Master Lock MGH6500IE, MGH3000G User Manual

R

PORTABLE GASOLINE

GENERATORS

OWNER’S OPERATION AND INSTALLATION MANUAL

Generator Models: HWI3000, MGH3000G, MGH3000, MGH3000PR, MGH4000C, MGH4000CI,

MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE, and MGH10000A

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

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.

2

106813

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 Cap/Fuel Gauge

Control
Panel

FUEL

F

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

Selector Switch

1
2

0
V

O
L

T
S

R
E

S
E

T

T

E
S

T

F
U

L
L

P
O
W

E
R

120

ONLY

E
N

M
0
0

0
0

0

HO

0

0

5

UR

S

1/10

120/240 Volt
Receptacle

Circuit
Breaker

Engine ON/
OFF Switch

120
240V

120/240 VOLTS

RESET

RESET

Provision for
Auto-Idle Switch

Oil Dipstick

Gas Tank

L

E

U

F

F

Alternator

Roll Cage

Ground
Lug

106813

Figure 1 - Portable Generator (Model MGH4000C Shown)

3

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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

• Spark-arresting muffler (except model
MGH10000A)

• Large fuel tank

• Oil alert system

• Electric starter (models MGH5000DIE,
MGH6500IE, and MGH10000A only)

• 15-Amp ground fault circuit interrupter
(GFCI) receptacle (Except HWI3000
Model)

UNPACKING

1. Remove generator from carton.

2. Remove any protective packaging ap-

plied to generator for shipment.

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

MGH5000DIE, MGH6500IE, and
MGH10000A 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
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.

4

106813

OWNER’S MANUAL

SPECIFICATIONS

MGH4000C MGH5000DI

MGH5000D

MODEL HWI3000 MGH3000G MGH3000 MGH3000PR MGH4000CI MGH5000DIE

Electrical

Rated Wattage 2500 2500 2500 2500 4000 5000
Rated Amperage

120 V 20.8 20.8 20.8 20.8 33.3 41.7
240 V –– –– –– –– 16.7 20.8

Receptacle

120-V Duplex –– –– –– –– Yes Yes
120-V, 20-A Duplex Yes –– –– –– ––
120-V, 15-A GFCI No Yes Yes Yes Yes Yes
120-V Twist-Lock No No No No 30 Amp 30 Amp
120/240-V Twist-Lock No No No No 20 Amp 20 Amp
120-V Full-Power Switch No No No No Yes Yes
120/240-V, 50-A No No No No No No

General

Honda Engine H.P. 5.5 5.5 5.5 5.0 8 9
Honda Model GX160K1VX GX160K1VX GX160K1VX GC160VXA GX240K1VA GX270VA
Fuel Type Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline
Fuel Tank Capacity 3.9 qt. 3.9 qt. 3.9 qt. 3.9 qt. 5 gal. 8 gal.
Oil Alert System Yes Yes Yes Yes Yes Yes
Start Method Recoil Recoil Recoil Recoil Recoil Recoil/Elec.
Weight (pounds) 85.5 85.5 85.5 84 139 173

* Single-phase, 1.0 power factor

MGH6000D

MODEL MGH6000DI MGH6500IE MGH10000A

Electrical

Rated Wattage 6000 6500 10,000
Rated Amperage

120 V 50 57 83.3
240 V 25 28.3 41.7

Receptacle

120-V Duplex Yes Yes Yes
120-V, 20-A Duplex –– –– ––
120-V, 15-A GFCI Yes Yes Yes
120-V Twist-Lock 30 Amp 30 Amp 30 Amp
120/240-V Twist-Lock 20 Amp 30 Amp 30 Amp
120-V Full-Power Switch Yes No No
120/240-V, 50-A No No Yes

General

Honda Engine H.P. 11 13 20
Honda Model GX340K1VA GX390K1VXE GX620VXA3
Fuel Type Gasoline Gasoline Gasoline
Fuel Tank Capacity 8 gal. 8 gal. 13 gal.
Oil Alert System Yes Yes Yes
Start Method Recoil Electric Electric
Weight (pounds) 191 247 350
* 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.

106813

5

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PORTABLE GASOLINE GENERATORS

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.

Model
MGH3000PR

FULL POWER SELECTOR
SWITCH

All models except HWI3000, MGH3000G,
MGH3000, MGH3000PR, MGH6500IE,
and MGH10000A 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:

selector switch while powering electrical
items. Unplug all items before moving switch.
Failure to do so can damage switch. Models
HWI3000, MGH3000G, MGH3000,
MGH3000PR, MGH6500IE, and
MGH10000A do not have this switch. These
models provide full power to all receptacles.

Do not move the full power

ELECTRIC START

(Models MGH5000DIE,
MGH6500IE, and MGH10000A)

Models MGH5000DIE, MGH6500IE, and
MGH10000A have electric starters. A bat­tery is not supplied with generator. You
must provide a 12-volt, 32-amp-hour bat­tery. For more battery information, see Bat-
tery, page 8.

GROUND FAULT CIRCUIT
INTERRUPTER RECEPTACLE

All models (Except HWI3000) have a 120­volt ground fault circuit interrupter (GFCI)
receptacle. The GFCI receptacle is on the
control panel or top cover of alternator (mod­els MGH3000G, MGH3000, and
MGH3000PR 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.
very small children may still be affected.

Note:

Infants and

Models HWI3000,
MGH3000G, MGH3000,
MGH4000C, MGH4000CI,
MGH5000D, MGH5000DI,
MGH6000D, and
MGH6000DI

Models
MGH5000DIE,
MGH6500IE, and
MGH10000A

Figure 2 - Engine Switch Location

ENGINE SW

ON

OFF

HONDA

OFFONSTART

ENGINE SW

CIRCUIT
BREAKER

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:

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.

A minimum current load of

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.

6

106813

OWNER’S MANUAL

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:

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

(Models MGH5000DIE,
MGH6500IE, and MGH10000A)

This circuit breaker, or fuse, protects the
battery charging circuit. A short circuit will
trip the circuit breaker. The circuit breaker
will also trip if you install battery wrong.
Push circuit breaker button to reset. On
Model MGH10000A, the fuse is located
inside of the Keyswitch box.

OFFONSTART

Engine Circuit
Breaker Button

Figure 5 - Engine Circuit Breaker

ENGINE SW

CIRCUIT
BREAKER

ON/push OFF

Yo u

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

Note:

20

Tripped

20

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. For Model MGH10000A
only, the oil should be between the two
dots on dipstick.

3. If level is low, fill to top of oil filler neck
(see Figure 7). For Model MGH10000A
only, fill to top dot on dipstick. Only use
oil recommended in engine owner’s
manual.

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

Oil

Figure 7 - Checking Oil Level (Model
MGH4000C 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. 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.

106813

7

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PORTABLE GASOLINE GENERATORS

HANDLES AND
TOP COVER

(Model MGH10000A)

Follow the steps below to attach the handles
and top cover to Model MGH10000A:

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 8).
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 9).

Roll Cage

EL

FU

F

Washers

Bolts

Handle

Lock Nuts

BATTERY

(Models MGH5000DIE,
MGH6500IE, and MGH10000A)

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 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.

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 10). The starter solenoid is
located directly above the starter on
Model MGH10000A. This cable is fac­tory installed.

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 11.

Figure 8 – Attaching Handles to Roll Cage

SEMS Screws

Top Cover

L

E
U
F

F

SEMS
Screws

Figure 9 – Attaching Top Cover to Roll
Cage

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.

Models MGH5000DIE, MGH6500IE, and
MGH10000A 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.

8

Starter
Solenoid

Red, Positive (+)
Battery Cable

Figure 10 - Connecting Red, Positive (+)
Battery Cable to Engine Starter Solenoid
(Model MGH6500IE Shown)

Black,
Negative (–)
Battery Cable

Figure 11 - Connecting Black, Negative (-)
Battery Cable to Engine Block (Model
MGH6500IE Shown)

106813

OWNER’S MANUAL

BATTERY

Continued

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 12).

Note:

Model MGH10000A battery is
located on opposite side as shown (see
Figure 13).

2. Locate the red, positive (+) battery
cable from starter solenoid. Connect it
to the positive (+) battery terminal (see
Figures 14 and 15).

3. Locate the black, negative (–) battery
cable attached to engine block. Connect
it to the negative (–) battery terminal
(see Figures 14 and 15).

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.

Battery Mounting Bracket

Nut

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
0

0

0

0

H

0

O

0

U

5

R

S

1
/
1

0

Figure 12 - Battery Hold-Down System
(Model MGH6500IE Shown)

Nut

L

E
U
F

F

Hook
Bolt

Figure 13 - Battery Hold-Down System
(Model MGH10000A Shown)

Battery

Hook Bolt

Battery
Mounting
Bracket

Battery

F
UL

L
P

O

W
E

R

120
O
NL

Y

120

240V

E
N

M
0
00

0

00

H

O

0

U

5

RS

1/

10

TO ENGINE
BLOCK

TO STARTER
SOLENOID

Figure 14 - Connecting Positive and
Negative Cables to Battery
(Model MGH6500IE Shown)

TO STARTER
SOLENOID

TO ENGINE

L

E
U
F

F

BLOCK

Figure 15 - Connecting Positive and
Negative Cables to Battery
(Model MGH10000A Shown)

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

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 three­wire or double-insulated power
tools.

Grounding generator helps prevent electric
shock from a ground fault condition. Locate
ground lug on end of generator housing (see
Figure 16). 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.

L

FUE

F

Alternator

Figure 16 - Grounding Generator
(Model MGH4000C Shown)

Ground Lug

Copper or
Brass
Grounding
Point

Ground Wire

106813

9

R

PORTABLE GASOLINE GENERATORS

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 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
must install a double-throw trans­fer switch. This isolates existing
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.

DETERMINING
ELECTRICAL LOAD
FOR GENERATOR

You must decide what electrical load your
generator can power. Do this before using
generator. Use the following four-step
method. It will help you select a load that is
not too large. Make sure total wattage of all
electrical loads does not exceed rated 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 pow­ered 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. Remember,
1KW = 1000 watts.

Note:

The name­plate may not list wattage. It may only
list volts and amps. The formula for
finding wattage is: Volts x Amps =
Watts. For example: An appliance
nameplate states 3 amps at 120 volts. 3
amps x 120 volts = 360 watts.

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 differ-

ent size motors. For example: an elec­tric motor nameplate states 5 amps at
120 volts. 5 amps x 120 volts = 600
watts running. Multiply this figure by

3. This will show the starting watts
needed. 600 watts x 3 = 1800 watts to
start. When figuring the generator load
for motors, you must use the starting
watts figure. Do not use the running
watts figure.

Note:

Some motors 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.

Chart 1 - Typical Electric Appliance Wattages

Running Starting

Equipment Watts Watts

Light bulb (100W) 100 100
Radio 150 150
Fan 200 600
Television 400 400
Furnace fan

with blower 600 1800
Vacuum cleaner 600 750
Sump pump
Refrigerator/freezer 800 2400
6" Circular saw 800 1000
Floodlight 1000 1000

(1/3 hp)

(1/3 hp)

700 2100

Equipment Watts Watts

1/2" Drill 1000 1250
Toaster 1200 1200
Coffee maker 1200 1200
Skillet 1200 1200
14" Chain saw 1200 1500
Water well pump

(1/2 hp) 1000 3000

Hot plate/range

(per burner) 1500 1500
10" Table saw 2000 6000
Water heater

(storage-type)

Running Starting

5000 5000

Chart 2

Approximate Starting Watts*

Motor Approximate Universal Repulsion Split

HP Running Motors Induction Capacitor Phase

Rating Watts (small appliance) Motors Motors Motors

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.

10

106813

OWNER’S MANUAL

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
contains poisonous 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.

Note:

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

Model MGH10000A also has a 120/240V,
50-amp receptacle (see Figure 17).

Model HWI3000 has only the 120V, 20­amp duplex receptacle.

Models MGH3000G, MGH3000 and
MGH3000PR have only the 120V, 15-amp
GFCI duplex receptacle.

120V, 15-Amp GFCI Duplex

120V, 15-Amp Duplex

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

120 VOLTS

RESET

TEST

120

ONLY

120
240V

EN

M

0

00

00

H

0

O

05

U

R

S

1

/1

0

120V, 30-Amp
Twist-Lock

RESET

240 VO

LTS

RESET

RESET

RESET

POWER CORD AND PLUG
REQUIREMENTS

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

• Three-wire, 30-amp cord
120/240V, 20 or 30-amp twist-lock

receptacle

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

•Four-wire, 20-amp or 30-amp cord

120/240V, 50-amp receptacle

• NEMA L14-50P

•Four-wire, 50-amp cord

R

E

SE

T

R

E

SE

T

USING RECEPTACLE

Note:

Do not exceed amperage rating of
receptacles. Exceeding rating will trip re­ceptacle 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 HWI3000,
MGH3000G, MGH3000, and MGH3000PR)
have the following receptacles (see Figure 17):

• 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

106813

120/240V, 50-Amp

(Model MGH10000A only)

Figure 18 - Cord and Plug Configurations

Figure 17 - Receptacle Locations

Continued

11