R
PORTABLE GASOLINE
GENERATORS
SUPPLEMENTAL INSTRUCTIONS FOR FACTORY
INSTALLED AUTO-IDLE EQUIPPED GENERATORS
FUEL
F
1
2
0
V
O
L
T
S
R
E
S
E
T
T
E
S
T
F
U
L
L
P
S
O
E
W
L
E
E
120/240 VOLTS
C
R
T
O
R
1
2
0
O
N
L
Y
RESET
1
2
0
2
4
0
V
RESET
Generator Models: MGH4000CI, MGH5000CI, MGH5000CIE, MGH6000CI,
and MGH7000CI
(See Owner’s Manual and Installation Manual for General Operation)
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.
WARNING: Improper installation, adjustment,
HONDA
OFFONSTART
ENGINE SW
CIRCUIT
BREAKER
ON/push OFF
alteration, service, or maintenance can cause injury
or property damage. Only a qualified electrical service person should service and repair generator.
• Generator produces high voltage. Use extreme
caution when working on electrical parts.
• Turn off generator and let cool before installation.
Severe burns may result.
• Remove spark plug wire from spark plug before
installation. This will prevent accidental starting.
• Use only factory-approved replacement parts.
STOPPING ENGINE
IMPORTANT:
locked in preset position. Do not adjust throttle.
Follow the steps below to stop engine.
1. Remove all electrical loads from generator (see Disconnect-
ing Electrical Loads in owner's manual, page 13). 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 1 and 2).
The loaded engine speed is preset. The throttle is
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 well-vented.
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 in owner's manual, page 8). Make sure
oil level is full before starting. See Engine Oil in owner's manual,
page 8.
Before starting the engine, disconnect all electric loads from
generator.
STARTING
IMPORTANT:
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:
nected. Start engine before adding electrical loads.
The loaded engine speed is preset. The throttle is
Never start generator with electrical loads con-
OPERATION INSTRUCTIONS
1. If the engine is cold, turn Auto-Idle switch off.
2. Start Engine. Allow engine to warm up with no load for five
minutes.
3. Turn Auto-Idle switch on. Engine will slow to idle speed. En-
gine idle speed is preset. Idle speed adjustment should not be
necessary.
4. Operate generator according to specifications outlined in
owner’s manual.
5. Engine will automatically increase to normal operating speed
when you plug load into any generator outlet.
6. Auto-Idle system should be turned off when generator is shut
down.
ENGINE SW
ON
OFF
Figure 1- Engine Switch For All Models Except MGH5000CIE
and MGH7000CI
Figure 2 - Engine Switch For Models MGH5000CIE and
MGH7000CI
4. Turn fuel valve lever off. Do this by moving valve lever fully
to the left (see Figure 3).
Fuel Valve Lever
(Off Position)
Figure 3 - Fuel Valve Lever Off
2
104030
ADJUSTING THE IDLE SPEED
IMPORTANT:
• Only if the idle speed becomes too high
• If engine idle speed will not regulate (engine idles and speeds
up again and again).
1. Turn Auto-Idle switch off. Start engine. Allow engine to warm
up with no load for five minutes.
2. Hold plunger in solenoid body to manually engage solenoid
and set idle speed.
WARNING: Always set the idle speed before
turning on the Auto-Idle. If idle speed is not set, the
large resistor on the control board may become hot.
Heat from the resistor may damage the protective
coating on the control board.
3. Slowly pull solenoid bracket away from engine. This will slow
the engine. Make sure to hold plunger into solenoid during
this step.
4. With a volt meter, check the no-load output voltage at the 120volt duplex receptacle. At proper idle speed (2680 minimum
RPM) the meter should read 50-60 volts. Lower settings will
cause the auto-idle to not operate properly.
5. After reaching proper idle speed, tighten M8 nut to secure
solenoid mounting bracket.
6. Turn Auto-Idle switch on. Make sure solenoid is engaged.
When solenoid is engaged, the solenoid pulls plunger back
into solenoid.
7. If the engine speed is too slow, the engine will want to “hunt.”
When engine hunts, it speeds up and then slows down repeatedly. When this occurs, increase engine speed by adjusting
throttle stop screw on carburetor (refer to
justment
8. Replace engine linkage cover.
Key Part
No. Number Description Qty.
1 100324-03 Solenoid Assembly (includes 1
2 22822000 Roll Pin 1
3 100755-01 Linkage Rod 1
4 100328-01 Bolt, M8 x 25mm 1
5 100329-01 Lock Nut, M8 1
6 100320-01 Yellow Wire 1
7 100322-01 White Wire (with 2 flags) 1
8 100322-02 White Wire (with 1 flag 1
9 100756-01 Solenoid Mounting Bracket 1
10 100366-01 Rocker Switch 1
11 100105-01 Control Board Assembly 1
12 100321-01 Nylon Spacer 4
13 WP-3C Flat Washer, #10 4
14 26499000 Hex Head Screw, 10-32 x 3/4" 4
15 26514000 Lock Nut, 10-32 4
16 100495-01 Board and Switch Mounting 1
17 02407002 Plain Washer, 5/16" 1
18 100334-01 Auto-Idle Decal 1
Adjust the idle speed
Carburetor Ad-
in Honda Engine Manual).
plunger, nut, and lock washer)
and 1 spade)
Template
Engine Governor Arm
Governor Spring
12. Nylon Spacer
11. Control Board
14. Screw
EN
GINE
OF
F
ENG
IN
E
OFF
13. Flat Washer
3. Linkage Rod
1
3
2. Roll Pin
1.Solenoid Plunger
2
Existing Lock Washer
4. Bolt
E
N
G
I
N
E
O
F
F
9.Solenoid Bracket
17. Plain
Washer
5. M8 Lock Nut
15. Lock Nut
DESA INTERNATIONAL
S2
S1
L1
L2
11. Control Box
104030
3
To Solenoid
White
120/240V 20A
Receptacle
White
Black
Green
Black
Red
Red
White
T2
Full Pwr
Selector
Hour
Meter
Switch
Red
Black
Black
Black
White
Red
Green/Yellow
s
1 s2
•
•
Circuit
Breaker
T1
20A, 25A
or 30A
Circuit
Breaker
T3
20A, 25A
or 30A
T4
Yellow
Black
Red
Black
White
120V, 15A
Receptacle
Duplex
White
120V, 15A
Receptacle
Red
GFCI
HOT
LINE
Green
Black
Green
HITE
W
White
120V, 30A
Receptacle
Green
Circuit
Breaker
20A
Circuit
Breaker
20A
To Solenoid
Capacitor
W
Main
Green
T2
Windings
Red
Black
T1
T3
Yellow
White
hite
T1
T4
T3
T2
Auxiliary
Phase
Diode
Stator
W
hite
Brown
T4
Rotor
Diode
L1
T1
110/120V
Stator
T2
220/240V
T3
110/120V
T4
L2
Wiring Diagram, 4000, 5000, and 6000 Watt Models
120V, 15A
Receptacle
GFCI
HOT
LINE
WHITE
Black
White
Green
White
White
Stator
Brown
Black
120V, 15A
Receptacle
White
T2
Green
T1 T2 T3 T4
L1
110/120V
Stator
220/240V
110/120V
Circuit
Breaker
20A
Circuit
Breaker
20A
L2
Green/Yellow
120/240V 30A
Switch
Circuit
Breaker
30A
Circuit
Breaker
30A
T1 T2T3T4
T4
Yellow
RedT1
T3
Receptacle
Black
Black
Green
White
Black
Hour
Meter
Black
Windings
T2
Red
Black
s
1 s2
•
Red
Capacitor
White
White
Main
T1
Red
White
T3
Yellow
120V, 15A
Receptacle
Duplex
T4
Diode
Auxiliary
Phase
Rotor
Diode
Wiring Diagram, 7000 Watt Model
Resistance in Ohms
Rated Stator Main Stator Auxiliary Rotor Primary Rotor Secondary Capacitor, Diodes,
Watts Winding * Winding ∆ Winding † Winding † MFD 450 Volt (2) 800 Volt
4000 0.71 2.17 0.54 2.07 40 70 Amp
5000 0.54 1.38 0.61 2.29 50 70 Amp
6000 0.37 1.01 0.68 2.57 60 70 Amp
7000 0.28 0.78 0.77 2.9 70 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.
P.O. Box 90004
Bowling Green, KY 42102-9004
Technical Service Department 1-800-858-8501
www.desatech.com
104030-01
Rev. B
07/03
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