Master Lock MGH8500AIE, MGH10000C User Manual
PORTABLE GASOLINE
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GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
Generator Models: MGH8500AIE and MGH10000C
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
R
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
-
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-
-
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.
2
117846
OWNER’S MANUAL
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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
Control Panel
Ground Lug
Handles (2)
Alternator
Gas Cap/Fuel Gauge
Auto-Idle Switch
Oil Dipstick
Oil Filler Cap
Choke Lever
-
Engine
Engine ON/
OFF Switch
Figure 1 - Portable Generator - Model MGH10000C
Air Filter Housing
Oil
Filter
Gas Tank
Wheels (2)
Roll Cage
120/240 Volt Receptacle
120/240 Volt, 50 Amp
Receptacle
Circuit Breaker
Run Lamp
Hour Meter
120 Volt Receptacle
(Duplex)
120 Volt Receptacle (GFCI)
120 Volt Receptacle
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PRODUCT
IDENTIFICATION
(Continued)
Gas Tank
Gas Cap/Fuel Gauge
Ground
Bolt
Alternator
120 Volt
Receptacle (GFCI)
Hour Meter
Auto-Idle Switch
Control Panel
Figure 2 - Portable Generator - Model MGH8500AIE
GENERAL
INFORMATION
Master portable generators are rugged and
compact. These generators use brushless
alternators for dependable, trouble-free ser
vice. Honda gasoline engines provide long
life under heavy use. Honda engines have
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
• Electric starter
• 15-Amp ground fault circuit interrupter
(GFCI) receptacle
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 and installed. See Battery, page 8 for battery
installation instructions.
120/240 Volt Receptacle
Circuit Breaker
Roll Cage
4
Choke
Lever
Oil Filter
120 Volt
Receptacle
120 Volt Receptacle
(Duplex)
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.
117846
OWNER’S MANUAL
HONDA
OFFONSTART
ENGINE SW
SPECIFICATIONS GENERATOR
MODEL MGH10000C MGH8500AIE
Electrical
Rated Wattage .........................
Rated Amperage
120 V ....................................
240 V .................................... 41.7 ...............................35.4
Receptacle
120-V, 20-A Duplex .................... Yes ................................ Yes
120-V, 15-A GFCI ...................... Yes ................................ Yes
120-V Twist-Lock ...................
120/240-V Twist-Lock .............
120/240-V, 50-A ......................... Yes ................................. No
General
Honda Engine H.P. ......................
Honda Model ....................GX620K1VXE2 .............GX620K1VXE2
Fuel Type ............................... Gasoline ........................ Gasoline
Fuel Tank Capacity ..................
Oil Alert System ......................... Yes ................................ Yes
Auto-Idle .................................... Yes ................................ Yes
Hour Meter ................................. Yes ................................ Yes
Start Method .......................... Electric .......................... Electric
Weight (pounds) ........................
10,000 ............................8500
83.3 ...............................70.8
30 Amp ............................. Yes
30 Amp ............................. Yes
20 .................................. 20
13 gal. ............................8 gal.
350 ................................ 325
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.
* Single-phase, 1.0 power factor
Note: Ratings apply to SAE standard
conditions. Reduce ratings 3
each 1000 feet above sea level and 1% for
each 10° Fahrenheit rise above 60°F.
1
/2% for
Figure 3 - Engine Switch Location
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GENERATOR
FEATURES
Continued
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 8.
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. 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.
ENGINE CIRCUIT BREAKER
This fuse protects the battery charging circuit. A short circuit will trip the break the
fuse. The fuse will also break if you install
battery wrong. Replace fuse if engine will
not start. The fuse is located inside of the
keyswitch box.
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 5 - Receptacle Circuit Breaker
Button
Note: High ambient temperature will cause
nuisance tripping.
Tripped
Figure 4 - GFCI Receptacle
6
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OWNER’S MANUAL
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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 between the two dots
on dipstick.
3. If level is low, fill to top dot on dipstick.
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 (MGH8500AIE
Shown)
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.
HANDLES AND TOP
COVER
Follow the steps below to attach the handles
and top cover to Model MGH10000C:
1. Remove the two bolts, lock nuts, and
washers holding side panels to control
panel end of roll cage. Insert bolts
with washers through two holes in the
handle and then back through roll cage
and side screen panels (See Figure 7).
Tighten the lock nuts against the side
screen panels.
2. Place top cover on top of generator roll
cage with notch on control panel side.
Use four #8 sems screws provided to attach cover to roll cage (See Figure 8).
Roll Cage
Washers
Bolts
Handle
Figure 7 – Attaching Handles to Roll Cage
-
Top Cover
Lock Nuts
SEMS Screws
117846
SEMS
Screws
Figure 8 – Attaching Top Cover to Roll
Cage
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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.
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, d r i n k larg e
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: Make sure battery connections are the correct polarity. Electric start
generators use negative ground, 12-volt DC
starting system.
A battery is not supplied with generator. A
12-volt, 32 Amp-Hour minimum, group U1,
lug terminal battery is recommended. 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.
MOUNTING BATTERY TO
GENERATOR
1. Secure battery to generator using battery hold-down system. This system
consists of the battery mounting bracket, hook bolts, and nuts (see Figures 9
and 10).
2. Locate the red, positive (+) battery
cable from starter solenoid. Connect it
-
to the positive (+) battery terminal (see
Figures 11 and 12).
3. Locate the black, negative (–) battery
cable attached to engine block. Connect
it to the negative (–) battery terminal
(see Figures 11 and 12).
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.
Nut
Battery Mounting
Bracket
Battery
Hook Bolt
Figure 9 - MGH8500AIE - Battery HoldDown System (Alternator Removed for
Clarity)
Nut
Hook
Bolt
Figure 10 - MGH10000C - Battery HoldDown System
Battery Mounting
Bracket
Battery
8
To Engine
Block (–)
To Starter Solenoid (+)
Figure 11 - MGH8500AIE - Connecting
Positive and Negative Cables to Battery
(Alternator Removed for Clarity)
To Starter
Solenoid
To Engine
Block
Figure 12 - MGH10000C - Connecting
Positive and Negative Cables to Battery
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
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FUEL
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 lug on generator housing
(see Figure 13).
2. Loosen SEMS nut on ground lug. Note:
Do not remove SEMS nut or set screw
from ground lug.
3. Attach a spade connector to #10-8
stranded-copper ground wire. Place
spade connector on ground bolt between
flat washer and SEMS nut. Tighten
SEMS nut (see Detail A, Figure 13).
4. Drive grounding point into ground.
Note: Grounding point can be a stake,
grounding rod, or pipe. Grounding
point should be copper or brass.
5. Attach gro und wire to grou ndi ng
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 be
ing used to carry combustible
materials or gases.
Flat Washer
SEMS Nut
Ground Bolt
Spade Connector
Detail A
Ground
Wire
Copper or Brass
Grounding Point
Fig u r e 13 - Gr ounding Genera t or
(MGH8500AIE Shown)
Alternator
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 install 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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117846
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