Magnum MPG 3800C User manual

PORTABLEGENERATOR
MPG 3800 •MPG 3800C
OPERATING/PARTS MANUAL

2
INTRODUCTION
Thismanualprovidesinformationandprocedurestosafelyoperateandmaintaintheportablegenerator. Foryour
ownsafetyand protection from physical injury,carefullyread,understand,andobservethesafety instructions
described in this manual. The information contained in this manual was based on machines in production at the
time of publication. Magnum Products LLC reserves the right to change any portion of this information without
notice.
DO NOT MODIFY or use this equipment for any application other than which it was designed for.
MagnumProductsLLCrecommendsthat atrainedand licensedprofessionalperform allelectricalwiring andtesting
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codesand OccupationalSafety andHealthAssociation(OSHA) guidelines.
Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC or
can be found at www.m-p-llc.com. An engine operator’s manual was also supplied with the unit at the time of
shipmentfromthefactory. Themanualprovidesdetailedoperation and maintenance procedures for the engine.
Additionalcopiesofthismanualareavailablefromtheenginemanufacturer.
MAGNUM PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: [phone]
Fax: [phone]
Toll Free: 1-800-926-9768
www.m-p-llc.com
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.
WARNING
For technical or parts QUESTIONS, please contact Magnum Products’ Customer Support or
Technical Support team at 920-361-4442. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit,
or call Magnum Products to locate a dealer in your area.
UnitModelNumber:
UnitSerialNumber:

TABLE OF CONTENTS
3
Page
INTRODUCTION ..............................................................................................................................2
TABLEOFCONTENTS ...................................................................................................................3
SAFETYNOTES.............................................................................................................................4
OPERATINGSAFETY.....................................................................................................................4
ENGINESAFETY ...........................................................................................................................5
ELECTRICALSAFETY....................................................................................................................5
UNITSERIALNUMBER LOCATION ................................................................................................6
SAFETYSYMBOL SUMMARY.......................................................................................................6
SPECIFICATIONS ...........................................................................................................................7
COMPONENTLOCATIONS.............................................................................................................8
CONTROLPANELCOMPONENTS.................................................................................................9
GROUNDINGTHEGENERATOR ..................................................................................................10
CONNECTINGELECTRICAL LOADS ............................................................................................10
GFCITESTINSTRUCTIONS .........................................................................................................10
PREVENTIONOFOVERLOAD.....................................................................................................10
WATTAGECONSUMPTIONOFEQUIPMENT............................................................................... 11
USEOF EXTENSIONCORDS ...................................................................................................... 11
EXTENSIONCORDSELECTIONCHART ......................................................................................12
ADDINGENGINEOIL ...................................................................................................................12
ADDINGGASOLINE .....................................................................................................................12
STARTINGTHEENGINE...............................................................................................................13
POWERINGTHELOADS .............................................................................................................13
STOPPINGTHE ENGINE .............................................................................................................14
MAINTENANCESCHEDULE ........................................................................................................15
DAILYMAINTENANCECHECKSANDTIPS .................................................................................15
LIFTINGTHEGENERATOR ..........................................................................................................15
UNITDECALS...............................................................................................................................16
CONTROLPANELASSEMBLY.....................................................................................................17
FRAMEAND FUELTANKASSEMBLY ....................................................................................18-19
ENGINEAND GENERATORASSEMBLY.................................................................................20-21
ACWIRINGDIAGRAM..................................................................................................................22
DCWIRING DIAGRAM..................................................................................................................23

Note: Notescontainadditional information importanttoaprocedureand will befoundwithintheregular
text body of this manual.
4
OPERATING SAFETY
Beforeusingthegeneratorbesureyoureadandunderstandalloftheinstructions! Thisequipmentwas
designedforspecificapplications;DONOTmodifyor use this equipment for any application other than
whichitwasdesignedfor. Equipmentoperatedimproperlyorbyuntrainedpersonnelcanbedangerous!
Readtheoperatinginstructionsandfamiliarizeyourselfwiththe location and proper use of all instruments
andcontrols. Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefamiliarwiththeequip-
mentbeforebeingallowedtooperateorsetupthegenerator. Thefollowingpointsshouldbepracticedat
all times:
•Theareaimmediatelysurroundingthegeneratorshouldbedry,clean,andfreeofdebris.
• NEVER startaunit in need of repair.
• NEVERoperateunitonacombustiblesurface.
• NEVER operatethegeneratorifanyofthefollowingconditionsexistduringoperation:
1. Noticeablechangeinenginespeed.
2. Loss of electrical output.
3. Equipmentconnectedtothe generator overheats.
4. Sparkingoccurs.
5. Enginemisfiresorthere is excessive engine/generator vibration.
6. Protectivecoversarelooseormissing.
7. Iftheambientairtemperatureisabove110° F.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
ThismanualcontainsDANGERS,WARNINGS,CAUTIONS,NOTICESandNOTESwhichmustbe
followedtopreventthepossibilityofpersonalinjuryordeath,damagetoequipment,orimproperservice.
Thefollowingformatting options willapplywhencallingthe readersattentiontotheDANGERS, WARN-
INGS,CAUTIONS,NOTICESandNOTES.
SAFETY NOTES
NOTICE
Indicatesa hazardoussituationwhich,ifnotavoided,
mayresultin property orequipmentdamage.
DANGER
INDICATESAHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,
WILLRESULTINDEATHORSERIOUSINJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

5
ENGINE SAFETY
Internalcombustionenginespresentspecialhazardsduringoperationandfueling! Failuretofollowthe
safetyguidelinesdescribed below could result in severeinjuryordeath. Readand follow all safety
warnings described in the engine operator’s manual. A copy of this manual was supplied with unit when it
wasshippedfrom the factory.
• DO NOT runengineindoors or in an area with poorventilationunlessexhausthosesare used.
Engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilationequipment.
• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
inanenclosedareawithpoorventilation.
• DO NOT operate with the fuel tank cap loose or missing.
• DO NOT touch or lean against hot exhaust or engine parts.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
•Keephands, feetandloose clothingawayfrom movingpartson thegeneratorand engine.
•If equipped, batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can
cause eye damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are neces-
sary when working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from
thecorrespondingterminalbeforeperforminganyserviceontheengineorothercomponents.
ELECTRICAL SAFETY
While the engine is running, potentially lethal voltages are present at the outlets located on the control
panel. Failureto follow the safety guidelines describedbelowcould result in severe injuryordeath.
•Onlya qualified andlicensedelectrician should make connectionsto the generator.
• NEVER washtheunitwithanyhighpressurehosesorpowerwashers.
• NEVER allowwatertoaccumulatearoundthebaseoftheunit. Ifwaterispresent,DONOT service!
• NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the
engineandgenerator foranymoistureand drytheunitbefore use.
• NEVER start the engine with any of the circuit breakers switched on or with any loads connected to
thecontrolpanel. Seriousgeneratordamage will result.
• ALWAYSdisconnecttheNEGATIVE(-)batterycablefromthecorrespondingterminalbeforeperform-
inganyserviceontheengine, generatororanyother components. RemovetheNEGATIVE(-) battery
cable from the corresponding terminal if the unit is to be stored or transported.

6
Unit ID Tag
215 Power Drive • Berlin, WI 54923
1-800-926-9768
MODEL
SERIAL NUMBER
MPG 5600
000000
120/240 120/240
41.7/20.8 46.7/23.3
kglbs. amb. temp.
rpm hz phase
kW
V
A
CONTINUOUS MAXIMUM
kW
V
A
1 Ø
Refer to the location illustrated at right to find the unit ID
tag. Important information, such as the unit serial
numberandmodel number are found on this tag. Record
the information from this tag, so it is available if the tag is
lost or damaged. When ordering parts or requesting
technical service information, you may be asked to
specifythisinformation.
SAFETY SYMBOL SUMMARY
Thisequipmenthasbeensuppliedwithnumeroussafetyandoperatingdecals. Thesedecalsprovideimportant
operatinginstructionsandwarn of dangers andhazards. Replaceanymissingorhard-to-readdecals and use care
when washing or cleaning the unit. Decal placement and part numbers can be found in the parts section of this
manual. Below is a summary of the intended meanings for the symbols used on the decals.
UNIT SERIAL NUMBER LOCATION
Read and understand the
supplied operator’s manual
before operating unit.
Hot surface(s) nearby.
Fire/explosion hazard; Keep
open flames away from unit.
Unit electrical ground.
Use unleaded gasoline only.
Lift here only.
Asphyxiation hazard; Operate
in well ventilated area.
Dangerous voltage may be
present. Disconnect battery
before servicing.
Check oil level daily.
Two-person lift only.
Safety alert symbol; Used to
alert you to potential personal
injury hazards.
Stop engine before fueling.
G

7
Readthismanualcarefully before attempting to use this generator. The potential for property damage, personal
injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this
unit. Each manual details specific information regarding items such as set-up, use and service requirements.
MAGNUMMODEL MPG 3800 MPG 3800C
Engine
EngineMake....................................................... Honda .............................................. Honda
EngineModel ...................................................... GX240 .............................................. GX240
Power-netprime*................................................. 7.1 hp (5.3 kW)................................ 7.1 hp (5.3 kW)
FuelConsumption-netprime ............................. 0.68gph(2.57Lph) .......................... 0.68gph(2.57Lph)
Displacement ...................................................... 15in3(242cm3)................................ 15in3(242cm3)
RecoilStart ......................................................... Yes .................................................. Yes
Generator
GeneratorFrequency .......................................... 60 Hz ............................................... 60 Hz
Maximum Output Watts ...................................... 3800 ................................................ 3800
ContinuousOutput Watts.................................... 3400 ................................................ 3400
MaximumAmps .................................................. 32A.................................................. 32A
Electrical
MainCircuitBreaker............................................ 16Amp-2 pole.................................. 16Amp-2pole
Voltage(Receptacles) ......................................... 120/240V ......................................... 120/240V
120V, 20ADuplex - qty........................................ 2 ...................................................... 2
120/240, 20ATwist Lock - qty ............................. 1 ...................................................... 1
120/240, 30ATwist Lock - qty ............................. 1 ...................................................... 1
Capacities
FuelTank ............................................................ 6.6 gal. (25 L)................................... 6.6 gal. (25 L)
ApproximateRuntime......................................... 9.7hours.......................................... 9.7hours
Weights and Dimensions
DryWeight.......................................................... 185 lbs. (84 kg) ................................ 185 lbs. (84 kg)
OperatingWeight ................................................ 226 lbs. (103 kg) .............................. 226 lbs. (103 kg)
Dry Weight, w/Wheel Kit Option.......................... 212 lbs. (96 kg)................................ 212 lbs. (96 kg)
Operating Weight,w/WheelKit Option ................ 253 lbs. (115 kg) .............................. 253 lbs. (115 kg)
Dimensions (L x W x H) ...................................... 36.8 x 21.4 x 21.5 in. ....................... 36.8 x 21.4 x 21.5 in.
934.7 x 543.6 x 546.1 mm ............... 934.7 x 543.6 x 546.1 mm
Dimensions, Wheel Kit Option (L x W x H) ......... 36.8 x 27.0 x 27.0 in. ....................... 36.8 x 27.0 x 27.0 in.
934.7 x 686.0 x 686.0 mm ............... 934.7 x 686.0 x 686.0 mm
* The power rating of the engine indicated in this document is the net power output tested on a production engine for
the engine model and measured in accordance with SAE J1349 at 3600 rpm. Mass production engines may vary
fromthisvalue. Actual power output for the engine installedin the final machine willvarydependingonnumerous
factors,includingtheoperatingspeedoftheengine in application, environmental conditions, maintenance, and other
variables.
SPECIFICATIONSARESUBJECTTOCHANGEWITHOUTNOTICE.
SPECIFICATIONS

FUEL TANK
CAP
FUEL LEVEL
GAUGE
FUEL SHUT
OFF VALVE
(UNDER TANK)
RECOIL
STARTER
CONTROL
PANEL
ENGINE
STARTING
BATTERY
BATTERY
TRAY
(OPTIONAL)
ENGINE
EXHAUST
WHEEL KIT
(OPTIONAL)
HANDLE -
WHEEL KIT
(OPTIONAL)
CENTRAL
LIFTING EYE
A
IR FILTER
HOUSING
ENGINE CHOKE
(UNDER TANK)
COMPONENT LOCATIONS
8

GROUND FAULT
SENSING MODULE
WARNING
TEST BEFORE EACH USE
SEE INSTRUCTIONS
RESET
RESET
P
O
W
E
R
F
A
U
L
T
ABCDE
FG H
MPG 3800
CONTROL PANEL COMPONENTS
A. ENGINE START SWITCH: This switch must be in the ON position to start the engine. To stop the engine,
place switch in OFF position.
B. AUTO IDLE SWITCH: When this switch is engaged, the engine speed will return to idle whenever the
generatorisnotunderload.
C. VOLTAGE SWITCH: This switch changes voltage on the L14-30Routletfrom120V to 240V.
D. MAIN CIRCUIT BREAKER: This unit containsa 16Acircuit breaker.
E. GFCI TEST MODULE: This module is the ground fault circuit interrupter to protect all electrical outlets.
F. 120/240V TWIST-LOCK CONVENIENCE OUTLET: ThisL14-30Routletisusedtoconnectadditionalloadsor
equipmenttothegenerator.
G. 120V TWIST-LOCK CONVENIENCE OUTLET: This L5-30R outlet is used to connect additional loadsor
equipmenttothegenerator.
H. 120V DUPLEX CONVENIENCE OUTLETS: These 120V outlets are usedtoconnectadditionalloadsor
equipmenttothegenerator.
9

GROUND SOURCE
LOCATION
GROUNDING THE GENERATOR
PREVENTION OF OVERLOAD
Exceeding wattage capacity can result in damage to the generator and to the connected electrical devices. Adhere
tothefollowingtoprevent exceeding wattage capacities:
• Calculate the total wattage of all electrical devices to be connected at one time to the generator.
• ThetotalshouldNOT begreater than the generator’swattagecapacity.
• Thewattagefrom various devices can be foundonthedevice’s data plate or decal. See the Wattage
Consumptionof Equipment section on page 11 for a listingofdevices and their running watts.
• Ifyou cannot locate the running wattageforadevice, multiply volts times ampere rating.
GFCI TEST INSTRUCTIONS
NOTICE:
ALWAYS test GFCI outlets before connecting any loads to the generator.
Thedevice green LED is “ON” andcircuitbreaker is at “ON” position.
1. Press the “TEST” button. The green LED should go out and red LED should come on. The circuit breaker
shouldtriggerto the off position.
2. If the LED does not change state, or the breaker does not trip, DO NOT USE! Consult an electrician for
assistance.
3. Pressthe “RESET” button. TheredLED should turn offand green LED should turn on.
4. Manually reset the circuit breaker to the on position to restore circuit power.
TheNationalElectricalCode(NEC)requiresthatthe
generatorbeproperly connected toanapprovedground
source. The ground connection for this unit is located on
thegeneratorsupportleg.
CONNECTING ELECTRICAL LOADS
Allowtheenginetowarm-upbeforeconnectingany
devices to the unit. Connect the desired 120 or 240 volt
AC, single phase, 60 Hz electrical loads.
10