R
PORTABLE GASOLINE
GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
FUEL
F
120 VOLTS
RESET
TEST
FULL POWER
SELECTOR
120
ONLY
120
240V
1
2
0
/2
4
0
V
O
L
ENM
T
S
00000005
HOURS
1/10
R
R
E
S
S
E
T
T
E
E
FUEL
F
1
2
0
V
O
L
T
S
R
E
S
E
T
T
E
S
T
Auto-Idle
ON
OFF
ENM
00000005
H
O
U
R
S
1
/
1
0
RESET
RESET
240 VOLTS
Generator Models: HWI3000, MGH3000, MGH4000D, MGH4000DI, MGH5000D, MGH5000DI,
MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, MGH7000DI, and MGH10000A
IMPORTANT: Read and understand this manual before operating or servicing
generator. Improper use of generator can cause serious injury. Keep this
manual for future reference.
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OWNER’S MANUAL
SAFETY
PRODUCT
INFORMATION
IDENTIFICATION
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
F
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)
120 VOLTS
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.
RESET
TEST
FULL POWER
120
ONLY
120
240V
120/240 VOLTS
ENM
120 Volt
Receptacle
(Duplex)
00000005
HOURS
1/10
RESET
RESET
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.
FUEL
F
• Remove oily rags and other items
that create fire hazards.
Fuel
Valve
• 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.
Lever
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 MGH4000D Shown)
105202
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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 models provide depend-
able, trouble-free service. The alternators
are brushless with revolving fields. Honda
gasoline engines provide long life under
heavy use. Honda engines have overhead
valves (OHV). This provides high perfor-
mance with lower fuel consumption. These
engines are governed to maintain engine
speed of 3600 RPM under load. 3600 RPM
engine speed provides 120/240V, 60 Hz
power.
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
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.
• Electric starter (models MGH5000DIE,
MGH7000D, MGH7000DI, and
MGH10000A only)
• 15-Amp ground fault circuit interrupter
(GFCI) receptacle (Except HWI3000
Model)
UNPACKING
1. Remove generator from carton.
2. Remove any protective packaging ap-
plied to generator for shipment.
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 model
MGH5000DIE,
MGH7000D,
MGH7000DI, and MGH10000A only.
These cables are in a separate bag in-
side generator carton. You must install
these cables to engine. See Battery,
page 8 for installation instructions.
105202
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OWNER’S MANUAL
SPECIFICATIONS
MGH5000D
MGH4000D MGH5000DI MGH6000D
MGH4000DI MGH5000DIE MGH6000DI MGH7000DI MGH10000A
MGH7000D
MODEL
HWI3000 MGH3000
Electrical
Rated Wattage
2500
2500
4000
5000
6000
7000
10,000
Rated Amperage
120 V
20.8
––
20.8
––
33.3
16.7
41.7
20.8
50
25
57
28.3
83.3
41.7
240 V
Receptacle
120-V Duplex
––
Yes
No
No
No
––
––
Yes
––
Yes
––
Yes
––
Yes
––
Yes
––
120-V, 20-A Duplex
120-V, 15-A GFCI
120-V Twist-Lock
120/240-V Twist-Lock
Yes
No
No
No
No
Yes
Yes
Yes
Yes
Yes
30 Amp
20 Amp
Yes
30 Amp
20 Amp
Yes
30 Amp
20 Amp
Yes
30 Amp
30 Amp
No
30 Amp
30 Amp
No
120-V Full-Power Switch No
120/240-V, 50-A
No
5.5
No
No
No
No
Yes
General
Honda Engine H.P.
Honda Model
Fuel Type
5.5
8
GX240K1VA
Gasoline
5 gal.
9
11
GX340K1VA
Gasoline
5 gal.
13
20
GX160K1VX GX160K1VX
GX270VA
Gasoline
5 gal.
GX390K1VXE GX620VXA3
Gasoline
3.9 qt.
Yes
Gasoline
3.9 qt.
Yes
Gasoline
5 gal.
Yes
Gasoline
5 gal.
Yes
Fuel Tank Capacity
Oil Alert System
Start Method
Yes
Yes
Yes
Recoil
85.5
Recoil
85.5
Recoil
139
Recoil/Elec.
173
Recoil
Electric
247
Electric
325
Weight (pounds)
191
* Single-phase, 1.0 power factor
Note: Ratings apply to SAE standard conditions. Reduce ratings 3 1/2% for each 1000 feet above sea level and 1% for each 10° Fahrenheit
rise above 60°F.
105202
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PORTABLE GASOLINE GENERATORS
120 VOLT ONLY: This position sends full
GROUND FAULT CIRCUIT
INTERRUPTER RECEPTACLE
GENERATOR
FEATURES
power to the 120V receptacles only. 240V
power is not available. Use this position
when powering 120V items only.
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
(model MGH3000 only). The GFCI pro-
tects 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 insula-
tion, etc.
OIL ALERT SYSTEM
120/240 VOLT: This position sends full
power to the 120/240V receptacle. It also
powers the 120V receptacles at reduced
wattage capacity.
Theoilalertsystemprotectstheenginefrom
low oil damage. This system automatically
shuts down the engine and prevents engine
restarting if the oil level falls too low.
Full Pow er
Note:Whenthishappens, theengineswitch
remains in the ON position. The oil alert
system is wired into the ON/OFF Switch.
120 V
ONLY
120/
240V
Selector
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).
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.
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.
120 VOLT ONLY Position
Test Procedure
See engine owner’s manual for more
information.
Full Pow er
Check the GFCI receptacle every month.
This insures it is working right.
120 V
ONLY
120/
240V
ENGINE SW
ON
Selector
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.
OFF
120/240 VOLT Position
Models HWI3000, MGH3000, MGH4000D,
MGH4000DI, MGH5000D, MGH5000DI,
MGH6000D, and MGH6000DI
Figure 3 - Full Power Selector Switch
WARNING: If RESET button
does not pop out, do not use the
GFCI receptacle. Contact a quali-
fied electrician for repairs.
IMPORTANT: Do not move the full power
selector switch while powering electrical
items.Unplugallitemsbeforemovingswitch.
Failure to do so can damage switch. Models
HWI3000, MGH3000, MGH7000D,
MGH7000DI,andMGH10000Adonothave
thisswitch. Thesemodelsprovidefullpower
to all receptacles.
HONDA
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.
Models
MGH5000DIE,
ON
OFF
START
MGH7000D,
MGH7000DI, and
MGH10000A
ENGINE SW
ELECTRIC START
(Models MGH5000DIE,
MGH7000D, MGH7000DI, and
MGH10000A)
CIRCUIT
BREAKER
Figure 2 - Engine Switch Location
FULL POWER SELECTOR
SWITCH
Models MGH5000DIE, MGH7000D,
MGH7000DI, andMGH10000Ahaveelec-
tric starters. A battery is not supplied with
generator. You must provide a 12-volt, 32-
amp-hour battery. For more battery infor-
mation, see Battery, page 8.
RESET
TEST
All models except HWI3000, MGH3000,
MGH7000D,
MGH7000DI,
and
MGH10000A have a full power selector
switch on the control panel. The switch has
two positions: 120 VOLT ONLY, and 120/
240 VOLT.
Figure 4 - GFCI Receptacle
105202
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OWNER’S MANUAL
ENGINE OIL
GENERATOR
FUEL
WARNING:Gasolinepresents
a hazard of fire or explosion.
Gasoline is flammable. Its vapor
is explosive.
FEATURES
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.
Continued
ENGINE CIRCUIT BREAKER
(Models MGH5000DIE,
MGH7000D, MGH7000DI, and
MGH10000A)
• Keep fuel out of children’s
reach.
CHECKING OIL LEVEL AND
ADDING OIL
•
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.
Follow steps below to check oil level. Make
sure engine is level and stopped.
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.
1. Remove dipstick (see Figure 7). Wipe
dipstick clean.
2. Insert dipstick into oil filler neck. Do
not screw it in. Oil level should be at
top of filler neck. Oil should cover most
of dipstick. For Model MGH10000A
only, the oil should be between the two
dots on dipstick.
• 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.
ON
OFF
START
ENGINE SW
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.
Engine Circuit
Breaker Button
CIRCUIT
BREAKER
ON/push OFF
• 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.
Note: If oil level is too low, oil alert system
will shutdown engine and prevent engine
from restarting.
Figure 5 - Engine Circuit Breaker
RECEPTACLE CIRCUIT
BREAKER
The circuit breakers protect the receptacles
and alternator. Overloading generator will
trip circuit breaker. A short circuit in item
being powered will also trip breaker. If this
occurs, unplug electrical load from recep-
tacle. Let circuit breaker cool down. Push
circuit breaker button to reset.
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.
Oil Level
At Top Of
Filler Neck
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.
Dipstick
Oil
See engine owner’s manual for more
information.
Figure 7 - Checking Oil Level (Model
MGH4000D Shown)
20
Normal
20
Tripped
Figure 6 - Receptacle Circuit Breaker
Button
Note: High ambient temperature will cause
nuisance tripping.
105202
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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.
BATTERY
(Models MGH5000DIE,
MGH7000D, MGH7000DI, and
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.
Black,
Negative (–)
Battery Cable
INSTALLING BATTERY
CABLES TO ENGINE
1. Attach the red, positive (+) battery
cable to the starter solenoid on engine
(see Figure 8). The starter solenoid is
located directly above the starter on
Model MGH10000A. This cable is fac-
tory installed.
Figure 9 - Connecting Black, Negative (-)
Battery Cable to Engine Block (Model
MGH7000D Shown)
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.
MOUNTING BATTERY TO
GENERATOR
1. Secure battery to generator by battery
hold-down system. This system consists
of the battery mounting bracket, hook
bolts, and nut (see Figure 10).
CAUTION:Donotovertighten
positive terminal on starter sole-
noid. Positive terminal could ro-
tate and cut into negative termi-
nal, causing a short.
Note: Model MGH10000A battery is
located on opposite side as shown (see
Figure 11, page 9).
• If battery acid gets on your
skin, wash with water.
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 opposite side of engine from starter
solenoid.Attach cable as shown in Fig-
ure 9.
• Ifbatteryacidgetsinyoureyes,
flush with water at least 15
minutes. 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. Locate the red, positive (+) battery
cable from starter solenoid. Connect it
to the positive (+) battery terminal (see
Figures 12 and 13, page 9).
3. Locate the black, negative (–) battery
cable attached to engine block. Connect
it to the negative (–) battery terminal
(see Figures 12 and 13, page 9).
4. Check battery before starting engine.
Make sure fluid levels are full. Make
sure battery is charged.
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.
See engine owner’s manual for more
information.
Starter
Solenoid
Battery
Mounting
Bracket
IMPORTANT: Make sure battery connec-
tions are the correct polarity. Electric start
generatorsusenegativeground, 12-voltDC
starting system.
Red, Positive (+)
Battery Cable
Nut
Figure 8 - Connecting Red, Positive (+)
Battery Cable to Engine Starter Solenoid
(Model MGH7000D Shown)
FULL POWER
120
ONLY
120
240V
ENM
00000005
H
O
U
R
S
1
Models MGH5000DIE, MGH7000D,
MGH7000DI, and MGH10000A have an
electric starter. A battery is not supplied
withgenerator. Youmustprovidea12-volt,
32-amp-hourbattery.Thepositiveandnega-
tivebatterycablesaresuppliedwithgenera-
tor. You must install these cables before
mounting battery.
/10
Battery
Hook
Bolt
Figure 10 - Battery Hold-Down System
(Model MGH7000D Shown)
105202
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OWNER’S MANUAL
BATTERY
GENERATOR
GROUNDING
EXTENSION
CORDS
Continued
Only use grounded extension cords. Be sure
touseextensioncordwithproperwiregauge
size. See chart below.
WARNING: You must prop-
erly earth-ground generator be-
fore starting. This will help guard
against deadly electric shock.
Only use grounded plugs with
generator.Onlyusegroundedex-
tension cords. Only use three-
wire or double-insulated power
tools.
FUEL
F
Nut
Recommended Minimum Wire
Gauges (AWG) for Extension
Cords
Battery
Ampere
Load
AWG for Length of
Cord in Feet
Grounding generator helps prevent electric
shock from a ground fault condition. Locate
ground lug on end of generator housing (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
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.
50'
100'
150'
Battery
Mounting
Bracket
Hook
Bolt
2
3
4
5
6
18
18
16
16
16
16
16
14
14
12
10
18
18
16
16
16
14
14
14
12
12
10
18
18
16
16
14
12
12
12
10
10
8
Figure 11 - Battery Hold-Down System
(Model MGH10000A Shown)
8
10
12
14
16
20
FULL POWER
TO ENGINE
BLOCK
120
ONLY
120
240V
ENM
00000005
1/10
HOURS
TO STARTER
SOLENOID
WARNING: For a grounding
point, do not use metal pipe be-
ing used to carry combustible
materials or gases.
Figure 12 - Connecting Positive and
Negative Cables to Battery
(Model MGH7000D Shown)
Ground Lug
FUEL
F
Copper or Brass
Grounding Point
FUEL
F
TO
STARTER
SOLENOID
TO
ENGINE
BLOCK
Ground Wire
Alternator
Figure 14 - Grounding Generator
(Model MGH4000DShown)
Figure 13 - Connecting Positive and
Negative Cables to Battery
(Model MGH10000A Shown)
105202
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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
2. Enter running watts of each item ex-
cept motors. The light bulb or appli-
ance nameplate lists its wattage. Re-
member, 1KW = 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.
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.
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
Running Starting
Equipment
Watts
Watts Equipment
Watts
Watts
Light bulb (100W)
Radio
Fan
100
150
200
400
100
150
600
400
1/2" Drill
Toaster
Coffee maker
Skillet
1000
1200
1200
1200
1200
1250
1200
1200
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
600
700
800
800
1000
1800
750
2100
2400
1000
1000
Vacuum cleaner
Sump pump (1/3 hp)
Refrigerator/freezer
6" Circular saw
Floodlight
1000
3000
1500
2000
1500
6000
5000
5000
Chart 2
Approximate Starting Watts*
Repulsion
DETERMINING
Motor
HP
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 1/2
2
3
275
400
450
600
850
1000
1600
2000
3000
400
500
600
750
1000
1250
1750
2350
x
600
850
975
1300
1900
2300
3200
3900
5200
850
1200
1700
1950
2600
x
x
x
x
x
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.
1050
1350
1800
2600
3000
4200
5100
6800
* – Always use starting watts, not running watts, when figuring correct electrical load.
x – Motors of higher horsepower are not generally used.
105202
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OWNER’S MANUAL
Model MGH10000A also has a 120/240V,
50-amp receptacle (see Figure 15).
POWER CORD AND PLUG
REQUIREMENTS
OPERATION
GENERAL INFORMATION
Model HWI3000 has only the 120V, 20-
amp duplex receptacle.
120V, 30-amp twist-lock receptacle
• NEMA L5-30P plug
This generator is not large enough to power
your entire home. Do not connect generator Model MGH3000 has only the 120V, 15-
toanyexistingelectricalcircuits.Plugitems amp GFCI duplex receptacle.
directly into generator receptacles. Do not
• Three-wire, 30-amp cord
120/240V, 20 or 30-amp twist-lock
receptacle
exceedamperageratingofreceptacles.Only
120V, 15-Amp GFCI Duplex
120V, 15-Amp Duplex
120/240V, 20 or 30-
use grounded cords.
• NEMA L14-20P (20-amp) or L14-30P
(30-amp) plug
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, 50-amp receptacle
• NEMA L14-50P
Amp Twist-Lock
120 VOLTS
• Four-wire, 50-amp cord
RESET
TEST
120/240 Volt
20 Amp
120
ONLY
Neutral
120V
120V
120
240V
ENM
00000005
HOURS
1/10
RESET
RESET
w
G
L14-20P
Plug
X
(Hot)
Ground
(Green)
Y
X
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.
Ground
W
Y
(Hot)
(Neutral)
RESET
RESET
240 VOLTS
Neutral
120V 120V
L14-20P
Plug
120/240 Volt
20 and 30
Amp
RESET
w
G
Y
X
Ground
L14-50P
Plug
RESET
Note:Wesupplytheengineowner’smanual
with generator. Refer to that manual for
questions concerning engine operation.
Ground
G
w
Y
X
X
(Hot)
Ground
(Green)
Neutral
120V
120V
120V
120V
w
USING RECEPTACLE
Neutral
Y
X
G
W
L14-30P
Plug
Note: Do not exceed amperage rating of
receptacles. Exceeding rating will trip re-
ceptacle circuit breaker.
Y
(Hot)
120/240V, 50-Amp
(Model MGH10000A only)
(Neutral)
Ground
Figure 16 - Cord and Plug Configurations
Figure 15 - Receptacle Locations
Usereceptaclesproperly.Improperusecould
damage generator. Use only grounded ex-
tension cords. Power only grounded or
double-insulated items. Do not overload
receptacles. All generators (except models
HWI3000 and MGH3000) have the follow-
ing receptacles (see Figure 15):
• 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
105202
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PORTABLE GASOLINE GENERATORS
4. Start the engine.
OPERATION
Choke Button
Pulled Out
(Closed Position)
A. Recoil Starter
Continued
Turn engine switch to the ON position
PRESTART
(see Figures 19 and 20). 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.
Figure 18 - Choke Button Closed (Model
MGH10000A Only)
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.
ENGINE SW
ON
OFF
B. Electric Starter (Models
MGH5000DIE,
MGH7000DI, and MGH10000A Only)
MGH7000D,
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 20). Hold it there
until engine starts. When engine starts,
let switch return to the ON position.
Figure 19 - Engine Switch In ON Position
(All Models Except MGH5000DIE,
MGH7000D, and MGH10000A)
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
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.
HONDA
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.
ON
OFF
START
Engine
Switch
5. As engine warms up, slowly move
choke lever fully to the right (see Fig-
ure 21). This opens the choke. On
Model MGH10000A, the choke will
automatically open.
ENGINE SW
IMPORTANT: Never start generator with
electrical loads connected. Start engine be-
fore adding electrical loads.
CIRCUIT
BREAKER
ON/push OFF
1. Make sure gasoline tank is full. See
Fuel, page 7 for fuel information.
Figure 20 - Engine Switch (Models
MGH5000DIE, MGH7000D, MGH7000DI,
and MGH10000A Only)
Choke Lever (Closed Position)
2. Move fuel valve lever to the ON posi-
tion (see Figure 17).
3. Move choke lever fully to the left (see
Figure 17) or pull choke button out
(Model MGH10000A only, see Figure
18). This closes the choke.
Choke Lever (Open Position)
Note:You may not need to close choke
if engine is warm or air temperature is
high.
Fuel Valve Lever (ON Position)
Figure 17 - Fuel Valve Lever On, Choke
LeverClosed (ModelMGH4000DShown)
Figure 21 - Choke Lever Opened (Model
MGH7000D Shown)
105202
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OWNER’S MANUAL
Fuel Valve Lever
(Off Position)
STOPPING ENGINE
OPERATION
IMPORTANT: The engine speed is preset.
The throttle is locked in preset position. Do
not adjust throttle.
Continued
HIGH ALTITUDE OPERATION
Follow the steps below to stop engine.
This generator will not perform well at high
altitudes without proper adjustment. See
engine owner’s manual for details.
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.
Make sure total wattage of all electrical
loads does not exceed rated wattage of gen-
erator. Overloading may shorten generator
life. It could also cause internal damage to
generator. Overloading will trip circuit
breaker.
3. Turn engine switch to the OFF posi-
tion (see Figure 22).
Figure 23 - Fuel Valve Lever Off (Model
MGH7000D Shown)
4. Turn fuel valve lever off. Do this by
moving valve lever fully to the left (see
Figure 23).
IMPORTANT: (All models except
HWI3000, MGH3000, MGH7000D,
MGH7000DI, andMGH10000A)Keepfull
power selector switch in the 120 VOLT
ONLYpositionifonlypowering120Vitems.
Only move switch to 120/240 VOLT posi-
tion if powering 240V items.
ENGINE SW
ON
OFF
1. Check items to be powered. Their
nameplate lists their wattage ratings.
Note: The wattage ratings for some
electrical motors are misleading. They
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.
Models HWI3000, MGH3000, MGH4000D,
MGH4000DI, MGH5000D, MGH5000DI,
MGH6000D and MGH6000DI
HONDA
2. Start engine. Let engine reach full
speed.
3. Connect electrical loads one at a time.
If the load consists of electric motors,
start them first. Always start the larg-
est first. Start each motor individually.
ON
OFF
START
ENGINE SW
DISCONNECTING ELECTRIC
LOADS
CIRCUIT
BREAKER
Remove electrical loads one at a time. Re-
move voltage sensitive items first. Voltage
sensitive items include TVs, VCRs, and
other home electronic items.
ON/push OFF
Models MGH5000DIE, MGH7000D,
MGH7000DI, and MGH10000A
Figure22-EngineSwitchInOFFPosition
105202
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PORTABLE GASOLINE GENERATORS
IMPORTANT: Keep generator level when
servicing.Neverturngeneratorupsidedown
or stand it on end to service.
MAINTENANCE
WARNING: The muffler be-
comesveryhotduringoperation.
The muffler remains hot for a
while after shutdown. Let engine
cool before storing.
AND REPAIRS
Note:Wesupplytheengineowner’smanual
with generator. Refer to that manual for
questions concerning engine maintenance
and repairs.
WARNING: Only a qualified
electrical service person should
service and repair the alternator
on this generator. Use only fac-
toryapprovedreplacementparts.
IMPORTANT: Keep generator level while
in storage. Never store generator upside
down or standing on end.
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.
Note:Wesupplytheengineowner’smanual
with generator. Refer to that manual for
questions concerning engine storage.
Use a fuel additive, such as STA-BIL® or an
equivalent,whenstoringgeneratorwithfuel
in fuel tank. This will minimize fuel gum
deposits from forming in engine.
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.
STORAGE
WARNING: Remove all fuel
fromfueltankbeforestoringgen-
erator.Storefuelinapprovedcon-
tainer. Store fuel in a well-vented
areafreeofopenflamesorsparks.
Cover and store generator in a clean, dry
place. Do not expose generator to extreme
high or low temperatures during storage.
CAUTION: Shut off generator
before performing maintenance.
TROUBLESHOOTING
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 en-
gine troubleshooting.
OBSERVED PROBLEM
POSSIBLE CAUSE
REMEDY
No voltage when starting generator with no
electrical load
1. Defective capacitor
2. Winding short circuit or loose
connections
3. Defective rotor diode
4. Loss of residual magnetism
1. Replace capacitor
2. Check resistance of coils (see Electri-
cal Component Specifications, page 15)
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. Defective rotor diode
3. Partial short circuit in winding
2. Replace both diodes on rotor
3. Check resistance of coils (see Electri-
cal Component Specifications, page 15)
4. Replace capacitor
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
105202
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OWNER’S MANUAL
ELECTRICAL
COMPONENT
SPECIFICATIONS
Resistance in Ohms
Stator
Main
Winding * Winding
Stator
Auxiliary
Rotor
Primary Secondary
Winding † Winding †
Rotor
Capacitor,
MFD
450 Volt
Diodes (2)
800 Volt
Model
∆
HWI3000
MGH3000
1.6
1.6
5.9
5.9
6.9
6.9
1.33
1.33
2.07
2.29
2.29
2.57
2.9
16
16
40
50
50
60
70
80
6 Amp
6 Amp
MGH4000D, MGH4000DI
MGH5000D, MGH5000DI
MGH5000DIE
MGH6000D, MGH6000DI
MGH7000D, MGH7000DI
MGH10000A
0.71
0.54
0.54
0.37
0.28
0.40
2.17
1.38
1.38
1.01
0.78
0.90
0.54
0.61
0.61
0.68
0.77
0.37
70 Amp
70 Amp
70 Amp
70 Amp
70 Amp
70 Amp
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
120V/15A
(MGH3000)
Black
L1
HOT
GFCI
Black
20A
WHITE
Receptacle
120V/20A
(HWI3000)
Circuit
Breaker
T1
L1
T3
T2
T4
L2
L2
L2
110/120V
Yellow
L1
Rotor
Stator
White
Auxiliary
Phase
C
D
Brown
Black
Main
Windings
T4
T3
Red
T2
T1
Yellow
Green
Figure 24 - Wiring Diagram, Models HWI3000 and MGH3000
Red
Black
White
Green/Yellow
Green
White
Red
120V, 15A
Receptacle
120/240V 20A
Receptacle
120V, 15A
Receptacle
120V, 30A
Receptacle
Circuit
Breaker
20A
White
Circuit
Duplex
GFCI
T1
T2
Breaker
25A
Circuit
Breaker
20A
Full Pwr
Selector
Switch
Red
Black
Black
Circuit
Breaker
25A
White
T3
LINE
T4
Yellow
Black
Hour
Meter
Green
Black
White
Green
Red
Red
Black
Black
Green
Red
Main
Windings
Auxiliary
Phase
Capacitor
White
Stator
White
T1 T4 T3 T2
T2
T1
T4
Rotor
Diode
Diode
Stator
White
T3
T1
L1
T2
T3
T4
L2
Green
220/240V
Red
Black
Yellow
110/120V
110/120V
Brown
Continued
Figure 25 - Wiring Diagram, Models MGH4000D, MGH5000D, MGH5000DIE, and MGH6000D
105202
15
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R
PORTABLE GASOLINE GENERATORS
WIRING DIAGRAMS
at
o
r
Continued
Green/Yellow
Green
Black
120/240V 30A
Receptacle
120V, 15A
Receptacle
120V, 15A
Receptacle
120V, 15A
Receptacle
Circuit
Breaker
20A
White
White
Circuit
Breaker
30A
Duplex
GFCI
T1
Red
T3
White
White
Black
T2
Circuit
Breaker
20A
Circuit
Breaker
30A
LINE
Hour
Meter
T4
White
Yellow
Green
Black
Black
Red
ob
Black
Black
Red
Main
Windings
Auxiliary
Phase
Capacitor
White
d
n
Stator
T2 T3
220/240V
110/120V
White
T1 T4 T3 T2
Stator
White
T4
Rotor
T2
T1
T3
T1
L1
T4
L2
Green
Red
Diode
Diode
Black
Yellow
110/120V
Brown
Figure 26 - Wiring Diagram, Model MGH7000D
of
White
White
Green
Black
Black
Green
125V, 30A
Receptacle
125V, 15A
Receptacle
GFCI 125V, 15A
Receptacle
250V 30A
Auto-Idle
Control Board
Receptacle
d
o
Red
250V 50A
Receptacle
Circuit
Breaker
20A
Circuit
Breaker
30A
White White
White
Red
Circuit
Breaker
45A
White
White
Black
To
Auto-Idle
Solenoid
Black
Black
Run
Circuit
Breaker
20A
Light
Circuit
Breaker
30A
Yellow
Circuit
Breaker
45A
e
Hour Meter
White
Black
Red
Green
Black
Black
Black
Yellow
Red
Black
White
Black
Black
Red
Main
Windings
Capacitor
White
Stator
T4
Rotor
Diode
T2
T1
T3
Stator
T1 T4 T3 T2
T1
L1
T2
T3
T4
L2
Diode
220/240V
110/120V
110/120V
Figure 27 - Wiring Diagram, Model MGH10000A
105202
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OWNER’S MANUAL
TECHNICAL
SERVICE
REPLACEMENT
PARTS
PARTS CENTRALS
These Parts Centrals are privately owned
businesses. Theyhaveagreedtosupportour
You may have further questions about in- Note: Use only original replacement parts.
customer’s needs by providing original re-
placement parts and accessories.
stallation, operation, or troubleshooting.
Thiswillprotectyourwarrantycoveragefor
parts replaced under warranty.
If so, contact DESA International’s Techni-
cal Service Department at 1-800-323-5190.
Baltimore Electric
1348 Dixwell Avenue
Hamden, CT 06514
1-800-397-7553
PARTS UNDER WARRANTY
Contactauthorizeddealersofthisproduct.If
they cannot supply original replacement
part(s), either contact your nearest Parts
Central or call DESA International’s Tech-
203-248-7553
SERVICING THE
ENGINE
Parts Company of America
nicalServiceDepartmentat1-800-323-5190. 1657 Shermer Road
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:
Northbrook, IL 60062
1-800-323-0620
708-498-5900
When calling DESA International, have
ready
• your name
Portable Heater Parts
342 N. County Road 400 East
Valparaiso, IN 46383
• your address
Engines Gasoline, Honda
• model number of your generator
• how generator is malfunctioning
• purchase date
1-800-362-6951
219-462-7441
ACCESSORIES
Heavy-Duty Wheel Kit – PA2020
For models MGH4000D,
MGH4000DI, MGH5000D,
MGH5000DI, MGH5000DIE,
MGH6000D, MGH6000DI,
MGH7000D, and MGH7000DI
F B D
Usually, we will ask you to return the defec-
tive part to the factory.
1349 Adams Street
Bowling Green, KY 42103
502-846-1199
PARTS NOT UNDER
WARRANTY
1-800-654-8534
Master Parts Dist.
1184 Wilson Ave. NW
Grand Rapids, MI 49544-3458
1-800-446-1446
616-791-0505
Fax: 616-791-8270
Contact authorized dealers of this product.
If they cannot supply original replacement
part(s), either contact your nearest Parts
Central or call DESA International’s Parts
Department at 1-800-972-7879 for referral
information.
Wheelbarrow-style wheel kit. Makes gen-
erator easy for one person to move.
This kit includes:
• Large 12-inch wheels for easy rolling
When calling DESA International, have Four Flags Power Products
• Powder coated tubing and plated hard-
ware for long life
ready
1115 Stateline Road
Niles, MI 49120-4728
1-800-268-4983
• model number of your generator
• the replacement part number
• Long handles with thick grips for greater
comfort and control
616-684-2697
Completeinstallationinstructionsincluded.
Laportes Parts & Service
2444 N 5th Street
Hartsville, SC 29550
803-332-0191
Automatic Idle Kit – PA2010
For models MGH4000D,
MGH5000D, MGH6000D, and
MGH7000D
MTA Distributors
555 Hickory Hills Blvd.
Nashville, TN 37189-9244
1-800-264-0225
Automatically reduces engine speed when
no power is being used. Reduces fuel con-
sumption and engine noise. Increases en-
gine life.
615-299-8777
Tuco Industrial Products
5223 18th Street SW
Lynwood, WA 98037-4506
425-743-9533
Completeinstallationandoperationinstruc-
tions included.
1-800-735-1268
105202
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PORTABLE GASOLINE GENERATORS
1a
ILLUSTRATED
PARTS LIST
2a
For Models HWI3000 and
MGH3000 Alternator Assembly
1b
7
This list contains replaceable parts used in
your generator. When ordering parts, fol-
low the instructions listed under Replace-
ment Parts on page 17 of this manual.
2b
4
22
5
6
3
14
21
20
15
19
13
17
12
16
15
13
7
8
18
9
7
10
11
7
KEY PART
KEY PART
NO.
NUMBER
DESCRIPTION
QTY.
NO.
NUMBER
DESCRIPTION
QTY.
099722-01
Alternator Assembly
(HWI3000)*
Alternator Assembly
(MGH3000)*
Top Cover (HWI3000)
Top Cover (MGH3000)
120V, 20A Duplex
Receptacle (HWI3000)†
120V, 15A Duplex (GFCI)
Receptacle (MGH3000)†
Circuit Breaker, 20 Amp †
Capacitor
Screw, M4 x 20
Terminal Block
Screw, M5 x 13
End Plate
Ground Lug
Flanged Nut, 8mm
11
12
13
14
15
16
17
18
19
20
21
22
099861-01
099842-01
26310000
27001005S
WLE-4
Bottom Cover
Draw Bolt
Screw, M6 x 16
Engine Flange
Lock Washer, 1/4"
Stator
Bearing
Diode
Rotor
Fan
1
1
4
1
4
1
1
2
1
1
4
4
1
099722-02
1
1
1
1a
1b
2a
099849-01
100074-01
104201-01
**
27001002
27001009S
**
27001006
26327006
WLE-5
1
2b
100445-01
1
1
1
1
1
13
1
1
3
4
5
6
7
8
9
10
22616009
27002002S
26333000
099863-01
099701-01
099848-01
17587000
099891-01
Bolt, 5/16-24 x 5/8"
Lock Washer, 5/16"
PARTS AVAILABLE - NOT SHOWN
099866-03
099866-04
099867-02
Safety Information Decal
Safety Information Decal
Operation Decal
1
1
1
1
† Includes fastening hardware.
* Includes reference numbers 1 through 22.
** Parts not available. Included in alternator assembly.
105202
18
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OWNER’S MANUAL
23
ILLUSTRATED
PARTS LIST
For Models MGH4000D,
MGH4000DI, MGH5000D,
MGH5000DI, MGH5000DIE,
MGH6000D, MGH6000DI,
MGH7000D, and MGH7000DI
Alternator Assembly
25
24
22
9
15
21
20
19
9
10
This list contains replaceable parts used
in your generator. When ordering parts,
follow the instructions listed under Re-
placement Parts on page 17 of this
manual.
8
14
7
18
6
5
13
16
12
4
1
17
2
11
3
PART NUMBER FOR MODEL
MGH5000D
KEY MGH4000D
NO. MGH4000DI
MGH5000DI
MGH5000DIE MGH6000DI MGH7000DI
MGH6000D
MGH7000D
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
——
099863-02
17587000**
M11084-26
099847-03
WLE-5
099723-04
099844-01
099701-01
099760-01
——
099863-02
17587000**
M11084-26
099847-04
WLE-5
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
1
1
6
1
1
1
1
1
4
4
1
1
4
1
1
4
1
1
1
1
2
1
1
1
4
4
1
2
3
4
5
6
7
8
099844-01
099701-01
099760-01
099863-01
099863-02
17587000**
M11084-26
099847-01
WLE-5
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
099843-01
27004002S
——
099843-01
27005003S
——
099843-01
099845-01
100054-01
*
099843-01
27007004S
100054-01
*
*
*
27003002
27003002
27003002
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**
WLE-6**
099891-01
099892-01
099842-04
27003003
27003012S
*
27003008
27003007S
26322004**
WLE-6**
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"
* Part not available by itself. Must purchase Alternator Assembly.
**Available at your local hardware store.
105202
19
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R
PORTABLE GASOLINE GENERATORS
19
ILLUSTRATED
18
PARTS LIST
20
For Model MGH10000A
13
17
8
Alternator Assembly
21
15
This list contains replaceable parts used in
26
yourgenerator.Whenorderingparts,follow
the instructions listed under Replacement
Parts on page 17 of this manual.
10
12
24
14
5
11
23
25
1
2
6
4
16
22
9
7
3
KEY
NO.
PART
NUMBER
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
†
Stator
Rotor
Draw Bolt
Fan
Balancing Disc
Lifting Eyes
D.E. Bracket
N.D.E. Bracket
Mounting Bolts
Nuts
*
*
1
1
1
1
1
2
1
1
4
4
1
6
1
1
1
2
1
1
1
1
1
1
4
1
2
1
1
103188-01
103191-01
103192-01
103193-01
103194-01
103195-01
099847-05
270010105
103189-01
099701-01
103198-01
103199-01
103200-01
27003012S
103201-01
099845-02
103204-01
099892-02
103202-01
103190-01
27003155
103203-01
WLE-5
Top Box
Screw and Washer
Plastic Cap
Bearing
Borelly Washer
Diode
Terminal Block
Capacitor
Tie Wrap
Foam Pad
Capacitor Bracket
Engine Flange
Bolts
'O' Ring
Washer
Hex Head Nut
Alternator Assembly
099891-01
102938-01
* Part not available by itself. Must purchase Alternator Assembly.
105202
20
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OWNER’S MANUAL
ILLUSTRATED
PARTS LIST
For Models HWI3000 and
MGH3000 Roll Cage
This list contains replaceable parts used in
yourgenerator.Whenorderingparts,follow
the instructions listed under Replacement
Parts on page 17 of this manual.
1
3
4
3
4
2
3
4
7
3
3
4
5
6
6
8
5
5
9
4
3
4
7
3
4
3
3
KEY
NO.
PART
NUMBER
DESCRIPTION
Roll Cage
QTY.
1
2
3
4
5
6
7
8
9
105155-01
099754-01
NEC-5C
1
1
9
7
3
2
1
1
1
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 1 1/2
Ground Strap
Washer, 5/16" x 1 1/2"
Bolt, 5/16-18 x 3/4"
105202
21
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R
PORTABLE GASOLINE GENERATORS
ILLUSTRATED
PARTS LIST
For Models MGH4000D,
MGH4000DI, MGH5000D,
MGH5000DI, MGH5000DIE,
MGH6000D, MGH6000DI,
MGH7000D, and MGH7000DI
Fuel Tank and Roll Cage
3
FUEL
F
5
1
2
4
15
26
24
9
23
25
27
8
6
7
7
6
11
13
10
22
11
16
21
20
14
23
23
16
11
11
11
16
14
13
16
12
18
10
16
17
19
16
17
16
11
13
16
11
16
11
105202
22
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OWNER’S MANUAL
ILLUSTRATED
PARTS LIST
For Models MGH4000D,
MGH4000DI, MGH5000D,
MGH5000DI, MGH5000DIE,
MGH6000D, MGH6000DI,
MGH7000D, and MGH7000DI
Fuel Tank and Roll Cage
KEY
NO.
PART
NUMBER
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
9
25954000
099832-01
25978000
M51043-01
099701-01
19508001
25985005
099743-01
099752-01
099752-02
103880-01
NEC-5C
14138000
099853-02
WLE-5
WLI-3
WP-5C
HC5-11C
099756-01
099750-01
099749-01
NEC-5C
100410-01
M10908-74**
WP-4C
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†
Roll Cage∆
Lock Nut, 1/4-20
Lock Nut, 5/16-18
Ground Strap
1
1
1
4
1
2
1
1
1
1
5
8
1
3
3
1
9
2
1
2
1
2
4
3
5
1
1
1
This list contains replaceable parts used in
your generator. When ordering parts, fol-
low the instructions listed under Replace-
ment Parts on page 17 of this manual.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
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"
099965-01
WP-3C
099742-01
Linkage Cover
Washer, #10
90° Fitting with barbs
PARTS AVAILABLE - NOT SHOWN
099866-01
Safety Information Decal *
Safety Information Decal **
Operation Decal *
1
1
1
1
1
1
3
099866-02
100003-01
100003-02
099873-01
099873-02
03157000
Operation Decal **
Battery Cable (Positive, Red)**
Battery Cable (Negative, Black)**
Fuel Line Grommet
*
For models MGH4000D, MGH5000D, MGH5000DIE, and MGH6000D only
** For model MGH7000D only
∆ For models MGH4000D and MGH5000D only
†
For models MGH6000D and MGH7000D only
*** Available at your local hardware store
105202
23
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R
PORTABLE GASOLINE GENERATORS
ILLUSTRATED
PARTS LIST
For Model MGH10000A Fuel
Tank and Roll Cage
3
FUEL
31
F
1
30
2
4
29
26
9
28
24
37
6
7
11
24
10
12
8
25
24
13
23
22
14
5
11
27
11
24
11
18
20
25
24
25
24
11
32
24
17
13
16
15
11
19
24
11
21
35
34
33
34
36
105202
24
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OWNER’S MANUAL
KEY
NO.
PART
NUMBER
ILLUSTRATED
PARTS LIST
For Model MGH10000A Fuel
Tank and Roll Cage
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
9
Gas Cap/Fuel Gage
Gas Tank (with 90° fitting)
Breather Assembly
1/4-20 x 1" Screw
1/2-20 x 1" Bolt
Gas Line Clamp
Fuel Line
3/8 Lock Washer*
Roll Cage
1/4-20 Lock Nut
5/16-18 Lock Nut
Ground Strap
25954000
099832-01
25978000
M51043-01
260302006
19508001
25985006
WLE-6
105111-01
103880-01
NEC-5C
14138000
17529000
WLE-5
1
1
1
1
2
2
1
1
1
4
18
1
3
1
1
1
2
1
2
1
2
4
1
24
10
4
2
4
2
2
2
1
2
4
2
2
1
1
1
1
1
3
2
1
This list contains replaceable parts used in
your generator. When ordering parts, fol-
low the instructions listed under Replace-
ment Parts on page 17 of this manual.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
∆
Shock Mounts
5/16" Lock Washer
3/8-16 x 1-1/4" Screw*
3/8" Flat Washer*
5/16-18 x 1-3/4" Bolt
Engine Spreader
5/16-18 Hook Bolt
Battery Mounting Bracket
Axle
#8-18 x 1/2" Sems Screw
1/4-20 x 1/2" Screw*
5/16" Washer
5/16-18 x 3/4" Bolt
1/4" Washer
1/2" Lock Washer
5/16-18 x 2.50 Screw
Handle
Handle Grip
Handle Plug
Stand
U-Bolt
Flat Washer
Wheels
HC6-10C
WP-6C
HC5-11C
102962-01
099750-01
099749-01
102933-01
100410-01
M10908-74
WP-5C
26007004
WP-4C
WLI-8
H8C5-20C
105035-01
103046-01
103057-01
102936-02
100135-01
WP-16C
102932-01
C4-12C
099742-01
099866-02
100003-04
099873-04
Cotter Pin
90º Fitting with Barbs
Safety Information Decal
Operation Decal
Red Battery Cable (Positive)
∆
∆
∆
Black Battery Cable (Negative) 099873-02
∆
Grommet
Screw (.250 x .75)
Wheel Kit Hardware
03157000
HC4-6C
103818-01
∆
∆
∆ Not shown
* Available at your local hardware store
105202
25
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R
PORTABLE GASOLINE GENERATORS
ILLUSTRATED
2
12
PARTS LIST
2
For Models MGH4000D,
MGH4000DI, MGH5000D,
MGH5000DI, MGH5000DIE,
MGH6000D, MGH6000DI,
MGH7000D, and MGH7000DI
Control Panel
5
1
3
RESET
TEST
6
Reset
Reset
120 Volt
7
4
This list contains replaceable parts used in
your generator. When ordering parts, fol-
low the instructions listed under Replace-
ment Parts on page 17 of this manual.
7
FULL POWER
SELECTOR
120 ONLY
13
13
120/240V
120/240 VOLTS
7
RESET
RESET
14
ENM
00000005
HOURS 1/10
11
9
10
PART NUMBER FOR MODEL
MGH5000D
KEY MGH4000D MGH5000DI MGH6000D MGH7000D
NO. MGH4000DI MGH5000DIE MGH6000DI MGH7000DI DESCRIPTION
QTY.
1
2
3
4
5
6
7
103349-01
22616009
099833-01
15324000
100445-01
099956-01
22616009
—
103349-02
22616009
099833-01
15324000
100445-01
099956-01
—
22616011
—
099834-01
103349-03
22616009
099833-01
15324000
100445-01
099956-01
—
103349-04
22616009
099833-01
15324000
100445-01
—
Control Panel
Circuit Breaker, 20 Amp *
120V, 30A Twist-Lock Receptacle *
120V, 15A Duplex Receptacle *
120V, 15A Duplex (GFCI) Receptacle *
Full Power Selector Switch *
Circuit Breaker, 20 Amp *
Circuit Breaker, 25 Amp *
Circuit Breaker, 30 Amp *
120/240V, 20A Twist-Lock Receptacle *
1
2
1
1
1
1
2
2
2
1
—
—
—
—
22616010
099834-01
22616010
—
8
099834-01
—
—
—
099835-01
101350-01
099760-01
100410-01
100149-01
22261000
099997-01
103348-04
103348-08
100177-07
120/240V, 30A Twist-Lock Receptacle *
Hour Meter
Bushing
Sems Screw, #8-18 x 1/2"
Control Box
U-Nut
1
1
1
4
1
8
1
1
1
1
9
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
103348-02
103348-06
100177-07
101350-01
099760-01
100410-01
100149-01
22261000
099997-01
103348-03
103348-07
100177-07
10
11
12
13
14
†
Switch Plug
Control Panel Assembly
Control Panel Assembly - Auto Idle Models
Panel Schematic Decal
†
∆
* Includes fastening hardware
∆ Not shown
† Includes reference numbers 1 through 13
105202
26
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OWNER’S MANUAL
ILLUSTRATED
PARTS LIST
For Model MGH10000A Control
Panel
2
2
14
6
16
1
RESET
TEST
3
11
12
Reset
Reset
120 Volt
7
Auto Idle
Selector
5
Off
4
5
On
12
200 Vp;t
15
Reset
Reset
5
8
9
Reset
Reset
ENM
00000005
HOURS
1/10
13
10
4
KEY
NO.
PART
NUMBER
DESCRIPTION
QTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
†
Control Panel
20 Amp Circuit Breaker
103182-01
22616009
099833-01
100410-01
22261000
100445-01
103183-01
103184-01
26299000
101350-01
099834-01
22616010
099760-01
103185-01
100366-01
15324000
102927-01
100177-05
103257-01
103258-02
1
2
1
16
20
1
1
2
1
1
1
2
1
1
1
1
1
1
120V, 30A Twist-Lock Receptacle
#8-18 x 1/2" Sems Screw
U-Nut
120V, 15A Duplex (GFCI) Receptacle
125/250V, 50A Receptacle
45 Amp Circuit Breaker
Run Light
Hour Meter
120/240V, 20A Twist-Lock Receptacle
30 Amp Circuit Breaker
Bushing
Control Box
Rocker Switch
120V, 15A Duplex Receptacle
Control Panel Assembly
Panel Schematic Diagram
Auto Idle PC Board Kit
Solenoid Assembly Kit (With Bracket)
∆
∆
∆
1
1
† Includes reference numbers 1 through 16
∆ Not shown
105202
27
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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.
Note: The two-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda
warrants the engine. See engine owner’s manual for engine warranty information.
TWO-YEAR LIMITED WARRANTY
GASOLINE PORTABLE GENERATORS
DESA International warrants each alternator, generator, or electric product of its manufacture, to be free from defects
in material and workmanship for two years from the date of first purchase from an authorized dealer, provided that the
product has been properly installed, maintained, and operated in accordance with all applicable instructions. The bill
of sale or proof of purchase must be presented at the time a claim is made under this warranty.
This warranty is extended only to the original retail purchaser. This warranty covers only the parts and labor required
to restore this unit to its proper operating condition. Warranty parts must be obtained through factory authorized
dealers and service centers for this product. These dealers and service centers will provide original factory replace-
ment parts. Failure to use original factory replacement parts voids this warranty.
This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that
fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration,
modification, tampering, contaminated fuels, repair using improper parts, or repair by anyone other than an authorized
dealer or service center. Routine maintenance is the responsibility of the owner. Travel, handling, transportation, and
incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of
the owner.
DESA International makes no warranty with respect to the engine and engine components not of its manufacture.
They are subject to warranties of their manufacturers.
To the full extent allowed by the law of the jurisdiction that governs the sale of the product, this express warranty
excludes any and all other expressed warranties and limits the duration of any and all implied warranties, including
warranties of merchantability and fitness for a particular purpose to two years from the date of first purchase, and
DESA International’s liability is hereby limited to the purchase price of the product and DESA International shall not
be liable for any other damages whatsoever including indirect, incidental, or consequential damages.
Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental
or consequential damages, so the above limitation of damages may not apply to you.
This warranty provides the original purchaser with specific rights. For information regarding those rights, please
consult the applicable state laws.
INTERNATIONAL
2701 Industrial Drive
P.O. Box 90004
Bowling Green, KY 42102-9004
105202 01
105202-01
REV. A
09/98
NOT A UPC
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