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R
PORTABLE GASOLINE
GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
Generator Models: MGR2900, MGR4500I, and MGR6000I
IMPORTANT: Read and understand this manual before operating or servic-
ing generator. Improper use of generator can cause serious injury. Keep this
manual for future reference.
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R PORTABLE GASOLINE GENERATORS CAUTION: indicates a hazard which will or • Do not use generator in highly con- SAFETY can cause minor personal injury or property ductive areas. These areas include INFORMATION metal decking and steelwork. damage if you ignore warning. • Only use grounded extension cords. 1. Gasoline presents a hazard of fire or • Do not use any worn or damaged WARNINGS explosion. Gasoline is flammable. Its electric cords. Electric shock or dam- vapor is explosive. IMPORTANT:
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E F FUEL OWNER’S MANUAL SAFETY PRODUCT INFORMATION IDENTIFICATION Continued 9. Only a qualified electrical service person Gas Tank Gas Cap/Fuel Gauge should service and repair generator. • Generator produces high voltage. Use extreme caution when working on electrical parts. • Always remove spark plug wire from spark plug before servicing. This will 120 Volt prevent accidental starting. Receptacle • When working on generator, avoid hot (Duplex) muffler, exhaust manifold, and engine pa
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R PORTABLE GASOLINE GENERATORS GENERAL VENTILATION DUST, DIRT, RAIN, INFORMATION AND SNOW DANGER: Use only in well- Master portable generators are rugged and vented areas. Make sure area WARNING: Do not use genera- compact. These generators use brushless has plenty of free-moving, fresh, tor outdoors in rain or snow. Do alternators for dependable, trouble-free outside air. Never run generator not use generator near standing service. Robin’s gasoline engines provide in an enclosed or con
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OWNER’S MANUAL SPECIFICATIONS MODEL MGR2900 MGR4500I MGR6000I Note: Ratings apply to SAE standard Electrical 1 conditions. Reduce ratings 3 /2% for Rated Wattage 2500 4500 6000 each 1000 feet above sea level and 1% for Rated Amperage each 10° Fahrenheit rise above 60°F. 120 V 20.8 37.5 50 240 V –– 18.8 25 Receptacle 120-V, 20-A Duplex –– Yes Yes 120-V, 15-A GFCI Yes Yes Yes 120-V Twist-Lock –– 30 Amp 30 Amp 120/240-V Twist-Lock –– 20 Amp 30 Amp 120-V Voltage Selector Switch –– Yes
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RESET TEST R PORTABLE GASOLINE GENERATORS VOLTAGE SELECTOR GROUND FAULT CIRCUIT GENERATOR SWITCH INTERRUPTER RECEPTACLE FEATURES All models except MGR2900 have a voltage All models have a 120-volt ground fault selector switch on the control panel. The OIL ALERT SYSTEM circuit interrupter (GFCI) receptacle. The switch has two positions: 120 VOLT ONLY, GFCI receptacle is on the control panel or top The oil alert system protects the engine from and 120 + 240 VOLT. cover of alternator (MGR
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OWNER’S MANUAL GENERATOR ENGINE OIL FUEL We ship the generator without oil in the FEATURES WARNING: Gasoline presents engine crankcase. You must add oil before Continued a hazard of fire or explosion. starting engine. See engine owner’s manual Gasoline is flammable. Its vapor for specific oil type. RECEPTACLE CIRCUIT is explosive. BREAKER CHECKING OIL LEVEL AND • Keep fuel out of children’s The circuit breakers protect the receptacles reach. ADDING OIL and alternator. Overloading generato
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E F E F FUEL FUEL R PORTABLE GASOLINE GENERATORS 5. Drive grounding point into ground. EXTENSION STANDBY Note: Grounding point can be a stake, CORDS grounding rod, or pipe. Grounding INSTALLATION point should be copper or brass. Only use grounded extension cords. Be sure TO HOME OR 6. Attach ground wire to grounding point. to use extension cord with proper wire gauge BUILDING size. See chart below. You must supply the ground wire and ground- ing point. These do not come with generator.
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OWNER’S MANUAL 3. Electric motors present a special prob- Note: Some motors require nearly the DETERMINING lem. They require up to three-times same wattage to run as to start. These ELECTRICAL LOAD their rated wattage to start. Chart 2, be- items include saws, drills, hair dryers, low, shows starting watts for different and food mixers. See Chart 1 for typical FOR GENERATOR size motors. For example: an electric appliance wattage examples. motor nameplate states 5 amps at 120 You must decid
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RESET TEST ENM 00000005 HOURS 1/10 120V 120V GFCI 120V TWISTLOCK HOUR METER 120/240V TWISTLOCK VOLTAGE 120 120 + ONLY 240 AUTO-IDLE SELECTOR OFF ON RESET RESET RESET RESET R PORTABLE GASOLINE GENERATORS USING RECEPTACLE POWER CORD AND PLUG OPERATION REQUIREMENTS Note: Do not exceed amperage rating of GENERAL INFORMATION receptacles. Exceeding rating will trip re- 120V, 30-amp twist-lock receptacle ceptacle circuit breaker. This generator is not large enough to power • NEMA L5-30P plug y
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OWNER’S MANUAL 4. Start the engine. OPERATION Turn engine switch to the ON position Continued (see Figure 12). Remove slack from starter rope by lightly pulling starter PRESTART grip. Next, pull starter rope briskly. Operate generator on a firm, dry, and clean IMPORTANT: Do not let starter grip surface. The surface must be level. Protect snap back against engine. Return it gen- generator from heavy dust, sand, dirt, rain, tly. This will prevent damage to starter. or snow. Do not locate
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E F E F FUEL FUEL RESET TEST ENM 00000005 HOURS 1/10 120V 120V GFCI 120V TWISTLOCK HOUR METER 120/240V TWISTLOCK VOLTAGE 120 120 + ONLY 240 AUTO-IDLE SELECTOR OFF ON RESET RESET RESET RESET R PORTABLE GASOLINE GENERATORS Solenoid Mounting Adjusting the Idle Speed OPERATION M10 Bolts Bracket (Models MGR4500I and Continued MGR6000I) AUTO-IDLE OPERATION IMPORTANT: Adjust the idle speed only: IMPORTANT: Never start engine with elec- • If the idle speed becomes too high. trical loads connecte
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OWNER’S MANUAL STOPPING ENGINE OPERATION MAINTENANCE Continued IMPORTANT: The engine speed is preset. AND REPAIRS The throttle is locked in preset position. Do HIGH ALTITUDE OPERATION not adjust throttle. WARNING: Only a qualified This generator will not perform well at high Follow the steps below to stop engine. electrical service person should altitudes without proper adjustment. See service and repair the alternator 1. Remove all electrical loads from genera- engine owner’s manual for
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R PORTABLE GASOLINE GENERATORS ® Use a fuel additive, such as STA-BIL or an STORAGE TECHNICAL equivalent, when storing generator with fuel in fuel tank. This will minimize fuel gum SERVICE WARNING: Remove all fuel from deposits from forming in engine. fuel tank before storing generator. You may have further questions about as- Store fuel in approved container. Cover and store generator in a clean, dry sembling, operating, or maintaining this Store fuel in a well-vented area free place.
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L I N E OWNER’S MANUAL ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Capacitor, Main Auxiliary Primary Secondary MFD Diodes (2) Model Winding * Winding ‡ Winding † Winding † 450 Volt 1000 Volt MGR2900 1.6 5.9 6.9 1.33 16 6 Amp MGR4500I 0.835 1.852 4.91 — 40 8 Amp MGR6000I 0.741 1.582 5.55 — 40 8 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
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Stator T1 T2 T3 T4 220/240V L2 L1 White 110/120V 110/120V 120V, 20A 120V, 30A 120V, 15A Receptacle Receptacle Receptacle Stator GFCI Brown White Capacitor White White Wht Wht Wht Auxiliary LINE Phase Rotor Diode Diode White Blue T4 Wht Hour Meter Black T3 T2 120/240V Main 20A/30A Full Pwr Windings Red T1 Receptacle Selector White Switch White Auto-Idle Green T2 Wht T1 T4 T3 T2 Circuit Circuit Circuit Circuit Breaker Breaker Breaker Breaker 20A 25A/30A 25A/30A 20A White White R PORTABLE GASOLINE
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OWNER’S MANUAL 1 7 ILLUSTRATED PARTS LIST For Model MGR2900 Alternator 2 Assembly 4 This list contains replaceable parts used in 22 5 your generator. When ordering parts, follow 6 3 the instructions listed under Replacement 14 21 Parts on page 23 of this manual. 20 15 13 19 17 16 15 13 7 12 8 18 9 7 10 11 7 KEY PART KEY PART NO. NUMBER DESCRIPTION QTY. NO. NUMBER DESCRIPTION QTY. 099722-02 Alternator Assembly* 14 27001005S Engine Flange 1 1 100074-01 Top Cover 1 15 WLE-4 Lock Washer, 1/4" 4
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R PORTABLE GASOLINE GENERATORS 1 ILLUSTRATED 2 PARTS LIST For Models MGR4500I and MGR6000I Alternator Assembly This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 23 of this manual. 3 4 5 7 6 12 1 1 8 9 10 13 15 16 17 14 PART NUMBER FOR MODEL KEY NO. MGR4500I MGR6000I DESCRIPTION QTY. 114285-01 114285-02 Alternator Assembly 1 1 115243-01 115243-01 Top Cover, Alternator 1 2 M10908-27 M10908-27
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OWNER’S MANUAL ILLUSTRATED PARTS LIST 1 For Model MGR2900 Roll Cage This list contains replaceable parts used in your generator. When ordering parts, follow 2 the instructions listed under Replacement Parts on page 23 of this manual. 3 2 3 3 2 4 2 6 5 2 3 KEY PART NO. NUMBER DESCRIPTION QTY. 1 114673-01 Roll Cage 1 2 NEC-5C Lock Nut, 5/16-18 5 3 103289-02 Shock Mount 3 4 * Bolt, 5/16-18 x 1/2" 1 5 WLE-5 Lock Washer, 5/16" 1 6 115388-01 Grounding Strap 1 * Available at any hardware store
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E F F U E L SAFETY INFORMATION Unleaded Gasoline Only R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGR4500I and MGR6000I Fuel Tank and Roll Cage 1 10 9 2 3 4 7 15 6 16 5 17 15 16 8 15 14 17 12 13 12 1 1 13 16 15 10 18 114716 20 120V 120V GFCI 120V TWISTLOCK RESET TEST HOUR METER 120/240V ENM TWISTLOCK 00000005 HOURS 1/10 VOLTAGE 120 120 + ONLY 240 AUTO-IDLE SELECTOR OFF ON RESET RESET RESET RESET
