

At full speed, the engine runs at

3600 RPM under load. The en-

gine must maintain 3600 RPM for

generator to create correct volt-

age. Running engine at lower

speeds will damage generator

and powered items.

II. Turn the starting key clockwise to

START positon (see Figure 18, page

11). Hold it there until 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. Af-

ter 15 seconds, try starting again.

Figure 14 - Cord and Plug Configurations

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OWNER’S MANUAL

3. Push down engine stop lever (see Fig-

HIGH ALTITUDE OPERATION

OPERATION

Continued

ure 19). This releases engine run lever

and stops engine. Do not stop engine

with the decompression lever.

This generator will not perform well at high

altitudes without proper adjustment. Contact

a Yanmar dealer for adjustment information.

B. Recoil Starter

I. Slowly pull starter rope until you

feel strong resistance. Gently re-

turn starter rope to engine.

4. Turn the starter key to the OFF position.

ADDING ELECTRICAL LOADS

5. Turn fuel valve lever off. Do this by

moving valve lever to the “S” position

(see Figure 20).

IMPORTANT: Do not overload generator.

Makesuretotalwattageofallelectricalloads

does not exceed rated wattage of generator.

Overloading may shorten generator life. It

could also cause internal damage to genera-

II. Push decompression lever all the

way down (see Figure 17). Decom-

pression lever will stay in this po-

sition until you pull starter rope.

6. Slowly pull starter rope until you feel

strong resistance. Gently return starter

rope to engine. This action closes the in-

take and exhaust valves. This prevents

rust from forming while not using engine.

III. Firmly grasp starter grip with both tor. Overloading will trip circuit breaker.

hands. Remove slack from starter

rope by lightly pulling starter grip.

IMPORTANT: Keep full power selector

switch in the 120 VOLT ONLY position if

onlyu powering 120V items. Only move

switch to 120/240 VOLT position if power-

ing 240V items.

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.

1. Check items to be powered. Their

nameplate lists their wattage ratings.

RUN

IMPORTANT: Do not let starter grip

snap back against engine. Return it gen-

tly. This will prevent damage to starter.

Note: The wattage ratings for some

electrcal motors are misleading. They

may require up to 3-times their rated

wattage to start. You must figure total

electrical load wattage. Make sure to-

tal wattage of all electrical loads does

not exceed rated wattage of generator.

See Determining Electrical Load For

Generator, pages 8 and 9.

STOP

WARNING: Never use gaso-

line, paint thinner, or any other

flammableliquidasastartingaid.

An explosion may occur.

Engine Stop

Lever

Figure 19 - Pushing Down Engine Stop

Lever

If engine does not start, repeat steps under

B. Recoil Starter.

2. Start engine. Let engine reach full speed.

3. Connect electrical loads one at a time.

If the load consists of electric motors,

start them first. Always start the larg-

est first. Start each motor individually.

Decompression

Lever

DISCONNECTING

ELECTRICAL LOADS

Fuel Valve Lever

Remove electrical loads one at a time. Re-

move voltage sensitive items first. Voltage

sensitive items include TVs, VCRs, and

other home electronic items.

Figure20-FuelValveLeverIn“S”Position

STOPPING ENGINE

Follow the steps below to stop engine.

Figure 17 - Decompression Lever

Starting Key

1. Remove all electrical loads from gen-

erator (see Disconnecting Electrical

Loads, above). Remove electrical loads

one at a time.

OIL

CHARGE

OFF

2. Let engine run for two or three min-

utes after removing electrical loads.

This lets engine cool slightly.

Figure 18 - Starting Key

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PORTABLE DIESEL GENERATOR

STORAGE

MAINTENANCE

AND REPAIRS

CAUTION: Shut off generator

before performing maintenance.

WARNING: Remove all fuel

fromfueltankbeforestoringgen-

erator.Storefuelinapprovedcon-

tainer. Store fuel in a well-vented

areafreeofopenflamesorsparks.

IMPORTANT: Keep generator level when

servicing.Neverturngeneratorupsidedown

or stand it on end to service.

WARNING: Only a qualified

electrical service person should

service and repair the alternator

on this generator. Use only fac-

toryapprovedreplacementparts.

Note:Wesupplytheengineowner’smanual

with generator. Refer to that manual for

questions concerning engine maintenance

and repairs.

WARNING: The muffler be-

comesveryhotduringoperation.

The muffler remains hot for a

while after shutdown. Let engine

cool before storing.

CAUTION: You must always

run the engine at full speed. Do

not run engine at lower speeds.

At full speed, the engine runs at

3600 RPM under load. The en-

gine must maintain 3600 RPM for

generator to create correct volt-

age. Running engine at lower

speeds will damage generator

and powered items.

Non-enginepartsrequirelittlemaintenance.

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.

IMPORTANT: Keep generator level while

in storage. Never store generator upside

down or standing on end.

Note:Wesupplytheengineowner’smanual

with generator. Refer to that manual for

questions concerning engine storage.

Cover and store generator in a clean, dry

place. Do not expose generator to extreme

high or low temperatures during storage.

TROUBLESHOOTING

WARNING: Only a qualified electrical service person should service

and repair generator. Use only factory approved replacement parts.

Note: For additional help, visit DESA

International’stechnicalservicewebsite

at www.desatech.com.

Note: See engine owner’s manual for en-

gine troubleshooting.

OBSERVED PROBLEM

REMEDY

POSSIBLE CAUSE

No voltage when starting generator with no

electrical load

1. Replace capacitor

1. Defective capacitor

2. Winding short circuit or loose

connections

3. Defective rotor diode

4. Loss of residual magnetism

2. Check resistance of coils (see Electri-

cal Component Specifications, page 13)

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor ter-

minals for 2-3 seconds

Voltage is less than normal voltage with no

electrical load

1. Set engine speed to 3720 RPM (62 Hz)

with no load

1. Engine speed too low

2. Clean arrester. See engine owner’s manual

3. Replace both diodes on rotor

4. Check resistance of coils (see Electri-

cal Component Specifications, page 13)

5. Replace capacitor

2. Clogged spark arrester

3. Defective rotor diode

4. Partial short circuit in winding

5. Defective capacitor

Voltmeterreadingmorethan10%highwith

no electrical load

1. Set engine speed to 3720 RPM (62 Hz)

with no load

1. Engine speed too high

Voltmeter reading correct with no electrical

load, but more than 10% low when electri-

cal load is added

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized engine service

center

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

www.desatech.com

107359

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OWNER’S MANUAL

ELECTRICAL

COMPONENT

SPECIFICATIONS

Resistance in Ohms

Stator

Main

Winding * Winding

Stator

Rotor

Capacitor,

MFD

450 Volt

Auxiliary

Primary Secondary

Winding † Winding †

Diodes (2)

800 Volt

Model

∆

MGY5000C

0.54

1.38

0.61

2.29

70 Amp

∆

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.

WIRING DIAGRAMS

Red

Black

White

Green/Yellow

Green

White

Red

120V, 15A

Receptacle

120/240V 20A

Receptacle

120V, 15A

Receptacle

120V, 30A

Receptacle

Circuit

Breaker

20A

White

Circuit

Breaker

25A

Duplex

GFCI

Circuit

Breaker

20A

Full Pwr

Selector

Switch

Red

Black

Circuit

Breaker

25A

White

LINE

Yellow

Black

Hour

Meter

Green

Black

White

Green

Red

Black

Green

Red

Main

Windings

Auxiliary

Phase

Capacitor

White

Stator

White

T1 T4 T3 T2

Rotor

Diode

Stator

White

Green

220/240V

Red

Black

Yellow

110/120V

Brown

Figure 21 - Alternator Wiring Diargram

Charge

Lamp

Key

Switch

Green

Green/White

Green

Black

Green

Charge

Regulator

Yellow

White

Red

Charge

Coil

Yellow

White

Fuse

White

Red

Starter

Motor/

Red

Shutdown

Solenoid

Black

Green/White

Battery

Yellow

Red

Oil

Pressure

Switch

Red

Bridge

Relay

85 White

Black

Green/White

Red

White

Low Oil

Pressure Lamp

Black

Continued

Figure 22 - Engine Wiring Diagram

107359

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PORTABLE DIESEL GENERATOR

Portable Heater Parts

Heavy-Duty Wheel Kit – PA2000

Wheelbarrow-style wheel kit. Makes gen-

erator easy for one person to move.

TECHNICAL

SERVICE

You may have further questions about as-

sembling, operating, or maintaining this

product. If so, you can visit our Technical

Service web site at www.desatech.com or

contact our Technical Service Department

at1-800-858-8501(EnglishOnly).Youmay

also write to:

342 North County Road 400 East

Valparaiso, IN 46383-9704

219-462-7441

1-800-362-6951

This kit includes:

www.portableheaterparts.com

[email protected]

• Large 12-inch wheels for easy rolling

• Plated tubing and hardware for long life

• Long handles with thick grips for greater

comfort and control

FBD

1349 Adams Street

Bowling Green, KY 42103-3414

270-846-1199

Completeinstallationinstructionsincluded.

1-800-654-8534

[email protected]

REPAIR SERVICE

DESA Power Tools™

P.O. Box 90004

Bowling Green, KY 42102-9004

ATTN: Technical Service Power Tools

Master Part Distributors

1251 Mound Avenue NW

Grand Rapids, MI 49504-2672

616-791-0505

Note: Only use original replacement parts.

Thiswillprotectyourwarrantycoveragefor

parts replaced under warranty.

1-800-446-1446

www.masterparts.net

Bowden Electric Motor Service

1681 S. Wesleyan Blvd.

Rocky Mount, NC 27803

252-446-4203

East Coast Energy

10 East Route 36

West Long Branch, NJ 07764-1501

1-800-755-8809

Laportes

2444 N 5th Street

Hartsville, SC 29550-7704

843-332-0191

EachAuthorizedServiceCenterisindepen-

dently owned and operated.

When contacting DESA Power Tools™,

have ready

• Your Name

WARRANTY SERVICE

• Your Address

If product requires warranty service, return it

to nearest Authorized Service Center. You

must show proof of purchase. If faulty materi-

als or workmanship caused damage, we will

repairorreplaceproductwithoutcharge.Note:

Normal wear, misuse, abuse, neglect, or acci-

dental damage is not covered under warranty.

• Your Phone Number

• Model Number of Product

• Date of Purchase (Include copy of receipt

for written requests).

SERVICING THE

ENGINE

For Yanmar engine replacement parts, con-

tact Parts Company of America at 1-800-

323-0620. Yanmar engine servicing should

be handled by your nearest authorized

Yanmar engine service firm. Contact

Yanmar at 1-714-630-9415 for nearest au-

thorized Yanmar engine service firm.

MTA Distributors

555 Hickory Hills Blvd.

Nashville, TN 37189-9244

615-299-8777

NON-WARRANTY SERVICE

If product requires service, return it to near-

est Authorized Service Center. Repairs will

be billed to you at regular repair list prices.

For additional Service Center or warranty

information, call 1-800-858-8501 or visit

our Technical Service web site at

www.desatech.com.

1-800-264-0225

Industrial Hardware

4109 Bainbridge Blvd.

Chesapeake, VA 23324-1403

804-543-2232

1-800-788-0008

[email protected]

Mills Lawn and Garden

928 Commonwealth Place

Virginia Beach, VA 23464

757-361-9293

PARTS CENTRALS

REPLACEMENT

PARTS AND

ACCESSORIES

These Parts Centrals are privately owned

businesses. Theyhaveagreedtosupportour

customer’s needs by providing original re-

placement parts and accessories.

www.mills-parts.com

Tuco Industrial Products

5223 180th Street SW

Suite 4A-1

Lynnwood, WA 98037-4506

425-743-9533

1-800-735-1268

www.tucoheat.com

For original replacement parts and accesso-

ries,contactyournearestAuthorizedDealer

or Authorized Service Center for this prod-

uct. If they can not supply the part or acces-

sory,contactyournearestPartsCentrallisted

onpages14and15.EachAuthorizedDealer,

Authorized Service Center, and Parts Cen-

tral is independently owned and operated.

Tool & Equipment

5 Manila Drive

Hamden, CT 06514-0322

203-248-7553

1-800-397-7553

Grainger Parts Operations

1657 Shermer Road

Northbrook, IL 60062-5362

708-498-5900

1-800-323-0620

www.grainger.com

See pages 15 through 18 for an Illustrated

Parts List.

If you need additional referral information,

contact our Technical Service Department

(see Technical Service, page 14).

In Canada call 1-800-561-3372 for parts

information.

107359

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

ALTERNATOR ASSEMBLY

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 14- of this manual.

KEY PART

NO.

NUMBER

DESCRIPTION

QTY.

099723-02

099844-01

099701-01

099760-01

099863-01

099863-02

17587000

M11084-26

099847-02

WLE-5

Alternator Assembly

End Cover

Screw, M5 x 10mm

Bushing

Terminal Block (4-block)

Terminal Block (2-block)

Ground Lug

Screw, #10-16 x 3/8"

Stator Bolt

Lock Washer, 5/16"

Bearing Housing

Capacitor

099843-01

27005003S

Stator

27003002

27003015S

27001010S

27003013S

099842-02

27003003

27003012S

27003008

101839-01

26322004

WLE-6

Fan Bracket

Screw, M8 x 20

Rotor Nut

Washer

Draw Bolt

Bearing

Diode

Rotor

Fan

Engine Flange

Bolt, 3/8-16 x 5/8"

Lock Washer, 3/8"

Foam Pad

099892-01

* Part not available by itself. Must purchase Alternator Assembly.

107359

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PORTABLE DIESEL GENERATOR

ILLUSTRATED

PARTS LIST

FUEL TANK AND ROLL CAGE

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 14 of this manual.

KEY PART

NO. NUMBER

KEY PART

NO. NUMBER

DESCRIPTION

QTY.

DESCRIPTION

QTY.

099935-01

HC4-6C

Fuel Tank Assembly

Screw, 1/4-20 x 3/4"

Washer, 1/4"

099749-01

099750-01

14138000

M10908-74

100410-01

Battery Bracket

Hook Bolt

WP-4C

Ground Strap

103880-01

099943-01

099945-01

04110002

WP-5C

Nut, 1/4-20

Screw, 1/4-20 x 1/2"

Screw, #8-10 x 1/2"

Roll Cage

Spreader

PARTS AVAILABLE - NOT SHOWN

Bolt, 5/16-18 x 1 ¹/2"

Washer, 5/16"

Nut, 5/16-18

099947-01

Safety Information

Decal

NEC-5C

26302006

WLI-8

099948-01

099873-01

Operation Decal

Screw, 1/2-20 x 1"

Lockwasher, 1/2"

Shock Mounts

Bolt, 5/16-18 x 3/4"

Washer, 5/16"

Shock Mount

Battery Cable

(Positive)

099873-02

099954-01

Battery Cable

(Negative)

17529000

26007004

WLE-5

Spark Arrestor

103289-01

107359

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

CONTROL PANEL

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 14 of this manual.

RESET

TEST

120

LTS

FULL POWER

SELECTOR

120 ONLY

120/240V

120/240

LTS

ESE

ENM

00000005

KEY PART

NO. NUMBER

DESCRIPTION

QTY.

103349-02

22616009

099833-01

100445-01

099956-01

22616011

099834-01

101350-01

099760-01

24306006

100149-01

22261000

WLI-2BL

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 *

Hour Meter

Bushing

Screw, #8-18 x 1/2"

Control Box

Speed Nut, #8

†

Lock Washer, #8

Switch Plug

120V, 15A Duplex Receptacle *

Control Panel Assembly

099997-01

099836-01

103348-02

PARTS AVAILABLE - NOT SHOWN

100177-07

Panel Schematic Decal

* Includes fastening hardware

† Includes reference numbers 1 through 15

107359

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PORTABLE DIESEL GENERATOR

ILLUSTRATED

PARTS LIST

SWITCH CONTROL BOX

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 14 of this manual.

KEY PART

NO. NUMBER

DESCRIPTION

QTY. NO. NUMBER

DESCRIPTION

QTY.

101037-01

22721000

099936-01

Switch control box

Low oil light

26509000

26002006

15020000

WP-3C

Full bridge

#8-32 x 3/8" Screw

Grommet

Key switch, lamp, and

harness assembly

#10 Flat washer

101039-01

099760-01

101040-01

1/4-28 Keps Nut

26499000

#10-32 x 3/4"

Hex-head screw

Strain relief bushing

1/4-20 x 5/8"

Hex Head Sems

†

26490000

26494000

26492000

101038-01

101036-01

101035-01

101103-01

Solenoid

M4 x 8 Hex-head screw

M3 x 8 Hex-head screw

Control Box Cover

Cable

26498000

NTF-3C

Relay

#10-32 Hex locknut

RN12000100 Adhesive-backed

PVC foam

Conduit

Connector

Switch Control Box

Assembly

#6-32 x 1/2"

Hex tapping screw

PARTS AVAILABLE - NOT SHOWN

101042-01 Wire Nut

#6 Internal-tooth

lockwasher

* Available from your local hardware store

† Includes reference numbers 1 through 23

107359

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OWNER’S MANUAL

NOTES

_______________________________________________________________________________________________

107359

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WARRANTY INFORMATION

KEEP THIS WARRANTY

Model

Serial No.

Date Purchased

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 five-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda warrants the engine.

See engine owner’s manual for engine warranty information.

FIVE-YEAR LIMITED WARRANTY

PORTABLE GENERATORS

DESA Power Tools™ warrants each alternator, generator, or electric product of its manufacture, to be free from

defects in material and workmanship for five years from the date of ﬁrst purchase from an authorized dealer, provided

that the product has been properly installed, maintained, and operated in accordance with all applicable instructions.

The bill of sale or proof of purchase must be presented at the time a claim is made under this warranty.

This warranty is extended only to the original retail purchaser. This warranty covers only the parts and labor required

to restore this unit to its proper operating condition. Warranty parts must be obtained through factory authorized

dealers and service centers for this product. These dealers and service centers will provide original factory replace-

ment parts. Failure to use original factory replacement parts voids this warranty.

This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that

fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration,

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.

DESA Power Tools™ 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 any and all implied warranties, including

warranties of merchantability and fitness for a particular purpose to five years from the date of first purchase, and DESA

Power Tools’™ liability is hereby limited to the purchase price of the product and DESA Power Tools™ shall not be

liable for any other damages whatsoever including indirect, incidental, or consequential damages.

Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental

or consequential damages, so the above limitation of damages may not apply to you.

This warranty provides the original purchaser with specific rights. For information regarding those rights, please

consult the applicable state laws.

P.O. Box 90004

Bowling Green, KY 42102-9004

107359-01

www.desatech.com

REV. C

06/04

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