Master Lock Power Supply MGH3000G User Manual

PORTABLE GASOLINE

GENERATORS

OWNER’S OPERATION AND INSTALLATION MANUAL

Generator Models: HWI3000, MGH3000G, MGH3000, MGH3000PR, MGH4000C, MGH4000CI,

MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE, 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.

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OWNER’S MANUAL

SAFETY

PRODUCT

IDENTIFICATION

INFORMATION

Continued

9. Only a qualified electrical service per-

son should service and repair generator.

• Generator produces high voltage.

Use extreme caution when working

on electrical parts.

Gas Cap/Fuel Gauge

Control

Panel

• 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.

FUEL

120 Volt

Receptacle

• Do not work on generator when tired.

• Use only factory approved replace-

ment parts.

Full Power

Selector Switch

120 Volt

Receptacle

(GFCI)

10. 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.

120

ONLY

120

240V

120/240 VOLTS

120 Volt

Receptacle

(Duplex)

RESET

1/10

Provision for

Auto-Idle Switch

11. Never operate generator

• if engine speed changes greatly

• if engine misfires often

Run Lamp

Hour Meter

• if powered items overheat

• if electrical output drops

• if it is sparking

• if it produces smoke or flames

• if it vibrates at high levels

• if it has a damaged receptacle

Roll Cage

Gas Tank

120/240 Volt

Receptacle

Circuit

Breaker

12. Keep generator and nearby areas clean.

• Keep generator free of oil, mud, and

other foreign matter.

Choke

Lever

• Remove anything that creates slip-

pery areas around generator.

• Remove oily rags and other items

that create fire hazards.

Fuel

Valve

Lever

• 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.

13. Know how to stop engine quickly.

Know how to use all controls.

Ground

Lug

14. Prolonged exposure to loud noise can

cause hearing loss.

Starter Grip

• When working around generator,

wear approved hearing protection.

• Remember neighbors when using

generator.

Alternator

Engine

Engine ON/

OFF Switch

Oil Dipstick

Figure 1 - Portable Generator (Model MGH4000C Shown)

106813

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PORTABLE GASOLINE GENERATORS

HIGH AND LOW

GENERAL

VENTILATION

TEMPERATURE

OPERATION

INFORMATION

DANGER: Use only in well-

ventedareas.Makesureareahas

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

containspoisonouscarbonmon-

oxide gas. Overexposure will

causelossofconsciousnessand

will lead to death.

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

overheadvalves(OHV). Thisprovideshigh

performance with lower fuel consumption.

These engines are governed to maintain

enginespeedof3600RPMunderload.3600

RPM engine speed provides 120/240V, 60

Hz power.

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.

Thisgeneratorneedscoolingairtorunprop-

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.

Additional Features

• Circuit breaker protection

• Spark-arresting muffler (except model

MGH10000A)

• Large fuel tank

• Oil alert system

DUST, DIRT, RAIN,

AND SNOW

• Electric starter (models MGH5000DIE,

MGH6500IE, and MGH10000A only)

• 15-Amp ground fault circuit interrupter

(GFCI) receptacle (Except HWI3000

Model)

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-

ating generator in these condi-

tions increases the risk of elec-

trocution. Severe injury or death

can occur.

UNPACKING

1. Remove generator from carton.

2. Remove any protective packaging ap-

plied to generator for shipment.

Do not use generator in extremely dusty or

dirtyconditions. Thiswillseverelyaffectits

life. Keep generator clean. Do not allow

dust, dirt, rain, or snow to collect on it.

Protect generator from outdoor elements.

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

MGH5000DIE, MGH6500IE, and

MGH10000A only. These cables are in

a separate bag inside generator carton.

You must install these cables to engine.

See Battery, page 8 for installation in-

structions.

106813

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OWNER’S MANUAL

MGH5000D

MGH5000DI

SPECIFICATIONS

MGH4000C

MODEL

HWI3000

MGH3000G

MGH3000

MGH3000PR MGH4000CI MGH5000DIE

Electrical

Rated Wattage

2500

4000

5000

Rated Amperage

120 V

20.8

––

20.8

––

20.8

––

20.8

––

33.3

16.7

41.7

20.8

240 V

Receptacle

120-V Duplex

––

Yes

––

Yes

––

Yes

––

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

Yes

30 Amp

20 Amp

Yes

30 Amp

20 Amp

Yes

General

Honda Engine H.P.

Honda Model

Fuel Type

5.5

GX160K1VX

Gasoline

3.9 qt.

5.5

GX160K1VX

Gasoline

3.9 qt.

5.5

GX160K1VX

Gasoline

3.9 qt.

5.0

GC160VXA

Gasoline

3.9 qt.

Yes

GX240K1VA

Gasoline

5 gal.

GX270VA

Gasoline

8 gal.

Fuel Tank Capacity

Oil Alert System

Start Method

Yes

Recoil

139

Recoil/Elec.

173

Weight (pounds)

85.5

* Single-phase, 1.0 power factor

MGH6000D

MODEL

MGH6000DI

MGH6500IE

MGH10000A

Electrical

Rated Wattage

6000

6500

10,000

Rated Amperage

120 V

Note: Ratings apply to SAE standard

conditions. Reduce ratings 3 /2% for

each 1000 feet above sea level and 1%

foreach10°Fahrenheitriseabove60°F.

28.3

83.3

41.7

240 V

Receptacle

120-V Duplex

Yes

––

Yes

––

Yes

––

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

Yes

30 Amp

20 Amp

Yes

30 Amp

Yes

General

Honda Engine H.P.

Honda Model

Fuel Type

GX340K1VA

Gasoline

8 gal.

GX390K1VXE

Gasoline

8 gal.

GX620VXA3

Gasoline

13 gal.

Yes

Fuel Tank Capacity

Oil Alert System

Start Method

Yes

Recoil

Electric

247

Electric

350

Weight (pounds)

191

* Single-phase, 1.0 power factor

106813

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PORTABLE GASOLINE GENERATORS

FULL POWER SELECTOR

SWITCH

All models except HWI3000, MGH3000G,

MGH3000, MGH3000PR, MGH6500IE,

andMGH10000Ahaveafullpowerselector

switch on the control panel. The switch has

two positions: 120 VOLT ONLY, and 120/

240 VOLT.

ELECTRIC START

GENERATOR

FEATURES

(Models MGH5000DIE,

MGH6500IE, and MGH10000A)

Models MGH5000DIE, MGH6500IE, and

MGH10000A have electric starters. A bat-

tery is not supplied with generator. You

must provide a 12-volt, 32-amp-hour bat-

tery. For more battery information, see Bat-

tery, page 8.

OIL ALERT SYSTEM

Theoilalertsystemprotectstheenginefrom

low oil damage. This system automatically

shuts down the engine and prevents engine

restarting if the oil level falls too low.

120 VOLT ONLY: This position sends full

power to the 120V receptacles only. 240V

power is not available. Use this position

when powering 120V items only.

Note:Whenthishappens, theengineswitch

remains in the ON position. The oil alert

system is wired into the ON/OFF Switch.

GROUND FAULT CIRCUIT

INTERRUPTER RECEPTACLE

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).

120/240VOLT:Thispositionsendsfullpower

to the 120/240V receptacle. It also powers the

120Vreceptaclesatreducedwattagecapacity.

All models (Except HWI3000) 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 MGH3000G, MGH3000, and

MGH3000PR only). The GFCI protects you

againsthazardouselectricalshockcausedwhen

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.

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.

IMPORTANT: Do not move the full power

selector switch while powering electrical

items.Unplugallitemsbeforemovingswitch.

Failure to do so can damage switch. Models

HWI3000, MGH3000G, MGH3000,

See engine owner’s manual for more

information.

MGH3000PR,

MGH6500IE,

and

MGH10000A do not have this switch. These

models provide full power to all receptacles.

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

notreceiveseriousinjury. Note:Infantsand

very small children may still be affected.

Model

MGH3000PR

120/240 VOLT

Position

120 VOLT ONLY

Position

Test Procedure

Check the GFCI receptacle every month.

This insures it is working right.

Figure 3 - Full Power Selector Switch

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.

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.

Models HWI3000,

MGH3000G, MGH3000,

MGH4000C, MGH4000CI,

MGH5000D, MGH5000DI,

MGH6000D, and

MGH6000DI

ENGINE SW

OFF

WARNING: If RESET button

does not pop out, do not use the

GFCI receptacle. Contact a quali-

fied electrician for repairs.

HONDA

Models

MGH5000DIE,

MGH6500IE, and

MGH10000A

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 genera-

tor and powered items.

OFF

START

ENGINE SW

CIRCUIT

BREAKER

Figure 2 - Engine Switch Location

106813

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OWNER’S MANUAL

RECEPTACLE CIRCUIT

BREAKER

GENERATOR

FEATURES

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.

Continued

Oil Level

At Top Of

Filler Neck

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. 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.

Dipstick

Electricmotorsneedhigherstartingcurrent.

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.

Oil

Figure 7 - Checking Oil Level (Model

MGH4000C Shown)

FUEL

WARNING:Gasolinepresents

a hazard of fire or explosion.

Gasoline is flammable. Its vapor

is explosive.

• Keep fuel out of children’s

reach.

RESET

TEST

Normal

Tripped

•

Refuel generator in a well-

ventedarea.Donotfillfueltank

in the dark. Do not refuel while

engine is running. Unhook all

electrical loads and shut off

engine before refueling.

Figure 6 - Receptacle Circuit Breaker

Button

Note: High ambient temperature will cause

nuisance tripping.

Figure 4 - GFCI Receptacle

ENGINE CIRCUIT BREAKER

(Models MGH5000DIE,

MGH6500IE, 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.

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.

• Do not overfill fuel tank. Al-

ways allow room for fuel to

expand.Ifyouoverfilltank,fuel

can overflow onto hot engine.

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.

CHECKING OIL LEVEL AND

ADDING OIL

Follow steps below to check oil level. Make

sure engine is level and stopped.

• Never smoke in refueling area.

Never allow open flames or

sparks in area.

• Store fuel in approved con-

tainer. Store fuel in a well-

ventedareafreeofopenflames

or sparks.

1. Remove dipstick (see Figure 7). Wipe

dipstick clean.

OFF

START

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.

ENGINE SW

Engine Circuit

Breaker Button

CIRCUIT

BREAKER

ON/push OFF

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.

3. If level 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.

Figure 5 - Engine Circuit Breaker

Note: If oil level is too low, oil alert system

will shutdown engine and prevent engine

from restarting.

See engine owner’s manual for more

information.

106813

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PORTABLE GASOLINE GENERATORS

Always wear safety glasses when working

with battery. Make sure battery terminals

are clean. Make sure cable connections are

tight.

HANDLES AND

BATTERY

(Models MGH5000DIE,

TOP COVER

MGH6500IE, and MGH10000A)

(Model MGH10000A)

Always shut down engine before removing

or attaching battery cables. Always remove

the negative (–) cable first. Always attach

negative (–) cable last.

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.

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.

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.

WARNING: Battery contains

sulfuric acid. Contact with skin

or eyes may cause severe burns.

Do not tilt generator with battery

installed.Tiltingcouldcausebat-

tery acid to spill. Wear protective

clothing and face shield when

servicing. Keep out of children’s

reach.

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).

CAUTION:Donotovertighten

positive terminal on starter sole-

noid. Positive terminal could ro-

tate and cut into negative termi-

nal, causing a short.

Roll Cage

• If battery acid gets on your

skin, wash with water.

• Ifbatteryacidgetsinyoureyes,

flushwithwateratleast15min-

utes. Call a 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.

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 11.

Washers

Bolts

Lock Nuts

Handle

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.

Starter

Solenoid

Figure8–AttachingHandlestoRollCage

SEMS Screws

Top Cover

Red, Positive (+)

Battery Cable

IMPORTANT: Make sure battery connec-

tions are the correct polarity. Electric start

generators use negative ground, 12-volt DC

starting system.

Figure 10 - Connecting Red, Positive (+)

Battery Cable to Engine Starter Solenoid

(Model MGH6500IE Shown)

Models MGH5000DIE, MGH6500IE, and

MGH10000A have an electric starter. A

battery is not supplied with generator. You

must provide a 12-volt, 32-amp-hour bat-

tery.Thepositiveandnegativebatterycables

are supplied with generator. You must in-

stall these cables before mounting battery.

SEMS

Screws

Black,

Negative (–)

Battery Cable

Figure 9 – Attaching Top Cover to Roll

Cage

Figure 11 - Connecting Black, Negative (-)

Battery Cable to Engine Block (Model

MGH6500IE Shown)

106813

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OWNER’S MANUAL

BATTERY

GENERATOR

Continued

GROUNDING

TO ENGINE

120

BLOCK

120

240V

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).

WARNING: You must prop-

erly earth-ground generator be-

TO STARTER

SOLENOID

fore starting. This will help guard

against deadly electric shock.

Only use grounded plugs with

generator.Onlyusegroundedex-

tension cords. Only use three-

wire or double-insulated power

Note: Model MGH10000A battery is

located on opposite side as shown (see

Figure 13).

Figure 14 - Connecting Positive and

Negative Cables to Battery

(Model MGH6500IE Shown)

tools.

2. Locate the red, positive (+) battery

cable from starter solenoid. Connect it

to the positive (+) battery terminal (see

Figures 14 and 15).

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

supplythegroundwireandgroundingpoint.

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.

TO STARTER

SOLENOID

TO ENGINE

3. Locate the black, negative (–) battery

cable attached to engine block. Connect

it to the negative (–) battery terminal

(see Figures 14 and 15).

BLOCK

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.

Figure 15 - Connecting Positive and

Negative Cables to Battery

(Model MGH10000A Shown)

Battery Mounting Bracket

WARNING: For a grounding

point, do not use metal pipe be-

ing used to carry combustible

materials or gases.

Nut

EXTENSION

CORDS

Only use grounded extension cords. Be sure

touseextensioncordwithproperwiregauge

size. See chart below.

Battery

Ground Lug

FUE

Hook Bolt

Recommended Minimum Wire

Gauges (AWG) for Extension

Cords

Copper or

Brass

Grounding

Point

Figure 12 - Battery Hold-Down System

(Model MGH6500IE Shown)

Ampere

Load

AWG for Length of

Cord in Feet

Nut

Battery

Mounting

Bracket

50'

100'

150'

Battery

Ground Wire

Alternator

Figure 16 - Grounding Generator

(Model MGH4000C Shown)

Hook

Bolt

Figure 13 - Battery Hold-Down System

(Model MGH10000A Shown)

106813

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PORTABLE GASOLINE GENERATORS

ent size motors. For example: an elec-

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.

STANDBY

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 = 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.

INSTALLATION TO

HOME OR

BUILDING

WARNING: Have standby in-

stallation performed by a skilled,

licensed electrician. Do not let

anyone else wire into a utility

circuit. Personal injury, equip-

mentdamage,ordamagetohome

could occur.

2. Enter running watts of each item ex-

cept motors. The light bulb or appliance

nameplate lists its wattage. Remember,

1KW = 1000 watts. Note: The name-

plate may not list wattage. It may only

list volts and amps. The formula for

finding wattage is: Volts x Amps =

Watts. For example: An appliance

nameplate states 3 amps at 120 volts. 3

amps x 120 volts = 360 watts.

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.

4. 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.

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-

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.

Chart 1 - Typical Electric Appliance Wattages

Running Starting

Equipment

Watts

Equipment

Watts

Light bulb (100W)

Radio

Fan

100

150

200

400

100

150

600

400

1/2" Drill

Toaster

Coffee maker

Skillet

1000

1200

1250

1200

1500

Television

WARNING: The electrician

mustinstalladouble-throwtrans-

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.

Furnace fan (1/3 hp)

with blower

14" Chain saw

Water well pump

(1/2 hp)

Hot plate/range

(per burner)

10" Table saw

Water heater

(storage-type)

600

700

800

1000

1800

750

2100

2400

1000

Vacuum cleaner

Sump pump (1/3 hp)

Refrigerator/freezer

6" Circular saw

Floodlight

1000

3000

1500

2000

1500

6000

5000

Chart 2

Approximate Starting Watts*

Repulsion

DETERMINING

Motor

Rating

Approximate

Running

Watts

Universal

Motors

Split

Phase

Motors

ELECTRICAL LOAD

FOR GENERATOR

Induction

Motors

Capacitor

Motors

(small appliance)

1/8

1/4

1/3

1/2

3/4

1 1/2

500

700

800

1100

1400

1700

2100

2450

3600

625

875

1100

1550

1750

2400

3100

3750

4620

5400

7900

1500

2100

2400

3300

4200

5100

6300

7350

10800

2250

3150

3600

4950

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 your

generator, see Specifications, page 5. Elec-

tric motors present a special problem when

figuring load. Read Step 3 carefully.

1000

1375

1750

2125

2625

3075

* – Always use starting watts, not running watts, when figuring correct electrical load.

x – Motors of higher horsepower are not generally used.

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OWNER’S MANUAL

Model MGH10000A also has a 120/240V,

50-amp receptacle (see Figure 17).

POWER CORD AND PLUG

REQUIREMENTS

OPERATION

GENERAL INFORMATION

This generator is not large enough to power

your entire home. Do not connect generator

Model HWI3000 has only the 120V, 20-

amp duplex receptacle.

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

Models MGH3000G, MGH3000 and

• Three-wire, 30-amp cord

toanyexistingelectricalcircuits.Plugitems MGH3000PR have only the 120V, 15-amp

directly into generator receptacles. Do not GFCI duplex receptacle.

exceedamperageratingofreceptacles.Only

120/240V, 20 or 30-amp twist-lock

receptacle

120V, 15-Amp GFCI Duplex

use grounded cords.

• NEMA L14-20P (20-amp) or L14-30P

(30-amp) plug

120V, 15-Amp Duplex

DANGER: Use only in well-

• Four-wire, 20-amp or 30-amp cord

ventedareas.Makesureareahas

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

containspoisonouscarbonmon-

oxide gas. Overexposure will

causelossofconsciousnessand

will lead to death.

120/240V, 20 or

30-Amp Twist-Lock

120/240V, 50-amp receptacle

• NEMA L14-50P

120 VOLTS

• Four-wire, 50-amp cord

RESET

TEST

120

ONLY

120

240V

120V, 30-Amp

Twist-Lock

DANGER:Neverconnectgen-

erator to any existing electrical

circuits.Thegeneratoroutputwill

back-feed into the utility power

line.Thismayelectrocuteapower

companylinerepairperson.Also,

if generator is powering electri-

calcircuits,thechanceofanelec-

trical fire exists.

RESET

240 VO

LTS

RESET

Note:Wesupplytheengineowner’smanual

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.

120/240V, 50-Amp

(Model MGH10000A only)

Figure 18 - Cord and Plug Configurations

Figure 17 - Receptacle Locations

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 HWI3000,

MGH3000G, MGH3000, and MGH3000PR)

have the following receptacles (see Figure 17):

• 120V, 15-amp GFCI duplex receptacle

• 120V, 30-amp twist-lock receptacle

• 120/240V, 20 or 30-amp twist-lock

receptacle

• 120V, 15-amp duplex receptacle

Continued

106813

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PORTABLE GASOLINE GENERATORS

4. Start the engine.

Choke Rod

Pulled Out

(Closed

OPERATION

A. Recoil Starter

Continued

Move engine lever or turn engine

Position)

PRESTART

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.

Operate generator on a firm, dry, and clean

surface. The surface must be level. Protect

generator from heavy dust, sand, dirt, rain,

orsnow. Donotlocategeneratornearstand-

ing water and snow. Make sure area is well-

vented.

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 nec-

essary. Be sure engine is on a level sur-

face. See Oil Alert System, page 6.

WARNING: Only responsible

adults should use generator.

Neverletanyoneoperategenera-

tor without proper instructions.

Figure 20 - Choke Rod Closed (Model

MGH3000PR Only)

B. Electric Starter (Models

MGH5000DIE, MGH6500IE, and

MGH10000A Only)

Choke Button

Pulled Out

(Closed

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.

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.

Position)

Before starting the engine, disconnect all

electric loads from generator.

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.

STARTING

Figure 21 - Choke Button Closed (Model

MGH10000A Only)

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.

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.

IMPORTANT: Never start generator with

electrical loads connected. Start engine be-

fore adding electrical loads.

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.

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).

Figure 22 - Engine Lever In ON Position

(Model MGH3000PR Only)

Choke Lever (Closed Position)

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.

ENGINE SW

OFF

Figure 23 - Engine Switch In ON Position

(All Models Except MGH5000DIE,

Note:You may not need to close choke

if engine is warm or air temperature is

high.

Fuel Valve Lever (ON Position)

MGH6500IE,

MGH3000PR)

MGH10000A,

and

Figure 19 - Fuel Valve Lever On, Choke

LeverClosed (ModelMGH4000CShown)

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OWNER’S MANUAL

Note: The 250Volt/50Amp receptacle 8. Turn Auto-Idle switch ON. Make sure

OPERATION

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).

solenoid is engaged. When engaged, the

punger is pulled back into the solenoid.

Continued

9. If the 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).

HONDA

6. TheAuto-Idle system should be turned

OFF when generator is shut down.

OFF

START

Engine

Switch

ENGINE SW

Adjusting the Idle Speed

CIRCUIT

BREAKER

IMPORTANT: Adjust the idle speed only:

ON/push OFF

10. Replace the engine linkage cover

(Models MGH4000CI, MGH5000DI,

MGH5000DIE, MGH6000DI, and

MGH6500IE).

• If the idle speed becomes too high.

Figure 24 - Engine Switch (Models

• If the engine idle speed will not regulate (en-

gine idles and speeds up again and again).

MGH5000DIE,

MGH6500IE,

and

MGH10000A Only)

1. Turn Auto-Idle switch OFF. Start en-

gine. Allow engine to warm up with no

load for five minutes.

Choke Lever (Open Position)

Solenoid Mounting Bracket

M8 Nut

WARNING:Alwayssettheidle

speedbeforeturningontheAuto-

Idle. If idle speed is not set, the

largerresistoronthecontrolboard

may become hot. Heat from the

resistor may damage the protec-

tive coating on the control board.

Figure 25 - Choke Lever Opened (Model

MGH6500IE Shown)

2. Remove engine linkage cover (Models

AUTO-IDLE OPERATION

MGH4000CI,

MGH5000DI,

IMPORTANT:Neverstartenginewithelec-

trical loads connected. Start engine before

adding electrical loads.

MGH5000DIE, MGH6000DI, and

MGH6500IE).

3. Push plunger into solenoid body to manu-

ally engage solenoid and set idle speed.

1. If engine is cold, turn the Auto-Idle

switch OFF (see Figure 26).

Figure 27 - Solenoid Bracket Location,

Models MGH4000CI, MGH5000DI,

MGH5000DIE, MGH6000DI, and

MGH6500IE Only

4. Loosen the M8 nut that holds the sole-

noid mounting bracket to the generator

(Models MGH4000CI, MGH5000DI,

MGH5000DIE, MGH6000DI, and

MGH6500IE. See Figure 27). Do not

loosen bolt that holds the solenoid

mounting bracket to the generator on

Model MGH10000A (see Figure 28).

2. Start engine. Allow engine to warm up

with no load for five minutes.

3. TurnAuto-Idle switch ON. Engine will

slow to idle speed. Engine idle speed

is preset. Idle speed adjustment should

not be necessary.

Solenoid

Mounting

Bracket

4. Operate generator according to speci-

fications outlined in owner's manual.

5. Slowly pull solenoid bracket away from

engine (on Model MGH10000A this will

require bending the bracket slightly).

5. Engine will automatically increase to

normal operating speed when you plug

load into any generator outlet.

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.

Bolt

Auto-Idle Switch

120 VO

LTS

RESET

TEST

7. After reaching proper idle speed,

tighten M8 nut to secure solenoid

mounting bracket (Models MGH4000CI,

_HOURS0

1/10

MGH5000DI,

MGH5000DIE,

MGH6000DI, and MGH6500IE (see

Figure 27).

Figure 28 - Solenoid Bracket Location,

Model MGH10000A Only

Figure 26 - Control Panel

106813

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PORTABLE GASOLINE GENERATORS

Fuel Valve Lever

(Off Position)

STOPPING ENGINE

OPERATION

Continued

IMPORTANT: The engine speed is preset.

The throttle is locked in preset position. Do

not adjust throttle.

HIGH ALTITUDE OPERATION

This generator will not perform well at high

altitudes without proper adjustment. See

engine owner’s manual for details.

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.

ADDING ELECTRICAL

LOADS

2. Let engine run for two or three min-

utes after removing electrical loads.

This lets engine cool slightly.

IMPORTANT: Do not overload generator.

Makesuretotalwattageofallelectricalloads

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.

3. Turn engine switch to the OFF posi-

tion (see Figure 29).

Figure 30 - Fuel Valve Lever Off (Model

MGH6500IE Shown)

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).

IMPORTANT:(AllmodelsexceptHWI3000,

MGH3000,MGH3000PR,MGH6500IE,and

MGH10000A)Keepfullpowerselectorswitch

in the 120 VOLT ONLY position if only pow-

ering 120V items. Only move switch to 120/

240 VOLT position if powering 240V items.

MAINTENANCE

AND REPAIRS

WARNING: Only a qualified

electrical service person should

service and repair the alternator

on this generator. Use only fac-

toryapprovedreplacementparts.

1. Check items to be powered. Their

nameplate lists their wattage ratings.

Model

MGH3000PR

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.

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.

2. Start engine. Let engine reach full

speed.

Models HWI3000,

MGH3000G, MGH3000,

MGH4000C, MGH4000CI,

MGH5000D, MGH5000DI,

MGH6000D and

ENGINE SW

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.

OFF

MGH6000DI

CAUTION: Shut off generator

before performing maintenance.

DISCONNECTING ELECTRIC

LOADS

IMPORTANT: Keep generator level when

servicing.Neverturngeneratorupsidedown

or stand it on end to service.

HONDA

Remove electrical loads one at a time. Re-

move voltage sensitive items first. Voltage

sensitive items include TVs, VCRs, and

other home electronic items.

Note:Wesupplytheengineowner’smanual

with generator. Refer to that manual for

questions concerning engine maintenance

and repairs.

Models

MGH5000DIE,

MGH6500IE, and

MGH10000A

OFF

START

ENGINE SW

CIRCUIT

BREAKER

Non-enginepartsrequirelittlemaintenance.

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.

ON/push OFF

Figure29-EngineSwitchInOFFPosition

106813

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OWNER’S MANUAL

Use a fuel additive, such as STA-BIL^®or an

equivalent,whenstoringgeneratorwithfuel

STORAGE

TECHNICAL

in fuel tank. This will minimize fuel gum SERVICE

WARNING: Remove all fuel

deposits from forming in engine.

fromfueltankbeforestoringgen-

erator.Storefuelinapprovedcon-

tainer. Store fuel in a well-vented

areafreeofopenflamesorsparks.

You may have further questions about as-

Cover and store generator in a clean, dry

place. Do not expose generator to extreme

high or low temperatures during storage.

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

at1-800-858-8501(EnglishOnly).Youmay

also write to:

SERVICING THE

ENGINE

WARNING: The muffler be-

comesveryhotduringoperation.

The muffler remains hot for a

while after shutdown. Let engine

cool before storing.

DESA Specialty Products™

ATTN: Technical Service Specialty Products

P.O. Box 90004

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:

Bowling Green, KY 42102-9004

IMPORTANT: Keep generator level while

in storage. Never store generator upside

down or standing on end.

When contacting DESA Specialty Prod-

ucts™, have ready

Engines Gasoline, Honda

or visit:

www.honda-engines.com

Note:Wesupplytheengineowner’smanual

with generator. Refer to that manual for

questions concerning engine storage.

• Your Name

• Your Address

or call Honda direct:

1-800-426-7701

• Your Phone Number

• Model Number of Product

• Serial Number

• Date of Purchase (Include copy of receipt

for written requests).

TROUBLESHOOTING

Note: For additional help, visit DESA

International’stechnicalservicewebsite

at www.desatech.com.

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

REMEDY

POSSIBLE CAUSE

No voltage when starting generator with no

electrical load

1. Replace capacitor

1. Defective capacitor

2. Winding short circuit or loose

connections

3. Defective rotor diode

4. Loss of residual magnetism

2. Check resistance of coils (see Electri-

cal Component Specifications, page 16)

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor ter-

minals for 2-3 seconds

Voltage is less than normal voltage with no

electrical load

1. Set engine speed to 3720 RPM (62 Hz)

with no load

1. Engine speed too low

2. Replace both diodes on rotor

3. Check resistance of coils (see Electri-

cal Component Specifications, page 16)

4. Replace capacitor

2. Defective rotor diode

3. Partial short circuit in winding

4. Defective capacitor

Voltmeterreadingmorethan10%highwith

no electrical load

1. Set engine speed to 3720 RPM (62 Hz)

with no load

1. Engine speed too high

Voltmeter reading correct with no electrical

load, but more than 10% low when electri-

cal load is added

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized engine service

center

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

www.desatech.com

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PORTABLE GASOLINE GENERATORS

ELECTRICAL

COMPONENT

SPECIFICATIONS

Resistance in Ohms

Stator

Main

Stator

Rotor

Capacitor,

MFD

450 Volt

Auxiliary

Primary

Secondary

Diodes (2)

800 Volt

Model

Winding * Winding ∆ Winding † Winding †

HWI3000

MGH3000G

1.6

1.95

1.6

0.71

0.54

0.37

0.28

0.40

5.9

5.2

5.9

2.17

1.38

1.01

0.78

0.90

6.9

6.79

6.9

0.54

0.61

0.68

0.77

0.37

1.33

1.31

1.33

2.07

2.29

2.57

2.9

6 Amp

70 Amp

MGH3000, MGH3000PR

MGH4000C, MGH4000CI

MGH5000D, MGH5000DI

MGH5000DIE

MGH6000D, MGH6000DI

MGH6500IE

MGH10000A

0.50

∆

Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow).

Resistance between brown and white leads.

†

Remove diodes to check resistance.

WIRING DIAGRAMS

Stator

Receptacle

Black

120V/15A

(MGH3000)

HOT

GFCI

Black

20A

WHITE

Receptacle

120V/20A

(HWI3000)

Circuit

Breaker

110/120V

Yellow

Rotor

Stator

White

Auxiliary

Phase

Brown

Black

Main

Windings

Red

Yellow

Green

Figure31-WiringDiagram,ModelsHWI3000,MGH3000G,MGH3000,andMGH3000PR

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OWNER’S MANUAL

WIRING DIAGRAMS

Continued

Red

Black

Green/Yellow

Green

White

120V, 15A

Receptacle

White

120V, 15A

Receptacle

Red

120/240V 20A

Receptacle

120V, 30A

Receptacle

Circuit

Breaker

20A

White

Circuit

Breaker

25A

Duplex

GFCI

Circuit

Breaker

20A

Full Pwr

Selector

Switch

Red

Black

Circuit

Breaker

25A

White

LINE

Yellow

Black

Hour

Meter

Green

Black

White

Green

Red

Black

Green

Black

Red

Main

Windings

Auxiliary

Phase

Capacitor

White

Stator

White

T1 T4 T3 T2

Rotor

Diode

Stator

White

Green

220/240V

Red

Black

Yellow

110/120V

Brown

Figure 32 - Wiring Diagram, Models MGH4000C, MGH5000D, and MGH6000D

White

Red

Black

White

Green/Yellow

Green

White

Red

120V, 15A

Receptacle

120/240V 20A

Receptacle

120V, 15A

Receptacle

120V, 30A

Receptacle

s₁s₂

Circuit

Breaker

20A

White

•

Circuit

Breaker

Duplex

GFCI

20A, 25A

or 30A

To Solenoid

Circuit

Breaker

20A

Full Pwr

Selector

Switch

Red

Black

Circuit

Breaker

20A, 25A

or 30A

White

LINE

Black

White

Yellow

Black

Hour

Meter

Green

Black

White

Green

Red

Black

Green

•

Black

Red

Main

Windings

Auxiliary

Phase

Capacitor

White

Stator

White

Rotor

Diode

Stator

White

T1 T4 T3 T2

Green

220/240V

Red

Black

Yellow

110/120V

Brown

Figure 34 - Wiring Diagram, Models MGH4000CI, MGH5000DI, MGH5000DIE, and MGH6000DI

Continued

106813

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PORTABLE GASOLINE GENERATORS

WIRING DIAGRAMS

Continued

Green/Yellow

Switch

Green

White

Black

120/240V 30A

Receptacle

120V, 15A

Receptacle

120V, 15A

Receptacle

120V, 15A

Receptacle

Circuit

Breaker

20A

s₁s₂

•

White

Circuit

Duplex

GFCI

Red

White

Breaker

30A

To Solenoid

White

Black

Circuit

Breaker

20A

Circuit

Breaker

30A

LINE

Hour

Meter

White

Yellow

Green

Black

Red

Black

Red

Main

Windings

Auxiliary

Phase

Capacitor

White

Stator

T2 T3

220/240V

110/120V

White

T1 T4 T3 T2

Stator

White

Rotor

Green

Red

Diode

Black

Yellow

110/120V

Brown

Figure 35 - Wiring Diagram, Model MGH6500IE

White

Green

White

Green

Black

GFCI 125V, 15A

Receptacle

Black

125V, 30A

Receptacle

125V, 15A

Receptacle

250V 30A

Receptacle

Auto-Idle

Control Board

Red

250V 50A

Receptacle

Circuit

Breaker

20A

Circuit

Breaker

30A

White White

White

Red

Circuit

Breaker

45A

White

Black

Auto-Idle

Solenoid

Black

Run

Circuit

Breaker

20A

Light

Circuit

Breaker

30A

Yellow

Circuit

Breaker

45A

Hour Meter

White

Black

Red

Green

Black

Yellow

Red

Black

White

Black

Red

Main

Windings

Capacitor

White

Stator

Rotor

Diode

Stator

T1 T4 T3 T2

Diode

220/240V

110/120V

Figure 36 - Wiring Diagram, Model MGH10000A

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

For Models HWI3000,

MGH3000G, 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 32 of this manual.

KEY PART

NO.

NUMBER

DESCRIPTION

QTY.

NO. NUMBER

DESCRIPTION

QTY.

099722-01

Alternator Assembly

(HWI3000)*

17587000

099891-01

099861-01

099842-01

26310000

27001005S Engine Flange

WLE-4

27001002

27001009S Diode

27001006

26327006

WLE-5

Ground Lug

Flanged Nut, 8mm

Bottom Cover

Draw Bolt

099722-02

Alternator Assembly

(MGH3000G, MGH3000,

and MGH3000PR)*

Top Cover (HWI3000)

Top Cover (MGH3000G,

MGH3000, and

MGH3000PR)

120V, 20A Duplex

Receptacle (HWI3000)†

120V, 15A Duplex (GFCI)

Receptacle (MGH3000G,

MGH3000 and

Screw, M6 x 16

099849-01

100074-01

Lock Washer, 1/4"

Stator

Bearing

104201-01

100445-01

Rotor

Fan

Bolt, 5/16-24 x 5/8"

Lock Washer, 5/16"

MGH3000PR)†

Circuit Breaker, 20 Amp †

22616009

27002002S Capacitor

26333000

099863-01

099701-01

099848-01

PARTS AVAILABLE - NOT SHOWN

Screw, M4 x 20

099866-03

Safety Information Decal

Operation Decal

Terminal Block

Screw, M5 x 13

End Plate

099866-04

099867-02

† Includes fastening hardware.

* Includes reference numbers 1 through 22.

** Parts not available. Included in alternator assembly.

106813

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Models MGH4000C,

MGH4000CI, MGH5000D,

MGH5000DI, MGH5000DIE,

MGH6000D, MGH6000DI,

MGH6500IE Alternator

Assembly

This list contains replaceable parts used

in your generator. When ordering parts,

follow the instructions listed under Re-

placement Parts on page 32 of this

manual.

PART NUMBER FOR MODEL

MGH5000D

KEY MGH4000C

NO. MGH4000CI

MGH5000DI

MGH5000DIE MGH6000DI MGH6500IE

MGH6000D

DESCRIPTION

QTY.

099723-01

099723-02

099844-01

099701-01

099760-01

099863-01

099863-02

17587000**

M11084-26

099847-02

WLE-5

099723-03

099844-01

099701-01

099760-01

——

099723-04

099844-01

099701-01

099760-01

——

Alternator Assembly

End Cover

Screw, M5 x 13

Bushing

Terminal Block (4-block)

Terminal Block (2-block)

Ground Lug

Screw, #10-16 x 3/8"

Stator Bolt

Lock Washer, 5/16"

Bearing Housing

Capacitor

Terminal Post

Stator

099844-01

099701-01

099760-01

099863-01

099863-02

17587000**

M11084-26

099847-01

WLE-5

099863-02

17587000** 17587000**

099863-02

M11084-26

099847-03

WLE-5

099843-01

27006001S

100054-01

M11084-26

099847-04

WLE-5

099843-01

27007004S

100054-01

099843-01

27004002S

——

099843-01

27005003S

——

27003002

Fan Bracket

27003015S** 27003015S** 27003015S** 27003015S** Screw, M8 x 20

099891-01

099892-01

099842-01

27003003

27003012S

27003008

27003007S

26322004**

WLE-6**

099891-01

099892-01

099842-02

27003003

27003012S

27003008

27003007S

26322004**

WLE-6**

099891-01

099892-01

099842-03

27003003

27003012S

27003008

27003007S

26322004** 26322004**

099891-01

099892-01

099842-04

27003003

27003012S

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"

27003008

27003007S

WLE-6**

* Part not available by itself. Must purchase Alternator Assembly.

**Available at your local hardware store.

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

For Model MGH10000A

Alternator Assembly

This list contains replaceable parts used in

yourgenerator.Whenorderingparts,follow

the instructions listed under Replacement

Parts on page 32 of this manual.

KEY

NO.

PART

NUMBER

DESCRIPTION

QTY.

Stator

Rotor

Draw Bolt

Fan

103188-01

103191-01

103192-01

103193-01

103194-01

103195-01

099847-05

099891-01

103189-01

099701-01

103198-01

103199-01

103200-01

27003012S

103201-01

099845-02

103204-01

099892-02

103202-01

103190-01

Balancing Disc

Lifting Eyes

D.E. Bracket

N.D.E. Bracket

Mounting Bolts

Nuts

†

Top Box

Screw and Washer

Plastic Cap

Bearing

Borelly Washer

Diode

Terminal Block

Capacitor

Tie Wrap

Foam Pad

Capacitor Bracket

Engine Flange

Screw M8 x 20

'O' Ring

Washer

Hex Head Nut

Alternator Assembly

103203-01

WLE-5

099891-01

102938-01

* Part not available by itself. Must purchase Alternator Assembly.

** Standard hardware item available from local hardware store.

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Model MGH3000G

Alternator Assembly

This list contains replaceable parts used in

yourgenerator.Whenorderingparts,follow

the instructions listed under Replacement

Parts on page 32 of this manual.

KEY

NO.

PART

NUMBER

DESCRIPTION

QTY.

099831-01

WLE-4

Handle (includes 2 spacers)

1/4" Lock Washer

M6 x 35 Screw

099769-01

NEC-5C

5/16-18 Nut

099754-01

13401000

WP-5C

Engine Spreader

Rubber Bumper

5/16" Flat Washer

5/16-18 x 1" Screw

5/16-18 x 1¹/₂" Screw

Isolator Spacer

19165004

04110002

099767-01

21834000

19166004

5/16 x 1¹/₂" Washer

5/16-18 x 2" Screw

Note: Fuel tank is available from Engine Mfg. Co. only.

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

For Models HWI3000, MGH3000,

and MGH3000PR Roll Cage

This list contains replaceable parts used in

yourgenerator.Whenorderingparts,follow

the instructions listed under Replacement

Parts on page 32 of this manual.

KEY

NO.

PART

NUMBER

105155-01

099754-01

NEC-5C

DESCRIPTION

Roll Cage

QTY.

Engine Spreader

Lock Nut, 5/16-18

Flat Washer, 5/16"

Shock Mount

WP-5C

099853-02

04110002

14138000

21834000

100406-01

Screw, 5/16-18 x 1¹/2

Ground Strap

Washer, 5/16" x 1¹/2"

Bolt, 5/16-18 x 3/4"

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Models MGH4000C,

MGH4000CI, MGH5000D,

MGH5000DI, MGH5000DIE,

MGH6000D, MGH6000DI,

and MGH6500IE

Fuel Tank and Roll Cage

FUEL

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OWNER’S MANUAL

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.

ILLUSTRATED

PARTS LIST

For Models MGH4000C, MGH4000CI, MGH5000D, MGH5000DI,

MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE

Fuel Tank and Roll Cage

KEY MGH4000C MGH5000D

NO. MGH4000CI MGH5000DI MGH6000DI MGH6500IE

MGH5000DIE

MGH6000D

DESCRIPTION

QTY.

25954000

099832-01

25978000

HC4-8C

099701-01

19508001

25985005

099743-01

099752-02

25954001

107021-01

—

25954001

107021-01

—

25954001

107021-01

—

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

—

099701-01

19508001

25985005

099743-01

106063-01

—

103880-01

—

NEC-5C

14138000

099853-02

WLE-5

099701-01

19508001

25985005

099743-01

106063-01

—

103880-01

—

NEC-5C

14138000

099853-02

WLE-5

099701-01

19508001

25985005

099743-01

106063-01

—

103880-01

—

NEC-5C

14138000

099853-02

WLE-5

Roll Cage

10 103880-01

—

11 NEC-5C

—

12 14138000

13 099853-02

14 WLE-5

15 WLI-3

16 WP-5C

—

17 HC5-14C

18 099756-01

22 100410-01

23 M10908-74

—

24 WP-4C

25 099965-01

26 WP-3C

27 103676-01

Lock Nut, 1/4-20

Lock Nut, 5/16-18

Ground Strap

Shock Mounts

Lock Washer, 5/16"

Lock Washer, #10

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"

Washer, 1/4"

WLI-3

—

WP-5C

WLI-3

—

WP-5C

—

WP-5C

HC5-14C

099756-01

—

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

HC5-14C

099756-01

099750-01

099749-01

NEC-5C

100410-01

—

M10908-74

WP-4C

099965-01

WP-3C

—

100410-01

M10908-74

—

WP-4C

099965-01

WP-3C

103676-01

HC4-16C

107110-01

Linkage Cover

Washer, #10

90° Fitting with barbs

Bolt, 1/4-20 X 2"

Spacer .25 X .500

103676-01

HC4-16C

107110-01

—

PARTS AVAILABLE - NOT SHOWN

099866-02

100003-01

—

Safety Information Decal

Operation Decal

Battery Cable (Positive, Red)

Battery Cable (Negative, Black)

Fuel Line Grommet

100003-01

100003-02*

099873-01*

099873-02*

03175000

100003-01

—

100003-02

099873-01

099873-02

03175000

Only on MGH5000DIE electric start models

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Model MGH10000A Fuel

Tank and Roll Cage

FUEL

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OWNER’S MANUAL

ILLUSTRATED

PARTS LIST

For Model MGH10000A

Fuel Tank and Roll Cage

KEY

NO.

PART

NUMBER

DESCRIPTION

QTY.

079503-25AA

105905-01

105906-01

102933-03

102932-01

WP-16C

C4-12C

100135-01

NEC-5C

Gas Tank Assembly

Roll Cage

Axle Mount

Axle

Wheels

Flat Washer, 1"

Cotter Pin

U-Bolt

Lock Nut, 5/16-18

Flat Washer, 5/16"

Lock Nut,1/4-20

Flat Washer, 1/4"

Gas Cap w/Fuel Gage

Fuel Line

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 32 of this manual.

WP-5C

103880-01

WP-4C

097190-06

M51151-02

M10990-3

106988-01

25985008

105035-01

103046-01

103057-01

H8C5-20C

099750-01

099749-01

105908-01

17529000

102962-02

H5C4-24C

26302006

WLI-8

14138000

M10908-74

WLE-5

106775-02

106775-01

106776-01

100410-01

HC5-14C

Bushing

Barbed Connector, 1/4"

Fuel Line

Handle

Grip

Plug

Bolt, 5/16-18 x 2.5"

Bolt, J-Hook 5/16-18

Battery Bracket

Battery Mount

Shock Mount

Spreader

Bolt, 1/4-20 x 3"

Bolt, 1/2-10 x 1"

Internal Tooth Lockwasher

Ground Strap

Tapping Screw, 1/4-20 x .5"

External Tooth Lockwasher

Side Panel

Top Cover

Sems Screw, 8-18

Bolt, 5/16-18 x 1.75"

PARTS AVAILABLE - NOT SHOWN

099866-05

Safety Information Decal

Operation Decal

Battery Cable (Positive, Red)

Battery Cable (Negative, Black)

Screw, 1/4-20 x .75"

Muffler

100003-04

099873-01

099873-05

HC4-6C

105951-01

106108-01

Muffler Hanger

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Models MGH4000C,

MGH4000CI, MGH5000D,

MGH5000DI, MGH5000DIE,

MGH6000D, MGH6000DI, and

MGH6500IE Control Panel

RES

EST

Reset

120 Vol

This list contains replaceable parts used in

your generator. When ordering parts, fol-

low the instructions listed under Replace-

ment Parts on page 32 of this manual.

ONL

ENM

00000005

1/10

PART NUMBER FOR MODEL

MGH5000D

KEY

NO.

MGH4000C MGH5000DI MGH6000D

MGH4000CI MGH5000DIE MGH6000DI MGH6500IE DESCRIPTION

QTY.

103349-01

22616009

099833-01

104202-01

100445-01

099956-01

22616009

—

103349-02

22616009

099833-01

104202-01

100445-01

099956-01

—

22616011

—

099834-01

—

101350-01

099760-01

100410-01

100149-01

22261000

099997-01

103348-02

103348-06

100177-07

103349-03

22616009

099833-01

104202-01

100445-01

099956-01

—

103349-05

22616009

099833-01

104202-01

100445-01

—

Control Panel

Circuit Breaker, 20 Amp *

120V, 30A Twist-Lock Receptacle *

120V, 20A 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, #8-18 x 1/2"

Control Box

U-Nut

Switch Plug

—

22616010

099834-01

—

22616010

—

099834-01

—

099835-01

101350-01

099760-01

100410-01

100149-01

22261000

099997-01

—

101350-01

099760-01

100410-01

100149-01

22261000

099997-01

103348-01

103348-05

100177-07

101350-01

099760-01

100410-01

100149-01

22261000

099997-01

103348-03

103348-07

100177-07

†

Control Panel Assembly

Control Panel Assembly - Auto Idle Models

Panel Schematic Decal

†

∆

103348-09

100177-07

* Includes fastening hardware

∆ Not shown

† Includes reference numbers 1 through 13

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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 32 of this manual.

RESET

TEST

Reset

120 Vol

Idle

Sel

200

Reset

0000000

OURS

KEY

NO.

PART

NUMBER

DESCRIPTION

QTY.

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

104202-01

102927-01

100177-05

103257-01

103258-02

Control Panel

Circuit Breaker, 20 Amp

120V, 30A Twist-Lock Receptacle

Sems Screw, #8-18 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, 20A Duplex Receptacle

Control Panel Assembly

Panel Schematic Diagram

Auto Idle PC Board Kit

Solenoid Assembly Kit (With Bracket)

∆

† Includes reference numbers 1 through 16

∆ Not shown

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PORTABLE GASOLINE GENERATORS

ILLUSTRATED

PARTS LIST

For Solenoid and Control Board

Assemblies and Mounting

Solenoid Assembly and Mounting

Control Board Assembly and Mounting

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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, fol-

low the instructions listed under Replace-

ment Parts on page 32 of this manual.

KEY

NO.

PART

NUMBER

DESCRIPTION

QTY.

100105-01

26499000

100321-01

WP-C3

26514000

100324-03

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)

Retaining Ring*

Linkage Rod*

Linkage Rod

103812-01

100755-02

100755-01

22822000

102939-01

100756-01

103811-01

100328-01

02407002

100329-01

Roll Pin

Solenoid Mounting Bracket*

Solenoid Mounting Bracket

Nylon Washer*

Bolt, M8 x 25mm ^†

Flat Washer, 5/16" ^†

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

* Model MGH10000A Only

† All Models Except MGH10000A

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PORTABLE GASOLINE GENERATORS

FBD

REPLACEMENT

PARTS AND

REPAIR SERVICE

1349 Adams Street

Bowling Green, KY 42103-3414

270-846-1199

Note: Only use original replacement parts.

Thiswillprotectyourwarrantycoveragefor

parts replaced under warranty.

1-800-654-8534

[email protected]

ACCESSORIES

Master Part Distributors

1251 Mound Avenue NW

Grand Rapids, MI 49504-2672

616-791-0505

EachAuthorizedServiceCenterisindepen-

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.

For original replacement parts and accesso-

ries,contactyournearestAuthorizedDealer

or Authorized Service Center for this prod-

uct. If they can not supply the part or acces-

sory,contactyournearestPartsCentrallisted

below.EachAuthorizedDealer,Authorized

Service Center, and Parts Central is inde-

pendently owned and operated.

1-800-446-1446

www.masterparts.net

Bowden Electric Motor Service

1681 S. Wesleyan Blvd.

Rocky Mount, NC 27803

252-446-4203

WARRANTY SERVICE

If product requires warranty service, return it

to nearest Authorized Service Center. You

must show proof of purchase. If faulty materi-

als or workmanship caused damage, we will

repairorreplaceproductwithoutcharge.Note:

Normal wear, misuse, abuse, neglect, or acci-

dental damage is not covered under warranty.

East Coast Energy

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).

10 East Route 36

West Long Branch, NJ 07764-1501

1-800-755-8809

Laportes

2444 N 5th Street

Hartsville, SC 29550-7704

843-332-0191

In Canada call 1-800-561-3372 for parts

information.

MTA Distributors

555 Hickory Hills Blvd.

Nashville, TN 37189-9244

615-299-8777

NON-WARRANTY SERVICE

If product requires service, return it to near-

est Authorized Service Center. Repairs will

be billed to you at regular repair list prices.

Heavy-Duty Wheel Kit – PA2020

For Models MGH4000C,

MGH4000CI, MGH5000D,

MGH5000DI, MGH5000DIE,

MGH6000D, MGH6000DI,

MGH6500IE

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

1-800-264-0225

Industrial Hardware

4109 Bainbridge Blvd.

Chesapeake, VA 23324-1403

804-543-2232

PARTS CENTRALS

1-800-788-0008

These Parts Centrals are privately owned

businesses. Theyhaveagreedtosupportour

customer’s needs by providing original re-

placement parts and accessories.

[email protected]

Mills Lawn and Garden

928 Commonwealth Place

Virginia Beach, VA 23464

757-361-9293

Tool & Equipment

5 Manila Drive

www.mills-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

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

Completeinstallationinstructionsincluded.

Automatic Idle Kit – PA2010

For Models MGH4000C,

MGH5000D, MGH6000D, and

MGH6500IE

Automatically reduces engine speed when

no power is being used. Reduces fuel con-

sumption and engine noise. Increases en-

gine life.

Portable Heater Parts

342 North County Road 400 East

Valparaiso, IN 46383-9704

219-462-7441

1-800-362-6951

www.portableheaterparts.com

[email protected]

Completeinstallationandoperationinstruc-

tions included.

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OWNER’S MANUAL

NOTES

_______________________________________________________________________________________________

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PORTABLE GASOLINE GENERATORS

NOTES

_______________________________________________________________________________________________

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OWNER’S MANUAL

NOTES

_______________________________________________________________________________________________

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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 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

dealers and service centers for this product. These dealers and service centers will provide original factory replace-

ment parts. Failure to use original factory replacement parts voids this warranty.

This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that

fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration,

modification, tampering, contaminated fuels, repair using improper parts, or repair by anyone other than an authorized

dealer or service center. Routine maintenance is the responsibility of the owner. Travel, handling, transportation, and

incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of

the owner.

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 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

consult the applicable state laws.

Bowling Green, KY 42102-9004

www.desatech.com

106813-01

REV. F

08/04

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