R
PORTABLE GASOLINE
GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
RESET |
120 |
VOLTS |
|
RESET
TEST
FULL 
SELECTORPOWER 120 ONLY
120 240V
120/240 |
VOLTS |
|
RESET
RESET
Generator Models: MGH3000, MGH4000A, MGH5000A, MGH6000, and MGH7000
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.
CONTENTS
2
SECTION |
PAGE |
Safety Information ....................................................................... |
3 |
Product Identification .................................................................. |
6 |
General Information .................................................................... |
7 |
Specifications .............................................................................. |
7 |
Unpacking ................................................................................... |
7 |
Ventilation ................................................................................... |
8 |
Dust, Dirt, Rain, and Snow ......................................................... |
8 |
High and Low Temperature Operation ....................................... |
8 |
Generator Features ...................................................................... |
9 |
Oil Alert System ................................................................... |
9 |
Full Power Selector Switch .................................................. |
9 |
Electric Start (Model MGH7000 Only) ................................ |
9 |
Ground Fault Circuit Interrupter Receptacle ...................... |
10 |
Engine Circuit Breaker (Model MGH7000 Only) |
.............. 10 |
Receptacle Circuit Breaker ................................................. |
11 |
Engine Oil .................................................................................. |
11 |
Fuel ............................................................................................ |
12 |
Battery (Model MGH7000 Only) .............................................. |
12 |
Generator Grounding ................................................................. |
15 |
Extension Cords ........................................................................ |
16 |
Standby Installation To Home Or Building .............................. |
16 |
Determining Electrical Load For Generator ............................. |
16 |
Operation ................................................................................... |
18 |
General Information ............................................................ |
18 |
Using Receptacle ................................................................ |
18 |
Power Cord and Plug Requirements ................................... |
19 |
Prestart ................................................................................ |
20 |
Starting ................................................................................ |
20 |
High Altitude Operation ..................................................... |
22 |
Adding Electrical Loads ..................................................... |
22 |
Disconnecting Electrical Loads .......................................... |
22 |
Stopping Engine .................................................................. |
23 |
Maintenance and Repairs .......................................................... |
24 |
Storage ....................................................................................... |
24 |
Troubleshooting......................................................................... |
25 |
Electrical Component Specifications ........................................ |
25 |
Wiring Diagrams ....................................................................... |
26 |
Parts Centrals ............................................................................. |
27 |
Technical Service ...................................................................... |
28 |
Servicing The Engine ................................................................ |
28 |
Replacement Parts ..................................................................... |
28 |
Accessories ................................................................................ |
28 |
Illustrated Parts Lists ........................................................... |
29-34 |
Warranty Information ................................................. |
Back Cover |
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.
Early signs of carbon monoxide poisoning resemble 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.! WARNING Gasoline presents a hazard of fire or explosion. Gasoline is
flammable. Its vapor is explosive.
•Keep fuel out of children’s reach.
•Refuel generator in a well-vented area. Do not fill fuel tank in the dark. Do not refuel while engine is running. Unhook all electrical loads and shut off engine before refueling.
•Do not overfill fuel tank. Always allow 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.
Continued 3
SAFETY INFORMATION
Continued
4
2.! WARNING 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 flammable vapors are present. Some vapors are heavier than air. These vapors settle in low-lying places.
•Do not use generator in enclosed spaces. This includes motor home or RV generator compartments.
3.! WARNING 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 damage to generator may result.
•Do not wear damp clothing or wet shoes when using generator.
4.! WARNING 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 during 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.! WARNING 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.! WARNING 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.! 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.
Continued
SAFETY INFORMATION
Continued
8.! WARNING 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.
9.! WARNING 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.! WARNING 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.! CAUTION 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.! CAUTION Keep generator and nearby areas clean.
•Keep generator free of oil, mud, and other foreign matter.
•Remove anything that creates slippery 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 maintained. Be familiar with its use.
13.! CAUTION Know how to stop engine quickly. Know how to use all
controls.
14.! CAUTION Prolonged exposure to loud noise can cause hearing loss.
•When working around generator, wear approved hearing protection.
•Remember neighbors when using generator.
5
PRODUCT IDENTIFICATION
6
Gas Cap/Fuel Gage
Control
Panel
Run
120 Volt Lamp
Receptacle
RESET |
120 |
VOLTS |
|
RESET
TEST
FULL |
POWER |
|
|
SELECTOR |
|
120 |
|
ONLY |
|
|
120 |
|
240V |
120 Volt Receptacle (GFCI)
120/240 |
VOLTS |
|
RESET
RESET
Full Power
Selector
Switch
120/240 Volt
Receptacle Circuit
Breaker
Choke
Lever
Fuel
Valve
Lever
Starter Grip
Engine Engine
ON/OFF
Switch
Provision for
Auto-Idle Switch
Roll Cage
Gas Tank
Ground
Lug
Alternator
Oil Dipstick
Figure 1 - Portable Generator (Model MGH4000A Shown)
GENERAL INFORMATION
SPECIFICATIONS
UNPACKING
Master portable generators are rugged and compact. These models provide dependable, 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 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 (model MGH7000 only)
•15-Amp ground fault circuit interrupter (GFCI) receptacle
MODEL |
MGH3000 |
MGH4000A |
MGH5000A |
MGH6000 |
MGH7000 |
Electrical Specifications |
|
|
|
|
|
Rated Wattage |
2500 |
4000 |
5000 |
6000 |
6800 |
Rated Amperage |
|
|
|
|
|
120 Volt |
20.8 |
33.3 |
41.7 |
50 |
57 |
240 Volt |
–– |
16.7 |
20.8 |
25 |
28.3 |
Receptacle Specifications |
|
|
|
|
|
120-Volt, 15-Amp GFCI |
Yes |
Yes |
Yes |
Yes |
Yes |
120-Volt, Twist-Lock |
No |
30 Amp |
30 Amp |
30 Amp |
30 Amp |
120/240-Volt, Twist-Lock |
No |
20 Amp |
20 Amp |
20 Amp |
30 Amp |
120-Volt Full-Power Switch No |
Yes |
Yes |
Yes |
No |
|
General Specifications |
|
|
|
|
|
Honda Engine H.P. |
5.5 |
8 |
9 |
11 |
13 |
Honda Model |
GX160K1VX |
GX240K1VA |
GX270VA |
GX340K1VA GX390K1VXE |
|
Fuel Type |
Gasoline |
Gasoline |
Gasoline |
Gasoline |
Gasoline |
Fuel Tank Capacity |
3.9 qt. |
5 gal. |
5 gal. |
5 gal. |
5 gal. |
Oil Alert System |
Yes |
Yes |
Yes |
Yes |
Yes |
Start Method |
Recoil |
Recoil |
Recoil |
Recoil |
Electric |
Weight (pounds) |
85.5 |
139 |
173 |
191 |
247 |
* 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.
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 model MGH7000 only. These cables are in a separate bag inside generator carton. You must install these cables to engine. See Battery, page 12 for installation instructions.
7
VENTILATION
DUST, DIRT,
RAIN, AND
SNOW
HIGH AND LOW TEMPERATURE OPERATION
8
DANGER
Use only in well-vented areas. Make sure area has plenty of free-moving, fresh, outside air. Never run generator in an enclosed or confined area. Never run generator inside occupied building. Engine exhaust contains poisonous carbon monoxide gas. Overexposure will cause loss of consciousness
and will lead to death.
This generator needs cooling air to run 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.
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.
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.
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 11).
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.
|
|
|
HONDA |
|
ENGINE SW |
|
|
|
ON |
|
|
All Models |
OFF |
|
ON |
Model |
OFF START |
||
Except |
|
|
|
MGH7000 |
|
MGH7000 |
|
|
|
Only |
ENGINE SW |
|
|
|
CIRCUIT |
|
|
|
BREAKER |
Figure 2 - Engine Switch Location
FULL POWER SELECTOR SWITCH
All models except MGH3000 and MGH7000 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.
FULL POWER |
FULL POWER |
|
SELECTOR |
|
SELECTOR |
120V |
120 |
120V |
120 |
ONLY |
240V |
ONLY |
240V |
120 VOLT ONLY Position |
120/240 VOLT Position |
Figure 3 - Full Power Selector Switch
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. Model MGH7000 does not have this switch. This model provides full power to all receptacles.
ELECTRIC START (Model MGH7000 Only)
Model MGH7000 has an electric starter. A battery is not supplied with generator. You must provide a 12-volt, 32-amp-hour battery. For more battery information,
see Battery, page 12.
9
GENERATOR FEATURES
Continued
10
GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE
All models 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 protects you against hazardous electrical shock caused when your body becomes a path through which electricity travels to reach ground. This could happen when you touch an appliance or cord that is ‘live’ through faulty mechanism, damp or worn insulation, etc.
When protected by the GFCI, you may still feel a shock, but the GFCI should cut it off quickly. A person in normal health should not receive serious injury. Note: Infants and very small children may still be affected.
Test Procedure
Check the GFCI receptacle every month. This insures it is working right.
1.Push black TEST button. Red RESET button should pop out. This should trip GFCI, resulting in no electrical power at receptacle. Verify this by plugging test lamp with good bulb into receptacle. 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.
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. 
RESET
TEST
Figure 4 - GFCI Receptacle
ENGINE CIRCUIT BREAKER (Model MGH7000 Only)
This circuit breaker 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
OFF 
START
Engine Circuit
ENGINE SW
Breaker Button
CIRCUIT
BREAKER
ON/push OFF
Figure 5 - Engine Circuit Breaker
GENERATOR FEATURES
Continued
ENGINE OIL
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.
20
20
Normal |
Tripped |
Figure 6 - Receptacle Circuit Breaker Button
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.
Oil Level
At Top Of
Filler Neck
Dipstick
Oil
Figure 7 - Checking Oil Level
11
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