Desa Hwi3000a, Mgh3000ga, Mgh3000a, Mgh4000d, Mgh4000di User Manual

PORTABLE GASOLINE

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GENERATORS

OWNER’S OPERATION AND INSTALLATION MANUAL

Generator Models: HWI3000A, MGH3000GA, MGH3000A, MGH4000D, MGH4000DI, MGH5000E,

MGH5000EI, MGH5000EIE, and MGH6500AIE

IMPORTANT: Read and understand this manual before operating or servicing generator. Improper use of generator can cause serious injury. Keep this manual for future reference.

PORTABLE GASOLINE GENERATORS

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SAFETY INFORMATION

WARNINGS

IMPORTANT: Read this owner’s manual and the engine owner’s manual carefully. Become familiar with this generator before trying to operate or service it. Know its uses, limitations, and any hazards involved. Improper use of generator can cause severe injury or death from explosion, ﬁre, burns, electrical shock, or carbon monoxide poisoning.

DANGER: Carbon monoxide

poisoning may lead to death!

Engine exhaust contains poisonous carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death. Use only in well-vented areas. Make sure area has plenty of free-moving, fresh, outside air. Never run generator in an enclosed or conﬁned area. Never run generator inside occupied building.

Carbon Monoxide Poisoning: Early signs of carbon monoxide poisoning re semble the ﬂu, with headaches, dizziness, and nausea. If you have these signs, get fresh air at once! Some people are more affected by carbon monoxide than others. These include pregnant women, persons with heart or lung disease or anemia, those under the inﬂuence of alcohol, and those at high altitudes. Make certain you read and understand all warnings. Keep this manual for reference. It is your guide to safe and proper operation of this generator.

Safety information appears throughout these instructions. Pay close attention to them. Below are deﬁnitions for the safety information listed throughout this manual.

DANGER: indicates a hazard which will cause severe personal injury, death, or substantial property damage if you ignore warning

WARNING: indicates a hazard which can cause severe personal injury, death, or substantial property damage if you ignore warning.

CAUTION: indicates a hazard which will or can cause minor personal injury or property damage if you ignore warning.

.

1. Gasoline presents a hazard of ﬁre or explosion. Gasoline is ﬂammable. Its vapor is explosive.

• Keep fuel out of children’s reach.

• Refuel generator in a well-vented

area. Do not ﬁll fuel tank in the dark. Do not refuel while engine is run ning. Unhook all electrical loads and shut off engine before refueling.

• Do not overﬁll fuel tank. Always al-

low room for fuel to expand. If you overﬁll tank, fuel can overﬂow onto hot generator. This can cause ﬁre or explosion. After refueling, tightly close fuel tank cap.

• Do not spill fuel. Fuel or fuel vapor

may ignite. If fuel spills, make sure area is dry before starting engine.

• Never smoke in refueling area. Never

allow open ﬂames or sparks in area.

• Store fuel in approved container.

Store fuel in a well-vented area free of open ﬂames or sparks.

2. Guard against ﬁre hazard. Keep operation area well-vented. Keep generator at least three feet away from any object. Do not place ﬂammable objects near generator.

• Do not use generator where ﬂam-

mable vapors are present. Some

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vapors are heavier than air. These vapors settle in low-lying places.

• Do not use generator in enclosed

spaces. This includes motor home or RV generator compartments.

3.

Guard against electric shock. Generator produces high voltage. This high voltage can cause severe electric shock. Only responsible adults should use generator.

• Properly ground generator before

starting.

•

Never let anyone operate or service generator without proper instructions.

• Avoid contact with live terminals or

bare wires.

• Do not use generator outdoors in rain

or snow.

• Do not use generator near standing

water or snow.

• Do not use if generator is wet or

damp.

• Do not use generator in highly conductive areas. These areas include metal decking and steelwork.

• Only use grounded extension cords.

• Do not use any worn or damaged electric cords. Electric shock or dam-

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age to generator may result.

• Do not wear damp clothing or wet shoes when using generator.

4. Guard against burns. Hot engine parts can cause severe injury. Use caution and remain alert when using generator.

• Keep children and animals away from

generator while it is running or hot.

• Keep all covers and shields in place.

Keep them tightly secured.

• The mufﬂer becomes very hot dur-

ing operation. The mufﬂer remains hot for a while after shutdown. Do not touch muffler while it is hot. Do not let mufﬂer touch anything ﬂammable. Let engine cool before transporting or storing.

5. Have standby installation to home or building performed by a licensed electrician. Do not let anyone else wire into a utility circuit. Personal injury, equipment damage, or damage to home could occur.

6. Never connect generator to any existing electrical circuits. The generator output will back-feed into the utility power line. This may electrocute a power company line repair person. Also, if generator is powering electrical circuits, the chance of an electrical ﬁre exists.

7. 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 wellvented area.

8. Battery contains sulfuric acid. Battery acid is poisonous if swallowed. Contact with skin or eyes may cause severe burns. Do not tilt generator with battery installed. Tilting could cause battery acid to spill. Wear protective clothing and face shield when servicing. Keep out of children’s reach.

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OWNER’S MANUAL

FUEL

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FUE

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F

1 2 0

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N L

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1 2

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E S

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SAFETY INFORMATION

Continued

9.

Only a qualiﬁed electrical service person should service and repair generator.

• Generator produces high voltage. Use extreme caution when working on electrical parts.

• Always remove spark plug wire from spark plug before servicing. This will prevent accidental starting.

•

When working on generator, avoid hot mufﬂer, exhaust manifold, and engine parts. Severe burns may occur.

• Do not work on generator when tired.

• Use only factory approved replacement parts.

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.

11. Never operate generator

• if engine speed changes greatly

• if engine misﬁres often

• 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

12. Kee p generator and nearby areas clean.

• Keep generator free of oil, mud, and

other foreign matter.

• Remove anything that creates slip

pery areas around generator.

• Remove oily rags and other items

that create ﬁre hazards.

• Keep a fire extinguisher nearby.

Make sure it is rated ABC by the NFPA. They are good for all uses. Consult your local ﬁre department.

• Keep ﬁre extinguisher well main-

tained. Be familiar with its use.

13. Know how to stop engine quickly. Know how to use all controls.

14. Prolonged exposure to loud noise can cause hearing loss.

• When working around generator,

wear approved hearing protection.

• Remember neighbors when using

generator.

PRODUCT IDENTIFICATION

Gas Cap/Fuel Gauge

Control Panel

120 Volt Receptacle

Full Power

120 Volt Receptacle (GFCI)

120 Volt Receptacle (Duplex)

Run Lamp

Hour Meter

Choke Lever

Fuel

-

Valve Lever

Starter Grip

Engine

Figure 1 - Portable Generator (Model MGH4000D Shown)

Selector Switch

120/240 Volt Receptacle

Circuit Breaker

Engine ON/ OFF Switch

Provision for Auto-Idle Switch

Roll Cage

Gas Tank

Ground Lug

Alternator

Oil Dipstick

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PORTABLE GASOLINE GENERATORS

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GENERAL INFORMATION

Master portable generators are rugged and compact. These generators use brushless alternators for dependable, trouble-free service. Honda gasoline engines provide long life under heavy use. Honda engines have overhead valves (OHV). This provides high performance with lower fuel consumption. These engines are governed to maintain engine speed of 3600 RPM under load. 3600 RPM engine speed provides 120/240V, 60 Hz power.

Additional Features

• Circuit breaker protection

• Spark-arresting mufﬂer

• Large fuel tank

• Oil alert system

• Electric starter (models MGH5000EIE

and MGH6500AIE)

• 15-Amp ground fault circuit interrupter

(GFCI) receptacle (Except HWI3000A Model)

UNPACKING

1. Remove generator from carton.

2. Remove any protective packaging applied to generator for shipment.

3. Check for loose or missing parts. Check for shipping damage. If any parts are missing or damaged, promptly inform dealer where you bought generator.

4. Battery cables are supplied for models MGH5000EIE and MGH6500AIE only. These cables are in a separate bag inside generator carton. You must install these cables to engine. See Battery, page 8 for installation instructions.

VENTILATION

DANGER: Use only in wellvented areas. Make sure area has plenty of free-moving, fresh, outside air. Never run generator in an enclosed or conﬁned area. Never run generator inside occupied building. Engine exhaust con tains p o isonous carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death.

This generator needs cooling air to run properly. Never block free-ﬂowing, cooling air to generator. Overheating will occur without cooling air. This will damage the generator. Keep generator at least three feet away from any object.

DUST, DIRT, RAIN, AND SNOW

WARNING: Do not use generator outdoors in rain or snow. Do not use generator near standing water or snow. Do not use if generator is wet or damp. Operating generator in these conditions increases the risk of electrocution. Severe injury or death can occur.

Do not use generator in extremely dusty or dirty conditions. This will severely affect its life. Keep generator clean. Do not allow dust, dirt, rain, or snow to collect on it. Protect generator from outdoor elements.

HIGH AND LOW TEMPERATURE OPERATION

Air temperature affects generator output. Output drops 1% for each 10° temperature rise above 60° F. Very low temperatures may make the engine hard to start. See engine owner’s manual for more information.

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OWNER’S MANUAL

SPECIFICATIONS

MGH5000E

MGH4000D MGH5000EI

MODEL HWI3000A MGH3000GA MGH3000A MGH4000DI MGH5000EIE MGH6500AIE

Electrical

Rated Wattage

Rated Amperage

120 V

240 V

Receptacle

120-V Duplex

120-V, 20-A Duplex Yes

120-V, 15-A GFCI

120-V Twist-Lock

120/240-V Twist-Lock

120-V Full-Power Switch

120/240-V, 50-A

General

Honda Engine H.P.

Honda Model GX160K1VX GX160K1VX GX160K1VX GX240K1VA GX270VA GX390K1VXE

Fuel Type

Fuel Tank Capacity

Oil Alert System Yes Yes Yes Yes Yes Yes

Start Method

Weight (pounds)

2500 2500 2500 4000 5000 6500

20.8 20.8 20.8 33.3 41.7 57

–– –– –– 16.7 20.8 28.3

–– –– –– Yes Yes Yes

–– –– –– –– ––

No Yes Yes Yes Yes Yes

No No No 30 Amp 30 Amp 30 Amp

No No No 20 Amp 20 Amp 30 Amp

No No No Yes Yes No

No No No No No No

5.5 5.5 5.5 8 9 13

Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline

3.9 qt. 3.9 qt. 3.9 qt. 5 gal. 8 gal. 8 gal.

Recoil Recoil Recoil Recoil Recoil/Elec. Electric

85.5 85.5 85.5 139 173 247

* Single-phase, 1.0 power factor

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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.

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PORTABLE GASOLINE GENERATORS

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HONDA

OFFONSTART

ENGINE SW

CIRCUIT BREAKER

ENGINE SW

ON

OFF

GENERATOR FEATURES

OIL ALERT SYSTEM

The oil alert system protects the engine from low oil damage. This system automatically shuts down the engine and prevents engine restarting if the oil level falls too low.

Note: When this happens, the engine switch remains in the ON position. The oil alert system is wired into the ON/OFF Switch.

If this system shuts down the engine, the engine will not start until you add oil. Add oil to engine (see Engine Oil, page 7).

Note: Operate generator on a level surface. If not level, the oil may ﬂow away from the oil level sensing device. This will cause the oil alert system to shut down engine.

See engine owner’s manual for more information.

Models HWI3000A, MGH3000GA, MGH3000A, MGH4000D, MGH4000DI, MGH5000E, and MGH5000EI

FULL POWER SELECTOR SWITCH

A l l m o d e l s ex c e p t HW I 3 0 0 0 A , M G H3 0 00 G A, M GH 3 00 0 A a n d MGH6500AIE have a full power selector switch on the control panel. The switch has two positions: 120 VOLT ONLY, and 120/240 VOLT.

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.

120/240 VOLT: This position sends full power to the 120/240V receptacle. It also powers the 120V receptacles at reduced wattage capacity.

IMPORTANT: Do not move the full power selector switch while powering electrical items. Unplug all items before moving switch. Failure to do so can damage switch. Models HWI3000A, MGH3000GA, MGH3000A, and MGH6500AIE do not have this switch. These models provide full power to all receptacles.

ELECTRIC START

(Models MGH5000EIE and MGH6500AIE)

Models MGH5000EIE and MGH6500AIE have electric starters. A battery is not supplied with generator. You must provide a 12volt, 32-amp-hour battery. For more battery information, see Battery, page 8.

GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE

All models (Except HWI3000A) have a 120volt ground fault circuit interrupter (GFCI) receptacle. The GFCI receptacle is on the control panel or top cover of alternator (models MGH3000GA and MGH3000A only). The GFCI protects you against hazardous electrical shock caused when your body becomes a path through which electricity travels to reach ground. This could happen when you touch an appliance or cord that is ‘live’ through faulty mechanism, damp or worn insulation, etc.

When protected by the GFCI, you may still feel a shock, but the GFCI should cut it off quickly. A person in normal health should not receive serious injury. Note: Infants and very small children may still be affected.

Models MGH5000EIE and MGH6500AIE

Figure 2 - Engine Switch Location

120 VOLT ONLY

Position

Figure 3 - Full Power Selector Switch

120/240 VOLT

Position

AUTO-IDLE SYSTEM

The Auto-Idle System allows the engine to idle down or run at a slower speed when the generator is not being used to supply power. The Auto-idle system can be turned ON or OFF by a rocker switch on the control panel. When the switch is in the OFF position, the engine runs at full speed all of the time. When the switch is in the ON position, the engine slows down to idle speed until an electrical load is applied. When a load is applied to the generator (an electrical item is plugged in and turned on) the engine speeds up to the preset speed required to produce the correct voltage.

IMPORTANT: A minimum current load of 1 Amp is required to disengage the auto idle solenoid and cause the engine to come up to speed for correct voltage. Powering items at reduced engine speed will damage generator and powered items.

6

Test Procedure

Check the GFCI receptacle every month. This insures it is working right.

1. Push black TEST button. Red RESET button should pop out. This should trip GFCI, resulting in no electrical power at receptacle. Verify this by plugging test lamp with good bulb into recep tacle. If lamp does not work, GFCI receptacle is good.

WARNING: If RESET button does not pop out, do not use the GFCI receptacle. Contact a qualiﬁed electrician for repairs.

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OWNER’S MANUAL

HONDA

OFFONSTART

ENGINE SW

CIRCUIT BREAKER

ON/push OFF

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E

S

E

T

E

S

T

20

GENERATOR FEATURES

Continued

2. If the GFCI receptacle tests okay, restore power by pushing the RESET button back in. The test lamp should work at this time. IMPORTANT: You must press the RESET button ﬁrmly and fully. It should lock into place. If the GFCI does not lock into place, do not use receptacle. Contact a qualiﬁed electrician for repairs.

Figure 4 - GFCI Receptacle

ENGINE CIRCUIT BREAKER

(Models MGH5000EIE and MGH6500AIE)

This circuit breaker, or fuse, protects the battery charging circuit. A short circuit will trip the circuit breaker. The circuit breaker will also trip if you install battery wrong. Push circuit breaker button to reset.

Engine Circuit Breaker Button

Figure 5 - Engine Circuit Breaker

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RECEPTACLE CIRCUIT BREAKER

The circuit breakers protect the receptacles and alternator. Overloading generator will trip circuit breaker. A short circuit in item being powered will also trip breaker. If this occurs, unplug electrical load from receptacle. Let circuit breaker cool down. Push circuit breaker button to reset.

Electric motors need higher starting current. They require up to three-times their rated wattage to start. The starting current needed may be too high. This can cause nuisance circuit breaker tripping. To help prevent this, start electric motors ﬁrst. Connect additional items to generator after starting motors. If this continues to happen, reduce the total generator load.

Normal

Figure 6 - Receptacle Circuit Breaker Button

Tripped

Note: High ambient temperature will cause nuisance tripping.

ENGINE OIL

We ship the generator without oil in the engine crankcase. You must add oil before starting engine. See engine owner’s manual for speciﬁc oil type.

CHECKING OIL LEVEL AND ADDING OIL

Follow steps below to check oil level. Make sure engine is level and stopped.

1. Remove dipstick (see Figure 7). Wipe dipstick clean.

2. Insert dipstick into oil ﬁller neck. Do not screw it in. Oil level should be at top of ﬁller neck. Oil should cover most of dipstick.

3. If level is low, ﬁll to top of oil ﬁller neck (see Figure 7). Only use oil recommended in engine owner’s manual.

Note: If oil level is too low, oil alert system will shutdown engine and prevent engine from restarting.

7

Oil Level At Top Of Filler Neck

Oil

Figure 7 - Checking Oil Level (Model MGH4000D Shown)

Dipstick

FUEL

WARNING: Gasoline presents a hazard of ﬁre or explosion. Gasoline is ﬂammable. Its vapor is explosive.

• Keep fuel out of children’s

reach.

•

Refuel generator in a wellvented area. Do not ﬁll fuel tank in the dark. Do not refuel while engine is running. Unhook all electrical loads and shut off engine before refueling.

• Do not overﬁll fuel tank. Always

allow room for fuel to expand. If you overﬁll tank, fuel can overﬂow onto hot engine. This can cause ﬁre or explosion. After refueling, tightly close fuel tank cap.

• Do not spill fuel. Fuel or fuel

vapor may ignite. If fuel spills, make sure area is dry before starting engine.

• Never smoke in refueling area.

Never allow open ﬂames or sparks in area.

• Store fuel in approved contain-

er. Store fuel in a well-vented area free of open ﬂames or sparks.

Use clean, fresh, unleaded gasoline. Use gasoline with octane rating of 86 or higher. Service station gasoline pumps should dis play the octane rating. Using gasoline with lower octane level could damage engine. Avoid getting dirt, dust, or water in fuel tank. Do not mix oil with gasoline.

See engine owner’s manual for more information.

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PORTABLE GASOLINE GENERATORS

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TO STARTER SOLENOID

TO ENGINE BLOCK

1 2

0 O N

L

Y

12

0

2

4 0

V

E

N

M

0

00

0 0

00

5

H O

U

R S

1 /1 0

F

U

L L

P O W

E R

1 2 0 O N L Y

1

2 0

2

4 0 V

E

N

M

0

00

0 05

H O

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/1 0

FULL PO

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BATTERY

(Models MGH5000EIE and MGH6500AIE)

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.

WARNING: Battery contains sulfuric acid. Contact with skin or eyes may cause severe burns. Do not tilt generator with battery installed. Tilting could cause bat tery acid to spill. Wear protective clothing and face shield when servicing. Keep out of children’s reach.

• If battery acid gets on your skin,

wash with water.

• If battery acid gets in your eyes,

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. Follow with milk of magnesia or vegetable oil. Call a doctor at once.

Always wear safety glasses when working with battery. Make sure battery terminals are clean. Make sure cable connections are tight.

Always shut down engine before removing or attaching battery cables. Always remove the negative (–) cable ﬁrst. Always attach negative (–) cable last.

INSTALLING BATTERY CABLES TO ENGINE

1. Attach the red, positive (+) battery cable to the starter solenoid on engine (see Figure 8). This cable is factory installed.

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CAUTION: Do not over tighten positive terminal on starter solenoid. Positive terminal could rotate and cut into negative ter minal, causing a short.

2. Attach the black, negative (–) battery cable to the engine block. Use the bolt, nut, and two washers provided with the battery cables. Use long mounting hole on opposite side of engine from starter solenoid. Attach cable as shown in Figure 9.

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).

2. Locate the red, positive (+) battery cable from starter solenoid. Connect it to the positive (+) battery terminal (see Figure 11).

3. Locate the black, negative (–) battery cable attached to engine block. Connect it to the negative (–) battery terminal (see Figure 11).

4. Check battery before starting engine. Make sure ﬂuid levels are full. Make sure battery is charged.

See engine owner’s manual for more information.

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Battery Mounting Bracket

Nut

Battery

Hook Bolt

CAUTION: If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when genera

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tor runs.

IMPORTANT: Make sure battery connec tions are the correct polarity. Electric start generators use negative ground, 12-volt DC starting system.

Models MGH5000EIE and MGH6500AIE have an electric starter. A battery is not supplied with generator. You must provide a 12-volt, 32-amp-hour battery. The positive and negative battery cables are supplied with generator. You must install these cables before mounting battery.

Starter Solenoid

Red, Positive (+) Battery Cable

Figure 8 - Connecting Red, Positive (+) Battery Cable to Engine Starter Solenoid

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(Model MGH6500AIE Shown)

Black, Negative (–) Battery Cable

Figure 9 - Connecting Black, Negative (-) Battery Cable to Engine Block (Model MGH6500AIE Shown)

8

Figure 10 - Battery Hold-Down System (Model MGH6500AIE Shown)

Figure 11 - Connecting Positive and Negative Cables to Battery (Model MGH6500AIE Shown)

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OWNER’S MANUAL

FUEL

F

EXTENSION CORDS

Only use grounded extension cords. Be sure to use extension cord with proper wire gauge size. See chart below.

Recommended Minimum Wire Gauges (AWG) for Extension Cords

Ampere AWG for Length of

Load Cord in Feet

50' 100' 150'

2 18 18 18

3 18 18 18 4 16 16 16 5 16 16 16 6 16 16 14 8 16 14 12 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8

GENERATOR GROUNDING

WARNING: You must properly earth-ground generator before starting. This will help guard against deadly electric shock. Only use grounded plugs with generator. Only use grounded extension cords. Only use three-wire or double-insulated power tools.

Grounding generator helps prevent electric shock from a ground fault condition. Locate ground lug on roll cage (see Figure 12). Attach a #10 stranded-copper ground wire to ground lug. Drive grounding point into ground. Grounding point can be a stake, grounding rod, or pipe. Grounding point should be copper or brass. Attach ground wire to grounding point. You must supply the ground wire and grounding point. These do not come with generator. Follow the National Electrical Code and all state and local codes. Consult your power company or a licensed electrician.

WARNING: For a grounding point, do not use metal pipe being used to carry combustible materials or gases.

Ground Lug

Copper or Brass Grounding Point

STANDBY INSTALLATION TO HOME OR BUILDING

WARNING: Have standby installation performed by a skilled, licensed electrician. Do not let anyone else wire into a utility circuit. Personal injury, equipment damage, or damage to home could occur.

IMPORTANT: This generator will not power your entire home. Most home utility electric service is more than 60 amps. This will exceed generator output. Only power needed items during a power outage. Make sure total wattage of electrical load does not exceed rated wattage of generator.

You may need to use this generator as a standby power source. During a power out age, the generator will power selected items in a building. Have generator and additional wiring installed by a skilled, licensed electrician. This is not a do-it-yourself job. Follow all local codes.

WARNING: The electrician must ins tall a double-throw transfer switch. This isolates ex isting electrical circuits from the utility power line. If not isolated, generator output will back-feed into utility power line. This may electrocute a power company line repair person.

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Ground Wire

Alternator

Fig u r e 12 - Gr ounding Genera t or (Model MGH4000D Shown)

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PORTABLE GASOLINE GENERATORS

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DETERMINING ELECTRICAL LOAD FOR GENERATOR

You must decide what electrical load your generator can power. Do this before us ing 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 wattage of generator. For rated wattage of your generator, see Speciﬁcations, page 5. Electric motors present a special problem when ﬁguring load. Read Step 3 carefully.

1. Make two lists of items you want pow ered by generator. List all motors and motor powered appliances in one. List all lights, small appliances, etc. in the other. For standby service to home or building, only include items you must power.

2. Enter running watts of each item except motors. The light bulb or appliance nameplate lists its wattage. Remem ber, 1KW = 1000 watts. Note: The nameplate may not list wattage. It may only list volts and amps. The formula

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for ﬁnding wattage is: Volts x Amps = Watts. For example: An appliance nameplate states 3 amps at 120 volts. 3 amps x 120 volts = 360 watts.

3. Electric motors present a special problem. They require up to three-times their rated wattage to start. Chart 2, below, shows starting watts for different size motors. For example: an electric

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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.

Typical Electric Appliance Wattages

Chart 1 Chart 2

Running

Equipment

Light bulb (100W)

Radio 150 150

Fan

Television

Furnace fan with blower

Vacuum cleaner

Sump pump

Refrigerator/freezer

6" Circular saw

Floodlight 1000 1000

1/2" Drill

Toaster

Coffee maker

Skillet 1200 1200

14" Chain saw

Water well pump (1/2 hp)

Hot plate/range (per burner)

10" Table saw

Water heater (storage-type)

(1/3 hp)

Watts

100 100

200 600

400 400

600 1800

600 750

700 2100

800 2400

800 1000

1000 1250

1200 1200

1200 1500

1000 3000

1500 1500

2000 6000

5000 5000

Starting

Watts

Motor

HP

Rating

1/8 500 625 1100 1500 2250

1/4 700 875 1550 2100 3150

1/3 800 1000 1750 2400 3600

1/2 1100 1375 2400 3300 4950

3/4 1400 1750 3100 4200 x

1 1700 2125 3750 5100 x

1 1/2 2100 2625 4620 6300 x

2 2450 3075 5400 7350 x

3 3600 x 7900 10800 x

* – Always use starting watts, not running watts, when ﬁguring correct electrical load. x – Motors of higher horsepower are not generally used.

Approximate

Running

Watts

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Approximate Starting Watts*

Universal

Motors

(small appliance)

Do not use the running watts ﬁgure. Note: Some motors require nearly the same wattage to run as to start. These items include saws, drills, hair dryers, and food mixers. See Chart 1 for typical appliance wattage examples.

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.

Repulsion

Induction

Motors

Capacitor

Motors

Split

Phase

Motors

10

118683

OWNER’S MANUAL

R

E

S

E

T

E

S

T

1

2

0

V

O

L

T

S

R

E

S

E

T

240 VO

LT

S

R

E

S

E

T

R

E

S

E

T

E

N

M

0

5

H

O

U

R

S

1

/ 1

0

1

2

0

O

N

L

Y

1

2

0 2

4

0

V

OPERATION

GENERAL INFORMATION

This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles. Only use grounded cords.

DANGER: Use only in wellvented areas. Make sure area has plenty of free-moving, fresh, outside air. Never run generator in an enclosed or conﬁned area. Never run generator inside occupied building. Engine exhaust con tains p o isonous carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death.

DANGER: Never connect generator to any existing electrical circuits. The generator output will back-feed into the utility power line. This may electrocute a power company line repair person. Also, if generator is powering electrical circuits, the chance of an electrical ﬁre exists.

USING RECEPTACLE

Note: Do not exceed amperage rating of receptacles. Exceeding rating will trip re ceptacle circuit breaker.

Use receptacles properly. Improper use could damage generator. Use only grounded extension cords. Power only grounded or doubleinsulated items. Do not overload receptacles. All generators (except models HWI3000A, MGH3000GA, and MGH3000A) have the following receptacles (see Figure 13):

• 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

Model HWI3000A has only the 120V, 20amp duplex receptacle.

Models MGH3000GA and MGH3000A have only the 120V, 15-amp GFCI duplex receptacle.

120V, 15-Amp GFCI Duplex

120V, 15-Amp Duplex

120/240V, 20 or 30Amp Twist-Lock

POWER CORD AND PLUG REQUIREMENTS

-

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

• Three-wire, 30-amp cord

12 0/240V, 20 or 30- a mp twist -lock receptacle

• NEMA L14-20P (20-amp) or L14-30P (30-amp) plug

• Four-wire, 20-amp or 30-amp cord

Note: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine operation.

118683

120V, 30-Amp Twist-Lock

Figure 13 - Receptacle Locations

11

Figure 14 - Cord and Plug Conﬁgurations

Continued

PORTABLE GASOLINE GENERATORS

R

E S

E

T T E

S T

1 2

0

V O

L T S

R

E S

E

T

240 VO

LT

S

O

F

A u

to

Id

le O N

R

E S

E

T

R

E

S E

T

R

E

S E

T

E

N M

0

0 0

5

H

O

U R

S

1 / 1 0

HONDA

OFFONSTART

ENGINE SW

CIRCUIT BREAKER

ENGINE SW

ON

OFF

OPERATION

Continued

PRESTART

Operate generator on a ﬁrm, dry, and clean surface. The surface must be level. Protect generator from heavy dust, sand, dirt, rain, or snow. Do not locate generator near standing water and snow. Make sure area is well-vented.

WARNING: Only responsible

adults should use generator. Never let anyone operate generator without proper instructions.

Note: If oil level is too low, oil alert system will keep engine from starting (see Oil Alert System, page 6). Make sure oil level is full before starting. See Engine Oil, page 7.

Before starting the engine, disconnect all electric loads from generator.

STARTING

IMPORTANT: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle. Preset position lets engine run at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.

IMPORTANT:

electrical loads connected. Start engine before adding electrical loads.

1. Make sure gasoline tank is full. See Fuel, page 7 for fuel information.

2. Move fuel valve lever to the ON posi tion (see Figure 15).

Choke Lever (Closed Position)

Never start generator with

3. Move choke lever fully to the left. This closes the choke.

Note: You may not need to close choke

if engine is warm or air temperature is high.

4. Start the engine.

A. Recoil Starter

Move engine lever or turn engine

switch to the ON position (see Figure

16). Remove slack from starter rope by lightly pulling starter grip. Next, pull starter rope briskly.

IMPORTANT: Do not let starter grip

snap back against engine. Return it gently. This will prevent damage to starter.

Note: If engine does not start, check

the oil in the crankcase. Add oil as necessary. Be sure engine is on a level surface. See Oil Alert System, page 6.

B.

Electric Starter (Models MGH5000EIE

and MGH6500AIE Only)

Turn the engine switch to the START position (see Figure 17). Hold it there until engine starts. When engine starts, let switch return to the ON position.

IMPORTANT: Do not use electric

starter more than ﬁve seconds. Starter motor damage may occur. If engine fails to start, release the switch and wait ten seconds. After ten seconds, try starting again.

Note: If engine does not start, check

the oil in the crankcase. Add oil as necessary. Be sure engine is on a level surface. See Oil Alert System, page 6.

5. As engine warms up, slowly move choke lever fully to the right (see Figure

-

18). This opens the choke.

Engine Switch

Figure 17 - Engine Switch (Models MGH5000EIE and MGH6500AIE Only)

Choke Lever (Open Position)

Figure 18 - Choke Lever Opened (Model MGH6500AIE Shown)

AUTO-IDLE OPERATION

IMPORTANT: Never start engine with electrical loads connected. Start engine before adding electrical loads.

1. If engine is cold, turn the Auto-Idle switch OFF (see Figure 19).

2. Start engine. Allow engine to warm up with no load for ﬁve minutes.

3. Turn Auto-Idle switch ON. Engine will slow to idle speed. Engine idle speed is preset. Idle speed adjustment should not be necessary.

4. Operate generator according to speciﬁcations outlined in owner's manual.

5. Engine will automatically increase to normal operating speed when you plug load into any generator outlet.

Auto-Idle Switch

Figure 15 - Fuel Valve Lever On, Choke Lever Closed (Model MGH4000D Shown)

Fuel Valve Lever (ON Position)

Figure 16 - Engine Switch In ON Position (All Models Except MGH5000EIE and MGH6500AIE)

12

Figure 19 - Control Panel

6. The Auto-Idle system should be turned OFF when generator is shut down.

118683

OWNER’S MANUAL

O

F F

E

NG

I NE

OPERATION

Continued

Adjusting the Idle Speed

IMPORTANT: Adjust the idle speed only:

• If the idle speed becomes too high.

• If the engine idle speed will not regulate (engine idles and speeds up again and again).

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

gine. Allow engine to warm up with no load for ﬁve minutes.

WARNING: Always set the idle speed before turning on the AutoIdle. If idle speed is not set, the larger resistor on the control board may become hot. Heat from the resistor may damage the protective coating on the control board.

2. Remove engine linkage cover (Mod els M G H40 0 0 D I, M G H 500 0 E I , MGH5000EIE, and MGH6500AIE).

3. Push plunger into solenoid body to manually engage solenoid and set idle speed.

4. Loosen nut that holds the solenoid mounting bracket to the generator (Models MGH4000DI, MGH5000EI, MGH5000EIE, and MGH6500AIE. See Figure 20).

5. Slowly pull solenoid bracket away from engine.

6. With a volt meter, check the no-load output voltage at the 120-volt duplex receptacle. At proper idle speed (2680 minimum RPM) the meter should read 50-60 volts. Lower settings will cause the Auto-Idle to not operate properly.

7. After reaching proper idle speed, tighten nut to secure solenoid mount ing bracket (Models MGH4000DI, MGH5000EI, MGH500 0EIE, and MGH6500AIE (see Figure 20).

8. Turn Auto-Idle switch ON. Make sure solenoid is engaged. When engaged, the plunger is pulled back into the solenoid.

9. If the engine speed is too slow, the engine will want to "hunt" or speed up and slow down repeatedly. When this occurs, increase engine speed by adjusting throttle stop screw on carburetor (refer to Carburetor Adjustment in Honda Engine Manual).

10. Replace the engine linkage cover (Models MGH4000DI, MGH5000EI, MGH5000EIE, and MGH6500AIE).

Nut

Solenoid Mounting Bracket

-

Figure 20 - Solenoid Bracket Location, Models MGH4000DI, MGH5000EI, MGH5000EIE, and MGH6500AIE Only

HIGH ALTITUDE OPERATION

This generator will not perform well at high

altitudes without proper adjustment. See engine owner’s manual for details.

ADDING ELECTRICAL LOADS

IMPORTANT: Do not overload generator. Make sure total wattage of all electrical loads does not exceed rated wattage of generator. Overloading may shorten generator life. It could also cause internal damage to generator. Overloading will trip circuit breaker.

I M P O R T A N T : (A l l m o d e ls e x cept H W I 3 0 0 0 A , MGH3000A, a n d MGH6500AIE) Keep full power selector switch in the 120 VOLT ONLY position if only powering 120V items. Only move switch to 120/240 VOLT position if powering 240V items.

1. Check items to be powered. Their

nameplate lists their 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.

2. Start engine. Let engine reach full

speed.

3. Connect electrical loads one at a time.

If the load consists of electric motors, start them ﬁrst. Always start the largest ﬁrst. Start each motor individually.

DISCONNECTING ELECTRIC LOADS

Remove electrical loads one at a time. Remove voltage sensitive items ﬁrst. Voltage sensitive items include TVs, VCRs, and other home electronic items.

118683

13

PORTABLE GASOLINE GENERATORS

R

HONDA

OFFONSTART

ENGINE SW

CIRCUIT BREAKER

ON/push OFF

OFF

ENGINE SW

ON

OPERATION

Continued

STOPPING ENGINE

IMPORTANT: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle.

Follow the steps below to stop engine.

1. Remove all electrical loads from generator (see Disconnecting Electrical Loads). Remove electrical loads one at a time.

2. Let engine run for two or three minutes after removing electrical loads. This lets engine cool slightly.

3. Turn engine switch to the OFF position (see Figure 21).

4. Turn fuel valve lever off. Do this by moving valve lever fully to the left (see Figure 22).

Models HWI3000A, MGH3000GA, MGH3000A, MGH4000D, MGH4000DI, MGH5000E, and MGH5000EI

Models MGH5000EIE and MGH6500AIE

MAINTENANCE AND REPAIRS

WARNING: Only a qualiﬁed electrical service person should service and repair the alternator on this generator. Use only factory approved replacement parts.

CAUTION: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle. Preset position lets engine run at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.

CAUTION: Shut off generator before performing maintenance.

IMPORTANT: Keep generator level when servicing. Never turn generator upside down or stand it on end to service.

Note: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine maintenance and repairs.

Non-engine parts require little maintenance. Keep generator clean. Use a damp cloth to clean outside surfaces. Never use water to clean generator. Water can cause damage to internal parts. Use vacuum to clean air inlet and outlet louvers of alternator.

STORAGE

WARNING: Remove all fuel from fuel tank before storing generator. Store fuel in approved container. Store fuel in a well-vented area free of open ﬂames or sparks.

WARNING: The mufﬂer becomes very hot during operation. The mufﬂer remains hot for a while after shutdown. Let engine cool before storing.

IMPORTANT: Keep generator level while in storage. Never store generator upside down or standing on end.

Note: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine storage.

Use a fuel additive, such as STA-BIL® or an equivalent, when storing generator with fuel in fuel tank. This will minimize fuel gum deposits from forming in engine.

Cover and store generator in a clean, dry place. Do not expose generator to extreme high or low temperatures during storage.

Figure 21 - Engine Switch In OFF Position

Fuel Valve Lever (Off Position)

Figure 22 - Fuel Valve Lever Off (Model MGH6500AIE Shown)

14

118683

OWNER’S MANUAL

SERVICING THE ENGINE

Honda parts and services should be handled by your nearest authorized engine service ﬁrm. Check the yellow pages of your tele phone directory under the listing:

-

Engines Gasoline, Honda

or visit:

www.honda-engines.com

or call Honda direct:

1-800-426-7701

TROUBLESHOOTING

Note: For additional help, visit DESA International’s technical service web site at www.desatech.com.

OBSERVED PROBLEM

No voltage when starting generator with no electrical load

TECHNICAL SERVICE

You may have further questions about assembling, operating, or maintaining this product. If so, you can visit our Technical Service web site at contact our Technical Service Department at 1-800-858-8501 (English Only). You may also write to:

DESA Specialty Products™ ATTN: Technical Service Specialty Products P.O. Box 90004 Bowling Green, KY 42102-9004

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.

POSSIBLE CAUSE

1. Defective capacitor

2. W i nd i ng s h o rt c i r c u i t o r l o o se connections

3. Defective rotor diode

4. Loss of residual magnetism

www.desatech.com or

When contacting DESA Specialty Prod ucts™, have ready

• Your Name

• Your Address

• Your Phone Number

• Model Number of Product

• Serial Number

• Date of Purchase (Include copy of receipt for written requests).

REMEDY

1. Replace capacitor

2. Check resistance of coils (see Electrical

Component Speciﬁcations,

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor ter-

minals for 2-3 seconds

-

page 16)

Voltage is less than normal voltage with no electrical load

Voltmeter reading more than 10% high with no electrical load

Voltmeter reading correct with no electrical load, but more than 10% low when electrical load is added

118683

1. Engine speed too low

2. Defective rotor diode

3. Partial short circuit in winding

4. Defective capacitor

1. Engine speed too high

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

www.desatech.com

15

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

with no load

2. Replace both diodes on rotor

3. Check resistance of coils (see Electrical

Component Speciﬁcations, page 16)

4. Replace capacitor

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

with no load

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized engine service

center

PORTABLE GASOLINE GENERATORS

R

ELECTRICAL COMPONENT SPECIFICATIONS

Resistance in Ohms

Stator

Main

Model

HWI3000A, MGH3000GA, MGH3000A 1.63 5.29 4.62 14 6 Amp

MGH4000D, MGH4000DI

MGH5000E, MGH5000EI, MGH5000EIE 0.570 3.129 3.31 18 70 Amp

MGH6500AIE .326 2.012 4.38 31.5 70 Amp

*

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

Δ

Resistance between brown and white leads.

†

Remove diodes to check resistance.

Winding *

0.709 5.33 13.25 16 70 Amp

Stator

Exciting

Winding Δ

Rotor

Primary

Winding †

Capacitor,

MFD

450 Volt

Diodes (2)

800 Volt

16

118683

Circuit

Breaker

25A

120/240V 20A

Receptacle

T4

120V, 15

A

Receptacle

120V, 30

A

Receptacle

White

Gree

n

Black

Red

Blac

k

Re

d

Blac

k

White

T3

Re

d

Gree

n

Stator

110/120V

T1

T2

T3

T4

L2

L1

110/120V

220/240V

Rotor

Stator

White

Brown

Auxiliary

Phase

Diode

T2

Green

Red

Black

Yellow

Main

Windings

T1

T3

T4

T1

T2

T3

T4

Green/Yellow

Yello

w

Red

Blac

k

Green

Diode

Capacito

r

White

GFCI

Circuit

Breaker

20A

LINE

WHITE

HOT

Circuit

Breaker

25A

Circuit

Breaker

20A

Gree

n

120V, 15

A

Receptacle

White

Black

Duplex

Full Pwr Selector

Switch

T2

Red

Blac

k

Blac

k

Red

White

Hour Meter

Black

White

WIRING DIAGRAMS

T2

Stator

110/120V

T1 T3 T2 T4

L2

L1

Rotor Stator

White

Brown

Auxiliary Phase

Green

Re

d

Black

Yellow

Main Windings

T1

T3

T4

L1

L2

L1

20A

Circuit Breaker

C

D

Receptacle 120V/15A (MGH3000)

Receptacle 120V/20A (HWI3000)

Yellow

Black

Yellow

GFCI

Black

HOT

WHITE

LINE

OWNER’S MANUAL

Figure 23 - Wiring Diagram, Models HWI3000A, MGH3000GA, and MGH3000A

Figure 24 - Wiring Diagram, Models MGH4000D and MGH5000E

118683

17

Continued

PORTABLE GASOLINE GENERATORS

R

120/240V 30A

Receptacle

T4

120V, 15A Receptacle

Circuit

Breaker

20A

Green

Black

Red

Black

T3

White

Green

RedT1

T2

White

Circuit

Breaker

30A

Circui

t

Breaker

30A

Black

Red

Yellow

Green/Yellow

Stator

110/120V

T1 T2 T3 T4

L2

L1

110/120V

220/240V

T2

Green

Red

Black

Yellow

Main

Windings

T1

T3

T4

T1 T2T3T4

Rotor

Diode

Stator

White

Brown

Capacitor

White

GFCI

120V, 15A

Receptacl

e

Auxiliary

Phase

LINE

WHITE

HOT

120V

, 15A

Receptacl

e

Circuit

Breaker

20A

Duplex

To Solenoid

Switch

•

s

1 s2

Hour

Meter

White

Black

Circuit

Breaker

20A, 25A

or 30

A

120/240V 20A

Receptacle

T4

120V

, 15A

Receptacle

120V

, 30A

Receptacle

White

Green

Black

Red

Black

Red

Black

White

T3

Red

Green

Stator

11

0/120V

T1

T2

T3

T4

L2

L1

11

0/120V

220/240V

Rotor

Stator

White

Brown

Auxiliary

Phase

Diode

T2

Green

Red

Black

Yellow

Main

Windings

T1

T3

T4

T1

T2

T3

T4

Green/Y

ellow

Ye

l

low

Red

Black

Green

Diode

Capacitor

White

GFCI

Circuit

Breaker

20A

LI

N

E

W

H

IT

E

H

O

T

Circuit

Breaker

20A, 25A

or 30A

Circuit

Breaker

20A

Green

120V

, 15A

Receptacle

White

Black

Duplex

White

To Solenoid

s

1 s2

•

Full Pwr Selector

Switch

T2

Red

Black

Red

White

Hour Meter

Black

White

WIRING DIAGRAMS

Continued

Figure 25 - Wiring Diagram, Models MGH4000DI, MGH5000EI, and MGH5000EIE

18

Figure 26 - Wiring Diagram, Model MGH6500AIE

118683

OWNER’S MANUAL

ILLUSTRATED PARTS LIST

For Model HWI3000A, MGH3000GA, and MGH3000A Alternator Assembly

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual.

10

11

12

1

3

6

7

8

9

5

17

16

2

4

19

13

14

KEY PART NO. NUMBER DESCRIPTION QTY.

118054-01 Alternator Assembly* 1 118703-01 End Cover 1 2a 100445-01 120V, 15A Duplex (GFCI) Receptacle (MGH3000GA, MGH3000A) † 1 2b 104201-01 120V, 20A Duplex (GFCI) Receptacle (HWI3000A) † 1 3 22616009 Circuit Breaker, 20 Amp † 1 4 118714-01 Shaft End Cap 1 5 118712-01 Capacitor 1 6 118710-01 Stator Bolt 4 7 17587000 Grounding Lug 1 8 118704-01 Bearing Housing 1 9 ** Stator 1 10 118705-01 Fan Bracket 1

18

15

KEY PART NO. NUMBER DESCRIPTION QTY.

11 26327006 Bolt, 5/16-24 x 5/8" 4 12 WLE-5 Lock Washer, 5/16" 4 13 118713-01 Flange 1 14 118706-01 Fan 1 15 ** Rotor 1 16 118708-01 Diode 2 17 118709-01 Varistor 2 18 118707-01 Bearing 1 19 118711-01 Draw Bolt 1

PARTS AVAILABLE - NOT SHOWN

118674-01 Safety Information Decal 1 118674-02 Safety Information Decal 1 099867-02 Operation Decal 1

† Includes fastening hardware. * Includes reference numbers 1 through 22. ** Parts not available. Included in alternator assembly.

118683

19

PORTABLE GASOLINE GENERATORS

R

ILLUSTRATED PARTS LIST

For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, MGH6000D, MGH6000DI, MGH6500AIE Alternator Assembly

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual.

9

1

4

5

6

3

7

8

15

14

13

12

2

16

10

11

PART NUMBER FOR MODEL

MGH5000E KEY MGH4000D MGH5000EI NO. MGH4000DI MGH5000EIE MGH6500AIE DESCRIPTION QTY.

118055-01 118055-02 118055-03 Alternator Assembly 1 1 118782-01 118782-01 118782-01 End Cover 1 2 118714-01 118714-01 118714-01 Shaft End Cap 1 3 118712-01 118783-01 118783-02 Capacitor 1 4 118784-01 118784-02 118784-04 Stator Bolt 4 5 118785-01 118785-01 118785-01 Bearing Housing 1 6 * * * Stator 1 7 118786-01 118786-01 118786-01 Fan Bracket 1 8 26322004** 26322004** 26322004** Bolt, 3/8-16 x 5/8" 4 9 WLE-6** WLE-6** WLE-6** Lock Washer, 3/8" 4 10 118787-01 118787-01 118787-01 Flange 1 11 118788-01 118788-01 118788-01 Fan 1 12 * * * Rotor 1 13 118708-01 118708-01 118708-01 Diode 2 14 118709-01 118709-01 118709-01 Varistor 2 15 118789-01 118789-01 118789-01 Bearing 1 16 118791-01 118791-02 118791-03 Draw Bolt 1

* Part not available by itself. Must purchase Alternator Assembly. **Available at your local hardware store.

20

118683

ILLUSTRATED

1

9

8

10

4

2

3

11

10

7

8

6

5

9

PARTS LIST

For Model MGH3000GA Alternator Assembly

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under

Parts

on page 32 of this manual.

Replacement

OWNER’S MANUAL

KEY PART NO. NUMBER DESCRIPTION QTY.

1 118669-01 Handle (includes 2 spacers) 1

3

/8" Bolt 1

2 WLE-4 1/4" Lock Washer 2 3 099769-01 M6 x 35 Bolt 2 4 NEC-5C 5/16-18 Nut 1 5 099754-01 Engine Spreader 1 6 118821-02 Rubber Bumper 2 7 WP-5C 5/16" Flat Washer 1 8 50009402 5/16-18 x 1/2" Bolt 2 9 118790-01 5/16-18 x 1 10 WLE-5 5/16" Lock Washer 2 11 118821-01 Rubber Bumper 1

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

118683

21

PORTABLE GASOLINE GENERATORS

R

2

7

4

5

3

2

3

2

6

2

1

ILLUSTRATED PARTS LIST

For Models HWI3000A and MGH3000A Roll Cage

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under

Parts

on page 32 of this manual.

Replacement

22

118683

ILLUSTRATED PARTS LIST

For Models HWI3000A and MGH3000A Roll Cage

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under

Parts

on page 32 of this manual.

Replacement

KEY PART NO. NUMBER DESCRIPTION QTY.

1 118916-02 Roll Cage 1 2 NEC-5C Lock Nut, 5/16-18 7 3 099853-03 Shock Mount 2 4 * Bolt, 5/16-18 x 1/2" 1 5 WLE-5 Lock Washer, 5/16" 1 6 14138002 Grounding Strap 1 7 099853-02 Shock Mount 1

OWNER’S MANUAL

* Available at any hardware store.

118683

23

PORTABLE GASOLINE GENERATORS

R

9

10

11

12

13

11

16

13

17

18

11

16

11

16

21

20

19

14

23

14

23

16

10

30

11

16

11

16

22

F

U

E

L

F

1

3

2

4

24

7

8

6

27

7

25

15

5

26

F

U

E

L

F

10

29

24

1

2

24

29

24

28

9

24

28

ILLUSTRATED PARTS LIST

For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE Fuel Tank and Roll Cage

24

118683

OWNER’S MANUAL

ILLUSTRATED

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.

PARTS LIST

For Models MGH4000D, MGH4000DI, MGH5000E,MGH5000EI, MGH5000EIE, and MGH6500AIE Fuel Tank and Roll Cage

MGH5000E KEY NO.

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 27 28 29 30

* Only on MGH5000EIE electric start models

MGH4000D MGH4000DI

25954000 099832-01 25978000 HC4-8C 099701-01 19508001 25985005 099743-01 118918-01 103880-01 — NEC-5C — 14138000 099853-02 WLE-5 WLI-3 WP-5C — HC5-14C 099756-01 — — — 100410-01 M10908-74 — WP-4C 099965-01 WP-3C 103676-01 — — 17587000

099866-02 100003-01 — — — 03175000

MGH5000EI

MGH5000EIE MGH6500AIE DESCRIPTION QTY.

25954001

107021-01

—

099701-01

19508001

25985005

099743-01

118917-01

—

103880-01

—

NEC-5C

14138000

099853-02

WLE-5

WLI-3

—

WP-5C

HC5-14C

099756-01

099750-01*

099749-01*

NEC-5C*

100410-01

M10908-74

M10908-74*

WP-4C

099965-01

WP-3C

103676-01

HC4-16C

107110-01

17587000

PARTS AVAILABLE - NOT SHOWN

—

100003-01

100003-02*

099873-01*

099873-02*

03175000

25954001 107021-01 — — 099701-01 19508001 25985005 099743-01 118917-01 — 103880-01 — NEC-5C 14138000 099853-02 WLE-5 WLI-3 — WP-5C HC5-14C 099756-01 099750-01 099749-01 NEC-5C 100410-01 — M10908-74 WP-4C 099965-01 WP-3C 103676-01 HC4-16C 107110-01 17587000

— — 100003-02 099873-01 099873-02 03175000

Gas Cap/Fuel Gage Gas Tank (with 90° ﬁtting) Breather Assembly Screw, 1/4-20 x 1" Screw, M5 x 10 Gas Line Clamp Fuel Line Fuel Filter Roll Cage Lock Nut, 1/4-20 Lock Nut, 1/4-20 Lock Nut, 5/16-18 Lock Nut, 5/16-18 Ground Strap Shock Mounts Lock Washer, 5/16" Lock Washer, #10 Flat Washer, 5/16" Flat Washer, 5/16" Bolt, 5/16-18 x 1 3/4" Engine Spreader Hook Bolt, 5/16-18 Battery Mounting Bracket Lock Nut, 5/16-18 Sems Screw, #8-18 x 1/2" Screw, 1/4-20 x 1/2" Screw, 1/4-20 x 1/2" Washer, 1/4" Linkage Cover Washer, #10 90° Fitting with barbs Bolt, 1/4-20 X 2" Spacer .25 X .500 Grounding Lug

Safety Information Decal Operation Decal Operation Decal Battery Cable (Positive, Red) Battery Cable (Negative, Black) Fuel Line Grommet

1 1 1 4 1 2 1 1 1 5 3 8

10

1 3 3 1 9

11

2 1 2 1 2 4 3 2 4 1 1 1 2 2 1

1 1 1 1 1 3

118683

25

PORTABLE GASOLINE GENERATORS

R

DESA

IN

T

ERNA

T

I

O

N

AL

S2

S1

L

1

L2

ILLUSTRATED PARTS LIST

For Solenoid and Control Board Assemblies and Mounting

10

9

6

11

12

7

8

Solenoid Assembly and Mounting

3

2

1

Control Board Assembly and Mounting

5

4

26

118683

ILLUSTRATED PARTS LIST

For Solenoid and Control Board Assemblies and Mounting

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under

Parts

on page 32 of this manual.

Replacement

OWNER’S MANUAL

KEY NO.

1 2 3 4 5 6

7

8 9 10 11 12

PART NUMBER

100105-01 26499000 100321-01 WP-C3 26514000 100324-03

100755-02 118632-01 22822000 118635-01 100328-01 108585-01 100329-01

100320-01 100322-01 100322-02 100366-01 100334-01

DESCRIPTION QTY.

Control Board Assembly Hex Head Screw, 10-32 x 3/4" Nylon Spacer Flat Washer, #10 Lock Nut, 10-32 Solenoid Assembly (Includes Plunger, Nut, and Lock Washer) Linkage Rod Linkage Rod (MGH6500AIE Only) Roll Pin Solenoid Mounting Bracket Bolt, M8 x 25mm Flat Washer, M8 Lock Nut, M8

PARTS AVAILABLE NOT SHOWN

Yellow Wire White Wire (with 2 Flags) White Wire (with 1 Flag and 1 Spade) Rocker Switch Auto-Idle Decal

1 4 4 4 4

1 1 1 1 1 1 1 1

1 1 1 1 1

118683

27

PORTABLE GASOLINE GENERATORS

R

FULL POWER

SELECT

OR

120/240

V

OL

TS

RE

S

E

T

RE

S

E

T

1

2

4

6

8

7

10

9

11

12

13

14

3

2

12

0

ON

L

Y

120/240

V

Reset

120 Volt

ENM

0000000

5

HO

U

R

S

1

/1

0

R

E

SE

T

ES

T

5

ILLUSTRATED PARTS LIST

For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE Control Panel

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under

Parts on page 32 of this manual.

Replacement

PART NUMBER FOR MODEL

MGH5000E

KEY

MGH4000D

NO.

MGH4000DI

1 2 3 4 5 6 7

8

103349-01 22616009 099833-01 104202-01 100445-01 099956-01 22616009 — — 099834-01

— 9 10 11 12 13 14 † †

Δ

* Includes fastening hardware Δ Not shown † Includes reference numbers 1 through 13

101350-01

099760-01

100410-01

100149-01

22261000

099997-01

118681-01

118681-03

100177-07

MGH5000EI MGH5000EIE MGH6500AIE

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 118681-02 118681-04 100177-07

103349-05 22616009 099833-01 104202-01 100445-01 — — — 22616010 — 099835-01 101350-01 099760-01 100410-01 100149-01 22261000 099997-01 — 118681-05 100177-07

DESCRIPTION QTY.

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 Control Panel Assembly

28

Control Panel Assembly - Auto Idle Models Panel Schematic Decal

1 2 1 1 1 1 2 2 2 1 1 1 1 4 1 8 1 1 1 1

118683

OWNER’S MANUAL

REPLACEMENT PARTS AND ACCESSORIES

For original replacement parts and accessories, contact your nearest Authorized Dealer or Authorized Service Center for this product. If they can not supply the part or accessory, contact your nearest Parts Central listed below. Each Authorized Dealer, Authorized Service Center, and Parts Central is independently owned and operated.

See pages 19 through 31 for an Illustrated Parts List.

If you need additional referral information, contact our Technical Service Department (see Technical Service, page 15).

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

Heavy-Duty Wheel Kit – PA2022 For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE

Wheelbarrow-style wheel kit. Makes generator easy for one person to move.

This kit includes:

• Large 12-inch wheels for easy rolling

• Powder coated tubing and plated hardware for long life

• Long handles with thick grips for greater comfort and control

Complete installation instructions included.

Automatic Idle Kit – PA2011 For Models MGH4000D and MGH5000E

Automatically reduces engine speed when no power is being used. Reduces fuel consumption and engine noise. Increases engine life.

Complete installation and operation instructions included.

REPAIR SERVICE

Note: Only use original replacement parts. This will protect your warranty coverage for parts replaced under warranty.

Each Authorized Service Center is independently owned and operated.

For additional Service Center or warranty information, call 1-800-858-8501 or visit our Technical Service web site at www.

desatech.com.

WARRANTY SERVICE

If product requires warranty service, return it to nearest Authorized Service Center. You must show proof of purchase. If faulty materials or workmanship caused damage, we will repair or replace product without charge. Note: Normal wear, misuse, abuse, neglect, or accidental damage is not covered under warranty.

NON-WARRANTY SERVICE

If product requires service, return it to nearest Authorized Service Center. Repairs will be billed to you at regular repair list prices.

PARTS CENTRALS

These Parts Centrals are privately owned businesses. They have agreed to support our customer’s needs by providing original replacement parts and accessories.

Tool & Equipment

5 Manila Drive Hamden, CT 06514-0322 203-248-7553 1-800-397-7553

Grainger Parts Operations

1657 Shermer Road Northbrook, IL 60062-5362 708-498-5900 1-800-323-0620 www.grainger.com

Portable Heater Parts

342 North County Road 400 East Valparaiso, IN 46383-9704 219-462-7441 1-800-362-6951 www.portableheaterparts.com sales@portableheaterparts.com techservice@portableheaterparts.com

FBD

1349 Adams Street Bowling Green, KY 42103-3414 270-846-1199 1-800-654-8534 franktalk@aol.com

Master Part Distributors

1251 Mound Avenue NW Grand Rapids, MI 49504-2672 616-791-0505 1-800-446-1446 www.masterparts.net

Bowden Electric Motor Service

1681 S. Wesleyan Blvd. Rocky Mount, NC 27803 252-446-4203

East Coast Energy

10 East Route 36 West Long Branch, NJ 07764-1501 1-800-755-8809

Laportes

2444 N 5th Street Hartsville, SC 29550-7704 843-332-0191

MTA Distributors

555 Hickory Hills Blvd. Nashville, TN 37189-9244 615-299-8777 1-800-264-0225

Industrial Hardware

4109 Bainbridge Blvd. Chesapeake, VA 23324-1403 804-543-2232 1-800-788-0008 catatem@erols.com

Mills Lawn and Garden

928 Commonwealth Place Virginia Beach, VA 23464 757-361-9293 www.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

118683

29

PORTABLE GASOLINE GENERATORS

R

NOTES

________________________________________________________________________________________________

30

118683

OWNER’S MANUAL

NOTES

________________________________________________________________________________________________

118683

31

WARRANTY INFORMATION

KEEP THIS WARRANTY

Model

Serial No.

Date Purchased

Always specify model and serial numbers when communicating with the factory.

We reserve the right to amend these speciﬁcations at any time without notice. The only warranty applicable is our standard written warranty. We make no other warranty, expressed or implied.

FIVE-YEAR LIMITED WARRANTY

GASOLINE PORTABLE GENERATORS

DESA Specialty Products™ makes no warranty with respect to the engine and engine components not of its manufacture. 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 replacement parts. Failure to use original factory replacement parts voids this warranty.

This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration, modiﬁcation, tampering, contaminated fuels, repair using improper parts, or repair by anyone other than an 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 con sult the applicable state laws.

-

Bowling Green, KY 42102-9004

www.desatech.com

118683-01

REV. A

03/06

Desa Hwi3000a, Mgh3000ga, Mgh3000a, Mgh4000d, Mgh4000di User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual