Master Lock HWI3000, MGH3000, MGH3000PR, MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, MGH7000DI, MGH10000A Portable Generator User Manual
Contents
1.2. Figure 33 Wiring Diagram Model MGH7000D White ME Green Yellow Green 5 Black L 120 240V 30A 120V 15A 120V 15A 120V 15A Circuit Receptacle Receptacle Receptacle Receptacle Breaker 6 20A 9 White T1 Circuit Red Breaker VE 30A White Circuit Breaker 20 Circuit Black Breaker T3 30A Hour Meter Black Red Black Bed Black ee ee Den Pe Sea es ae ees Capacitor Main Auxiliary Wink Windings Phase Stator ite White TI T4O T3O TAX T2 Tf ES T4 Rotor Stator Ti Ta 13 T4 Green White tt Red Diode 3t Diode u 220 240V D Black Brown 110 120V 110 120V Green Yellow Red 120 240V 20A To Solenoid Receptacle Circuit Breaker 20A 25A or 30A Circuit Breaker 20A 25A or 30A T2 White White 120V 15A Receptacle Full Pwr Selector Switch 120V 15A Receptacle 120V 30A Receptacle Circuit Breaker 20A LIC IL Circuit Breaker 20A Black Green Capacitor Main Auxiliary White Windings Phase Stator nie TID TAQ T3 T2 T4 Rotor Stator T lm 2 110 120V
3. PORTABLE GASOLINE GENERATORS OWNER S OPERATION AND INSTALLATION MANUAL Generator Models HWI3000 MGH3000 MGH3000PR MGH4000C MGH4000CI MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D MGH7000DI and MGH10000A 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 PORTABLE GASOLINE GENERATORS SAFETY INFORMATION A WARNINGS IMPORTANT Read this owner s manual and the engine owner s manual carefully Become famil iar with this generator before try ing to operate or service it Know its uses limitations and any haz ards involved Improper use of generator can cause severe in jury or death from explosion fire burns electrical shock or car bon monoxide poisoning AX 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 Carbon Monoxide Poisoning Early signs of carbon monoxide poisoning re semble the flu with headaches dizziness and nausea If you have these signs get fresh air at once Some people are
4. Z lt gt 25 QS 22 Bolts E p Figure 8 Attaching Handles to Roll Cage SEMS Screws Top Cover Figure 9 Attaching Top Cover to Holl Cage BATTERY Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A A WARNING Battery gives oft 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 bat tery 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 e Ifbattery acid getsin your eyes flush with water at least 15 minutes Calla doctor at once Battery acid is poisonous If swallowed drink large amounts of water or milk Fol low with milk of magnesia or vegetable oil Call a doctor at once A CAUTION If you remove bat tery insulate the red positive battery cable terminal Insulate with electrical tape Exposed ter minal may spark when generator runs IMPORTANT Make sure battery connec tions are the correct polarity Electric start generators use negative ground 12 volt DC starting system Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A have an el
5. Selector ENM HOURS 1 10 ENM HOURS 1 10 120 VOLT ONLY Position Figure 3 Full Power Selector Switch AUTO IDLE SYSTEM The Auto Idle System allows the engine to idle down or run at a slower speed when the generator is not being used to supply power The Auto idle system can be turned ON or OFF by a rocker switch on the control panel When the switch is in the OFF position the engine runs at full speed all of the time When the switch is in the ON position the engine slows down to idle speed until an electrical load is applied When a load is applied to the generator an electrical item is plugged in and turned on the engine speeds up to the preset speed required to produce the correct voltage IMPORTANT A minimum current load of Ampis required to disengage the auto idle solenoid and cause the engine to come up to speed for correct voltage Powering items at reduced engine speed will damage genera tor and powered items 120 240 VOLT Position 6 ELECTRIC START Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A have elec tric starters A battery is not supplied with generator You must provide a 12 volt 32 amp hour battery For more battery infor mation see Battery page 8 GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE All models
6. 110 120V Whi L Y Diode i on ile y 220 240V Brown Figure 34 Wiring Diagram Models MGH4000CI MGH5000DI MGH5000DIE and MGH6000DI Continued 106813 17 PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued r Green Yellow Green 1 Black 120 240V 30A 120V 15A 120V 15A 120V 15A Circui 7 i h ircuit Switch Receptacle Receptacle Receptacle Receptacle Breaker H White White 20A Circuit T1 Breaker To Solenoid Circuit Circuit Breaker 20A Breaker 30A Hour Meter Black Red Black Bed Black C has EE Capacitor Main Auxiliary Wii Windings Phase Stator ite Whit
7. cal Component Specifications page 15 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor ter minals for 2 3 seconds LA Voltage is less than normal voltage with no electrical load Engine speed too low 2 Defective rotor diode 3 Partial short circuit in winding 4 Defective capacitor 1 Set engine speed to 3720 RPM 62 Hz with no load 2 Replace both diodes on rotor 3 Check resistance of coils see Electri cal Component Specifications page 15 4 Replace capacitor Voltmeter reading more than 10 high with no electrical load 1 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 electri cal load is added 106813 Defective rotor diode 2 Electrical load too high Engine not running properly LA www desatech com 15 1 Replace both diodes on rotor 2 Do not overload generator 3 Contact an authorized engine service center MASTER PORTABLE GASOLINE GENERATORS ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Capacitor Main Auxiliary Primary Secondary MFD Diodes 2 Model Winding Winding A Winding T Winding T 450 Volt 800 Volt HWI3000 1 6 5 9 6 9 1 33 16 6 Amp MGH3000 MGH3000PR 1 6 5 9 6 9 1 33 16 6 Amp MGH4000C MGH4000
8. Add watts and starting watts of all items This total must not be larger than the rated wattage of your generator It is a good idea to have up to 2596 extra capacity for future needs or extra equipment Chart 1 Typical Electric Appliance Wattages Running Starting Equipment Running Watts Starting Equipment Watts Light bulb 100W Radio Fan Television Furnace fan 1 8 hp with blower Vacuum cleaner Sump pump 1 3 hp Refrigerator freezer 6 Circular saw Floodlight Chart 2 1 2 Drill Toaster Coffee maker Skillet 14 Chain saw Water well pump 1 2 hp Hot plate range per burner 10 Table saw Water heater storage type Approximate Starting Watts Universal Motors Approximate Running Watts small appliance Repulsion Induction Motors Capacitor Motors 275 400 450 600 850 1000 1600 2000 400 500 600 850 975 1300 850 1050 1350 1800 Always use starting watts not running watts when figuring correct electrical load x Motors of higher horsepower are not generally used 10 106813 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 AA DANGER Use only in well vent
9. Except HWI3000 have a 120 volt ground fault circuit interrupter GFCT receptacle The GFCI receptacle is on the control panel or top cover of alternator mod els MGH3000 and MGH3000PR only The GFCI protects you against hazardous electri cal shock caused when your body becomes a path through which electricity travels to reach ground This could happen when you touch an appliance 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 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 AA WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a quali fied electrician for repairs 106813 GENERATOR FEATURES Continued 2 If the GFCI receptacle tests okay re store power by pushing the RESET button back in The test lamp should work at this time MPORTANT You must press the RESET button firmly and fully It should lock into place If the GFCI does not l
10. Note If engine does not start check the oil in the crankcase Add oil as nec essary Be sure engine is on a level sur face See Oil Alert System page 6 B Electric Starter Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A Only Turn the engine switch to the START position see Figure 24 page 13 Hold it there until engine starts When en gine starts let switch return to the ON position IMPORTANT Do not use electric starter more than five seconds Starter motor damage may occur If engine fails to start release the switch and wait ten seconds After ten seconds try start ing again Note If engine does not start check the oil in the crankcase Add oil as nec essary Be sure engine is on a level sur face See Oil Alert System page 6 5 As engine warms up slowly move choke lever fully to the right see Fig ure 25 page 13 This opens the choke On Model MGH10000A the choke will automatically open Choke Lever Closed Position Fuel Valve Lever ON Position Figure 19 Fuel Valve Lever On Choke Lever Closed Model MGH4000C Shown Choke Rod Pulled Out Closed Position Figure 20 Choke Rod Closed Model MGH3000PR Only Choke Button Pulled Out Closed Position Figure 21 Choke Button Closed Model MGH10000A Only Figure 22 Engine Lever In ON Position Model MGH3000PR Only ENGINE SW ON TA Figure 23 Engine Switch In ON Posi
11. PARTS NOT UNDER WARRANTY Contact authorized dealers of this product If they cannot supply original replacement part s either contact your nearest Parts Central or call DESA International s Parts Department at 1 800 972 7879 for referral information When calling DESA International have ready model number of your generator the replacement part number PARTS CENTRALS These Parts Centrals are privately owned businesses They have agreed to support our customer s needs by providing original re placement parts and accessories Baltimore Electric 1348 Dixwell Avenue Hamden CT 06514 1 800 397 7553 203 248 7553 Parts Company of America 1657 Shermer Road Northbrook IL 60062 1 800 323 0620 708 498 5900 Portable Heater Parts 342 N County Road 400 East Valparaiso IN 46383 1 800 362 6951 219 462 7441 sales portableheaterparts com techservice portableheaterparts com FBD 1349 Adams Street Bowling Green KY 42103 270 846 1199 1 800 654 8534 Fax 1 800 846 0090 franktalk aol com Master Parts Dist 1251 Mound Ave NW Grand Rapids MI 49504 2672 1 800 446 1446 616 791 0505 Fax 616 791 8270 www nbmc com Laportes Parts amp Service 2444 N 5th Street Hartsville 29550 803 332 0191 MTA Distributors 555 Hickory Hills Blvd Nashville TN 37189 9244 1 800 264 0225 615 299 8777 Www mtadistributors com Tuco Industrial Products 5223 18th Street SW Lynwood WA 98037 4506 425 743
12. 240 V 50 A No Yes General Honda Engine H P 13 20 Honda Model GX390K1VXE GX620VXA3 Fuel Type Gasoline Gasoline Fuel Tank Capacity 8 gal 13 gal Oil Alert System Yes Yes Start Method Electric Electric Weight pounds 247 350 Single phase 1 0 power factor 106813 OWNER S MANUAL MGH4000C MGH3000PR MGH4O0O00CI 2500 4000 20 8 33 3 16 7 Yes Yes Yes No 30 Amp No 20 Amp No Yes No No 5 0 8 GC160VXA GX240K1VA Gasoline Gasoline 3 9 qt 5 gal Yes Yes Recoil Recoil 84 139 MGH5000D MGH5000DI MGH5000DIE 5000 41 7 20 8 Yes Yes 30 Amp 20 Amp Yes No 9 GX270VA Gasoline 8 gal Yes Recoil Elec 173 MGH6000D MGH6000DI 6000 50 25 Yes Yes 30 Amp 20 Amp Yes No 11 GX340K1VA Gasoline 8 gal Yes Recoil 191 Note Ratings apply to SAE standard conditions Reduce ratings 3 2 for each 1000 feet above sea level and 1 for each 10 Fahrenheit rise above 60 F MASTER PORTABLE GASOLINE GENERATORS GENERATOR FEATURES OIL ALERT SYSTEM Theoilalert system protects the engine from low oil damage This system automatically shuts down the engine and prevents engine restarting if the oil level falls too low Note When this happens the engine switch remains in the ON position The oil alert system is wired into the ON OFF Switch If this system shuts down the engine the engine will not start until you add oil Add oil to engine see Engine Oil page 7 Note Oper
13. and again 1 Turn Auto Idle switch OFF Start en gine Allow engine to warm up with no load for five minutes AA WARNING Always setthe idle speed before turning on the Auto Idle If idle speed is not set the larger resistor on the control board may become hot Heat from the resistor may damage the protec tive coating on the control board 2 Remove engine linkage cover Models MGH4000CI MGH5000DI MGH5000DIE MGH6000DI and MGH7000DI 3 Push plunger into solenoid body to manu ally engage solenoid and set idle speed 4 Loosen the M8 nut that holds the sole noid mounting bracket to the generator Models MGH4000CI MGH5000DI MGH5000DIE MGH6000DI and MGH7000DI See Figure 27 Do not loosen bolt that holds the solenoid mounting bracket to the generator on Model MGH10000A see Figure 28 5 Slowly pull solenoid bracket away from engine on Model MGH10000A this will require bending the bracket slightly 6 With a volt meter check the no load output voltage at the 120 volt duplex receptacle At proper idle speed 2680 minimum RPM the meter should read 50 60 volts Lower settings will cause the Auto Idle to not operate properly 7 After reaching proper idle speed tighten M8 nut to secure solenoid mounting bracket Models MGH4000CI MGH5000DI MGH5000DIE MGH6000DI and MGH7000DI see Figure 27 13 8 Turn Auto Idle switch ON Make sure solenoid is engaged When engaged the punger is p
14. 01 HC4 16C 107110 01 Gas Cap Fuel Gage Gas Tank with 90 fitting Breather Assembly Screw 1 4 20 x 1 Screw M5 x 10 Gas Line Clamp Fuel Line Fuel Filter Roll Cage Lock Nut 1 4 20 Lock Nut 1 4 20 Lock Nut 5 16 18 Lock Nut 5 16 18 Ground Strap Shock Mounts Lock Washer 5 16 Lock Washer 10 Flat Washer 5 16 Flat Washer 5 16 Bolt 5 16 18 x 1 3 4 Engine Spreader Hook Bolt 5 16 18 Battery Mounting Bracket Lock Nut 5 16 18 Sems Screw 88 18 x 1 2 Screw 1 4 20 x 1 2 Screw 1 4 20 x 1 2 Washer 1 4 Linkage Cover Washer 10 90 Fitting with barbs Bolt 1 4 20 X 2 Spacer 25 X 500 PARTS AVAILABLE NOT SHOWN 100003 01 03175000 Only on MGH5000DIE electric start models 100003 02 099873 01 099873 02 03175000 25 Safety Information Decal Operation Decal Operation Decal Battery Cable Positive Red Battery Cable Negative Black Fuel Line Grommet o ww N N O P N HD PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Model MGH10000A Fuel Tank and Roll Cage 106813 26 OWNER S MANUAL ILLUSTRATED PARTS LIST 079503 25AA Gas Tank Assembly 105905 01 Roll Cage 105906 01 Axle Mount 102933 03 Axle 102932 01 Wheels WP 16C Flat Washer 1 4 12 Cotter Pin 100135 01 U Bolt NEC 5C Lock Nut 5 16 18 WP 5C Flat Washer 5 16 103880 01 Lock Nut 1 4 20 WP 4C Flat Was
15. 20 amp duplex receptacle Models MGH3000 and MGH3000PR have only the 120V 15 amp GFCI duplex receptacle 120V 15 Amp GFCI Duplex 120V 15 Amp Duplex 120 240V 20 or 30 Amp Twist Lock 120V 30 Amp Twist Lock 120 240V 50 Amp Model MGH10000A only Figure 17 Receptacle Locations POWER CORD AND PLUG REQUIREMENTS 120V 30 amp twist lock receptacle NEMA L5 30P plug Three wire 30 amp cord 120 240V 20 or 30 amp twist lock receptacle NEMA L14 20P 20 amp or L14 30P 30 amp plug Four wire 20 amp or 30 amp cord 120 240V 50 amp receptacle e NEMA L14 50P Four wire 50 amp cord 120 240 Volt 20 Amp Neutral 120V 120V x L14 20P Hot Plug Ground Green Neutral 120V 120V MEL 120 240 Volt 14 20 20 and 30 Amp Ground Green Neutral PI Hot l Ground 9 Figure 18 Cord and Plug Configurations Continued MASTER PORTABLE GASOLINE GENERATORS OPERATION Continued PRESTART Operate generator on a firm dry and clean surface The surface must be level Protect generator from heavy dust sand dirt rain or snow Do not locate generator near stand ing water and snow Make sure area is well vented AA WARNING Only responsible adults should use generator Never letanyone operate genera tor without proper instructions Note If oil level is too low oil alert system will keep engine from starti
16. 5 02 Tie Wrap 103204 01 Foam Pad 099892 02 Capacitor Bracket 103202 01 Engine Flange 103190 01 Screw M8 x 20 ja O Ring 103203 01 Washer WLE 5 Hex Head Nut 099891 01 Alternator Assembly 102938 01 Part not available by itself Must purchase Alternator Assembly Standard hardware item available from local hardware store 1 1 1 1 1 2 1 1 4 4 1 6 1 1 1 2 1 1 1 1 1 1 4 1 2 1 1 22 106813 OWNER S MANUAL ILLUSTRATED PARTS LIST For Models HWI3000 MGH3000 and MGH3000PR Roll Cage This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 19 of this manual KEY PART NO NUMBER DESCRIPTION QTY 105155 01 Roll Cage 099754 01 Engine Spreader NEC 5C Lock Nut 5 16 18 WP 5C Flat Washer 5 16 099853 02 Shock Mount 04110002 Screw 5 16 18 x 1 2 14138000 Ground Strap 21834000 Washer 5 16 x 11 2 100406 01 Bolt 5 16 18 x 3 4 GQ OU 2 3 4 5 6 7 8 9 106813 23 MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C MGH4000Cl MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D and MGH7000DI Fuel Tank and Roll Cage 24 106813 OWNER S MANUAL This list contains replaceable parts used in your generator When ordering parts follow the instructions listed u
17. 6000D and MGH6000DI Models MGH5000DIE ON MGH7000D pu MGH7000DI and N MGH10000A N N NV E Figure 29 Engine Switch In OFF Position 14 Fuel Valve Lever Off Position Figure 30 Fuel Valve Lever Off Model MGH7000D Shown 106813 MAINTENANCE AND REPAIRS A WARNING Only a qualified electrical service person should service and repair the alternator on this generator Use only fac tory approved replacement parts A CAUTION The engine speed is preset The throttle is locked in preset position Do not adjust throttle Preset position lets en gine run at 3600 RPM under load The engine must maintain 3600 RPM for generator to create cor rect voltage Running engine at lower speeds will damage gen erator and powered items A CAUTION Shut off generator before performing maintenance TROUBLESHOOTING OWNER S MANUAL IMPORTANT Keep generator level when servicing Never turn generator upside down or stand it on end to service Note We supply the engine owner 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 STORAGE AX WARNING R
18. 9533 1 800 735 1268 Fax 425 742 0218 www tucoheat com MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models HWI3000 MGH3000 and MGH3000PR 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 19 of this manual PART NUMBER 099722 01 DESCRIPTION Alternator Assembly HWI3000 Alternator Assembly MGH3000 and MGH3000PR Top Cover HWI3000 Top Cover MGH3000 and MGH3000PR 120V 20A Duplex Receptacle HWI3000 T 120V 15A Duplex GFCI Receptacle MGH3000 and MGH3000PR t Circuit Breaker 20 Amp T Capacitor Screw M4 x 20 Terminal Block Screw M5 x 13 End Plate 099722 02 099849 01 100074 01 104201 01 100445 01 22616009 270020028 26333000 099863 01 099701 01 099848 01 T Includes fastening hardware Parts not available Included in alternator assembly NUMBER 17587000 099891 01 099861 01 099842 01 26310000 270010058 WLE 4 27001002 270010098 27001006 26327006 WLE 5 099866 03 099866 04 099867 02 DESCRIPTION Ground Lug Flanged Nut 8mm Bottom Cover Draw Bolt Screw M6 x 16 Engine Flange Lock Washer 1 4 Stator Bearing Diode Rotor Fan Bolt 5 16 24 x 5 8 Lock Washer 5 16 Safety Information Decal Safety Information Decal Operation Decal Includes reference numbers 1 throug
19. CI 0 71 2 17 0 54 2 07 40 70 Amp MGH5000D MGH5000DI 0 54 1 38 0 61 2 29 50 70 Amp MGH5000DIE 0 54 1 38 0 61 2 29 50 70 Amp MGH6000D MGH6000DI 0 37 1 01 0 68 2 57 60 70 Amp MGH7000D MGH7000DI 0 28 0 78 0 77 2 9 70 70 Amp MGH10000A 0 40 0 90 0 37 0 50 80 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 Stator d Black Suel Li Of NES 3 warem Ti T2 L4 Circuit HWI3000 L2 Breaker l DI 110125 12 Yellow L1 L2 Rotor Stator l White dm Brown a l MEE UM Leg en m J x Figure 31 Wiring Diagram Models HWI3000 MGH3000 and MGH3000PR o o ui Breaker Circuit Breaker 25A Red Main Windings T4 Red k Bl Auxiliary Ph Stator Rotor Stator Ta ba Tal Diode j I pisis j stew sou hao lack Yellow Figure 32 Wiring Diagram Models MGH4000C MGH5000D and MGH6000D 16 106813 OWNER S MANUAL WIRING DIAGRAMS
20. Control Box U Nut Switch Plug Control Panel Assembly Control Panel Assembly Auto Idle Models Panel Schematic Decal 106813 OWNER S MANUAL ILLUSTRATED PARTS LIST For Model MGH10000A 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 19 of this manual 103182 01 22616009 099833 01 100410 01 22261000 100445 01 103183 01 103184 01 26299000 101350 01 099834 01 22616010 099760 01 103185 01 100366 01 15324000 102927 01 100177 05 103257 01 103258 02 Control Panel Circuit Breaker 20 Amp 120V 30A Twist Lock Receptacle Sems Screw 88 18 x 1 2 U Nut 20V 15A Duplex GFCI Receptacle 125 250V 50A Receptacle Circuit Breaker 45 Amp Run Light Hour Meter 120 240V 20A Twist Lock Receptacle Circuit Breaker 30 Amp Bushing Control Box Rocker Switch 120V 15A Duplex Receptacle Control Panel Assembly Panel Schematic Diagram Auto Idle PC Board Kit Solenoid Assembly Kit With Bracket T Includes reference numbers 1 through 16 A Not shown 106813 29 MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting Solenoid Assembly and Mounting Control Board Assembly and Mounting 30 106813 OWNER S MANUAL ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Moun
21. E MGH7000D MGH7000DI and MGH10000A only 5 Amp ground fault circuit interrupter GFCI receptacle Except HWI3000 Model UNPACKING 1 Remove generator from carton 2 Remove any protective packaging ap plied to generator for shipment 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 supplied for models MGHSOOODIE MGH7000D MGH7000DI and MGH10000A only These cables are in a separate bag in side generator carton You must install these cables to engine See Battery page 8 for installation instructions VENTILATION AA DANGER Use only in well vented areas Make sure area has 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 contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death This generator needs cooling air to run prop 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 DUST DIRT RAIN AND SNOW A 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 a
22. Gauges AWG for Extension Cords Ampere AWG for Length of Load Cord in Feet 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 GENERATOR GROUNDING A 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 Only use grounded ex tension cords Only use three wire or double insulated power tools Grounding generator helps prevent electric shock from a ground fault condition Locate ground lug on end of generator housing see Figure 16 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 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 A WARNING For a grounding point do not use metal pipe be ing used to carry combustible materials or gases Ground Lug Copper or Brass Grounding Point Ground Wire 7 A Figure 16 Grounding Generator Model MGH4000C Shown MASTER PORTABLE GASOLINE GENERATORS STANDBY INSTALLATION
23. TO HOME OR BUILDING AA WARNING Have standby in stallation performed by a skilled licensed electrician Do not let anyone else wire into a utility circuit Personal injury equip ment 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 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 AX WARNING The electrician must installa double throw trans fer switch This isolates existing 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 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 exceed rated watt age of generator For rated wattage of y
24. UAL MGH7000D MGH7000DI 099723 04 099844 01 099701 01 099760 01 099863 02 17587000 M11084 26 099847 04 WLE 5 099843 01 270070048 100054 01 27003002 27003015S 099891 01 099892 01 099842 04 27003003 270030128 27003008 270030078 26322004 WLE 6 21 DESCRIPTION Alternator Assembly End Cover Screw M5 x 13 Bushing Terminal Block 4 block Terminal Block 2 block Ground Lug Screw 1110 16 x 3 8 Stator Bolt Lock Washer 5 16 Bearing Housing Capacitor Terminal Post Stator Fan Bracket Screw M8 x 20 Rotor Nut Flanged 8mm Foam Pad Draw Bolt Bearing Diode Rotor Fan Engine Flange Bolt 3 8 16 x 5 8 Lock Washer 3 8 O sch PF sch SH HSH sch OO sch MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED lt A PARTS LIST For Model MGH10000A Alternator Assembly This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 19 of this manual arv NUMBER QTY Stator Rotor j Draw Bolt 103188 01 Fan 103191 01 Balancing Disc 103192 01 Lifting Eyes 103193 01 D E Bracket 103194 01 N D E Bracket 103195 01 Mounting Bolts 099847 05 Nuts 099891 01 Top Box 103189 01 Screw and Washer 099701 01 Plastic Cap 103198 01 Bearing 103199 01 Borelly Washer 103200 01 Diode 27003012S Terminal Block 103201 01 Capacitor 09984
25. ate generator on a level surface If not level the oil may flow away from the oil level sensing device This will cause the oil alert system to shut down engine See engine owner s manual for more information Model MGH3000PR Models HWI3000 ENGINE SW MGH3000 MGH4000C ON MGH4000Cl MGH5000D 05777 MGHS5000DI MGH6000D and MGH6000DI Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A QD NS NN CIRCUIT N BREAKER A Figure 2 Engine Switch Locatio FULL POWER SELECTOR SWITCH All models except HWI3000 MGH3000 MGH3000PR MGH7000D MGH7000DI and MGH10000A have a full power selector switch on the control panel The switch has two positions 120 VOLT ONLY and 120 240 VOLT 120 VOLT ONL Y 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 positionsends full power to the 120 240V receptacle It also powers the 120V receptacles at reduced wattage capacity IMPORTANT Do not move the full power selector switch while powering electrical items Unplugallitems before moving switch Failure to do so can damage switch Models HWI3000 MGH3000 MGH3000PR MGH7000D MGH7000DI and MGH10000A do not have this switch These models provide full power to all receptacles
26. e Tid Tah 736 12 T2 Ti T3 T4 Rotor Stator 5 aol 113 14 Se White E Red Diode 3 Diode u 220 240V L2 Black Brown 110 20V 110 120V Figure 35 Wiring Diagram Model MGH7000DI White White Green Green Black Black 1 250V 30A 125V 15A GFCI 125V 15A 125V 30A Auto ldle Receptacle Receptacle Receptacle Receptacle Control Board c y 5 9 ri 250V 50A fl i Netea Receptacle HEHE AA n n Circuit white O AAA SE Breaker White T jaw 3 White E H Q Black Run Black Light Circuit T Solenoid Yellow circuit Breaker o Breaker 20A l 45A B Hour Meter ef Red HI EE Black Black Black Yellow LL Bed 5 Black Black i White T Black Capacitor Red Main White Windings T2 TS T4 Rotor Stator efo r r mp Stator Gm 74 CIS Y Diode 3 Diode id 220 240V L1 L2 Figure 36 Wiring Diagram Model MGH10000A 18 110120V 110 120V 106813 TECHNICAL SERVICE You may have further questions about in stallation operation or troubleshooting If so contact DESA International s Technical Service Department at 1 800 323 5190 You can also visit DESA International s technical service web site at www desatech com SERVICING THE ENGINE Honda parts and services should be handled by your nearest authorized engine service firm Check the yellow pages of your tele phone dir
27. e ratings Note The wattage ratings for some elec trical motors are misleading They may require up to three times their rated watt age to start You must figure total electri cal load wattage Make sure total wattage of all electrical loads does not exceed rated wattage of generator See Determining Electrical Load For Generator page 10 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 DISCONNECTING ELECTRIC LOADS Remove electrical loads one at a time Re move voltage sensitive items first Voltage sensitive items include TVs VCRs and other home electronic items STOPPING ENGINE IMPORTANT The engine speed is preset The throttle is locked in preset position Do not adjust throttle Follow the steps below to stop engine 1 Remove all electrical loads from gen erator see Disconnecting Electrical Loads Remove electrical loads one at a time 2 Let engine run for two or three min utes after removing electrical loads This lets engine cool slightly 3 Turn engine switch to the OFF posi tion see Figure 29 4 Turn fuel valve lever off except on Model MGH3000PR Do this by mov ing valve lever fully to the left see Fig ure 30 Model MGH3000PR Models HWI3000 MGH3000 MGH4000C MGH4000Cl MGH5000D Z J MGH5000DI MGH
28. ectory under the listing Engines Gasoline Honda ACCESSORIES Heavy Duty Wheel Kit PA2020 For Models MGH4000C MGH4000Cl MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D and MGH7000DI Wheelbarrow style wheel kit Makes gen erator easy for one person to move This kit includes Large 12 inch wheels for easy rolling Powder coated tubing and plated hard ware for long life Long handles with thick grips for greater comfort and control Complete installation instructions included Automatic Idle Kit PA2010 For Models MGH4000C MGH5000D MGH6000D and MGH7000D Automatically reduces engine speed when no power is being used Reduces fuel con sumption and engine noise Increases en gine life Complete installation and operation instruc tions included 106813 OWNER S MANUAL REPLACEMENT PARTS Note Use only original replacement parts This will protect your warranty coverage for parts replaced under warranty PARTS UNDER WARRANTY Contact authorized dealers of this product If they cannot supply original replacement part s either contact your nearest Parts Central or call DESA International s Tech nical 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 defec tive part to the factory
29. ectric starter A battery is not supplied with generator You must provide a 12 volt 32 amp hour battery The positive and nega tive battery cables are supplied with genera tor You must install these cables before mounting battery Always wear safety glasses when working with battery Make sure battery terminals 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 10 The starter solenoid is located directly above the starter on Model MGH10000A This cable is fac tory installed A CAUTION Do notovertighten positive terminal on starter sole noid Positive terminal could ro tate and cut into negative termi nal causing a short 2 Attachthe black negative battery cable to the engine block Use the bolt nut and two washers provided with the battery cables Use long mounting hole on oppo site side of engine from starter solenoid Attach cable as shown in Figure 11 Starter Solenoid Red Positive Battery Cable Figure 10 Connecting Red Positive Battery Cable to Engine Starter Solenoid Model MGH7000D Shown Black Negative Battery Cable Figure 11 Connecting Black Negative Batte
30. ed areas Make sure area has 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 contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death A DANGER Never connect gen erator to any existing electrical circuits The generator output will back feed into the utility power line This may electrocute a power company line repair person Also if generator is powering electri cal circuits the chance of an elec trical 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 re ceptacle circuit breaker Usereceptacles properly Improperuse could damage generator Use only groundedexten sion cords Power only grounded or double insulated items Do not overload receptacles All generators except models HWI3000 MGH23000 and MGH3000PR have the fol lowing receptacles see Figure 17 20V 15 amp GFCI duplex receptacle 1204 30 amp twist lock receptacle 120 240V 20 or 30 amp twist lock receptacle 120V 15 amp duplex receptacle 106813 OWNER S MANUAL Model MGH10000A also has a 120 240V 50 amp receptacle see Figure 17 Model HWI3000 has only the 120V
31. el vapor may ignite 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 Guard against fire hazard Keep opera tion area well vented Keep generator at least three feet away from any ob ject Do not place flammable objects near generator Do not use generator where flam mable vapors are present Some va pors are heavier than air These va pors 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 voltage This high voltage can cause severe electric shock Only re sponsible adults should use generator Properly ground generator before starting Never let anyone operate or service generator without proper instruc tions Avoid contact with live terminals or bare wires e 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 con ductive 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 dam age to generator may result Do not wear damp clothing or wet shoes when u
32. emove all fuel fromfueltank before storing gen erator Store fuel inapproved con tainer Store fuel in a well vented area free of open flames or sparks AX WARNING The muffler be comes 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 Use a fuel additive such as STA BIL or an equivalent when storing generator with fuel in fuel tank This will minimize fuel gum deposits from forming in engine Cover and store generator in a clean dry place Do not expose generator to extreme high or low temperatures during storage Note For additional help visit DESA International s technical service web site at www desatech com A WARNING Only a qualified electrical service person should service and repair generator Use only factory approved replacement parts Note See engine owner s manual for engine troubleshooting OBSERVED PROBLEM POSSIBLE CAUSE REMEDY No voltage when starting generator withno 1 Defective capacitor 1 Replace capacitor electrical load 2 Winding short circuit or loose 2 Check resistance of coils see Electri connections 3 Defective rotor diode 4 Loss of residual magnetism
33. g and face shield when servicing Keep out of children s reach 106813 SAFETY INFORMATION Continued 9 10 11 12 13 14 Only a qualified electrical service per son 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 prevent accidental starting 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 replace ment parts Store generator in a well vented area Make sure fuel tank is empty Never store with fuel in tank Vapors may reach an open flame or spark Fire or explosion may result Never operate generator if engine speed changes greatly if engine misfires often 18 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 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 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 main tained Be famil
34. h 22 20 F v PO sch sch 106813 ILLUSTRATED PARTS LIST For Models MGH4000C MGH4000Cl MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D and MGH7000DI Alternator Assembly This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Re placement Parts on page 19 of this manual MGH4000C MGHAOO00CI 099723 01 099844 01 099701 01 099760 01 099863 01 099863 02 17587000 M11084 26 099847 01 WLE 5 099843 01 270040028 OO OO JO Om OQ N 27003002 27003015S 099891 01 099892 01 099842 01 27003003 270030128 27003008 270030078 26322004 WLE 6 MGH5000D MGH5000DI MGH5000DIE 099723 02 099844 01 099701 01 099760 01 099863 01 099863 02 17587000 M11084 26 099847 02 WLE 5 099843 01 270050038 27003002 27003015 099891 01 099892 01 099842 02 27003003 27003012S 27003008 27003007S 26322004 WLE 6 PART NUMBER FOR MODEL MGH6000D MGH6000DI 099723 03 099844 01 099701 01 099760 01 099863 02 17587000 M11084 26 099847 03 WLE 5 099843 01 099845 01 100054 01 27003002 27003015 099891 01 099892 01 099842 03 27003003 270030128 27003008 270030078 26322004 WLE 6 Part not available by itself Must purchase Alternator Assembly Available at your local hardware store 106813 OWNER S MAN
35. her 1 4 097190 06 Gas Cap w Fuel Gage M51151 02 Fuel Line M10990 3 Bushing 106988 01 Barbed Connector 1 4 25985008 Fuel Line 105035 01 Handle 103046 01 Grip 103057 01 Plug H8C5 20C Bolt 5 16 18 x 2 5 099750 01 Bolt J Hook 5 16 18 099749 01 Battery Bracket 105908 01 Battery Mount 17529000 Shock Mount 102962 02 Spreader H5C4 24C Bolt 1 4 20 x 3 26302006 Bolt 1 2 10 x 1 WLI 8 Internal Tooth Lockwasher 14138000 Ground Strap M10908 74 Tapping Screw 1 4 20 x 5 WLE 5 External Tooth Lockwasher 106775 02 Side Panel 106775 01 Side Panel 106776 01 Top Cover 100410 01 Sems Screw 8 18 HC5 14C Bolt 5 16 18 x 1 75 099866 05 Safety Information Decal 100003 04 Operation Decal 099873 01 Battery Cable Positive Red 099873 05 Battery Cable Negative Black 4 6 Screw 1 4 20 x 75 For Model MGH10000A 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 19 of this manual OO JO O1 Go h 106813 27 MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C MGHAOOO0CI MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D and MGH7000DI Control Panel This list contains replaceable parts used in your generator When ordering
36. iar with its use Know how to stop engine quickly Know how to use all controls Prolonged exposure to loud noise can cause hearing loss When working around generator wear approved hearing protection Remember neighbors when using generator 106813 OWNER S MANUAL PRODUCT IDENTIFICATION Gas Cap Fuel Gauge Control Panel 120 Volt Receptacle 120 Volt Receptacle GFCI 120 Volt Receptacle Duplex Run Lamp Hour Meter 120 240 Volt Receptacle Circuit Breaker Choke Lever Fuel Valve Lever Starter MP e Engine Engine ON OFF Switch Oil Dipstick Figure 1 Portable Generator Model MGH4000C Shown 3 Roll Cage Gas Tank Ground Lug Alternator MASTER PORTABLE GASOLINE GENERATORS GENERAL INFORMATION Master portable generators are rugged and compact These models provide depend able trouble free service The alternators are brushless with revolving fields Honda gasoline engines provide long life under heavy use Honda engines have overhead valves OHV This provides high perfor mance with lower fuel consumption These engines are 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 except model MGH10000A Large fuel tank Oil alert system Electric starter models MGH5000DI
37. ine parts of this generator including the alternator Honda warrants the engine See engine owner s manual for engine warranty information TWO YEAR LIMITED WARRANTY GASOLINE 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 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
38. 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 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 DE S INTERNATIONAL 2701 Industrial Drive 106813 01 P O Box 90004 NOT A UPC Bowling Green KY 42102 9004 106813 01 REV B www desatech com 03 00
39. 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 infor mation listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substan tial property damage if you ignore warning WARNING indicates a hazard which can cause severe personal injury death or substan tial property damage if you ignore warning CAUTION indicates a hazard which will or can cause minor personal injury or prop erty damage if you ignore warning Gasoline presents a hazard of fire or ex plosion Gasoline is flammable Its va por is explosive 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 run ning Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Always al low room for fuel to expand If you overfill tank fuel can overflow onto hot generator This can cause fire or explosion After refueling tightly close fuel tank cap Do not spill fuel Fuel or fu
40. nder Replacement Parts on page 19 of this manual ILLUSTRATED PARTS LIST For Models MGH4000C MGHA4000CI MGH5000D MGH5000DI MGH5000DIE MGH6000D MGH6000DI MGH7000D and MGH7000DI Fuel Tank and Roll Cage KEY MGH4000C MGH5000D MGH6000D MGH7000D NO MGH4000CI MGH5000DI MGH6000DI MGH7000DI DESCRIPTION QTY MGH5000DIE 106813 OO JO Oo 25954000 099832 01 25978000 HC4 8C 099701 01 19508001 25985005 099743 01 099752 02 103880 01 NEC 5C 14138000 099853 02 WLE 5 WLI 3 WP 5C HC5 14C 099756 01 100410 01 M10908 74 WP 4C 099965 01 WP 3C 103676 01 099866 02 100003 01 03175000 25954001 107021 01 099701 01 19508001 25985005 099743 01 106063 01 103880 01 NEC 5C 14138000 099853 02 WLE 5 WLI 3 WP 5C HC5 14C 099756 01 099750 01 099749 01 NEC 5C 100410 01 M10908 74 M10908 74 WP 4C 099965 01 WP 3C 103676 01 HC4 16C 107110 01 100003 01 100003 02 099873 01 099873 02 03175000 25954001 107021 01 099701 01 19508001 25985005 099743 01 106063 01 103880 01 NEC 5C 14138000 099853 02 WLE 5 WLI 3 WP 5C HC5 14C 099756 01 100410 01 M10908 74 WP 4C 099965 01 WP 3C 103676 01 HC4 16C 107110 01 25954001 107021 01 099701 01 19508001 25985005 099743 01 106063 01 103880 01 NEC 5C 14138000 099853 02 WLE 5 WLI 3 WP 5C HC5 14C 099756 01 099750 01 099749 01 NEC 5C 100410 01 M10908 74 WP 4C 099965 01 WP 3C 103676
41. ne This can cause fire or explo sion After refueling tightly close fuel tank cap Do not spill fuel Fuel or fuel vapor may ignite If fuel spills make sure area is dry before starting engine e Neversmokein refueling area Never allow open flames or sparks in area Store fuel in approved con tainer Store fuel in a well vented area free of open flames or sparks Use clean fresh unleaded gasoline Use gasoline with octane rating of 86 or higher Service station gasoline pumps should dis play the octane rating Using gasoline with lower octane level could damage engine Avoid getting dirt dust or water in fuel tank Do not mix oil with gasoline See engine owner s manual for more information MASTER PORTABLE GASOLINE GENERATORS HANDLES AND TOP COVER Model MGH10000A Follow the steps below to attach the handles and top cover to Model MGH10000A 1 Remove the two bolts lock nuts and washers holding side panels to control panel end of roll cage Insert bolts with washers through two holes in the handle and then back through roll cage and side screen panels See Figure 8 Tighten the lock nuts against the side screen panels 2 Place top cover on top of generator roll cage with notch on control panel side Use four 8 sems screws provided to attach cover to roll cage See Figure 9 TIZ lt lt See 25 25 x 22222 LOE Lz aa ZZ
42. ng see Oil Alert System page 6 Make sure oil level is full before starting See Engine Oil page 7 Before starting the engine disconnect all electric loads from generator STARTING IMPORTANT The engine speed is preset The throttle is locked in preset position Do not adjust throttle Preset position lets en gine run at 3600 RPM under load The engine must maintain 3600 RPM for gen erator to create correct voltage Running engine at lower speeds will damage genera tor and powered items IMPORTANT Never start generator with electrical loads connected Start engine be fore adding electrical loads 1 Make sure gasoline tank is full See Fuel page 7 for fuel information 2 Move fuel valve lever to the ON posi tion except on Model MGH3000PR see Figure 19 3 Move choke lever fully to the left for all models except MGH3000PR or MGH10000A see Figure 19 Pull choke rod out for Model MGH3000PR see Figure 20 or choke button out for Model MGH10000A see Figure 21 This closes the choke Note You may not need to close choke if engine is warm or air temperature is high 4 Start the engine A Recoil Starter Move engine lever or turn engine switch to the ON position see Figures 22 and 23 Remove slack from starter rope by lightly pulling starter grip Next pull starter rope briskly IMPORTANT Do not let starter grip snap back against engine Return it gen tly This will prevent damage to starter
43. ock into place do not use receptacle Contact a qualified electrician for repairs Figure 4 GFCI Receptacle ENGINE CIRCUIT BREAKER Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A This circuit breaker or fuse protects the battery charging circuit A short circuit will trip the circuit breaker The circuit breaker will also trip if you install battery wrong Push circuit breaker button to reset On Model MGH10000A the fuse is located inside of the Keyswitch box ON OFF n START l ENGINE SW CIRCUIT BREAKER S Y Im Engine Circuit Breaker Button Nipush OFF H Figure 5 Engine Circuit Breaker 106813 OWNER S MANUAL RECEPTACLE CIRCUIT BREAKER 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 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 ad ditional items to generator after starting motors If this continues to happen reduce the total generator load Figure 6 Receptacle Circuit Breaker B
44. our generator see Specifications page 5 Elec tric motors present a special problem when figuring load Read Step 3 carefully 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 2 Enter running watts of each item ex cept motors The light bulb or appli ance nameplate lists its wattage Re member 1K W 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 3 Electric motors present a special prob lem They require up to three times their rated wattage to start Chart 2 below shows starting watts for differ ent size motors For example an elec tric 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 re quire 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
45. parts fol low the instructions listed under Replace ment Parts on page 19 of this manual PART NUMBER FOR MODEL KEY MGH4000C MGH4000Cl 103349 01 22616009 099833 01 15324000 100445 01 099956 01 22616009 099834 01 101350 01 099760 01 100410 01 100149 01 22261000 099997 01 103348 01 103348 05 100177 07 MGH5000D MGH5000DI MGH5000DIE MGH6000DI 103349 02 22616009 099833 01 15324000 100445 01 099956 01 22616011 099834 01 101350 01 099760 01 100410 01 100149 01 22261000 099997 01 103348 02 103348 06 100177 07 Includes fastening hardware A Not shown T Includes reference numbers 1 through 13 MGH6000D 103349 03 22616009 099833 01 15324000 100445 01 099956 01 22616010 099834 01 101350 01 099760 01 100410 01 100149 01 22261000 099997 01 103348 03 103348 07 100177 07 MGH7000D MGH7000DI 103349 04 22616009 099833 01 15324000 100445 01 22616010 099835 01 101350 01 099760 01 100410 01 100149 01 22261000 099997 01 103348 04 103348 08 100177 07 28 DESCRIPTION Control Panel Circuit Breaker 20 Amp 120V 30A Twist Lock Receptacle 120V 15A Duplex Receptacle 120V 15A Duplex GFCI Receptacle Full Power Selector Switch Circuit Breaker 20 Amp Circuit Breaker 25 Amp Circuit Breaker 30 Amp 120 240V 20A Twist Lock Receptacle 120 240V 30A Twist Lock Receptacle Hour Meter Bushing Sems Screw 88 18 x 1 2
46. ry Cable to Engine Block Model MGH7000D Shown 106813 BATTERY Continued MOUNTING BATTERY TO GENERATOR 1 Secure battery to generator by battery hold down system This system con sists of the battery mounting bracket hook bolts and nut see Figure 12 Note Model MGH10000A battery is located on opposite side as shown see Figure 13 2 Locate the red positive battery cable from starter solenoid Connect it to the positive battery terminal see Figures 14 and 15 3 Locate the black negative battery cable attached to engine block Connect it to the negative battery terminal see Figures 14 and 15 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 Battery Mounting Bracket ES Ka Hook Bolt Figure 12 Battery Hold Down System Model MGH7000D Shown Nut Battery Mounting Bracket Battery Figure 13 Battery Hold Down System Model MGH10000A Shown 106813 OWNER S MANUAL TO STARTER SOLENOID Figure 14 Connecting Positive and Negative Cables to Battery Model MGH7000D Shown TO STARTER SOLENOID Figure 15 Connecting Positive and Negative Cables to Battery Model MGH10000A Shown EXTENSION CORDS Only use grounded extension cords Be sure to useextension cord with proper wire gauge size See chart below Recommended Minimum Wire
47. sing 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 dur ing operation The muffler remains hot for a while after shutdown Do not touch muffler while it is hot Do not let muffler touch anything flam mable Let engine cool before trans porting or storing Have standby installation to home or building performed by a licensed elec trician Do not let anyone else wire into a utility circuit Personal injury equip ment damage or damage to home could occur Never connect generator to any exist ing electrical circuits The generator output will back feed into the utility power line This may electrocute a power company line repair person Also if generator is powering electri cal 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 Battery contains sulfuric acid Battery acid is poisonous if swallowed Con tact with skin or eyes may cause severe burns Do not tilt generator with bat tery installed Tilting could cause bat tery acid to spill Wear protective cloth in
48. ting This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 19 of this manual KEY PART NO NUMBER DESCRIPTION 100105 01 Control Board Assembly 26499000 Hex Head Screw 10 32 x 3 4 100321 01 Nylon Spacer WP C3 Flat Washer 10 26514000 Lock Nut 10 32 100324 03 Solenoid Assembly Includes Plunger Nut and Lock Washer 103812 01 Retaining Ring 100755 02 Linkage Rod 100755 01 Linkage Rod 22822000 Roll Pin 102939 01 Solenoid Mounting Bracket 100756 01 Solenoid Mounting Bracket 103811 01 Nylon Washer 100328 01 Bolt M8 x 25mm t 02407002 Flat Washer 5 16 t 100329 01 Lock Nut M8 t PARTS AVAILABLE NOT SHOWN 100320 01 Yellow Wire 100322 01 White Wire with 2 Flags 100322 02 White Wire with 1 Flag and 1 Spade 100366 01 Rocker Switch 100334 01 Auto Idle Decal Model MGH10000A Only T All Models Except MGH10000A 1 1 1 1 1 1 1 1 1 1 1 106813 31 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 eng
49. ting generator in these condi tions increases the risk of elec trocution 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 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 106813 SPECIFICATIONS MODEL HWI13000 MGH3000 Electrical Rated Wattage 2500 2500 Rated Amperage 120 V 20 8 20 8 240 V Receptacle 120 V Duplex 120 V 20 A Duplex Yes 120 V 15 A GFCI No Yes 120 V Twist Lock No No 120 240 V Twist Lock No No 120 V Full Power Switch No No 120 240 V 50 A No No General Honda Engine H P 5 5 5 5 Honda Model GX160K1VX GX160K1VX Fuel Type Gasoline Gasoline Fuel Tank Capacity 3 9 qt 3 9 qt Oil Alert System Yes Yes Start Method Recoil Recoil Weight pounds 85 5 85 5 Single phase 1 0 power factor MGH7000D MODEL MGH7000DI MGH10000A Electrical Rated Wattage 7000 10 000 Rated Amperage 120 V 57 83 3 240 V 28 3 41 7 Receptacle 120 V Duplex Yes Yes 120 V 20 A Duplex 120 V 15 A GFCI Yes Yes 120 V Twist Lock 30 Amp 30 Amp 120 240 V Twist Lock 30 Amp 30 Amp 120 V Full Power Switch No No 120
50. tion All Models Except MGH5000DIE MGH7000D MGH10000A and MGH3000PR 106813 OPERATION Continued A f Engine Switch Figure 24 Engine Switch Models MGH5000DIE MGH7000D MGH7000DI and MGH10000A Only Choke Lever Open Position Figure 25 Choke Lever Opened Model MGH7000D Shown AUTO IDLE OPERATION IMPORTANT Never start engine with elec trical loads connected Start engine before adding electrical loads 1 If engine is cold turn the Auto Idle switch OFF see Figure 26 2 Start engine Allow engine to warm up with no load for five minutes 3 Turn Auto Idle switch ON Engine will slow to idle speed Engine idle speed is preset Idle speed adjustment should not be necessary 4 Operate generator according to speci fications outlined in owner s manual 5 Engine will automatically increase to normal operating speed when you plug load into any generator outlet Auto Idle Switch Figure 26 Control Panel 106813 OWNER S MANUAL Note The 250 Volt 50 Amp receptacle is not connected through the Auto Idle circuit The Auto Idle switch must be turned off to get full power out of this receptacle see Figure 26 6 The Auto Idle system should be turned OFF when generator is shut down Adjusting the Idle Speed IMPORTANT Adjust the idle speed only If the idle speed becomes too high Ifthe engine idle speed will not regulate en gine idles and speeds up again
51. ulled back into the solenoid 9 Ifthe engine speed is too slow the en gine will want to hunt or speed up and slow down repeatedly When this Occurs increase engine speed by adjust ing throttle stop screw on carburetor refer to Carburetor Adjustment in Honda Engine Manual 10 Replace the engine linkage cover Models MGH4000CI MGH5000DI MGH5000DIE MGH6000DI and MGH7000DI Solenoid Mounting Bracket Figure 27 Solenoid Bracket Location Models MGH4000CI MGH5000DI MGH5000DIE MGH6000DI and MGH7000D Only Solenoid Mounting Bracket Figure 28 Solenoid Bracket Location Model MGH10000A Only MASTER PORTABLE GASOLINE GENERATORS OPERATION Continued HIGH ALTITUDE OPERATION This generator will not perform well at high altitudes without proper adjustment See engine owner s manual for details 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 genera tor Overloading will trip circuit breaker IMPORTANT AIl models except HWI3000 MGH3000 MGH3000PR MGH7000D MGH7000DI and MGH10000A 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 wattag
52. utton Note High ambient temperature will cause nuisance tripping 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 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 For Model MGH10000A only the oil should be between the two dots on dipstick 3 Iflevel is low fill to top of oil filler neck see Figure 7 For Model MGH10000A only fill to top dot on dipstick Only use oil recommended in engine owner s manual Note If oil level is too low oil alert system will shutdown engine and prevent engine from restarting At Top Of Figure 7 Checking Oil Level Model MGH4000C Shown FUEL WARNING Gasoline presents a hazard of fire or explosion Gasoline is flammable Its vapor is explosive 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 e Do not overfill fuel tank Al ways allow room for fuel to expand If you overfill tank fuel can overflow onto hot engi
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