Master MGH8500IE Owner's Manual
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PORTABLE GASOLINE
GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
F
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120V
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120V
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Generator Model: MGH8500IE
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.
R
PORTABLE GASOLINE GENERATORS
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 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. 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 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 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 con-
ductive 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. 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
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. Keep 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 Tank
Gas Cap/Fuel Gauge
E
Ground
Bolt
Alternator
120 Volt
Receptacle (GFCI)
Hour Meter
Auto-Idle Switch
Control Panel
Figure 1 - Portable Generator
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Choke
Lever
Oil Filter
120V
TWISTLOCK
120V
120V
CI
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120/240V
TWISTLOCK
120/240V
TWISTLOCK
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RESET
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120 Volt Receptacle
120/240 Volt Receptacle
120 Volt
Receptacle
(Duplex)
Circuit Breaker
Roll Cage
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PORTABLE GASOLINE GENERATORS
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
• Large fuel tank
• Oil alert system
• 15-Amp ground fault circuit interrupter
(GFCI) receptacle
• Electric starter
UNPACKING
1. Remove generator from carton.
2. Remove any protective packaging ap-
plied to generator for shipment.
3. Check for loose or missing parts. Check
for shipping damage. If any parts are
missing or damaged, please contact our
Technical Service Department at 1-800858-8501 (English Only).
4. Battery cables are supplied and in-
stalled on engine.
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
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.
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.
SPECIFICATIONS
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.
MGH8500IE
Electrical
Rated Wattage ................................. 8500
Rated Amperage
120 V ........................................... 70.8
240 V ........................................... 35.4
Receptacle
120-V, 20-A Duplex ........................... Yes
120-V, 15-A GFCI .............................. Yes
120-V Twist-Lock, 30 Amp ................ Yes
120/240-V Twist-Lock, 20 Amp ......... Yes
120/240-V Twist-Lock, 30 Amp ......... Yes
General
Honda Engine H.P. ...............................18
Honda Model ............................... EX-610
Fuel Type ................................... Gasoline
Fuel Tank Capacity .......................... 8 gal.
Oil Alert System ................................. Yes
Start Method ................................. Electric
Weight (pounds) ................................. 325
* Single-phase, 1.0 power factor
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OWNER’S MANUAL
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 6).
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
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.
ELECTRIC START
A battery is not supplied with generator.
You must provide a 12-volt, 32-amp-hour
battery. For more battery information, see
Battery, page 7.
GROUND FAULT CIRCUIT
INTERRUPTER RECEPTACLE
The GFCI receptacle is on the control panel.
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.
very small children may still be affected.
Test Procedure
Check the GFCI receptacle every month.
This insures it is working right.
1. Push TEST button. 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.
Note:
Infants and
OFFONSTART
Engine Switch
Figure 2 - Engine Switch Location
ENGINE SW
CIRCUIT
BREAKER
ON/push OFF
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:
Yo u
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 3 - GFCI Receptacle
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PORTABLE GASOLINE GENERATORS
GENERATOR
FEATURES
Continued
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.
Note:
High ambient temperature will cause
nuisance tripping.
20
Figure 4 - Receptacle Circuit Breaker
Button
ENGINE CIRCUIT BREAKER
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 the battery wrong.
Push circuit breaker button to reset. The
fuse is located inside of the Keyswitch box.
TrippedNormal
20
OIL ALERT
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 6). Wipe
dipstick clean.
2. Insert dipstick into oil filler neck. Oil
level should be at top of filler neck the
upper limit mark on dipstick.
3. If level is low, fill to top of oil filler neck
(see Figure 6). 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 Fill Cap
Upper
Limit
Lower
Limit
Dip Stick
Figure 6 - Checking Oil Level
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. Al-
ways 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 con-
tainer. Store fuel in a wellvented 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 display 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.
OFFONSTART
Engine Circuit
Breaker Button
Figure 5 - Engine Circuit Breaker
ENGINE SW
CIRCUIT
BREAKER
ON/push OFF
BATTERY
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.
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OWNER’S MANUAL
S
BATTERY
Continued
WARNING: Battery contains
sulfuric acid. 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.
• 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.
CAUTION: If you remove battery, insulate the red, positive (+)
battery cable terminal. Insulate with
electrical tape. Exposed terminal
may spark when generator runs.
IMPORTANT:
tions are the correct polarity. Electric start
generators use negative ground, 12-volt DC
starting system.
A battery is not supplied with generator. You
must provide a 12-volt, 32-amp-hour battery.
The positive and negative battery cables are
supplied with generator. You must install
these cables before mounting battery.
Always wear safety glasses when working
with battery. Make sure battery terminals are
clean. Make sure cable connections are tight.
Always shut down engine before removing
or attaching battery cables. Always remove
the negative (–) cable first. Always attach
negative (–) cable last.
INSTALLING BATTERY
CABLES TO ENGINE
1. Attach the red, positive (+) battery
cable to the starter solenoid on engine
(see Figure 7). The starter solenoid is
located directly above the starter.
Make sure battery connec-
CAUTION: Do not over tighten
positive terminal on starter solenoid. Positive terminal could rotate and cut into negative terminal, 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 8.
Starter
Solenoid
Red, Positive (+)
Battery Cable
Figure 7 - Connecting Red, Positive (+)
Battery Cable to Engine Starter Solenoid
Black,
Negative (–)
Battery Cable
Figure 8 - Connecting Black, Negative (-)
Battery Cable to Engine Block
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 9).
Nut
Battery Mounting
Bracket
V
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Battery
Hook Bolt
Figure 9 - Battery Hold-Down System
(Alternator Removed for Clarity)
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2. Locate the red, positive (+) battery
cable from starter solenoid. Connect it
to the positive (+) battery terminal (see
Figure 10).
3. Locate the black, negative (–) battery
cable attached to engine block. Connect
it to the negative (–) battery terminal
(see Figure 10).
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.
To Engine
Block (–)
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TEST
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00005
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To Starter Solenoid (+)
Figure 10 - Connecting Positive and
Negative Cables to Battery (Alternator
Removed for Clarity)
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'
2181818
3181818
4161616
5161616
6161614
8161412
10 16 14 12
12 14 14 12
14 14 12 10
16 12 12 10
20 10 10 8
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H
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PORTABLE GASOLINE GENERATORS
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. Follow
these steps to ground your generator:
1. Locate ground bolt on generator housing (see Figure 11).
2. Loosen SEM nut on ground bolt.
Do not remove SEM nut from bolt.
3. Attach a spade connector to the end of
a #10-8 stranded-copper ground wire.
4. Attach spade connector to ground bolt
between flat washer and SEM nut (see
Detail A in Figure 11).
5. Drive grounding point into ground.
Note:
Grounding point can be a stake,
grounding rod, or pipe. Grounding
point should be copper or brass.
6. Attach ground wire to grounding point.
Note:
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.
Flat Washer
SEMS Nut
Ground Bolt
Spade
Connector
Detail A
FUEL
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2
1
V
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2
1
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Ground
Wire
Copper or Brass
Grounding Point
Alternator
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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:
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 outage, 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
V
0
must install a double-throw transfer switch. This isolates existing
V
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electrical circuits from the utility
power line. If not isolated, generator output will back-feed into
T
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utility power line. This may electrocute a power company line
repair person.
This generator will not
Figure 11 - Grounding Generator
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