Desa Hwi3000a, Mgh3000ga, Mgh3000a, Mgh4000d, Mgh4000di, Mgh5000e, Mgh5000ei, Mgh5000eie, Mgh6500aie Portable Generator User Manual
Contents
1. PORTABLE GASOLINE GENERATORS OWNER S OPERATION AND INSTALLATION MANUAL Generator Models HWI3000A MGH3000GA MGH3000A MGH4000D MGH4000DI MGH5000E MGH5000El MGH5000EIE and MGH6500AIE 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 MASTER PORTABLE GASOLINE GENERATORS SAFETY INFORMATION A warninas IMPORTANT Read this owner s manual and the engine owner s manual carefully Become familiar with this generator before trying to operate or service it Know its uses limitations and any hazards involved Improper use of generator can cause severe injury or death from explosion fire burns electrical shock or carbon monoxide poisoning A DANGER Carbon monoxide poisoning may lead to death Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death Use only in well vented areas Make sure area has plenty of free moving fresh outside air Never run generator in an enclosed or confined area Never run generator inside occupied building 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 more affected by carbon monoxide than others These include pregnant2. Figure 21 Engine Switch In OFF Position Fuel Valve Lever Off Position AN N Figure 22 Fuel Valve Lever Off Model MGH6500AIE Shown MAINTENANCE AND REPAIRS AX WARNING Only a qualified electrical service person should service and repair the alternator on this generator Use only factory approved replacement parts A CAUTION The engine speed is preset The throttle is locked in preset position Do not adjust throttle Preset position lets engine run at 3600 RPM under load The engine must maintain 3600 RPM for generator to create correct voltage Running engine at lower speeds will damage gen erator and powered items A CAUTION Shut off generator before performing maintenance IMPORTANT Keep generator level when servicing Never turn generator upside down or stand it on end to service Note We supply the engine owner s manual with generator Refer to that manual for questions concerning engine maintenance and repairs Non engine parts require little maintenance Keep generator clean Use a damp cloth to clean outside surfaces Never use water to clean generator Water can cause damage to internal parts Use vacuum to clean air inlet and outlet louvers of alternator 14 STORAGE AX WARNING Removeallfuelfrom fuel tank before storing generator Store fuel in approved container Store fuel in awell vented area free of open flames or sparks AX WARNING The muffler be com
3. 28 3 Yes Yes 30 Amp 30 Amp No No 13 GX390K1VXE Gasoline 8 gal Yes Electric 247 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 The oil alert 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 Operate 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 Models HWI3000A ENGINE SW MGH3000GA MGH3000A R ON MGH4000D MGH4000DI OF MGH5000E and MGH5000EI Models MGH5000EIE and MGH6500AIE OFF o START D CIRCUIT BREAKER Z Figure 2 Engine Switch Location FULL POWER SELECTOR SWITCH All models except HWI3000A MGH3000GA MGH3000A and MGHO6S500AIE have a full power selector switch on the control panel The switch has two positions 120 VOLT ONLY and 120 240 VOLT 120
4. Ground Lug Copper or Brass Grounding Point 3 PF serrate Figure 12 Grounding Generator Model MGH4000D Shown Ground Wire STANDBY INSTALLATION TO HOME OR BUILDING AX 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 askilled licensed electri cian This is not a do it yourself job Follow all local codes AX WARNING The electrician must install a double throw transfer switch This isolates ex isting electrical circuits from the utility power line If not isolated generator output will back feed into utility power line This may electrocute a power company line repair person MASTER PORTABLE GASOLINE GENERATORS DETERMINING ELECTRICAL LOAD FOR GENERATOR You must decide what electrical load your generator can power Do this before us Ing generator Use
5. L L L L L MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000D MGH4000DI MGH5000E MGH5000EI MGH5000EIE and MGH6500AIE Control Panel This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual PART NUMBER FOR MODEL MGH5000E KEY MGH4000D MGH5000EI MGH4000DI MGH5000EIE MGH6500AIE DESCRIPTION 103349 01 103349 02 103349 05 Control Panel 1 22616009 22616009 22616009 Circuit Breaker 20 Amp 2 099833 01 099833 01 099833 01 120V 30A Twist Lock Receptacle 1 104202 01 104202 01 104202 01 120V 20A Duplex Receptacle 1 100445 01 100445 01 100445 01 120V 15A Duplex GFCI Receptacle 1 099956 01 099956 01 Full Power Selector Switch 1 22616009 Circuit Breaker 20 Amp 2 22616011 Circuit Breaker 25 Amp 2 22616010 Circuit Breaker 30 Amp 2 099834 01 099834 01 120 240V 20A Twist Lock Receptacle 1 099835 01 120 240V 30A Twist Lock Receptacle 1 101350 01 101350 01 101350 01 Hour Meter 1 099760 01 099760 01 099760 01 Bushing 1 100410 01 100410 01 100410 01 Sems Screw 8 18 x 1 2 4 100149 01 100149 01 100149 01 Control Box 1 22261000 22261000 22261000 U Nut 8 099997 01 099997 01 099997 01 Switch Plug 1 118681 01 118681 02 Control Panel Assembly 1 118681 03 118681 04 118681 05 Control Panel Assembly Auto Idle Models 1 100177 07
6. MGHS5000EIE and MGHO6S500A IE see Figure 20 8 Turn Auto Idle switch ON Make sure solenoid is engaged When engaged the plunger is pulled back into the solenoid ad If the engine speed is too slow the engine will want to hunt or speed up and slow down repeatedly When this occurs increase engine speed by adjusting throttle stop screw on carbu retor refer to Carburetor Adjustment in Honda Engine Manual 10 Replace the engine linkage cover Models MGH4000DI MGHSOOOEI MGHSQ000EIE and MGH6500AIE Figure 20 Solenoid Bracket Location Models MGH4000DI MGH5000EI MGHS5000EIE and MGH6500AlIE Only 13 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 All models ex cept HWI3000A MGH3000A and MGH6S00AIE 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 power ing 240V items 1 Check items to be powered Their nameplate lists their wattage ratings Note The wattage ratings for some electrical motors are misleading The
7. OWNER S MANUAL REPAIR SERVICE Note Only use original replacement parts This will protect your warranty coverage for parts replaced under warranty Each Authorized Service Center is indepen dently owned and operated For additional Service Center or warranty information call 1 800 858 8501 or visit our Technical Service web site at www desatech com WARRANTY SERVICE If productrequires warranty service returnitto nearest Authorized Service Center You must show proof of purchase If faulty materials or workmanship caused damage we will repair or replace product without charge Note Normal wear misuse abuse neglect or accidental damage is not covered under warranty NON WARRANTY SERVICE If product requires service return it to nearest Authorized Service Center Repairs will be billed to you at regular repair list prices PARTS CENTRALS These Parts Centrals are privately owned businesses They have agreed to support our customer s needs by providing original replacement parts and accessories Tool amp Equipment 5 Manila Drive Hamden CT 06514 0322 203 248 7553 1 800 397 7553 Grainger Parts Operations 1657 Shermer Road Northbrook IL 60062 5362 708 498 5900 1 800 323 0620 www grainger com Portable Heater Parts 342 North County Road 400 East Valparaiso IN 46383 9704 219 462 7441 1 800 362 6951 www portableheaterparts com sales portableheaterparts com techservice portableheaterpart
8. Continued 9 10 11 12 13 14 Only a qualified electrical service person should service and repair generator e Generator produces high voltage Use extreme caution when working on electrical parts e Always remove spark plug wire from spark plug before servicing This will prevent accidental starting e When working on generator avoid hot muffler exhaust manifold and engine parts Severe burns may occur e Do not work on generator when tired e 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 e if engine speed changes greatly if engine misfires often if powered items overheat e if electrical output drops if it is sparking if it produces smoke or flames e if it vibrates at high levels e if it has a damaged receptacle Keep generator and nearby areas clean Keep generator free of oil mud and other foreign matter e 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 familiar with its use Know how to stop engine quickly
9. Know how to use all controls Prolonged exposure to loud noise can cause hearing loss When working around generator wear approved hearing protection e Remember neighbors when using generator 118683 OWNER S MANUAL PRODUCT IDENTIFICATION Gas Cap Fuel Gauge Control Panel 120 Volt Receptacle 120 Volt Receptacle GFCI 120 Volt Receptacle Duplex Provision for Auto ldle Switch Run Lamp Hour Meter 120 240 Volt Roll Cage Receptacle Circuit Breaker Gas Tank Fuel Valve Lever Starter Grip Alternator Engine Engine ON OFF Switch Oil Dipstick Figure 1 Portable Generator Model MGH4000D Shown 3 MASTER PORTABLE GASOLINE GENERATORS GENERAL INFORMATION Master portable generators are rugged and compact These generators use brushless alternators for dependable trouble free ser vice Honda gasoline engines provide long life under heavy use Honda engines have overhead valves OHV This provides high performance 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 e Spark arresting muffler e Large fuel tank Oil alert system Electric starter models MGH5000EIE and MGH6S00AIE 15 Amp ground fault circuit interrupter GFCI receptacle Except
10. Products makes no warranty with respect to the engine and engine components not of its manufac ture They are subject to warranties of their manufacturers Honda warrants the engine See engine owner s manual for engine warranty information DESA Specialty Products warrants each generator excluding engine of its manufacture to be free from defects in material and workmanship for five years from the date of first purchase from an authorized dealer provided that the product has been properly installed maintained and operated in accordance with all applicable instructions The bill of sale or proof of purchase must be presented at the time a claim is made under this warranty This warranty is extended only to the original retail purchaser This warranty covers only the parts and labor required to restore this unit to its proper operating condition Warranty parts must be obtained through factory authorized deal ers and service centers for this product These dealers and service centers will provide original factory replacement 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 aut
11. Switch Figure 19 Control Panel 6 The Auto Idle system should be turned OFF when generator is shut down 118683 OPERATION Continued Adjusting the Idle Speed IMPORTANT Adjust the idle speed only If the idle speed becomes too high e Ifthe engine idle speed will not regulate en gine idles and speeds up again and again Turn Auto Idle switch OFF Start en gine Allow engine to warm up with no load for five minutes bd AX WARNING Always set the idle speed before turning on the Auto Idle If idle speed is not set the larger resistor onthe control board may become hot Heat from the resistor may damagethe protective coating on the control board 2 Remove engine linkage cover Mod els MGH4000DI MGHSOOOEI MGHSOOOEIE and MGH6500A IE 3 Push plunger into solenoid body to manu ally engage solenoid and set idle speed 4 Loosen nut that holds the solenoid mounting bracket to the generator Models MGH4000DI MGHSOOOEI MGHSOOOEIE and MGH6S500AIE See Figure 20 5 Slowly pull solenoid bracket away from engine 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 118683 OWNER S MANUAL 7 After reaching proper idle speed tighten nut to secure solenoid mount ing bracket Models MGH4000DI MGHS5000EI
12. T Shaft End Cap Capacitor Stator Bolt Grounding Lug Bearing Housing Stator Fan Bracket T Includes fastening hardware Includes reference numbers 1 through 22 Parts not available Included in alternator assembly ht A 19 i KEY PART KEY NO NUMBER DESCRIPTION QTY NO 11 OWNER S MANUAL 26327006 WLE 5 118713 01 118706 01 118708 01 118709 01 118707 01 118711 01 118674 01 118674 02 099867 02 Bolt 5 16 24 x 5 8 Lock Washer 5 16 Flange Fan Rotor Diode Varistor Bearing Draw Bolt Safety Information Decal Safety Information Decal Operation Decal MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000D MGH4000DI MGH5000E MGH5000El MGH5000EIE MGH6000D MGH6O000DI MGH6500AlIE Alternator Assembly This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual PART NUMBER FOR MODEL MGH5000E KEY MGH4000D MGH5000EI MGH4000DI MGH5000EIE MGH6500AIE DESCRIPTION 118055 01 118055 02 118055 03 Alternator Assembly 118782 01 118782 01 118782 01 End Cover 118714 01 118714 01 118714 01 Shaft End Cap 118712 01 118783 01 118783 02 Capacitor 118784 01 118784 02 118784 04 Stator Bolt 118785 01 118785 01 118785 01 Bearing Housing O Stator 118786 01 118786 01 118786 01 Fan Brac
13. VOLT ONLY This position sends full power to the 120V receptacles only 240V power is not available Use this position when powering 120V items only 120 240 VOLT This position sends full power to the 120 240V receptacle It also powers the 120V receptacles at reduced wattage capacity IMPORTANT Do not move the full power selector switch while powering electrical items Unplug all items before moving switch Failure to do so can damage switch Models HWI3000A MGH3000GA MGH3000A and MGH6500AIE do not have this switch These models provide full power to all receptacles r Full Pow el er Full Power 120 V 120 120 V 120 ONLY 240V ONLY 240V r Po Selecto ENM ENM 120 VOLT ONL 120 240 VOLT Position Position Figure 3 Full Power Selector Switch AUTO IDLE SYSTEM The Auto Idle System allows the engine toidle down or run at a slower speed when the gen erator is not being used to supply power The Auto idle system can be turned ON or OFF by arocker 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 pres
14. 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 Ifbattery acid gets on your skin wash with water Ifbattery acid gets in your eyes flush with water at least 15 minutes Call a doctor at once Battery acid is poisonous lfswallowed drinklargeamounts of water or milk Follow 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 terminal may spark when genera tor runs IMPORTANT Make sure battery connec tions are the correct polarity Electric start generators use negative ground 12 volt DC starting system Models MGHS000EIE and MGH6500AIE have an electric starter A battery is not supplied with generator You must provide a 12 volt 32 amp hour battery The positive and negative battery cables are supplied with generator You must install these cables before mounting battery Always wear safety glasses when working with battery Make sure battery 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 p
15. ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual 22 118683 OWNER S MANUAL ILLUSTRATED PARTS LIST For Models HWI3000A and MGH3000A Roll Cage This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual KEY PART NO NUMBER DESCRIPTION QTY 118916 02 Roll Cage NEC 5C Lock Nut 5 16 18 099853 03 Shock Mount Bolt 5 16 18 x 1 2 WLE 5 Lock Washer 5 16 14138002 Grounding Strap 099853 02 Shock Mount Available at any hardware store 118683 23 PORTABLE GASOLINE GENERATORS a uju Q dso a SS O O LO LO daN Z Z Zuo x al s ep 20086 o x S 9a Sss e aq Sry cS56c 118683 ILLUSTRATED PARTS LIST For Models MGH4000D MGH4000DI MGH5000E MGH5000EI MGHSOOOEIE and MGH6500AIE Fuel Tank and Roll Cage 118683 MGH5000E KEY MGH4000D MGH5000EI NO MGH4000DI MGHSOOOEIE MGH6500AIE DESCRIPTION O ON O O1 W DY 25954000 099832 01 25978000 HC4 8C 099701 01 19508001 25985005 099743 01 118918 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 17587000 OWNER S MANUAL This list contains replaceable parts used in your generator When ordering parts follow the instructions l
16. 100177 07 100177 07 Panel Schematic Decal 1 Includes fastening hardware A Not shown t Includes reference numbers 1 through 13 28 118683 REPLACEMENT PARTS AND ACCESSORIES For original replacement parts and acces sories contact your nearest Authorized Dealer or Authorized Service Center for this product If they can not supply the part or accessory contact your nearest Parts Central listed below Each Authorized Dealer Au thorized Service Center and Parts Central is independently owned and operated See pages 19 through 31 for an Illustrated Parts List If you need additional referral information contact our Technical Service Department see Technical Service page 15 In Canada call 1 800 561 3372 for parts information Heavy Duty Wheel Kit PA2022 For Models MGH4000D MGH4000DI MGH5000E MGH5000El MGH5000EIE and MGH6500AIE Wheelbarrow style wheel kit Makes genera tor easy for one person to move This kit includes e Large 12 inch wheels for easy rolling Powder coated tubing and plated hard ware for long life e Long handles with thick grips for greater comfort and control Complete installation instructions included Automatic Idle Kit PA2011 For Models MGH4000D and MGH5000E Automatically reduces engine speed when no power is being used Reduces fuel consumption and engine noise Increases engine life Complete installation and operation instruc tions included 118683
17. 2 9004 When contacting DESA Specialty Prod ucts have ready Your Name e Your Address Your Phone Number Model Number of Product Serial Number e Date of Purchase Include copy of receipt for written requests at www desatech com OBSERVED PROBLEM No voltage when starting generator with no electrical load Voltage is less than normal voltage with no electrical load Voltmeter reading more than 10 high with no electrical load Voltmeter reading correct with no electrical load but more than 10 low when electrical load is added 118683 Note See engine owner s manual for engine troubleshooting POSSIBLE CAUSE 1 Defective capacitor 2 Winding short circuit or loose connections 3 Defective rotor diode 4 Loss of residual magnetism 1 Engine speed too low 2 Defective rotor diode 3 Partial short circuit in winding 4 Defective capacitor 1 Engine speed too high 1 Defective rotor diode 2 Electrical load too high 3 Engine not running properly www desatech com 15 REMEDY 1 Replace capacitor 2 Check resistance of coils see Electrical Component Specifications page 16 3 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor ter minals for 2 3 seconds 1 Set engine speed to 3720 RPM 62 Hz with no load 2 Replace both diodes on rotor 3 Check resistance of coils see Electrical Component Specifications page 16 4 Replace capacitor 1
18. 4000D and MGH5000E Continued 118683 17 PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued White 120 240V 20A Receptacle 120V 15A 120V 15A Receptacle Receptacle 120V 30A Receptacle Circuit Circuit Breaker Auxiliary Phase Stator T4 Rotor Stator T1 T2 T3 T4 Diode 3 Diode L1 220 240V L2 110 120V 110 120V Figure 25 Wiring Diagram Models MGH4000DI MGHS5000EI and MGHS5000EIE White 120 240V 30A Switch Receptacle 120V 15A Receptacle 120V 15A Receptacle To Solenoid Circuit Breaker 30A T4 Yellow Main Auxiliary Windings Phase Stator T4 Rotor Stator T1 T2 T3 T4 Diode 3 Diode L1 220 240V L2 110 120V 110 120V Figure 26 Wiring Diagram Model MGH6500AIE 18 118683 ILLUSTRATED PARTS LIST For Model HWI3000A MGH3000GA and MGH3000A Alternator Assembly This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual 3 4 5 6 7 8 9 1 118054 01 118703 01 100445 01 104201 01 22616009 118714 01 118712 01 118710 01 17587000 118704 01 118705 01 Alternator Assembly End Cover 120V 15A Duplex GFCI Receptacle MGHS000GA MGH3000A T 120V 20A Duplex GFCI Receptacle HWI3000A T Circuit Breaker 20 Amp
19. EIE electric start models 100003 01 100003 02 099873 01 099873 02 03175000 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 WO a MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting Control Board Assembly and Mounting 26 118683 OWNER S MANUAL ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual KEY PART NO NUMBER DESCRIPTION 118683 100105 01 26499000 100321 01 WP C3 26514000 100324 03 100755 02 118632 01 22822000 118635 01 100328 01 108585 01 100329 01 Control Board Assembly Hex Head Screw 10 32 x 3 4 Nylon Spacer Flat Washer 10 Lock Nut 10 32 Solenoid Assembly Includes Plunger Nut and Lock Washer Linkage Rod Linkage Rod MGH6500AlIE Only Roll Pin Solenoid Mounting Bracket Bolt M8 x 25mm Flat Washer M8 Lock Nut M8 PARTS AVAILABLE NOT SHOWN 100320 01 100322 01 100322 02 100366 01 100334 01 Yellow Wire White Wire with 2 Flags White Wire with 1 Flag and 1 Spade Rocker Switch Auto Idle Decal 27 ee L
20. HWI3000A 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 MGHSOOOEIE and MGH6S500AIE only These cables are in a separate bag inside generator carton You must in stall these cables to engine See Battery page 8 for installation instructions VENTILATION AX DANGER Use only in well vented areas Make sure area has plenty of free moving fresh outside air Never run generator in an enclosed or confined area Never run generator inside oc cupied building Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death This generator needs cooling air to run prop erly Never block free flowing cooling air to generator Overheating will occur without cooling air This will damage the generator Keep generator at least three feet away from any object DUST DIRT RAIN AND SNOW Awarnine Do not use genera tor outdoors in rain or snow Do not use generator near standing water or snow Do not use if generator is wet or damp Operating generator in these conditions increases the risk of electrocution Severe injury or death can occur Do not use generator in extremely dusty or d
21. Push circuit breaker button to reset Electric motors need higher starting current They require up to three times their rated wattage to start The starting current needed may be too high This can cause nuisance circuit breaker tripping To help prevent this start electric motors first Connect additional items to generator after starting motors If this continues to happen reduce the total generator load Figure 6 Receptacle Circuit Breaker Button 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 3 If level is low fill to top of oil filler neck see Figure 7 Only use oil rec ommended in engine owner s manual Note If oil level is too low oil alert system will shutdown engine and prevent engine from restarting Oil Level At Top Of Filler Neck Oil Figure 7 Checking Oil Level Model MGH4000D Shown FUEL A WARNING Gasoline presents a hazard of fire or explosion Gasoline is flammable Its vapor
22. Set engine speed to 3720 RPM 62 Hz with no load Replace both diodes on rotor Do not overload generator 3 Contact an authorized engine service center Ne MASTER PORTABLE GASOLINE GENERATORS ELECTRICAL COMPONENT SPECIFICATIONS Resistance in ResistanceinOhms Stator Stator Rotor Main Exciting Primary Winding Winding A Winding T HWI3000A MGH3000GA MGHS3000A 1 63 MGH4000D MGH4000DI 0 709 MGHS5000E MGHSOOOE I MGH5000EIE 0 570 MGH6500AIE 326 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 118683 16 Capacitor MFD Diodes 2 450 Volt 800 Volt OWNER S MANUAL WIRING DIAGRAMS Stator Black Receptacle N 120V 15A O MGH3000 Receptacle 120V 20A TE Breaker L1 110 1120V L2 Yellow Rotor Stator White C Auxiliary Phase i T2 i I ee eee ee a Green Yellow Circuit Breaker 25A 120V 15A Receptacle 120 240V 20A Receptacle 120V 15A Receptacle 120V 30A Receptacle Circuit T1 Circuit L a es ee ee ee ee Capacitor Auxiliary Windings Phase Stator we T4 Rotor Stator pa Tol T3 T Diode 3 Diode L1 220 240V L2 110 120V 110 120V Figure 24 Wiring Diagram Models MGH
23. 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 e 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 flammable Let engine cool before transporting or storing Have standby installation to home or building performed by a licensed electrician Do not let anyone else wire into a utility circuit Personal injury equipment damage or damage to home could occur Never connect generator to any 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 electrical circuits the chance of an electrical fire exists Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking or running Only service or use battery in a well vented area Battery contains sulfuric acid Battery acid is poisonous if swallowed Contact with skin or eyes may cause severe burns Do not tilt generator with battery installed Tilting could cause battery acid to spill Wear protective clothing and face shield when servicing Keep out of children s reach 118683 SAFETY INFORMATION
24. V 15 amp GFCI duplex receptacle 120V 15 Amp GFCI Duplex 120V 15 Amp Duplex ka 120 240V 20 or 30 Amp Twist Lock 120V 30 Amp Twist Lock Figure 13 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 e NEMA L14 20P 20 amp or L14 30P 30 amp plug Four wire 20 amp or 30 amp cord 20 Amp Neutral 120V 120V L14 20P Plug Ground L14 20P Plug 120 240 Volt 20 and 30 Amp Figure 14 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 standing water and snow Make sure area is well vented AX WARNING Only responsible adults should use generator Never let anyone operate genera tor without proper instructions Note If oil level is too low oil alert system will keep engine from starting 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 po
25. charged See engine owner s manual for more information Battery Mounting Bracket TO STARTER SOLENOID Figure 11 Connecting Positive and Negative Cables to Battery Model MGH6500AIE Shown 118683 EXTENSION CORDS Only use grounded extension cords Be sure touse extension cord with proper wire gauge size See chart below Recommended Minimum Wire Gauges AWG for Extension Cords AWG for Length of Cord in Feet 18 18 118683 OWNER S MANUAL GENERATOR GROUNDING AX WARNING You must properly earth ground generator before starting This will help guard against deadly electric shock Only use grounded plugs with genera tor Only use grounded extension 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 roll cage see Figure 12 Attach a 10 stranded copper ground wire to ground lug Drive grounding point into ground Grounding point can be a stake grounding rod or pipe Grounding point should be copper or brass Attach ground wire to grounding point You must supply the ground wire and grounding point These do not come with generator Follow the National Electrical Code and all state and local codes Consult your power company or a licensed electrician AX WARNING For a grounding point do not use metal pipe be ing used to carry combustible materials or gases
26. es 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 118683 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 directory under the listing Engines Gasoline Honda or visit www honda engines com or call Honda direct 1 800 426 7701 TROUBLESHOOTING Note For additional help visit DESA International s technical service web site OWNER S MANUAL TECHNICAL SERVICE You may have further questions about as sembling operating or maintaining this product If so you can visit our Technical Service web site at www desatech com or contact our Technical Service Department at 1 800 858 8501 English Only Youmay also write to DESA Specialty Products ATTN Technical Service Specialty Products P O Box 90004 Bowling Green KY 4210
27. et speed required to produce the correct voltage IMPORTANT A minimum current load of 1 Amp is 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 generator and powered items 6 ELECTRIC START Models MGH5000EIE and MGH6500AIE Models MGH5000EIE and MGH6S500ATE have electric starters A battery 1s not sup plied with generator You must provide a 12 volt 32 amp hour battery For more battery information see Battery page 8 GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE All models Except HWI3000A have a 120 volt ground fault circuit interrupter GFCI receptacle The GFCI receptacle is on the control panel or top cover of alternator mod els MGH3000GA and MGH3000A only The GFCI protects you against hazardous electrical shock caused when your body becomes a path through which electricity travels to reach ground This could happen when you touch an 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 shou
28. horized dealer or service center Routine maintenance is the responsibility of the owner Travel handling transportation and incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of the owner 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 war ranties of merchantability and fitness for a particular purpose to five years from the date of first purchase and DESA Specialty Products liability is hereby limited to the purchase price of the product and DESA Specialty Products 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 con sult the applicable state laws DESA SPECIALTY PRODUCTS Bowling Green KY 42102 9004 www desatech com 118683 01 REV A 03 06
29. irty 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 foreach 10 temperature rise above 60 F Very low temperatures may make the engine hard to start See engine owner s manual for more information 118683 SPECIFICATIONS MODEL Electrical Rated Wattage Rated Amperage 120 V 240 V Receptacle 120 V Duplex 120 V 20 A Duplex 120 V 15 A GFCI 120 V Twist Lock 120 240 V Twist Lock 120 V Full Power Switch 120 240 V 50 A General Honda Engine H P Honda Model Fuel Type Fuel Tank Capacity Oil Alert System Start Method Weight pounds HWI3000A 2500 20 8 Yes No No No No No 20 GX160K1VX Gasoline 3 9 at Yes Recoil 85 5 Single phase 1 0 power factor 118683 MGH3000GA MGH3000A 2500 20 8 Yes No No No No 5 5 GX160K1VX Gasoline 3 9 at Yes Recoil 85 5 2500 20 8 Yes No No No No 5 5 GX160K1VX Gasoline 3 9 at Yes Recoil 85 5 MGH4000D MGH4000DI 4000 33 3 16 7 Yes Yes 30 Amp 20 Amp Yes No 8 GX240K1VA Gasoline 5 gal Yes Recoil 139 MGH5000E MGH5000EI MGH5000EIE 5000 41 7 20 8 Yes Yes 30 Amp 20 Amp Yes No 9 GX270VA Gasoline 8 gal Yes Recoil Elec 173 OWNER S MANUAL MGH6500AIE 6500 57
30. is explosive Keep fuel out of children s reach Refuel generator in a well vented area Do notfill fuel tank in the dark Do not refuel while engine is running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Always allow room for fuel to expand If you overfill tank fuel can overflow onto hot engine This can cause fire or explosion 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 Never smoke in refueling area Never allow open flames or sparks in area Store fuel in approved contain er 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 BATTERY Models MGHS5000EIE and MGH6500AIE AX WARNING Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking or running Only service or use battery in a well vented area A WARNING Battery contains sulfuric acid Contact with skin or eyes
31. isted under Replacement Parts on page 32 of this manual 25954001 107021 01 099701 01 19508001 25985005 099743 01 118917 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 17587000 25954001 107021 01 099701 01 19508001 25985005 099743 01 118917 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 01 HC4 16C 107110 01 17587000 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 8 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 Grounding Lug PARTS AVAILABLE NOT SHOWN ow oS JN A 1 3 3 1 9 h h PON O G BO DYN LN 099866 02 100003 01 03175000 Only on MGH5000
32. ket 26322004 26322004 26322004 Bolt 3 8 16 x 5 8 WLE 6 WLE 6 WLE 6 Lock Washer 3 8 118787 01 118787 01 118787 01 Flange 118788 01 118788 01 118788 01 Fan x Rotor 118708 01 118708 01 118708 01 Diode 118709 01 118709 01 118709 01 Varistor 118789 01 118789 01 118789 01 Bearing 118791 01 118791 02 118791 03 Draw Bolt CO OO N O O1 ON JN YO PE DBR HSH A S Part not available by itself Must purchase Alternator Assembly Available at your local hardware store 20 118683 OWNER S MANUAL ILLUSTRATED PARTS LIST For Model MGH3000GA Alternator Assembly This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under Replacement Parts on page 32 of this manual KEY PART NO NUMBER DESCRIPTION QTY 1 118669 01 Handle includes 2 spacers WLE 4 1 4 Lock Washer 099769 01 M6 x 35 Bolt NEC 5C 5 16 18 Nut 099754 01 Engine Spreader 118821 02 Rubber Bumper WP 5C 5 16 Flat Washer 50009402 5 16 18 x 1 2 Bolt 118790 01 5 16 18 x 1 Bolt WLE 5 5 16 Lock Washer 118821 01 Rubber Bumper O ON O Q W MY NW NO AN NN PO Note Fuel tank is available from Engine Mfg Co only 118683 21 MASTER PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models HWI3000A and MGH3000A Roll Cage This list contains replaceable parts used in your generator When
33. ld 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 receptacle is good AX WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a quali fied electrician for repairs 118683 GENERATOR FEATURES Continued 2 If the GFCI receptacle tests okay restore power by pushing the RESET button back in The test lamp should work at this time IMPORTANT You must press the RESET button firmly and fully It should lock into place If the GFCI does not lock into place do not use receptacle Contact a qualified electrician for repairs Figure 4 GFCI Receptacle ENGINE CIRCUIT BREAKER Models MGH5000EIE and MGH6500AIE 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 OFF 7 START AR q Engine Circuit Breaker Button oo ZS m ON push OFF Figure 5 Engine Circuit Breaker 118683 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 receptacle Let circuit breaker cool down
34. ll 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 oc cupied building Engine exhaust contains poisonous carbon monoxide 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 electrical circuits the chance of an electri cal fire exists Note We supply the engine owner s manual with generator Refer to that manual for ques tions concerning engine operation 118683 OWNER S MANUAL USING RECEPTACLE Note Do not exceed amperage rating of receptacles Exceeding rating will trip re ceptacle circuit breaker Use receptacles properly Improper use could damage generator Use only grounded exten sion cords Power only grounded or double insulated items Do not overload receptacles All generators except models HWI3000A MGH3000GA and MGH3000A have the following receptacles see Figure 13 e 120V 15 amp GFCI duplex receptacle e 120V 30 amp twist lock receptacle e 120 240V 20 or 30 amp twist lock receptacle e 120V 15 amp duplex receptacle Model HWI3000A has only the 120V 20 amp duplex receptacle Models MGH3000GA and MGH3000A have only the 120
35. ngine e Never smoke in refueling area Never allow open flames or sparks in area e 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 object Do not place flammable objects near generator e Do not use generator where flam mable vapors are present Some vapors are heavier than air These vapors settle in low lying places Do not use generator in enclosed spaces This includes motor home or RV generator compartments Guard against electric shock Generator produces high voltage This high voltage can cause severe electric shock Only re sponsible adults should use generator Properly ground generator before starting e Never let anyone operate or service generator without proper instructions e Avoid contact with live terminals or bare wires Do not use generator outdoors in rain or snow Do not use generator near standing water or snow e Do not use if generator is wet or damp e Do not use generator in highly con ductive areas These areas include metal decking and steelwork Only use grounded extension cords e Do not use any worn or damaged electric cords Electric shock or dam age to generator may result e Do not wear damp clothing or wet shoes when using generator Guard against burns Hot engine parts can cause severe injury
36. o 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 starting again Note If engine does not start check the oil in the crankcase Add oil as necessary Be sure engine is on a level surface See Oil Alert System page 6 5 As engine warms up slowly move choke lever fully to the right see Figure 18 This opens the choke ENGINE SW ON OFF Figure 16 Engine Switch In ON Position All Models Except MGH5000EIE and MGH6500AIE 12 Engine Switch _ Figure 17 Engine Switch Models MGH5000EIE and MGH6500AlIE Only Choke Lever Open Position Figure 18 Choke Lever Opened Model MGH6500AIE 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 19 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 lIdle
37. ositive battery cable to the starter solenoid on engine see Figure 8 This cable is factory installed A CAUTION Do not over tighten positive terminal on starter so lenoid Positive terminal could rotate and cut into negative ter minal causing a short 2 Attach the 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 9 Starter Solenoid Red Positive Battery Cable Figure 8 Connecting Red Positive Battery Cable to Engine Starter Solenoid Model MGH6500AIE Shown SSS S b PM VER ct N amp Z Black JUI Negative Battery Cable Figure 9 Connecting Black Negative Battery Cable to Engine Block Model MGH6500AIE Shown 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 10 2 Locate the red positive battery cable from starter solenoid Connect it to the positive battery terminal see Figure 11 3 Locate the black negative battery cable attached to engine block Connect it to the negative battery terminal see Figure 11 4 Check battery before starting engine Make sure fluid levels are full Make sure battery is
38. s com 29 FBD 1349 Adams Street Bowling Green KY 42103 3414 270 846 1199 1 800 654 8534 franktalk aol com Master Part Distributors 1251 Mound Avenue NW Grand Rapids MI 49504 2672 616 791 0505 1 800 446 1446 www masterparts net Bowden Electric Motor Service 1681 S Wesleyan Blvd Rocky Mount NC 27803 252 446 4203 East Coast Energy 10 East Route 36 West Long Branch NJ 07764 1501 1 800 755 8809 Laportes 2444 N Sth Street Hartsville SC 29550 7704 843 332 0191 MTA Distributors 555 Hickory Hills Blvd Nashville TN 37189 9244 615 299 8777 1 800 264 0225 Industrial Hardware 4109 Bainbridge Blvd Chesapeake VA 23324 1403 804 543 2232 1 800 788 0008 catatem erols com Mills Lawn and Garden 928 Commonwealth Place Virginia Beach VA 23464 757 361 9293 www imills parts com Tuco Industrial Products 5223 180th Street SW Suite 4A 1 Lynnwood WA 98037 4506 425 743 9533 1 800 735 1268 www tucoheat com MASTER PORTABLE GASOLINE GENERATORS OWNER S MANUAL 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 FIVE YEAR LIMITED WARRANTY GASOLINE PORTABLE GENERATORS DESA Specialty
39. sition lets engine run at 3600 RPM under load The engine must maintain 3600 RPM for generator to create correct voltage Running engine at lower speeds will damage generator and powered items IMPORTANT Never start generator with electrical loads connected Start engine before 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 see Figure 15 Choke Lever Closed Position A ra Lee qe Fuel Valve Lever ON Position Figure 15 Fuel Valve Lever On Choke Lever Closed Model MGH4000D Shown 3 Move choke lever fully to the left 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 Figure 16 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 Note If engine does not start check the oil in the crankcase Add oil as necessary Be sure engine is on a level surface See Oil Alert System page 6 B Electric Starter Models MGH5000EIE and MGH6500AIE Only Turn the engine switch to the START position see Figure 17 Hold it there until engine starts When engine starts let switch return t
40. 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 3 wattage of generator For rated wattage of your generator see Specifications page 5 Electric 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 Typical Electric Appliance Wattages Chart 1 equipment wans Wate Watts Watts Light bulb 100W Radio Fan Television Furnace fan 1 3 hp with blower Vacuum cleaner Sump pump 1 3 hp Refrigerator freezer 6 Circular saw Floodlight 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 Enter running watts of each item except motors The light bulb or appliance nameplate lists its wattage Remem ber IKW 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 Electric motors present a special prob lem They require up to three times their rated
41. wattage to start Chart 2 below shows starting watts for different size motors For example an electric motor nameplate states 5 amps at 120 volts 5 amps x 120 volts 600 watts running Multiply this figure by 3 This will show the starting watts needed 600 watts x 3 1800 watts to start When figuring the generator load for motors you must use the starting watts figure Chart 2 Do not use the running watts figure Note Some motors require nearly the same wattage to run as to start These items include saws drills hair dryers and food mixers See Chart 1 for typical appliance wattage examples 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 25 extra capacity for future needs or extra equipment Approximate Starting Watts Universal Motors small appliance Approximate Running 10 Repulsion Split Phase Motors Induction Motors Capacitor Motors Always use starting watts not running watts when figuring correct electrical load x Motors of higher horsepower are not generally used 118683 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 AX DANGER Use only in we
42. 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 informa tion listed throughout this manual DANGER indicates ahazard which will cause severe personal injury death or substantial property damage if you ignore warning WARNING indicates a hazard which can cause severe personal injury death or substan tial property damage if you ignore warning CAUTION indicates a hazard which will or can cause minor personal injury or property damage if you ignore warning Gasoline presents a hazard of fire or explosion Gasoline is flammable Its vapor is explosive Keep fuel out of children s reach e 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 fuel vapor may ignite If fuel spills make sure area is dry before starting e
43. y may require up to three times their rated wattage to start You must figure total electrical load wattage Make sure total wattage of all electrical loads does not exceed rated wattage of generator See Determining Electrical Load For Generator page 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 largest 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 MASTER PORTABLE GASOLINE GENERATORS OPERATION Continued 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 minutes after removing electrical loads This lets engine cool slightly 3 Turn engine switch to the OFF position see Figure 21 4 Turn fuel valve lever off Do this by moving valve lever fully to the left see Figure 22 Models HWI3000A MGHS3000GA MGH3000A MGH4000D MGH4000DI MGH5000E and MGH5000E ENGINE SW ON Models MGH5000EIE and MGH6500AIE
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