R
RESET
TEST
120 VOLTS
FUEL
F
R
E
S
E
T
1
2
0
/2
4
0
V
O
L
T
S
120
240V
FULL POWER
SELECTOR
120
ONLY
R
E
S
E
T
ENM
00000005
HOURS 1/10
PORTABLE GASOLINE
GENERATORS
OWNER’S OPERATION AND INSTALLATION MANUAL
FUEL
F
1
2
0
V
O
L
T
S
R
E
S
E
T
T
E
S
T
Auto-Idle
ON
OFF
ENM
00000005
HOURS 1/10
RESET
240 VOLTS
RESET
Generator Models: HWI3000, MGH3000, 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. W ear protective clothing and face shield when servicing.
Keep out of children’s reach.
2
103988
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
120 VOLTS
RESET
TEST
FULL POWER
120
ONLY
ENM
00000005
HOURS 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
FUEL
F
Alternator
Roll Cage
Ground
Lug
103988
Figure 1 - Portable Generator (Model MGH4000C Shown)
3
R
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 applied to generator for shipment.
3. Check for loose or missing parts. Check
for shipping damage. If any parts are
missing or damaged, promptly inform
dealer where you bought generator.
4. Battery cables are supplied for model
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 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
103988
OWNER’S MANUAL
SPECIFICATIONS
MGH5000C
MGH4000C MGH5000CI MGH6000C MGH7000C
MODEL HWI3000 MGH3000 MGH4000CI MGH5000CIE MGH6000CI MGH7000CI MGH10000
Electrical
Rated Wattage 2500 2500 4000 5000 6000 7000 10,000
Rated Amperage
120 V 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
120-V Twist-Lock No No 30 Amp 30 Amp 30 Amp 30 Amp 30 Amp
120/240-V Twist-Lock No No 20 Amp 20 Amp 20 Amp 30 Amp 30 Amp
120-V Full-Power Switch No No Yes Yes Yes No No
120/240-V, 5.0-A No No No No No No Yes
General
Honda Engine H.P. 5.5 5.5 8 9 11 13 20
Honda Model GX160K1VX GX160K1VX GX240K1VA GX270VA GX340K1VA GX390K1VXE GX620VXA3
Fuel Type Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline Gasoline
Fuel Tank Capacity 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
Start Method Recoil Recoil Recoil Recoil/Elec. Recoil Electric Electric
Weight (pounds) 85.5 85.5 139 173 191 247 325
* 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.
103988
5
R
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.
ENGINE SW
ON
OFF
Models HWI3000, MGH3000, MGH4000C,
MGH4000CI, MGH5000C, MGH5000CI,
MGH6000C, and MGH6000CI
HONDA
Models
MGH5000CIE,
MGH7000C,
MGH7000CI, and
MGH10000
Figure 2 - Engine Switch Location
FULL POWER SELECTOR
SWITCH
All models except HWI3000, MGH3000,
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.
OFFONSTART
ENGINE SW
CIRCUIT
BREAKER
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
120/
240V
120/
240V
selector switch while powering electrical
items. Unplug all items before moving
switch. Failure to do so can damage switch.
Models HWI3000, MGH3000, MGH7000C,
MGH7000CI, and MGH10000 do not have
this switch. These models provide full power
to all receptacles.
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 8.
6
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 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
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.
Figure 4 - GFCI Receptacle
Note:
Infants and
. IMPORTANT:
RESET
TEST
You
103988
OWNER’S MANUAL
GENERATOR
FEATURES
Continued
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
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 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.
20
Normal
Figure 6 - Receptacle Circuit Breaker
Button
Note:
High ambient temperature will cause
nuisance tripping.
103988
20
Tripped
7
R
PORTABLE GASOLINE GENERATORS
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.
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.
Make sure battery connec-
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 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
FULL POWER
120
ONLY
120
240V
ENM
00000005
H
O
U
R
S
1
/10
Figure 10 - Battery Hold-Down System
(Model MGH7000C Shown)
Battery
Hook
Bolt
8
103988
OWNER’S MANUAL
BATTERY
Continued
FUEL
Nut
Battery
Hook
Bolt
Figure 11 - Battery Hold-Down System
(Model MGH10000 Shown)
FULL POWER
120
ONLY
120
240V
ENM
00000005
HOURS 1/10
Figure 12 - Connecting Positive and
Negative Cables to Battery
(Model MGH7000C Shown)
F
Battery
Mounting
Bracket
TO ENGINE
BLOCK
TO STARTER
SOLENOID
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
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
Ground Lug
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
FUEL
TO
F
STARTER
SOLENOID
TO
ENGINE
BLOCK
Figure 13 - Connecting Positive and
Negative Cables to Battery
(Model MGH10000 Shown)
103988
Copper or Brass
Grounding Point
Alternator
Ground Wire
Figure 14 - Grounding Generator
(Model MGH4000C Shown)
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
1/8 275 400 600 850 1200
1/4 400 500 850 1050 1700
1/3 450 600 975 1350 1950
1/2 600 750 1300 1800 2600
3/4 850 1000 1900 2600 x
1 1000 1250 2300 3000 x
1 1/2 1600 1750 3200 4200 x
2 2000 2350 3900 5100 x
3 3000 x 5200 6800 x
* – Always use starting watts, not running watts, when figuring correct electrical load.
x – Motors of higher horsepower are not generally used.
10
103988
OWNER’S MANUAL
w
G
YX
w
G
YX
120V 120V
Neutral
Ground
Ground
X
(Hot)
W
(Neutral)
Y
(Hot)
Ground
(Green)
L14-30P
Plug
L14-20P
Plug
120V 120V
Neutral
w
G
YX
Ground
L14-50P
Plug
120/240 Volt
20 and 30
Amp
120V 120V
Neutral
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 MGH10000 also has a 120/240V,
50-amp receptacle (see Figure 15).
Model HWI3000 has only the 120V, 20amp duplex receptacle.
Model MGH3000 has only the 120V, 15amp GFCI duplex receptacle.
120V, 15-Amp GFCI Duplex
120V, 15-Amp Duplex
120/240V, 20 or 30Amp Twist-Lock
120 VOLTS
RESET
TEST
120
ONLY
120
240V
ENM
00000005
HOURS 1/10
120V, 30-Amp
Twist-Lock
RESET
240 VOLTS
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
120/240 Volt
20 Amp
RESET
RESET
Ground
(Green)
Y
(Hot)
X
(Hot)
W
(Neutral)
Neutral
120V 120V
w
YX
G
Ground
L14-20P
Plug
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
double-insulated items. Do not overload
receptacles. All generators (except models
HWI3000 and MGH3000) 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
103988
120/240V, 50-Amp
(Model MGH10000 only)
Figure 15 - Receptacle Locations
11
Figure 16 - Cord and Plug Configurations
Continued
R
PORTABLE GASOLINE GENERATORS
OPERATION
Continued
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 (see Figure 17).
3. Move choke lever fully to the left (see
Figure 17) or pull choke button out
(Model MGH10000 only, see Figure
18). This closes the choke.
Note:
if engine is warm or air temperature is
high.
The engine speed is preset.
Never start generator with
Y ou may not need to close choke
4. Start the engine.
A. Recoil Starter
Turn engine switch to the ON position
(see Figures 19 and 20). Remove slack
from starter rope by lightly pulling
starter grip. Next, pull starter rope
briskly.
IMPORTANT:
Do not let starter grip
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 sur face. 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 20). Hold it there
until engine starts. When engine starts,
let switch return to the ON position.
IMPORTANT:
Do not use electric
starter 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 sur face. See Oil Alert System, page 6.
5. As engine warms up, slowly move
choke lever fully to the right (see Figure 21). This opens the choke. On
Model MGH10000, the choke will automatically open.
Choke Lever (Closed Position)
Choke Button
Pulled Out
(Closed Position)
Figure 18 - Choke Button Closed (Model
MGH10000 Only)
ENGINE SW
ON
OFF
Figure 19 - Engine Switch In ON Position
(All Models Except MGH5000CIE,
MGH7000C, and MGH10000)
HONDA
OFFONSTART
Engine
Switch
Figure 20 - Engine Switch (Models
MGH5000CIE, MGH7000C, MGH7000CI,
and MGH10000 Only)
Choke Lever (Open Position)
ENGINE SW
CIRCUIT
BREAKER
ON/push OFF
Fuel Valve Lever (ON Position)
Figure 17 - Fuel Valve Lever On, Choke
Lever Closed (Model MGH4000C Shown)
12
Figure 21 - Choke Lever Opened (Model
MGH7000C Shown)
103988
OWNER’S MANUAL
OPERATION
Continued
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, 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.
1. Check items to be powered. Their
nameplate lists their wattage ratings.
Note:
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 10.
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
Do not overload generator.
(All models except
The wattage ratings for some
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. Turn engine switch to the OFF position (see Figure 22).
4. Turn fuel valve lever off. Do this by
moving valve lever fully to the left (see
Figure 23).
The engine speed is preset.
ENGINE SW
ON
OFF
Models HWI3000, MGH3000, MGH4000C,
MGH4000CI, MGH5000C, MGH5000CI,
MGH6000C and MGH6000CI
HONDA
OFFONSTART
ENGINE SW
CIRCUIT
BREAKER
Fuel Valve Lever
(Off Position)
Figure 23 - Fuel Valve Lever Off (Model
MGH7000C Shown)
Remove electrical loads one at a time. Remove voltage sensitive items first. Voltage
sensitive items include TVs, VCRs, and
other home electronic items.
103988
ON/push OFF
Models MGH5000CIE, MGH7000C,
MGH7000CI, and MGH10000
Figure 22 - Engine Switch In OFF Position
13
R
PORTABLE GASOLINE GENERATORS
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
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.
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.
Keep generator level while
TROUBLESHOOTING
Note:
See engine owner’s manual for en-
gine troubleshooting.
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
WARNING: Only a qualified electrical service person should service
and repair generator. Use only factory approved replacement parts.
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
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
14
103988
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 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
T1 T3 T2 T4
C
T3
Red
120/240V 20A
Receptacle
T3
White
Black
White
Brown
Black
Black
Green
L2
T4
Red
Black
Auxiliary
Phase
Main
Windings
Yellow
Black
Black
Red
White
L1
White
Full Pwr
Selector
Switch
Hour
Meter
Black
T2
110/120V
L1
Rotor Stator
D
T1
T2
Green
Figure 24 - Wiring Diagram, Models HWI3000 and MGH3000
Green/Yellow
Circuit
T1
Breaker
25A
Circuit
Breaker
25A
T4
Yellow
Black
Red
Black
L1
L2
L2
Yellow
GFCI
White
Receptacle
120V/15A
(MGH3000)
Receptacle
120V/20A
(HWI3000)
120V, 30A
Receptacle
Green
Circuit
Breaker
20A
Circuit
Breaker
20A
Black
LINE
Black
White
Duplex
HOT
WHITE
120V, 15A
Receptacle
Red
White
Green
GFCI
LINE
Black
Green
HOT
WHITE
20A
Circuit
Breaker
Yellow
Red
120V, 15A
Receptacle
Red
Capacitor
White
White
T1 T2T3T4
Green
T2
Main
Windings
Red
Black
T1
T3
Yellow
Auxiliary
Phase
Diode
White
Stator
Brown
T4
Rotor
Diode
Stator
T1 T2 T3 T4
220/240V
L1
110/120V
110/120V
L2
Figure 25 - Wiring Diagram, Models MGH4000C, MGH5000C, MGH5000CIE, and MGH6000C
103988
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
HOT
LINE
WHITE
Black
Green
White
White
White
Black
120V, 15A
Receptacle
T2
Green
Circuit
Breaker
20A
Circuit
Breaker
20A
Capacitor
White
White
T1 T2T3T4
Figure 26 - 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 27 - Wiring Diagram, Model MGH10000
16
103988
OWNER’S MANUAL
TECHNICAL
SERVICE
You may have further questions about installation, operation, or troubleshooting.
If so, contact DESA International’s Technical Service Department at 1-800-323-5190.
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
ACCESSORIES
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.
REPLACEMENT
PARTS
Note:
Use only original replacement parts.
This will protect your warranty coverage for
parts replaced under warranty.
Parts Under Warranty
Contact authorized dealers of this product. If
they cannot supply original replacement
part(s), either contact your nearest Parts
Central or call DESA International’s Technical Service Department at 1-800-323-5190.
When calling DESA International, have
ready
• your name
• your address
• model number of your generator
• how generator is malfunctioning
• purchase date
Usually, we will ask you to return the defec-
tive part to the factory.
Parts Not Under Warranty
Contact authorized dealers of this product.
If they cannot supply original replacement
part(s), either contact your nearest Parts
Central or call DESA International’s Parts
Department at 1-800-972-7879 for referral
information.
When calling DESA International, have
ready
• model number of your generator
• the replacement part number
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.
Baltimore Electric
1348 Dixwell Avenue
Hamden, CT 06514
1-800-397-7553
203-248-7553
Grainger Parts Company of
America
1657 Shermer Road
Northbrook, IL 60062
1-800-323-0620
708-498-5900
Portable Heater Parts
342 N. County Road 400 East
Valparaiso, IN 46383
1-800-362-6951
219-462-7441
F B D
1349 Adams Street
Bowling Green, KY 42103
502-846-1199
1-800-654-8534
Master Parts Dist.
1184 Wilson Ave. NW
Grand Rapids, MI 49544-3458
1-800-446-1446
616-791-0505
Fax: 616-791-8270
Four Flags Power Products
1115 Stateline Road
Niles, MI 49120-4728
1-800-268-4983
616-684-2697
Laportes Parts & Service
2444 N 5th Street
Hartsville, SC 29550
803-332-0191
MTA Distributors
555 Hickory Hills Blvd.
Nashville, TN 37189-9244
1-800-264-0225
615-726-2225
Tuco Industrial Products
P.O. Box 5076
Lynwood, WA 98046
206-743-9533
1-800-735-1268
103988
17
R
PORTABLE GASOLINE GENERATORS
ILLUSTRATED
PARTS LIST
For Models HWI3000 and
MGH3000 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.
1a
2a
1b
5
6
15
13
8
7
7
2b
3
16
15
13
7
9
10
4
22
14
21
20
19
17
12
18
KEY PART
NO. NUMBER DESCRIPTION QTY.
099722-01 Alternator Assembly
(HWI3000)* 1
099722-02 Alternator Assembly
(MGH3000)* 1
1a 099849-01 Top Cover (HWI3000) 1
1b 100074-01 Top Cover (MGH3000) 1
2a 104201-01 120V, 20A Duplex
Receptacle (HWI3000)† 1
2b 100445-01 120V, 15A Duplex (GFCI)
Receptacle (MGH3000)† 1
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
10 099891-01 Flanged Nut, 8mm 1
† Includes fastening hardware.
* Includes reference numbers 1 through 22.
** Parts not available. Included in alternator assembly.
11
7
KEY PART
NO. NUMBER DESCRIPTION QTY.
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
103988
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 Re-
placement Parts on page 17 of this
manual.
8
1
9
7
6
5
2
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
10
12
4
17
3
9
15
20
19
14
13
16
11
18
23
25
24
22
21
* Part not available by itself. Must purchase Alternator Assembly.
103988
19
R
PORTABLE GASOLINE GENERATORS
19
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.
25
23
17
21
12
11
2
6
18
20
8
15
5
1
14
24
13
26
10
22
4
3
7
16
9
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
103988
ILLUSTRATED
PARTS LIST
For Models HWI3000 and
MGH3000 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
103988
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
16
11
18
20
19
21
12
16
11
FUEL
F
1
4
24
22
103988
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 01076002 Washer, #10 1
27 099742-01 90° Fitting with barbs 1
Battery Mounting Bracket **
1
103988
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
* 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
Safety Information Decal *
Safety Information Decal **
1
1
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
FUEL
F
1
4
26
33
34
24
34
36
103988
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 260302006 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
∆ 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
∆ Not shown
NUMBER
QTY.
103988
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
Reset
120 Volt
Reset
ENM
00000005
HOURS 1/10
9
2
2
5
3
120 ONLY
FULL POWER
SELECTOR
RESET
TEST
4
7
120/240V
120/240 VOLTS
RESET
RESET
11
10
6
14
12
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
103988
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 099836-01 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
2
6
1
RESET
3
Reset
120 Volt
Reset
4
15
9
ENM
00000005
HOURS 1/10
10
TEST
Auto Idle
Off
On
Selector
200 Vp;t
Reset
Reset
13
4
16
12
Reset
Reset
14
11
12
7
5
5
8
5
103988
† 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 two-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.
TWO-YEAR LIMITED WARRANTY
GASOLINE PORTABLE GENERATORS
DESA International warrants each alternator, generator, or electric product of its manufacture, to be free from defects
in material and workmanship for two 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 International 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 two years from the date of first purchase, and
DESA International’s liability is hereby limited to the purchase price of the product and DESA International 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.
INTERNATIONAL
2701 Industrial Drive
P.O. Box 90004
Bowling Green, KY 42102-9004
103988 01
NOT A UPC
103988-01
REV. D
02/98
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