Master Lock MGY5000 User's Manual
Contents
1. 18 19 General Information sssini rennen 19 Using Receptacle eme 19 Power Cord and Plug Requirements 44 22222221 20 Prestart 2 enters E 21 Bleeding Fuel Lie nee neret entes 21 Ninus 21 High Altitude Operation eene 24 Adding Electrical 0 24 Disconnecting Electrical Loads ess 25 Stopping Engine ssc ceils eset pd etes 25 Maintenance and Repairs essere 26 SLOIABe ccs Ao ecce tt et cata A leat 26 Troubleshooting eret teet ete eot 27 Electrical Component Specifications 27 Witing Diagrams cepe cire tree cen edens 28 Technical Services iuit tee ete t ete 29 Servicing the Engien sierako tete teet 29 Replacement Parts taeda ie de e deter 29 ACCESSORY He Ue dus te eee dete te rr te ded 29 HT strated Parts 1515 reet rr et e eet ttes 30 33 Warranty Information Back Cover SAFETY WARNINGS INFORMATION 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 o2. MASTER PORTABLE DIESEL GENERATOR OWNER S OPERATION AND INSTALLATION MANUAL Generator Model MGY5000 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 CONTENTS SECTION PAGE Safety Information eerte ee eerie pr eei teta 3 Product Identification sese 6 General Information esses nre nennen 7 SDeCLHIICtIotis eie ie ia dete teet deleri 7 Unpack dosieran eret be tete tete 7 Ventlati n chere ERE ipe 8 Dust Dirt Rain and Snow eese eene 8 High and Low Temperature Operation eee 8 Getierator edades pce eet 8 Oil Alert Syst m 5 52 22 ombre 8 Battery Discharge Lamp eene 9 Full Power Selector Switch eene 9 Ground Fault Circuit Interrupter Receptacle 10 Electric Start npe e E p tee effe det 10 Receptacle Circuit Breaker 2 11 Spark ATfestet oti n Re dd 11 Engine Oil SR enu eid 12 Buel isc soi dai 13 Battery ne araa onee rones e eer ie eoe oet 13 Generator Groundine sidecases tei et op es 16 Extension Cords x ceteri m ee ote 17 Standby Installation To Home or Building 17 Determining Electrical Load For Generator
3. Battery Cable to Starter Solenoid on Engine Black Negative Battery Cable Figure 9 Connecting Black Negative Battery Cable to Engine Block BATTERY Continued 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 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 Make sure fluid levels are full Make sure battery is charged See engine owner s manual for more information 552 622 225 Battery Bracket Mounting Nut lt gt Battery Figure 10 Battery Hold Down System Cable From Engine Block N Figure 11 Connecting Positive and Negative Cables to Battery Red Positive Cable From Starter Solenoid GROUNDING A CAUTION You must properly earth ground generator before starting This will help guard against deadly electric shock Only use grounded plugs with generator Only use grounded extension cords Only use three wire or double insulated power tools Grounding generator helps pre
4. Charge Lamp Green White Yellow Charge Coil Green White Shutdown Solenoid Green White Pressure Lamp Figure 24 Engine Wiring Diagram TECHNICAL SERVICE SERVICING THE ENGINE REPLACEMENT PARTS ACCESSORY You may have further questions about installation operation or troubleshooting If so contact DESA International s Technical Service Department at 1 800 323 5190 For Yanmar engine replacement parts contact 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 authorized Yanmar engine service firm Note Use only original replacement parts This will protect your warranty cover age for parts replaced under warranty Parts Under Warranty Contact authorized dealers of this product If they cannot supply original replacement part 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 part s call DESA International s Parts Department at 1 800 972 7879 When calling DESA Inter
5. WLE 5 DESCRIPTION Fuel Tank Assembly Screw 1 4 20 x 3 4 Washer 1 4 Nut 1 4 20 Roll Cage Spreader Bolt 5 16 18 x 1 1 2 Washer 5 16 Nut 5 16 18 Screw 1 2 20 x 1 Lockwasher 1 2 Shock Mounts Bolt 5 16 18 x 3 4 Washer 5 16 FHA 20 PART NUMBER 26020000 099749 01 099750 01 14138000 M10908 74 100410 01 DESCRIPTION Shock Mount Battery Bracket Hook Bolt Ground Strap Screw 1 4 20 x 1 2 Screw 8 10 x 1 2 PARTS AVAILABLE NOT SHOWN 099947 01 099948 01 099873 01 099873 02 Safety Information Decal Operation Decal Battery Cable Positive Battery Cable Negative ILLUSTRATED PARTS LIST Control Panel PART NUMBER 100148 05 22616009 099833 01 100445 01 099956 01 22616011 099834 01 099804 01 099760 01 24306006 100149 01 22261000 WLI 2BL 099997 01 100177 01 DESCRIPTION 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 Lamp Bushing Screw 8 18 x 1 2 Control Box Speed Nut 8 Lock Washer 8 Switch Plug PARTS AVAILABLE NOT SHOWN Panel Schematic Decal Includes fastening hardware gt O BPH a HS AH KH FH BS ILLUSTRATED PART NUMBER 100131
6. in the other For standby service to home or building only include items you must power 2 Enter running watts of each item except motors The light bulb or appliance nameplate lists its wattage Remember IKW 1000 watts Note The name plate 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 name plate states 3 amps at 120 volts 3 amps x 120 volts 2 360 watts 3 Electric motors present a special problem They require up to 3 times their rated wattage to start Chart 2 below shows starting watts for different size motors For example an electric motor nameplate states 5 amps at 120 volts 5 amps x 120 volts 600 watts running Multiply this figure by 3 This will show the starting watts needed 600 watts x 3 2 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 Add watts and starting watts ofall items This total must not be larger than 5000 watts Itis a good idea to have up to 25 extra capacity for future needs or extra equipment Chart 1 Typical Electric Appliance Wattages Running Starting Running Watts Watts Watts Starting Equipment Equipment Watts
7. 01 22721000 099936 01 24306006 WLI 2BL 22261000 26498000 NTF 3C RN12000100 24478004 24477004 M10908 3 WLI 1C DESCRIPTION Switch Control Box Low Oil Light Key Switch Lamp and Harness Assy Hex Head Screw 318 18 x 1 2 Lock Washer 8 Speed Nut 8 Relay Hex Lock Nut 10 32 Adhesive Backed PVC Foam Connector Cover Connector Hex Tapping Screw 16 32 x 1 2 Internal Tooth Lock Washer 6 Available from your local hardware store PART NUMBER 26509000 M10908 27 15020000 WP 3C 26499000 26490000 26494000 26492000 100132 01 100085 01 099760 01 DESCRIPTION Full Bridge Hex Tapping Screw 10 32 x 1 2 Grommet Flat Washer 10 Hex Head Screw 10 32 x 3 4 Solenoid Hex Head Screw M4 x8 Hex Head Screw M3x8 Switch Control Box Bracket Female T Tap Connector Strain Relief Bushing PARTS CENTRALS These Parts Centrals are privately owned businesses They have agreed to support our customer s needs by providing original replacement parts and accessories Baltimore Electric 1348 Dixwell Avenue Hamden CT 06514 1 800 397 7553 203 248 7553 Parts Department 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 Rd 400 East Valparaiso IN 46383 All States 1 800 362 6951 219 462 7441 FBD 601 Hope S
8. Light bulb 100W Radio Fan Television Furnace fan 1 3 hp Vacuum cleaner Sump pump 1 3 hp Refrigerator freezer 6 Circular saw Floodlight Watts Approximate Running 1 2 Drill Toaster Coffee maker Skillet 14 Chain saw Water well pump 1 2 hp Hot plate range per burner Water heater Chart 2 Approximate Starting Watts Universal Motors small appliance Repulsion Induction Motors Capacitor Motors Split Phase Motors Always use starting watts not running watts when figuring correct electrical load Motors of higher horsepower are not generally used OPERATION GENERAL INFORMATION This generator is not large enough to power your entire home Do not connect generator to any existing electrical circuits Plug items directly into generator receptacles Do not exceed amperage rating of receptacles Only use grounded cords A 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 confined area Never run generator inside occupied building Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death A WARNING Never connect generator to any existing electrical circuits The generator output will back feed into the utility power line This may electrocute a po
9. 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 two years from the date of first purchase and DESA International s liability is hereby limited to the purchase price of the product and DESA International 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 INTERNATIONAL P O Box 90004 D Bowling Green KY 42102 9004 9 95
10. lower speeds will dam age generator and powered items Continued OPERATION Continued IMPORTANT Never start generator with electrical loads connected Start engine before adding electrical loads 1 Make sure fuel tank is full See Fuel page 13 for fuel information 2 Move fuel valve lever to the open position see Figure 15 3 Move engine run lever to the RUN position see Figure 16 Engine Run 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 in this position until you turn starting key II Turn the starting key clockwise to the START position see Figure 18 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 After 15 seconds try starting again b cc N Decompression Lever Figure 17 Decompression Lever Figure 18 Starting Key Continued OPERATION Continued In cold weather your engine may be hard to start If so remove the rubber plug on the rocker arm cover see Figure 19 Add 2 cc of engine oil in hole Replace rubber plug Repeat starting procedure A WARNING Never use gasoline paint thinner or any other fla
11. 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 Contact a qualified electrician for repairs Figure 4 GFCI Receptacle ELECTRIC START This model has an electric starter A battery is not supplied with generator You must provide a 12 volt 45 amp hour battery For more battery information see Battery page 13 FEATURES Continued RECEPTACLE CIRCUIT BREAKER The circuit breakers protect the receptacles and alternator Overloading generator will trip circuit breaker short circuit in item being powered will also trip breaker If this occurs unplug electrical load from receptacle Let circuit breaker cool down Push circuit breaker button to reset Electric motors need higher starting current 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 additional items to generator after starting motors If this continues to happen reduce the total generator load Tripped Figure 5 Receptacle Circuit Breaker Button SPARK ARRESTER We ship a spark arrester with this generator You must insta
12. 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 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
13. 0 240 VOLT Position Position Figure 3 Full Power Selector Switch 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 Continued FEATURES Continued GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE This generator has a 120 volt ground fault circuit interrupter receptacle The GFCI receptacle is on the control panel The GFCI protects you against hazardous electrical shock caused when your body becomes a path through which electricity travels to reach ground This could happen when you touch an appli ance or cord that is live through faulty mechanism damp or worn insulation etc When protected by the GFCI you may still feel a shock but the GFCI should cut it off quickly A person in normal health should not receive serious injury Note Infants and very small children may still be affected Test Procedure Check the GFCI receptacle every month This insures it is working right 1 Pushblack 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 receptacle If lamp does not work GFCI receptacle is good WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a qualified electrician for repairs 2 If the GFCI
14. 55 Diesel fuel presents a hazard of fire Diesel fuel is flammable 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 running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Always allow room for fuel to expand If you overfill tank fuel can overflow onto hot generator This can cause fire After refueling tightly close fuel tank cap 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 container Store fuel in a well vented area free of open flames or sparks Continued SAFETY INFORMATION Continued 2 Guard against fire hazard Keep operation area well vented Keep generator at least three feet away from any object Do not place flam mable objects near generator Do not use generator where flammable 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 Guard against electric shock Generator produces high volt age This high voltage can cause severe electric shock Only responsible adults should use the generator Properly ground generator before starting Never l
15. ERATION Continued DISCONNECTING ELECTRIC LOADS Remove electrical loads one at a time Remove voltage sensitive items first Voltage sensitive items include TVs VCRs and other home electronic items STOPPING ENGINE Follow the steps below to stop engine 1 2 Remove all electrical loads from generator see Disconnecting Electrical Loads above Remove electrical loads one at a time Let engine run for two or three minutes after removing electrical loads This lets engine cool slightly Push down engine stop lever see Figure 21 This releases engine run lever and stops engine Do not stop engine with the decompression lever Turn the starter key to the OFF position Turn fuel valve lever off Do this by moving valve lever to the S position see Figure 22 Slowly pull starter rope until you feel strong resistance Gently return starter rope to engine This action closes the intake and exhaust valves This prevents rust from forming while not using engine Stop Lever Figure 21 Pushing Down Engine Stop Lever Fuel Valve Lever Figure 22 Fuel Valve Lever In S Position MAINTENANCE AND REPAIRS STORAGE A WARNING Only a qualified electrical service person should service and repair the alternator on this generator Use only factory approved replacement parts CAUTION You must always run the engine at full speed Do not run engine at low
16. acid is poisonous If swallowed drink large amounts of water or milk Follow with milk of magnesia or vegetable oil Call a doctor at once Continued BATTERY Continued CAUTION If you remove battery insulate the red positive battery cable terminal Insulate with electrical tape Exposed terminal may spark when generator runs IMPORTANT Make sure battery connections are the correct polarity This generator use negative ground 12 volt DC starting system This generator has an electric starter A battery is not supplied with generator You must provide a 12 volt 45 amp hour battery The positive and negative 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 ENGINE 1 Attach the red positive battery cable to the starter solenoid on engine see Figure 8 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 Red Positive Battery Cable Figure 8 Connecting Red Positive
17. area Do not fill fuel tank in the dark Do not refuel while engine is running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Always allow room for fuel to expand If you overfill tank fuel can over flow onto hot engine This can cause fire After refueling tightly close fuel tank cap 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 container Store fuel in a well vented area free of open flames or sparks Use clean fresh diesel fuel Use diesel fuel with cetane rating of 45 or higher Avoid getting dirt dust or water in fuel tank See engine owner s manual for more information A 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 A 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 once Battery
18. enerator is powering electrical circuits the chance of an electrical fire exists 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 IN FO RM ATION swallowed Contact with skin or eyes may cause severe burns Do not tilt Continued 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 9 Only a qualified electrical service person should service and repair generator Generator produces high voltage Use extreme caution when working on electrical parts When working on generator avoid hot muffler exhaust manifold and engine parts Severe burns may occur Do not work on generator when tired Use only factory approved replacement parts 10 Store generator in a well vented area Make sure fuel tank is empty Never store with fuel in tank 11 EYES E 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 Keep generator and nearby a
19. ented 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 Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death This generator needs cooling air to run properly Never block free flowing cooling air to generator Overheating will occur without cooling air This will damage the generator Keep generator at least three feet away from any object A DANGER 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 Operating generator in these conditions increases the risk of electrocution Severe injury or death can occur 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 Low temperatures may make the engine hard to start See engine owner s manual for more information OIL ALERT SYSTEM The oil alert system protects the engine from low oil damage This system auto matically shuts down the engine and prevents engine restarting if the oil pressure falls too low If this system shuts down
20. er speeds At full speed the engine runs at 3600 RPM under load The engine must maintain 3600 RPM for generator to create correct voltage Running engine at lower speeds will damage generator and powered items A CAUTION Shut off generator before performing maintenance IMPORTANT Keep generator level when servicing Never turn generator upside down or stand it on end to service Note We supply the engine owner s manual with generator Refer to that manual for questions 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 A WARNING Remove all fuel from fuel tank before storing generator Store fuel in approved container Store fuel in a well vented area free of open flames or sparks A WARNING The muffler becomes very hot during operation The muffler remains hot for a while after shutdown Let engine cool before storing IMPORTANT Keep generator level while in storage Never store generator upside down or standing on end Note We supply the engine owner s manual 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 tempe
21. esel engine provides 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 Additional Features Circuit breaker protection Spark arresting muffler Large fuel tank Oil alert system Electric starter Pressurized lubrication system 15 Amp ground fault circuit interrupter receptacle MODEL MGY5000 Electrical Specifications Rated Wattage 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 factor Remove generator from carton Remove any protective packaging applied to generator for shipment 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 inside generator carton You must install these cables to engine See Battery page 13 for installation instructions VENTILATION DUST DIRT RAIN AND SNOW HIGH AND LOW TEMPERATURE OPERATION GENERATOR FEATURES A DANGER Use only in well v
22. et anyone operate or service generator without proper instructions 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 Do not use generator in highly conductive 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 damage to generator may result Do not wear damp clothing or wet shoes when using generator 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 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 LY ME 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 Never connect generator to any existing electrical circuits The generator output will back feed into the utility power line This may electro cute a power company line repair person Also if g
23. 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 A WARNING Only responsible adults should use generator Never let anyone operate generator without proper instructions Note If oil level is too low oil alert system will keep engine from starting see Oil Alert System page 8 Make sure oil level is full before starting See Engine Oil page 12 Before starting engine disconnect all electric loads from generator You may need to bleed fuel line to remove trapped air if starting engine for first time if starting engine after allowing generator to run out of fuel Follow the directions 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 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 fuel tank STARTING 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 engine must maintain 3600 RPM for generator to create correct voltage Running engine at
24. ll 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 arrester needs periodic cleaning A dirty spark arrester reduces engine output and increases fuel consumption It also makes starting difficult See engine owner s manual for cleaning instructions Muffler Clamp Spark Arrester Figure 6 Installing Spark Arrester 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 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 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 Iflevel 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 Oil Level At Top Of Filler Neck Figure 7 Checking Oil Level FUEL BATTERY A WARNING Diesel fuel presents a hazard of fire Diesel fuel is flammable Keep fuel out of children s reach Refuel generator in a well vented
25. mmable liquid as a starting aid An explosion may occur CAUTION 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 Engine Starting Rubber Oil Hole Plug 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 all the way down see Figure 20 Decompres sion lever will stay in this position until you pull starter rope Decompression Lever N O Figure 20 Decompression Lever Continued OPERATION Continued 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 engine Return it gently This will prevent damage to starter In cold weather your engine may be hard to start If so remove the rubber plug on the rocker arm cover see Figure 19 page 23 Add 2 cc of engine oil in hole Replace rubber plug Repeat starting procedure A WARNING Never use gasoline paint thinner or any other flammable liquid as a starting aid An explosion may occur A CAUTION Keep rubber plug o
26. n rocker arm in place when not adding oil for starting Rain dirt and other debris may enter the engine This can damage the engine If engine does not start repeat steps under B Recoil Starter on page 23 HIGH ALTITUDE OPERATION This generator will not perform well at high altitudes without proper 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 ONLY position if only powering 120V items Only move switch to 120 240 VOLT position if powering 240V items 1 Check items to be powered Their nameplate lists their wattage ratings Note The wattage ratings for some electrical motors are misleading They may require up to 3 times their rated wattage to start You must figure total electrical load wattage Make sure total wattage of all electrical loads does not exceed rated wattage of generator See Determining Electrical Load For Generator page 18 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 largest first Start each motor individually OP
27. national have ready model number of your generator the replacement part number Heavy Duty Wheel Kit PA2000 Wheelbarrow style wheel kit Makes generator easy for one person to move This kit includes Large 12 inch wheels for easy rolling Plated tubing and hardware for long life Long handles with thick grips for greater comfort and control Complete installation instructions included ILLUSTRATED PARTS LIST Alternator Assembly Part not available by itself Must purchase Alternator Assembly PART NUMBER 099723 02 099844 01 099701 01 099760 01 099863 01 099863 02 17587000 M11084 26 099847 02 WLE 5 099843 01 270050035 27003002 270030155 270010105 270030135 099842 02 27003003 270030125 27003008 101839 01 26322004 6 099892 01 DESCRIPTION Alternator Assembly End Cover Screw M5 x 13 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 Stator 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 1 4 0 0 ILLUSTRATED PARTS LIST Fuel Tank and Roll Cage PART NUMBER 099935 01 HC4 6C WP 4C NTC 4C 099943 01 099945 01 04110002 WP 5C NEC 5C 26302006 WLI 8 17529000 26007004
28. r carbon monoxide poisoning A DANGER Carbon monoxide poisoning may lead to death 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 Early signs of carbon monoxide poisoning resemble 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 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 indicates a hazard which can cause severe personal injury death or substantial property damage if you ignore warning CAUTION indicates a hazard which will or can cause minor personal injury or property damage if you ignore warning 1 7106
29. ratures during storage TROUBLE SHOOTING Note See engine owner s manual for engine troubleshooting A WARNING Only a qualified electrical service person should service and repair generator Use only factory approved replacement parts OBSERVED PROBLEM POSSIBLE CAUSE REMEDY No voltage when starting generator with no electrical load 1 Defective capacitor 2 Winding short circuit or loose connections 3 Defective rotor diode 4 Loss of residual 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 magnetism capacitor terminals for 2 3 seconds Voltage is less than 1 Engine speed too low Set engine speed to 3720 normal voltage with no electrical load 2 Clogged spark arrester 3 Defective rotor diode 4 Partial short circuit in winding 5 Defective capacitor 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 Voltmeter reading more than 10 high with no electrical load Engine speed too high 1 Set engine speed to 3720 RPM 62 Hz with no load Voltmeter reading correct with no electrical load but more than 10 low when electrical load is added 1 Defec
30. reas clean Keep generator free of oil mud and other foreign matter Remove anything that creates slippery areas around generator Remove oily rags and other items that create fire hazards 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 maintained Be familiar with its use 13 Know how to stop engine quickly Know how to use all controls 14 EYES E Prolonged exposure to loud noise can cause hearing loss When working around generator wear approved hearing protection Remember neighbors when using generator PRODUCT IDENTIFICATION Roll Cage Control Panel 120 Volt 11 xN 120 Volt po Engine Run Lever 206 Alert Lamp Receptacle fern Battery Discharge Full Power Lamp Selector Switch Electric Start 120 240 Volt Circuit Switch Receptacle Breaker Alternator Fuel Valve under fuel tank Fuel Gage Fuel Cap Decompression Lever Starter Grip Engine Muffler Oil Dipstick Figure 1 Portable Generator Fuel Tank Ground Lug Spark Arrester GENERAL INFORMATION SPECIFICATIONS UNPACKING This portable generator is rugged and compact It provides dependable trouble free service The alternator is brushless with revolving fields Yanmar di
31. the engine the engine will not start until you add oil The oil alert lamp is near engine starter switch see Figure 2 page 9 Add oil to engine see Engine Oil page 12 See engine owner s manual for more information Oil Alert Lamp 2 P Battery Discharge Lamp GENERATOR FEATURES Continued Figure 2 Battery Discharge Lamp and Oil Alert Lamp Location 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 happens the battery will not charge and will eventually run down Have battery charging circuit repaired by authorized service person 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 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 FULL POWER FULL POWER SELECTOR SELECTOR Mo 120V 120 120V 120 ONLY 240V ONLY 240V 120 VOLT ONLY 12
32. tive rotor diode 2 Electrical load too high 3 Engine not running properly 1 Replace both diodes on rotor 2 Do not overload generator 3 Contact an authorized engine service center ELECTRICAL Resistance in Ohms Stator Stator Rotor Rotor Capacitor COMPON ENT Main Auxiliary Primary Secondary MFD Diodes 2 SPECIFICA Model Winding Winding A Winding T Winding t 450 Volt 800 Volt TIONS MGY5000 0 54 1 38 0 61 2 29 50 70 Amp Connect T2 green and T3 black Measure resistance between T1 red and T4 yellow A Resistance between brown and white leads T Remove diodes to check resistance WIRING DIAGRAMS p Red Green Yellow Green White 120 240V 20A 120V 15A 120V 30A Receptacle Receptacle Receptacle Circuit Breaker 25 Circuit 20 Circuit Breaker 25A Selector Switch Black Red Red D re 1 Ra PER CE E Capacitor Main Auxiliary Whit Windings Phase Stator ite White T4O T3 Ti Rotor Stator Ti T2 T8 White E e Diode 5 Diode 1 220 240V 12 Brown 110 120V 110 120V Figure 23 Alternator Wiring Diagram
33. treet 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 amp Service 2444 North 5th Street Hartsville SC 29550 803 332 0191 Parts Department MTA Distributors 2940 Foster Creighton Drive Nashville TN 37204 1 800 264 0225 615 726 2225 Tuco Industrial Products P O Box 5076 Lynwood WA 98046 1 800 735 1268 206 743 9533 Parts Department NOTES 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 two year limited warranty below covers all non engine parts of this generator including the alternator Yanmar warrants the engine See engine owner s manual for engine warranty information TWO YEAR LIMITED WARRANTY PORTABLE GENERATORS DESA International warrants each alternator generator or electric product of its manufacture to be free from defects in material and workmanship for two years from the date of first purchase from an authorized dealer provided
34. ury equipment damage or damage to home could occur 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 can use this generator as a standby power source During a power outage the generator will power selected items in a building Have generator and additional wiring installed by a skilled licensed electrician This is not a do it yourself job Follow all local codes A WARNING The electrician must install a double throw transfer Switch This isolates existing electrical circuits from the utility power line If not isolated generator output will back feed into utility power line This may electrocute a power company line repair person 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 EL ECTRICAL that is not too large Make sure total wattage of all electrical loads does not exceed 5000 watts Electric motors present a special problem when figuring load Read LOAD FOR Step 3 carefully GENERATOR 1 DETERMINING Make two lists of items you want powered by generator List all motors and motor powered appliances in one List all lights small appliances etc
35. vent 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 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 licensed electrician A CAUTION For a grounding point do not use metal pipe being used to carry combustible materials or gases Alternator 27 Ground Lug Ground Wire Copper or Brass Grounding Point DSS So Figure 12 Grounding Generator EXTENSION CORDS STANDBY INSTALLATION TO HOME OR BUILDING Only use grounded extension cords Be sure to use extension cord with proper wire gauge size See chart below Recommended Minimum Wire Gauges AWG for Extension Cords 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 20 10 10 8 A WARNING Have standby installation performed by a skilled licensed electrician Do not let anyone else wire into a utility circuit Personal inj
36. wer 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 breaker Use receptacles properly Improper use could damage generator Use only grounded extension cords Power only grounded or double insulated items Do not overload receptacles This generator has the following receptacles see Figure 13 120V 15 amp GFCI duplex receptacle 120V 30 amp twist lock receptacle 120 240V 20 amp twist lock receptacle e 120V 15 Amp GFCI Duplex 120 240V 20 Amp m 120V 30 Amp Twist Lock Figure 13 Receptacle Locations Continued 19 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 120 Volt 30 Amp L5 30P Ground Plug Green wk Neutral 120 240 Volt 20 Amp Neutral 120V 120V Lr PE Ground X L14 20P Green Hot Plug f Ground 2 Cw Hot Neutral Figure 14 Cord and Plug Configurations OPERATION Continued PRESTART Operate generator on a
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