R PORTABLE GASOLINE GENERATORS OWNER’S OPERATION AND INSTALLATION MANUAL Generator Models: HWI3000A, MGH3000GA, MGH3000A, MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE 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 1. 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.
OWNER’S MANUAL 13. 14. 118683 E L 120 Volt Receptacle Full Power Selector Switch 120 Volt Receptacle (GFCI) 12 0 VO LTS RE SE TE T ST FU LL PO WE R 12 ON 0 LY 120 Volt Receptacle (Duplex) 12 24 0 0V 12 0/2 EN 00 M 00 00 05 UR HO S 1/1 40 VO LTS RE SE 0 RE SE T T Provision for Auto-Idle Switch Run Lamp Hour Meter Roll Cage 120/240 Volt Receptacle Circuit Breaker Gas Tank L Choke Lever U E 12. Control Panel F 11. Gas Cap/Fuel Gauge F 10.
R PORTABLE GASOLINE GENERATORS GENERAL INFORMATION Master portable generators are rugged and compact. These generators use brushless alternators for dependable, trouble-free service. Honda gasoline engines provide long life under heavy use. Honda engines have overhead valves (OHV). This provides high performance with lower fuel consumption. These engines are governed to maintain engine speed of 3600 RPM under load. 3600 RPM engine speed provides 120/240V, 60 Hz power.
OWNER’S MANUAL SPECIFICATIONS MGH5000E MGH5000EI MGH5000EIE MGH6500AIE 6500 HWI3000A MGH3000GA MGH3000A MGH4000D MGH4000DI 2500 2500 2500 4000 5000 120 V 20.8 20.8 20.8 33.3 41.7 57 240 V –– –– –– 16.7 20.8 28.
R PORTABLE GASOLINE GENERATORS FULL POWER SELECTOR SWITCH 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.
OWNER’S MANUAL GENERATOR FEATURES Continued 2. If the GFCI receptacle tests okay, restore power by pushing the RESET button back in. The test lamp should work at this time. IMPORTANT: You must press the RESET button firmly and fully. It should lock into place. If the GFCI does not lock into place, do not use receptacle. Contact a qualified electrician for repairs. RE SE TE T ST RECEPTACLE CIRCUIT BREAKER The circuit breakers protect the receptacles and alternator.
R PORTABLE GASOLINE GENERATORS BATTERY (Models MGH5000EIE and MGH6500AIE) 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.
OWNER’S MANUAL EXTENSION CORDS GENERATOR GROUNDING 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 Load 2 3 4 5 6 8 10 12 14 16 20 AWG for Length of Cord in Feet 50' 100' 150' 18 18 16 16 16 16 16 14 14 12 10 18 18 16 16 16 14 14 14 12 12 10 WARNING: You must properly earth-ground generator before starting. This will help guard against deadly electric shock.
R PORTABLE GASOLINE GENERATORS 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.
OWNER’S MANUAL OPERATION GENERAL INFORMATION This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles. Only use grounded cords. DANGER: Use only in wellvented areas. Make sure area has plenty of free-moving, fresh, outside air. Never run generator in an enclosed or confined area. Never run generator inside occupied building.
R PORTABLE GASOLINE GENERATORS OPERATION 3. 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 well-vented. 4. WARNING: Only responsible adults should use generator. Never let anyone operate generator without proper instructions.
OWNER’S MANUAL OPERATION Continued Adjusting the Idle Speed IMPORTANT: Adjust the idle speed only: • If the idle speed becomes too high. • If the 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. WARNING: Always set the idle speed before turning on the AutoIdle. If idle speed is not set, the larger resistor on the control board may become hot.
R PORTABLE GASOLINE GENERATORS OPERATION MAINTENANCE AND REPAIRS Continued STOPPING ENGINE IMPORTANT: The engine speed is preset. 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.
OWNER’S MANUAL SERVICING THE ENGINE TECHNICAL SERVICE 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: You may have further questions about assembling, operating, or maintaining this product. If so, you can visit our Technical Service web site at www.desatech.com or contact our Technical Service Department at 1-800-858-8501 (English Only).
R PORTABLE GASOLINE GENERATORS ELECTRICAL COMPONENT SPECIFICATIONS Model HWI3000A, MGH3000GA, MGH3000A MGH4000D, MGH4000DI MGH5000E, MGH5000EI, MGH5000EIE MGH6500AIE Resistance in Ohms Stator Stator Rotor Main Exciting Primary Winding * Winding Δ Winding † 1.63 5.29 4.62 0.709 5.33 13.25 0.570 3.129 3.31 .326 2.012 4.38 Capacitor, MFD 450 Volt 14 16 18 31.5 Diodes (2) 800 Volt 6 Amp 70 Amp 70 Amp 70 Amp * Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow).
OWNER’S MANUAL WIRING DIAGRAMS Stator T2 Rotor L2 L2 Stator White Black Brown T1 T2 Green Receptacle 120V/20A (HWI3000) Auxiliary Phase C D GFCI Yellow L2 L1 HOT WHITE Circuit Breaker T4 110/120V L1 20A Yellow T3 LINE Black T1 Receptacle 120V/15A (MGH3000) Black L1 Main T4 Windings T3 Red Black Yellow Figure 23 - Wiring Diagram, Models HWI3000A, MGH3000GA, and MGH3000A Red Black Red 120/240V 20A Receptacle White Circuit Breaker 25A Black White ck T4 Yellow White Bl
R PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued White Red Black Red 120/240V 20A Receptacle s 1 s2 White • T1 To Solenoid Circuit Breaker Duplex T2 20A, 25A or 30A Full Pwr Selector Switch Circuit Breaker Circuit Breaker 20A Black White White Black Hour Meter Green Black Red Black Main Windings Capacitor White T1 T4 T3 Green Red Green Black Red White White LINE T4 Yellow • Circuit Breaker 20A Red Black T3 20A, 25A or 30A 120V, 30A Receptacle GFCI HOT Bla
OWNER’S MANUAL ILLUSTRATED PARTS LIST 1 2 3 6 For Model HWI3000A, MGH3000GA, and MGH3000A Alternator Assembly 7 8 This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. 4 9 5 10 17 11 12 16 19 18 13 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 1 4 For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, MGH6000D, MGH6000DI, MGH6500AIE Alternator Assembly 5 This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. 9 2 6 3 7 8 16 15 14 13 12 11 10 PART NUMBER FOR MODEL MGH5000E KEY MGH4000D MGH5000EI NO.
OWNER’S MANUAL ILLUSTRATED PARTS LIST 1 For Model MGH3000GA Alternator Assembly This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. 2 9 10 4 7 8 8 10 6 5 11 6 9 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models HWI3000A and MGH3000A Roll Cage This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual.
OWNER’S MANUAL ILLUSTRATED PARTS LIST For Models HWI3000A and MGH3000A Roll Cage This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. KEY NO. PART NUMBER DESCRIPTION 1 2 3 4 5 6 7 118916-02 NEC-5C 099853-03 * WLE-5 14138002 099853-02 Roll Cage Lock Nut, 5/16-18 Shock Mount Bolt, 5/16-18 x 1/2" Lock Washer, 5/16" Grounding Strap Shock Mount * Available at any hardware store. 118683 23 QTY.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE Fuel Tank and Roll Cage U F F E L 3 5 15 26 2 1 4 24 9 23 25 7 6 27 7 8 6 1 11 11 16 20 11 16 13 16 16 17 16 11 21 19 2 12 U F 24 22 14 E L 10 30 11 16 18 13 29 F 13 10 23 23 14 10 24 29 10 16 11 28 17 24 16 11 24 28 9 24 118683
OWNER’S MANUAL ILLUSTRATED PARTS LIST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. For Models MGH4000D, MGH4000DI, MGH5000E,MGH5000EI, MGH5000EIE, and MGH6500AIE Fuel Tank and Roll Cage KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 10 9 6 11 For Solenoid and Control Board Assemblies and Mounting 12 7 8 Solenoid Assembly and Mounting 3 DE TE R NA TIO NA L L2 L1 S2 IN S1 SA 4 5 2 1 Control Board Assembly and Mounting 26 118683
OWNER’S MANUAL ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual. KEY NO. 1 2 3 4 5 6 7 8 9 10 11 12 118683 PART NUMBER 100105-01 26499000 100321-01 WP-C3 26514000 100324-03 DESCRIPTION QTY.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 2 For Models MGH4000D, MGH4000DI, MGH5000E, MGH5000EI, MGH5000EIE, and MGH6500AIE Control Panel 12 2 5 1 3 6 RE SE TE T ST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replacement Parts on page 32 of this manual.
OWNER’S MANUAL REPLACEMENT PARTS AND ACCESSORIES REPAIR SERVICE 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 below. Each Authorized Dealer, Authorized Service Center, and Parts Central is independently owned and operated. Each Authorized Service Center is independently owned and operated.
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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. FIVE-YEAR LIMITED WARRANTY GASOLINE PORTABLE GENERATORS DESA Specialty Products™ makes no warranty with respect to the engine and engine components not of its manufacture.
