Master Lock MGH3000PR, MGH4000C User Manual

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PORTABLE GASOLINE

GENERATORS

OWNER’S OPERATION AND INSTALLATION MANUAL

FUEL

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Generator Models: HWI3000, MGH3000, MGH3000PR, MGH4000C, MGH4000CI, MGH5000C,

MGH5000CI, MGH5000CIE, MGH6000C, MGH6000CI, MGH7000C, MGH7000CI, and MGH10000

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

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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 Cap/Fuel Gauge

Control
Panel

FUEL

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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

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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

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Alternator

Roll Cage

Ground
Lug

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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 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 (except model
MGH10000)

• Large fuel tank

• Oil alert system

• Electric starter (models MGH5000CIE,
MGH7000C, MGH7000CI, and
MGH10000 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 model

MGH5000CIE, MGH7000C,
MGH7000CI, and MGH10000 only.
These cables are in a separate bag in­side generator carton. You must install
these cables to engine. See Battery,
page 7 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

105420

OWNER’S MANUAL

SPECIFICATIONS

MGH5000C

MGH4000C MGH5000CI MGH6000C MGH7000C

MODEL HWI3000 MGH3000 MGH3000PR MGH4000CI MGH5000CIE MGH6000CI MGH7000CI MGH10000

Electrical

Rated Wattage 2500 2500 2500 4000 5000 6000 7000 10,000
Rated Amperage

120 V 20.8 20.8 20.8 33.3 41.7 50 57 83.3
240 V –– –– –– 16.7 20.8 25 28.3 41.7

Receptacle

120-V Duplex –– –– –– Yes Yes Yes Yes Yes
120-V, 20-A Duplex Yes –– –– –– –– –– –– ––
120-V, 15-A GFCI No Yes Yes Yes Yes Yes Yes Yes
120-V Twist-Lock No No No 30 Amp 30 Amp 30 Amp 30 Amp 30 Amp
120/240-V Twist-Lock No No No 20 Amp 20 Amp 20 Amp 30 Amp 30 Amp
120-V Full-Power Switch No No No Yes Yes Yes No No
120/240-V, 5.0-A No No No No No No No Yes

General

Honda Engine H.P. 5.5 5.5 5.0 8 9 11 13 20
Honda Model GX160K1VX GX160K1VX GC160VXA GX240K1VA GX270VA GX340K1VA GX390K1VXE GX620VXA3
Fuel Type Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline
Fuel Tank Capacity 3.9 qt. 3.9 qt. 3.9 qt. 5 gal. 5 gal. 5 gal. 5 gal. 5 gal.
Oil Alert System Yes Yes Yes Yes Yes Yes Yes Yes
Start Method Recoil Recoil Recoil Recoil Recoil/Elec. Recoil Electric Electric
Weight (pounds) 85.5 85.5 84 139 173 191 247 325

* 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.

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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

Models HWI3000,
MGH3000, MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH6000C,
and MGH6000CI

Models MGH5000CIE,
MGH7000C, MGH7000CI,
and MGH10000

Figure 2 - Engine Switch Location

ENGINE SW

ON

OFF

HONDA

OFFONSTART

ENGINE SW

CIRCUIT
BREAKER

FULL POWER SELECTOR
SWITCH

All models except HWI3000, MGH3000,
MGH3000PR, MGH7000C, MGH7000CI,
and MGH10000 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

120 V
ONLY

Selector

120 VOLT ONLY Position

Full Power

120 V
ONLY

Selector

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. Models
HWI3000, MGH3000, MGH3000PR,
MGH7000C, MGH7000CI, and MGH10000
do not have this switch. These models pro­vide full power to all receptacles.

120/
240V

120/
240V

ELECTRIC START

(Models MGH5000CIE,
MGH7000C, MGH7000CI, and
MGH10000)

Models MGH5000CIE, MGH7000C,
MGH7000CI, and MGH10000 have elec­tric starters. A battery is not supplied with
generator. You must provide a 12-volt, 32­amp-hour battery. For more battery infor­mation, see Battery, page 7.

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 (model
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.

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
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.

. IMPORTANT:

Note:

Infants and

You must press

6

105420

OWNER’S MANUAL

GENERATOR
FEATURES

Continued

RESET

TEST

Figure 4 - GFCI Receptacle

ENGINE CIRCUIT BREAKER

(Models MGH5000CIE,
MGH7000C, MGH7000CI, and
MGH10000)

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 MGH10000, the fuse is located in­side of the Keyswitch box.

OFFONSTART

Engine Circuit
Breaker Button

Figure 5 - Engine Circuit Breaker

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.

ENGINE SW

CIRCUIT
BREAKER

ON/push OFF

20

Normal

Figure 6 - Receptacle Circuit Breaker
Button

Note:

High ambient temperature will cause

nuisance tripping.

20

Tripped

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 MGH10000
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
MGH10000 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 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. 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.

BATTERY

(Models MGH5000CIE,
MGH7000C, MGH7000CI, and
MGH10000)

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

105420

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PORTABLE GASOLINE GENERATORS

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.

Models MGH5000CIE, MGH7000C,
MGH7000CI, and MGH10000 have an elec­tric starter. A battery is not supplied with
generator. You must provide a 12-volt, 32­amp-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.

Make sure battery connec-

INSTALLING BATTERY
CABLES TO ENGINE

1. Attach the red, positive (+) battery
cable to the starter solenoid on engine
(see Figure 8). The starter solenoid is
located directly above the starter on
Model MGH10000. 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 9.

Starter
Solenoid

Red, Positive (+)
Battery Cable

Figure 8 - Connecting Red, Positive (+)
Battery Cable to Engine Starter Solenoid
(Model MGH7000C Shown)

Black,
Negative (–)
Battery Cable

Figure 9 - Connecting Black, Negative (-)
Battery Cable to Engine Block (Model
MGH7000C Shown)

MOUNTING BATTERY TO
GENERATOR

1.

Secure battery to generator by battery
hold-down system. This system consists
of the battery mounting bracket, hook
bolts, and nut (see Figure 10).

Note:

Model MGH10000 battery is lo­cated on opposite side as shown (see
Figure 11, page 9).

2. Locate the red, positive (+) battery
cable from starter solenoid. Connect it
to the positive (+) battery terminal (see
Figures 12 and 13, page 9).

3. Locate the black, negative (–) battery
cable attached to engine block. Connect
it to the negative (–) battery terminal
(see Figures 12 and 13, page 9).

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

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2

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2
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0
0

0
0

0

H

0

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5

R
S

1
/
1
0

Figure 10 - Battery Hold-Down System
(Model MGH7000C Shown)

Nut

Battery

Hook Bolt

Battery

Hook
Bolt

Battery
Mounting
Bracket

Figure 11 - Battery Hold-Down System
(Model MGH10000 Shown)

8

105420

OWNER’S MANUAL

BATTERY

Continued

FU

LL PO

WER

120
O
NLY

120
240V

ENM

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Figure 12 - Connecting Positive and
Negative Cables to Battery (Model
MGH7000C Shown)

L

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F

TO
STARTER
SOLENOID

TO
ENGINE
BLOCK

TO ENGINE
BLOCK

TO STARTER
SOLENOID

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.

FUEL

F

Alternator

Figure 14 - Grounding Generator
(Model MGH4000C Shown)

Ground Lug

Copper or
Brass
Grounding
Point

Ground Wire

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.

This generator will not

Figure 13 - Connecting Positive and
Negative Cables to Battery (Model
MGH10000 Shown)

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 12). Attach a #10 stranded-copper
ground wire to ground lug. Drive grounding
point into ground. Grounding point can be a
stake, grounding rod, or pipe. Grounding
point should be copper or brass. Attach

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

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.

Continued

105420

9

R

PORTABLE GASOLINE GENERATORS

DETERMINING
ELECTRICAL LOAD
FOR GENERATOR

Continued

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.
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.

Note:

The nameplate may

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

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.

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,
MGH3000, and MGH3000PR) have the fol­lowing receptacles (see Figure 15):

• 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

10

105420

OWNER’S MANUAL

OPERATION

Continued

Model MGH10000 also has a 120/240V,
50-amp receptacle (see Figure 15).

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

Models 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

E
N

M

0

0

0

0

0

H

0

O

0

U

5

R

S

1

/1

0

120V, 30-Amp
Twist-Lock

R

ESET

240 VO

LTS

RESET

120/240V, 50-Amp

(Model MGH10000 only)

Figure 15 - Receptacle Locations

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

120/240 Volt

20 Amp

X

(Hot)

W

(Neutral)

X

(Hot)

W

(Neutral)

120V 120V

120V 120V

R

R

ES

E

SE

ET

T

120/240 Volt

20 and 30

Amp

Ground

(Green)

Ground
(Green)

(Hot)

Y

(Hot)

Y

Figure 16 - Cord and Plug Configurations

Neutral

w

YX

G

Ground

Neutral

w

YX

G

Ground

Neutral

120V 120V

w

YX

G

Ground

L14-20P
Plug

120V 120V

L14-30P
Plug

L14-20P
Plug

Ground

G

YX

w

Neutral

L14-50P
Plug

PRESTART

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

WARNING: Only responsible
adults should use generator.
Never let anyone operate genera­tor without proper instructions.

Note:

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

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

STARTING

IMPORTANT:

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

IMPORTANT:

electrical loads connected. Start engine be­fore adding electrical loads.

1. Make sure gasoline tank is full. See

Fuel, page 7 for fuel information.

2. Move fuel valve lever to the ON posi-

tion except on model MGH3000PR
(see Figure 17).

3. Move choke lever fully to the left for

all models except MGH3000PR and
MGH10000 (see Figure 17). Pull
choke rod for model MGH3000PR or
choke button for model MGH10000
out (see Figures 18 and 19). This
closes the choke.

Note:

choke if engine is warm or air tem­perature is high.

The engine speed is preset.

Never start generator with

You may not need to close

105420

Continued

11

R

PORTABLE GASOLINE GENERATORS

OPERATION

Continued

4. Start the engine.
A. Recoil Starter
Move engine lever or turn engine

switch to on position (see Figures 20
and 21). Remove slack from starter rope
by lightly pulling starter grip. Next, pull
starter rope briskly.

IMPORTANT:

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

Note:

If engine does not start, check
the oil in the crankcase. Add oil as nec­essary. Be sure engine is on a level sur­face. See Oil Alert System, page 6.

B. Electric Starter (Models
MGH5000CIE, MGH7000C,
MGH7000CI, and MGH10000 Only)

Turn the engine switch to the START
position (see Figure 22). Hold it there
until engine starts. When engine starts,
let switch return to the ON position.

IMPORTANT:

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

Note

: If engine does not start, check
the oil in the crankcase. Add oil as nec­essary. Be sure engine is on a level sur­face. See Oil Alert System, page 6.

5. As engine warms up, slowly move
choke lever fully to the right (see Fig­ure 23). This opens the choke. On
Model MGH10000, the choke will au­tomatically open.

Choke Lever (Closed Position)

Fuel Valve Lever (ON Position)

Figure 17 - Fuel Valve Lever On, Choke
Lever Closed (Model MGH4000C Shown)

Do not let starter grip

Do not use electric starter

Choke
Button
Pulled Out
(Closed
Position)

Figure 18 - Choke Rod Closed (Model
MGH3000PR Only)

Choke Button
Pulled Out
(Closed
Position)

Figure 19 - Choke Button Closed (Model
MGH10000 Only)

Figure 20 - Engine Lever In ON Position
(Model MGH3000PR Only)

ENGINE SW

ON

OFF

Figure 21 - Engine Switch In ON Position
(All Models Except MGH5000CIE,
MGH7000C, MGH7000CI, MGH10000, and
MGH3000PR)

HONDA

OFFONSTART

Engine
Switch

Figure 22 - Engine Switch (Models
MGH5000CIE, MGH7000C, MGH7000CI,
and MGH10000 Only)

Choke Lever (Open Position)

Figure 23 - Choke Lever Opened (Model
MGH7000C Shown)

ENGINE SW

CIRCUIT
BREAKER

ON/push OFF

HIGH ALTITUDE OPERATION

This generator will not perform well at high
altitudes without proper adjustment. See
engine owner’s manual for details.

ADDING ELECTRICAL
LOADS

IMPORTANT:

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

IMPORTANT:

HWI3000, MGH3000, MGH3000PR,
MGH7000C, MGH7000CI, and
MGH10000) Keep full power selector
switch in the 120 VOLT ONLY position if
only powering 120V items. Only move
switch to 120/240 VOLT position if pow­ering 240V items.

Do not overload generator.

(All models except

12

105420

OWNER’S MANUAL

HONDA

OFFONSTART

ENGINE SW

CIRCUIT
BREAKER

OPERATION

Continued

1. Check items to be powered. Their
nameplate lists their wattage ratings.

Note:

The wattage ratings for some
electrical motors are misleading. They
may require up to three-times their
rated wattage to start. You must figure
total electrical load wattage. Make sure
total wattage of all electrical loads does
not exceed rated wattage of generator.
See Determining Electrical Load For
Generator, page 9.

2. Start engine. Let engine reach full
speed.

3. Connect electrical loads one at a time.
If the load consists of electric motors,
start them first. Always start the larg­est first. Start each motor individually.

DISCONNECTING ELECTRIC
LOADS

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

STOPPING ENGINE

IMPORTANT:

The throttle is locked in preset position. Do
not adjust throttle.

Follow the steps below to stop engine.

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

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

3. Move engine lever or turn engine switch
to the OFF position (see Figure 24).

4. Turn fuel valve lever off except model
MGH3000PR. Do this by moving valve
lever fully to the left (see Figure 25).

The engine speed is preset.

Model
MGH3000PR

ENGINE SW

Models HWI3000,
MGH3000, MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH6000C,
and MGH6000CI

Models MGH5000CIE,
MGH7000C, MGH7000CI,
and MGH10000

Figure 24 - Engine Switch In OFF Position

Fuel Valve Lever
(Off Position)

ON

OFF

MAINTENANCE
AND REPAIRS

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

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

CAUTION: Shut off generator
before performing maintenance.

IMPORTANT:

servicing. Never turn generator upside down
or stand it on end to service.

Note:

We supply the engine owner’s manual

with generator. Refer to that manual for
questions concerning engine maintenance
and repairs.

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

Keep generator level when

105420

Figure 25 - Fuel Valve Lever Off (Model
MGH7000C Shown)

13

R

PORTABLE GASOLINE GENERATORS

STORAGE

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

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

IMPORTANT:

in storage. Never store generator upside
down or standing on end.

Note:

We supply the engine owner’s manual

with generator. Refer to that manual for
questions concerning engine storage.

Keep generator level while

TROUBLESHOOTING

Note:

For additional help, visit DESA

International’s Technical Service web
site at www.desatech.com.

Note:

See engine owner’s manual for en-

gine troubleshooting.

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

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

SERVICING THE
ENGINE

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

Engines Gasoline, Honda

WARNING: Only a qualified electrical service person should service

and repair generator. Use only factory approved replacement parts.

TECHNICAL
SERVICE

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

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

When contacting DESA Power Tools™,
have ready

•Your Name

•Your Address

•Your Phone Number

• Model Number of Product

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

www.desatech.com or

OBSERVED PROBLEM

No voltage when starting generator with no
electrical load

Voltage is less than normal voltage with no
electrical load

Voltmeter reading more than 10% high with
no electrical load

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

POSSIBLE CAUSE

1. Defective capacitor

2. Winding short circuit or loose
connections

3. Defective rotor diode

4. Loss of residual magnetism

1. Engine speed too low

2. Defective rotor diode

3. Partial short circuit in winding

4. Defective capacitor

1. Engine speed too high

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

www.desatech.com

14

REMEDY

1. Replace capacitor

2. Check resistance of coils (see Electri-
cal Component Specifications, page 15)

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor ter­minals for 2-3 seconds

1. Set engine speed to 3720 RPM (62 Hz)
with no load

2. Replace both diodes on rotor

3. Check resistance of coils (see Electri-
cal Component Specifications, page 15)

4. Replace capacitor

1. Set engine speed to 3720 RPM (62 Hz)
with no load

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized engine service
center

105420

OWNER’S MANUAL

ELECTRICAL
COMPONENT
SPECIFICATIONS

Resistance in Ohms

Stator Stator Rotor Rotor Capacitor,

Main Auxiliary Primary Secondary MFD Diodes (2)

Model Winding * Winding ∆ Winding † Winding † 450 Volt 800 Volt

HWI3000 1.6 5.9 6.9 1.33 16 6 Amp
MGH3000, MGH3000PR 1.6 5.9 6.9 1.33 16 6 Amp
MGH4000C, MGH4000CI 0.71 2.17 0.54 2.07 40 70 Amp
MGH5000C, MGH5000CI 0.54 1.38 0.61 2.29 50 70 Amp
MGH5000CIE 0.54 1.38 0.61 2.29 50 70 Amp
MGH6000C, MGH6000CI 0.37 1.01 0.68 2.57 60 70 Amp
MGH7000C, MGH7000CI 0.28 0.78 0.77 2.9 70 70 Amp
MGH10000 0.40 0.90 0.37 0.50 80 70 Amp

*

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

∆

Resistance between brown and white leads.

†

Remove diodes to check resistance.

WIRING DIAGRAMS

Stator

L1

Black

T1 T3 T2 T4

110/120V

L1

Rotor Stator

D

T3

T1

T2

Green

Red

C

White

Brown

Black

L2

T4

Auxiliary
Phase

Main
Windings

Yellow

L2

L2

L1

Black

Yellow

Figure 26 - Wiring Diagram, Models HWI3000, MGH3000, and MGH3000PR

120/240V 20A

Receptacle

T3

White

Black

Black

Green

Black

Red

Red

White

T2

Full Pwr

Selector

Hour
Meter

Switch

Red

Black

Black

White

Red

Green/Yellow

Circuit

T1

Breaker

Circuit

Breaker

Yellow

Black

Red

25A

25A

T4

20A

Circuit
Breaker

Black

Yellow

Black

White
120V, 15A
Receptacle

Duplex

LINE

HOT

WHITE

120V, 15A
Receptacle

Red

White

GFCI

HOT

LINE

Green
Black

GFCI

Green

WHITE

White

Receptacle
120V/15A
(MGH3000)

Receptacle
120V/20A
(HWI3000)

120V, 30A

Receptacle

Green

Circuit

Breaker

20A

Circuit

Breaker

20A

Capacitor

White

White

Main

Windings

T2

T1

T1

T4

T3

T2

Green

T3

Red

Black

Yellow

Auxiliary

Phase

Diode

White

Stator

Brown

T4

Rotor

Diode

L1

T1

110/120V

Stator

T2

220/240V

T3

110/120V

T4

L2

Figure 27 - Wiring Diagram, Models MGH4000C, MGH5000C, MGH5000CIE, and MGH6000C

105420

15

Continued

R

PORTABLE GASOLINE GENERATORS

WIRING DIAGRAMS

Continued

Red

Green/Yellow

Circuit

Breaker

30A

Circuit

Breaker

30A

T4

Yellow

120/240V 30A

Receptacle

RedT1

T3

Black

Black

White

Black

Meter

Black

Hour

Red

White

120V, 15A

Receptacle

Duplex

120V, 15A

Receptacle

GFCI

LINE

Green

Black

120V, 15A

Receptacle

White

White

T2

HOT

WHITE

White

Black

Green

Circuit

Breaker

20A

Circuit

Breaker

20A

Capacitor

White

White

T1 T2T3T4

Figure 28 - Wiring Diagram, Model MGH7000C

Auto-Idle

White
White

To
Auto-Idle
Solenoid

Control Board

S2

S1

T1-3

Solenoid

L1

L2

Red

Yellow

Capacitor

Red

Yellow

White

White

Circuit

Breaker

45A

Circuit

Breaker

T1 T2T3T4

45A

250V 50A

Receptacle

Red

Yellow

Black

Red

White

Green

Green

Windings

T2

Main

T2

Red

Green

Circuit

Breaker

30A

Circuit

Breaker

30A

T1

Main

Windings

T1

Black

T3

T3

Yellow

Red

T4

T4

250V 30A

Receptacle

Wh

White

Black

Diode

Diode

Rotor

Auxiliary

Phase

Rotor

Diode

Diode

Black Black

Black

Stator

Stator

White

Brown

White

Run

Light

Hour Meter

Black
White

Red

T1 T2 T3 T4

220/240V

L1

110/120V

WhiteWhite

125V, 15A

Receptacle

Green

Stator

T1 T2 T3 T4

220/240V

L1

110/120V

110/120V

Stator

110/120V

GFCI 125V, 15A

Receptacle

Green

L2

Black

L2

Green

Black

WhiteWhite

125V, 30A
Receptacle

Green

Black

Black

Black

Breaker

Circuit

Breaker

20A

Circuit

20A

Black

Figure 29 - Wiring Diagram, Model MGH10000

16

105420

OWNER’S MANUAL

REPLACEMENT
PARTS AND
ACCESSORIES

For original replacement parts and accesso­ries, contact your nearest Authorized Dealer
or Authorized Service Center for this prod­uct. If they can not supply the part or acces­sory, contact your nearest Parts Central listed
on page 17. Each Authorized Dealer, Au­thorized Service Center, and Parts Central is
independently owned and operated.

See pages 18 through 27 for an Illustrated
Parts List.

If you need additional referral information,
contact our Technical Service Department
(see Technical Service, page 14).

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

Heavy-Duty Wheel Kit – PA2000
For models MGH4000C,

MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CI

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

This kit includes:

• Large 12-inch wheels for easy rolling

• Plated tubing and hardware for long life

• Long handles with thick grips for greater
comfort and control

Complete installation instructions included.

Automatic Idle Kit – PA2010
For models MGH4000C,

MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CI

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

Complete installation and operation instruc­tions included.

REPAIR SERVICE

Note:

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

Each Authorized Service Center is indepen­dently owned and operated.

WARRANTY SERVICE

If product requires warranty service, return it
to nearest Authorized Service Center. You
must show proof of purchase. If faulty materi­als or workmanship caused damage, we will
repair or replace product without charge.

Note:

Normal wear, misuse, abuse, neglect, or acci­dental damage is not covered under warranty.

NON-WARRANTY SERVICE

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

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

www.desatech.com.

PARTS CENTRALS

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

Tool & Equipment

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

Grainger Parts Operations

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

Portable Heater Parts

342 North County Road 400 East
Valparaiso, IN 46383-9704
219-462-7441
1-800-362-6951
www.portableheaterparts.com
[e-mail]
[e-mail]

FBD

1349 Adams Street
Bowling Green, KY 42103-3414
270-846-1199
1-800-654-8534
[e-mail]

Master Part Distributors

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

Bowden Electric Motor Service

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

East Coast Energy

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

Laportes

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

MTA Distributors

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

Industrial Hardware

4109 Bainbridge Blvd.
Chesapeake, VA 23324-1403
804-543-2232
1-800-788-0008
[e-mail]

Mills Lawn and Garden

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

Tuco Industrial Products

5223 180th Street SW
Suite 4A-1
Lynnwood, WA 98037-4506
425-743-9533
1-800-735-1268
www.tucoheat.com

105420

17

R

5

6

16

18

17

19

20

14

10

3

8

9

7

12

13

15

13

15

21

22

7

11

7

4

1b

2b

7

1a

2a

PORTABLE GASOLINE GENERATORS

ILLUSTRATED
PARTS LIST

For Models HWI3000, MGH3000,
and MGH3000PR
Alternator Assembly

This list contains replaceable parts used in
your generator. When ordering parts, fol­low the instructions listed under Replace-
ment Parts on page 17 of this manual.

KEY PART
NO. NUMBER DESCRIPTION QTY.

099722-01 Alternator Assembly

(HWI3000)* 1

099722-02 Alternator Assembly

(MGH3000

and MGH3000PR)* 1
1a 099849-01 Top Cover (HWI3000) 1
1b 100074-01 Top Cover (MGH3000) 1
2a 104201-01 120V, 20A Duplex

2b 100445-01 120V, 15A Duplex (GFCI)

3 22616009 Circuit Breaker, 20 Amp † 1
4 27002002S Capacitor 1
5 26333000 Screw, M4 x 20 1
6 099863-01 Terminal Block 1
7 099701-01 Screw, M5 x 13 13
8 099848-01 End Plate 1
9 17587000 Ground Lug 1

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

Receptacle (HWI3000)† 1

Receptacle (MGH3000)† 1

KEY PART
NO. NUMBER DESCRIPTION QTY.

10 099891-01 Flanged Nut, 8mm 1
11 099861-01 Bottom Cover 1
12 099842-01 Draw Bolt 1
13 26310000 Screw, M6 x 16∆ 4
14 27001005S Engine Flange 1
15 WLE-4 Lock Washer, 1/4" 4
16 ** Stator 1
17 27001002 Bearing 1
18 27001009S Diode 2
19 ** Rotor 1
20 27001006 Fan 1
21 26327006 Bolt, 5/16-24 x 5/8" 4
22 WLE-5 Lock Washer, 5/16" 4

PARTS AVAILABLE - NOT SHOWN

099866-03 Safety Information Decal 1
099866-04 Safety Information Decal 1
099867-02 Operation Decal 1

18

105420

OWNER’S MANUAL

ILLUSTRATED
PARTS LIST

For Models MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CI
Alternator Assembly

This list contains replaceable parts used in
your generator. When ordering parts, fol­low the instructions listed under Replace-
ment Parts on page 17 of this manual.

PART NUMBER FOR MODEL

MGH5000C
KEY MGH4000C MGH5000CI MGH6000C MGH7000C
NO. MGH4000CI MGH5000CIE MGH6000CI MGH7000CI DESCRIPTION QTY.

099723-01 099723-02 099723-03 099723-04 Alternator Assembly 1
1 099844-01 099844-01 099844-01 099844-01 End Cover 1
2 099701-01 099701-01 099701-01 099701-01 Screw, M5 x 13 6
3 099760-01 099760-01 099760-01 099760-01 Bushing 1
4 099863-01 099863-01 —— —— Terminal Block (4-block) 1
5 099863-02 099863-02 099863-02 099863-02 Terminal Block (2-block) 1
6 17587000 17587000 17587000 17587000 Ground Lug 1
7 M11084-26 M11084-26 M11084-26 M11084-26 Screw, #10-16 x 3/8" 1
8 099847-01 099847-02 099847-03 099847-04 Stator Bolt 4
9 WLE-5 WLE-5 WLE-5 WLE-5 Lock Washer, 5/16" 4
10 099843-01 099843-01 099843-01 099843-01 Bearing Housing 1
11 27004002S 27005003S 099845-01 27007004S Capacitor 1
12 —— —— 100054-01 100054-01 Terminal Post 4
13 * * * * Stator 1
14 27003002 27003002 27003002 27003002 Fan Bracket 1
15 27003015S 27003015S 27003015S 27003015S Screw, M8 x 20∆ 4
16 099891-01 099891-01 099891-01 099891-01 Rotor Nut, Flanged 8mm 1
17 099892-01 099892-01 099892-01 099892-01 Foam Pad 1
18 099842-01 099842-02 099842-03 099842-04 Draw Bolt 1
19 27003003 27003003 27003003 27003003 Bearing 1
20 27003012S 27003012S 27003012S 27003012S Diode 2
21 * * * * Rotor 1
22 27003008 27003008 27003008 27003008 Fan 1
23 27003007S 27003007S 27003007S 27003007S Engine Flange 1
24 26322004 26322004 26322004 26322004 Bolt, 3/8-16 x 5/8"∆ 4
25 WLE-6 WLE-6 WLE-6 WLE-6 Lock Washer, 3/8" 4

8

1

9

7

6

5

2

10

12

4

17

3

9

15

20

19

14

13

11

18

16

23

25

24

22

21

* Part not available by itself. Must purchase Alternator Assembly.
∆ Standard hardware item.

105420

19

R

PORTABLE GASOLINE GENERATORS

ILLUSTRATED
PARTS LIST

For Model MGH10000 Alternator
Assembly

This list contains replaceable parts used in
your generator. When ordering parts, follow
the instructions listed under Replacement
Parts on page 17 of this manual.

22

3

19

18

17

21

12

23

25

4

2

11

6

16

9

7

20

8

15

5

1

14

24

13

26

10

KEY PART
NO. DESCRIPTION

NUMBER

1 Stator * 1
2 Rotor * 1
3 Draw Bolt 103188-01 1
4 Fan 103191-01 1
5 Balancing Disc 103192-01 1
6 Lifting Eyes 103193-01 2
7 D.E. Bracket 103194-01 1
8 N.D.E. Bracket 103195-01 1
9 Mounting Bolts 099847-05 4
10 Nuts 270010105 4
11 Top Box 103189-01 1
12 Screw and Washer 099701-01 6
13 Plastic Cap 103198-01 1
14 Bearing 103199-01 1
15 Borelly Washer 103200-01 1
16 Diode 27003012S 2
17 Terminal Block 103201-01 1
18 Capacitor 099845-02 1
19 Tie Wrap 103204-01 1
20 Foam Pad 099892-02 1
21 Capacitor Bracket 103202-01 1
22 Engine Flange 103190-01 1
23 Bolts 27003155 4
24 'O' Ring 103203-01 1
25 Washer WLE-5 2
26 Hex Head Nut 099891-01 1
† Alternator Assembly 102938-01 1

* Part not available by itself. Must purchase Alternator Assembly.

QTY.

20

105420

ILLUSTRATED
PARTS LIST

For Models HWI3000, MGH3000,
and MGH3000PR Roll Cage

This list contains replaceable parts used in
your generator. When ordering parts, follow
the instructions listed under Replacement
Parts on page 17 of this manual.

OWNER’S MANUAL

1

3
4

2

5

8

5

4

3

3
4

6

4

3

3

7

4

6

4

3

3
3
4

5

9

7

3

105420

KEY PART
NO. NUMBER DESCRIPTION QTY.

1 099781-01 Roll Cage 1
2 099754-01 Engine Spreader 1
3 NEC-5C Lock Nut, 5/16-18 9
4 WP-5C Flat Washer, 5/16" 7
5 099853-02 Shock Mount 3
6 04110002 Screw, 5/16-18 x 1 1/2 2
7 14138000 Ground Strap 1
8 21834000 Washer, 5/16" x 1 1/2" 1
9 100406-01 Bolt, 5/16-18 x 3/4" 1

21

R

PORTABLE GASOLINE GENERATORS

ILLUSTRATED
PARTS LIST

For Models MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CÎ
Fuel Tank and Roll Cage

13

16

11

15
26

25

11
16

14

3

7

23

23
14

10

5

2

9

23

27

6

7

6

8

11

10

13

22

11

16

17

16

16

16

17

11

11

16

13

18

16

11

20

19

21

12

16

11

L

E

U

F

F

1

4

24

22

105420

OWNER’S MANUAL

ILLUSTRATED
PARTS LIST

For Models MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CI
Fuel Tank and Roll Cage

This list contains replaceable parts used in
your generator. When ordering parts, fol­low the instructions listed under Replace-
ment Parts on page 17 of this manual.

KEY PART
NO. NUMBER DESCRIPTION QTY.

1 25954000 Gas Cap/Fuel Gage 1
2 099832-01 Gas Tank (with 90° fitting) 1
3 25978000 Breather Assembly 1
4 M51043-01 Screw, 1/4-20 x 1" 4
5 099701-01 Screw, M5 x 10 1
6 19508001 Gas Line Clamp 2
7 25985005 Fuel Line 1
8 099743-01 Fuel Filter 1
9 099752-01 Roll Cage† 1

099752-02 Roll Cage∆ 1
10 103880-01 Lock Nut, 1/4-20 5
11 NEC-5C Lock Nut, 5/16-18 8
12 14138000 Ground Strap 1
13 099853-02 Shock Mounts 3
14 WLE-5 Lock Washer, 5/16" 3
15 WLI-3 Lock Washer, #10 1
16 WP-5C Flat Washer, 5/16" 9
17 HC5-11C Bolt, 5/16-18 x 1 3/4" 2
18 099756-01 Engine Spreader 1
19 099750-01 Hook Bolt, 5/16-18 ** 2
20 099749-01
21 NEC-5C Lock Nut, 5/16-18 ** 2
22 100410-01 Sems Screw, #8-18 x 1/2" 4
23 M10908-74 Screw, 1/4-20 x 1/2" 3
24 WP-4C Washer, 1/4" 5
25 099965-01 Linkage Cover 1
26 WP-3C Washer, #10 1
27 099742-01 90° Fitting with barbs 1

PARTS AVAILABLE - NOT SHOWN

099866-01

099866-02

100003-01 Operation Decal * 1

100003-02 Operation Decal ** 1

099873-01 Battery Cable (Positive, Red)** 1

099873-02 Battery Cable (Negative, Black)** 1

03157000 Fuel Line Grommet 3

Battery Mounting Bracket **

Safety Information Decal *
Safety Information Decal **

1

1
1

105420

* For models MGH4000C, MGH5000C, MGH5000CIE, and MGH6000C only
** For model MGH7000C only
∆ For models MGH4000C and MGH5000C only
† For models MGH6000C and MGH7000C only

23

R

PORTABLE GASOLINE GENERATORS

ILLUSTRATED
PARTS LIST

For Model MGH10000 Fuel Tank
and Roll Cage

18

11

25

24

27

3

31

30

2

29

9

28

24

37

6

11

24

10

12

8

25

24

13

23

14

20

16

15

35

11

24

24

11

11

19

21

5

11
24

25

32

17

13

24

7

22

11

EL

FU

F

1

4

26

33

34

24

34

36

105420

OWNER’S MANUAL

ILLUSTRATED
PARTS LIST

For Model MGH10000 Fuel Tank
and Roll Cage

This list contains replaceable parts used in
your generator. When ordering parts, fol­low the instructions listed under Replace-
ment Parts on page 17 of this manual.

KEY PART
NO. DESCRIPTION

1 Gas Cap/Fuel Gage 25954000 1
2 Gas Tank (with 90° fitting) 099832-01 1
3 Breather Assembly 25978000 1
4 1/4-20 x 1" Screw M51043-01 1
5 1/2-20 x 1" Bolt 26302006 2
6 Gas Line Clamp 19508001 2
7 Fuel Line 25985006 1
8 3/8 Lock Washer WLE-6 1
9 Roll Cage 102752-01 1
10 1/4-20 Lock Nut 103880-01 4
11 5/16-18 Lock Nut NEC-5C 18
12 Ground Strap 14138000 1
13 Shock Mounts 17529000 3
14 5/16" Lock Washer WLE-5 1
15 3/8-16 x 1-1/4" Screw HC6-10C 1
16 3/8" Flat Washer WP-6C 1
17 5/16-18 x 1-3/4" Bolt HC5-11C 2
18 Engine Spreader 102962-01 1
19 5/16-18 Hook Bolt 099750-01 2
20 Battery Mounting Bracket 099749-01 1
21 Axle 102933-01 2
22 #8-18 x 1/2" Sems Screw 100410-01 4
23 1/4-20 x 1/2" Screw M10908-74 1
24 5/16" Washer WP-5C 24
25 5/16-18 x 3/4" Bolt 26007004 10
26 1/4" Washer WP-4C 4
27 1/2" Lock Washer WLI-8 2
28 5/16-18 x 2.50 Screw H8C5-20C 4
29 Handle 102920-01 2
30 Handle Grip 103046-01 2
31 Handle Plug 103057-01 2
32 Stand 102936-01 1
33 U-Bolt 100135-01 2
34 Flat Washer WP-16C 4
35 Wheels 102932-01 2
36 Cotter Pin C4-12C 2
37 90º Fitting with Barbs 099742-01 1

PARTS AVAILABLE - NOT SHOWN

Safety Information Decal 099866-02 1
Operation Decal 100003-04 1
Red Battery Cable (Positive) 099873-04 1
Black Battery Cable (Negative) 099873-02 1
Grommet 03157000 3
Screw (.250 x .75) HC4-6C 2
Wheel Kit Hardware 103818-01 1
Muffler 103047-01 1

NUMBER

QTY.

105420

25

R

PORTABLE GASOLINE GENERATORS

ILLUSTRATED
PARTS LIST

For Models MGH4000C,
MGH4000CI, MGH5000C,
MGH5000CI, MGH5000CIE,
MGH6000C, MGH6000CI,
MGH7000C, and MGH7000CI
Control Panel

This list contains replaceable parts used in
your generator. When ordering parts, fol­low the instructions listed under Replace-
ment Parts on page 17 of this manual.

1

R

1

e

2

s

0

e

V

t

o

lt

R

e

s

e

t

ENM

00000005

HOURS 1/10

9

2

2

5

3

120 ONLY

FULL POWER

SELECTOR

R

E

S

E

T

T

E

S

T

4

7

120/240V

120/240 VOLTS

RESET

RESET

11

10

14

12

6

7

13

7

13

PART NUMBER FOR MODEL

MGH5000C
KEY MGH4000C MGH5000CI MGH6000C MGH7000C
NO. MGH4000CI MGH5000CIE MGH6000CI MGH7000CI DESCRIPTION QTY.

1 103349-01 103349-02 103349-03 103349-04 Control Panel 1
2 22616009 22616009 22616009 22616009 Circuit Breaker, 20 Amp * 2
3 099833-01 099833-01 099833-01 099833-01 120V, 30A Twist-Lock Receptacle * 1
4 15324000 15324000 15324000 15324000 120V, 15A Duplex Receptacle * 1
5 100445-01 100445-01 100445-01 100445-01 120V, 15A Duplex (GFCI) Receptacle * 1
6 099956-01 099956-01 099956-01 — Full Power Selector Switch * 1
7 22616009 — — — Circuit Breaker, 20 Amp * 2

— 22616011 — — Circuit Breaker, 25 Amp * 2
— — 22616010 22616010 Circuit Breaker, 30 Amp * 2

8 099834-01 099834-01 099834-01 —

— — — 099835-01

120/240V, 20A Twist-Lock Receptacle *

120/240V, 30A Twist-Lock Receptacle *
9 101350-01 101350-01 101350-01 101350-01 Hour Meter 1
10 099760-01 099760-01 099760-01 099760-01 Bushing 1
11 100410-01 100410-01 100410-01 100410-01 Sems Screw, #8-18 x 1/2" 4
12 100149-01 100149-01 100149-01 100149-01 Control Box 1
13 22261000 22261000 22261000 22261000 U-Nut 8
14 099997-01 099997-01 099997-01 099997-01 Switch Plug 1
† 103348-01 103348-02 103348-03 103348-04 Control Panel Assembly 1
† 103348-05 103348-06 103348-07 103348-08 Control Panel Assembly - Auto Idle Models 1

∆ 100177-07 100177-07 100177-07 100177-07 Panel Schematic Decal 1

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

1
1

26

105420

ILLUSTRATED
PARTS LIST

OWNER’S MANUAL

For Model MGH10000 Control
Panel

KEY PART
NO. DESCRIPTION NUMBER QTY.

1 Control Panel 103182-01 1
2 20 Amp Circuit Breaker 22616009 2
3 120V, 30A Twist-Lock Receptacle 099833-01 1
4 #8-18 x 1/2" Sems Screw 100410-01 16
5 U-Nut 22261000 20
6 120V, 15A Duplex (GFCI) Receptacle 100445-01 1
7 125/250V, 50A Receptacle 103183-01 1
8 45 Amp Circuit Breaker 103184-01 2
9 Run Light 26299000 1
10 Hour Meter 101350-01 1
11 120/240V, 20A Twist-Lock Receptacle 099834-01 1
12 30 Amp Circuit Breaker 22616010 2
13 Bushing 099760-01 1
14 Control Box 103185-01 1
15 Rocker Switch 100366-01 1
16 120V, 15A Duplex Receptacle 15324000 1
† Control Panel Assembly 102927-01 1

∆ Panel Schematic Diagram 100177-05 1
∆ Auto Idle PC Board Kit 103257-01 1
∆ Solenoid Assembly Kit (With Bracket) 103258-02 1

2

14

2

6

1

RE

SET

3

Reset

120 Volt

Reset

4

15

9

ENM

00000005

H

O

U

R

S

1

/1

0

10

T

E

ST

Auto Idle

O

ff

O

n

S

elector

200 V

Reset

Reset

13

16

11

12

7

5

5

12

p;t

8

Reset

Reset

5

4

105420

† Includes reference numbers 1 through 16
∆ Not shown

27

WARRANTY INFORMATION

KEEP THIS WARRANTY

Model

Serial No.

Date Purchased

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

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

Note:

The five-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda warrants the engine.

See engine owner’s manual for engine warranty information.

FIVE-YEAR LIMITED WARRANTY

GASOLINE PORTABLE GENERATORS

DESA Power Tools™ warrants each alternator, generator, or electric product of its manufacture, to be free from defects in material and
workmanship for five years from the date of first purchase from an authorized dealer, provided that the product has been properly
installed, maintained, and operated in accordance with all applicable instructions. The bill of sale or proof of purchase must be presented
at the time a claim is made under this warranty.

This warranty is extended only to the original retail purchaser. This warranty covers only the parts and labor required to restore this unit
to its proper operating condition. Warranty parts must be obtained through factory authorized dealers and service centers for this product.
These dealers and service centers will provide original factory replacement parts. Failure to use original factory replacement parts voids
this warranty.

This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that fail or become
damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration, modification, tampering,
contaminated fuels, repair using improper parts, or repair by anyone other than an authorized dealer or service center. Routine
maintenance is the responsibility of the owner. Travel, handling, transportation, and incidental costs associated with warranty repairs
are not reimbursable under this warranty and are the responsibility of the owner.

DESA Power Tools™ makes no warranty with respect to the engine and engine components not of its manufacture. They are subject
to warranties of their manufacturers.

To the full extent allowed by the law of the jurisdiction that governs the sale of the product, this express warranty excludes any and all
other expressed warranties and limits the duration of any and all implied warranties, including warranties of merchantability and fitness
for a particular purpose to five years from the date of first purchase, and DESA Power Tools’™ liability is hereby limited to the purchase
price of the product and DESA Power Tools™ shall not be liable for any other damages whatsoever including indirect, incidental, or
consequential damages.

Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental or consequential
damages, so the above limitation of damages may not apply to you.

This warranty provides the original purchaser with specific rights. For information regarding those rights, please consult the applicable
state laws.

P.O. Box 90004
Bowling Green, KY 42102-9004

www.desatech.com

105420-01

REV. C

06/04