R PORTABLE GASOLINE GENERATORS F F U E L OWNER’S OPERATION AND INSTALLATION MANUAL 120 RE SE T VO LT S RE SE TE T ST FU LL SE PO LE WE CT R OR 12 0/2 40 VO LT S 12 ON 0 LY RE SE T 12 0 24 0V RE SE T Generator Models: MGH3000, MGH4000A, MGH5000A, MGH6000, and MGH7000 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.
CONTENTS 2 SECTION PAGE Safety Information ....................................................................... 3 Product Identification .................................................................. 6 General Information .................................................................... 7 Specifications .............................................................................. 7 Unpacking ................................................................................... 7 Ventilation ......
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.
SAFETY INFORMATION 2. ! WARNING 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 flammable 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. Continued 3. ! WARNING Guard against electric shock.
SAFETY INFORMATION 8. ! WARNING 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. Continued 9. ! WARNING Only a qualified electrical service person should service and repair generator. • Generator produces high voltage.
PRODUCT IDENTIFICATION Gas Cap/Fuel Gage F F U E L Control Panel Run Lamp 120 Volt Receptacle 12 RE SE T 0 VO LT S RE SE TE T ST FU LL SE PO LE WER CT OR 12 0/2 40 VO LT S 12 ON 0 LY RE SE T 12 0 24 0V RE SE T 120 Volt Receptacle (GFCI) Provision for Auto-Idle Switch Full Power Selector Switch 120/240 Volt Receptacle Circuit Breaker Roll Cage Gas Tank F F U E L Choke Lever Fuel Valve Lever Ground Lug Starter Grip Alternator Engine 6 Engine ON/OFF Switch Oil Di
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.
VENTILATION DANGER 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. 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.
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 11). Note: Operate generator on a level surface.
GENERATOR FEATURES Continued GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE All models have a 120-volt 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.
GENERATOR FEATURES Continued 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.
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. Always allow room for fuel to expand. If you overfill tank, fuel can overflow onto hot engine. This can cause fire or explosion.
BATTERY (Model MGH7000 Only) Continued CAUTION If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when generator runs. IMPORTANT: Make sure battery connections are the correct polarity. Electric start generators use negative ground, 12-volt DC starting system. Model MGH7000 has an electric starter. A battery is not supplied with generator. You must provide a 12-volt, 32-amp-hour battery.
BATTERY (Model MGH7000 Only) Continued MOUNTING BATTERY TO GENERATOR 1. Secure battery to generator by battery hold-down system. This system consists of the battery mounting bracket, hook bolts, and nut (see Figure 10). 2. Locate the red, positive (+) battery cable from starter solenoid. Connect it to the positive (+) battery terminal (see Figure 11). 3. Locate the black, negative (–) battery cable attached to engine block. Connect it to the negative (–) battery terminal (see Figure 11). 4.
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.
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 Load 2 3 4 5 6 8 10 12 14 16 20 STANDBY INSTALLATION TO HOME OR BUILDING 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 18 18 16 16 14 12 12 12 10 10 8 WARNING Have standby installation performed by a skilled, licensed electrician.
DETERMINING ELECTRICAL LOAD FOR GENERATOR Continued 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.
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 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.
OPERATION Continued 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 Volt 30 Amp Ground (Green) X (Hot) L5-30P Plug W X G W (Neutral) Neutral 120V 120V w 120/240 Volt 20 and 30 Amp Ground (Green) Y X G X (Hot) L14-20P Plug Ground Neutral 120V 120V w Y Y (Hot) W (Neutral) X G L14-30P Plug Ground
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 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, page 9).
OPERATION Continued 4. Start the engine. A. Recoil Starter Turn engine switch to the ON position (see Figures 16 and 17). 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 surface. See oil alert system, page 9.
OPERATION Choke Lever (Open Position) Continued Figure 18 - Choke Lever Opened 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: Do not overload generator. 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.
OPERATION 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, page 22). 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 19). 4. Turn fuel valve lever 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.
TROUBLESHOOTING Note: See engine owner’s manual for engine troubleshooting. WARNING Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts. OBSERVED PROBLEM POSSIBLE CAUSE REMEDY No voltage when starting generator with no electrical load 1. Defective capacitor 1. Replace capacitor 2. Winding short circuit or loose connections 2. Check resistance of coils (see Electrical Component Specifications, below) 3.
WIRING DIAGRAMS Stator Black L1 T1 T3 T2 20A L2 110/120V Receptacle 120V/15A GFCI Yellow L2 L1 Stator White Auxiliary Phase Black C D Brown T1 T2 Green Yellow Rotor HOT WHITE Circuit Breaker T4 L2 L1 LINE Black Main T4 Windings T3 Red Black Yellow Figure 21 - Wiring Diagram, Model MGH3000 Red Green/Yellow Black 120/240V 20A Receptacle Run Black Light GFCI White T3 Black T4 HOT Full Pwr Selector Switch Red White LINE Black White Black Red Black Black Red Green
WIRING DIAGRAMS Continued Green/Yellow Green Black Run Black Light 120/240V 30A Receptacle T1 Circuit Breaker 30A 120V, 15A Receptacle 120V, 15A Receptacle White GFCI Red White Circuit Breaker 20A HOT Circuit Breaker 30A T3 WHITE T2 LINE T4 White Yellow Green Black Black Red Black Black Red White White T1 Auxiliary Phase Main Windings Capacitor T4 T3 T2 T2 T1 T3 T4 Rotor Green Red Diode Black Diode Stator Stator T1 White L1 Yellow Brown T2 T3 T4 220/240V 110/1
TECHNICAL SERVICE SERVICING THE ENGINE REPLACEMENT PARTS You may have further questions about installation, operation, or troubleshooting. If so, contact DESA International’s Technical Service Department at 1-800-3235190. 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 Note: Use only original replacement parts.
ILLUSTRATED PARTS LIST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual. 1 For Model MGH3000 7 Alternator Assembly 2 4 23 5 6 3 21 14 16 15 22 20 18 17 14 11 8 7 16 13 19 9 10 12 7 KEY NO.
ILLUSTRATED PARTS LIST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual. 23 For Models MGH4000A, MGH5000A, MGH6000, and MGH7000 15 Alternator Assembly 22 9 25 21 19 9 24 20 10 8 14 7 18 6 5 13 16 12 17 4 1 26 2 11 3 KEY NO.
ILLUSTRATED PARTS LIST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual. For Model MGH3000 Roll Cage 1 2 3 4 3 4 3 7 4 3 3 4 5 6 6 8 5 5 9 9 9 7 4 9 3 KEY NO.
ILLUSTRATED PARTS LIST For Models MGH4000A, MGH5000A, MGH6000, and MGH7000 F U E F L 3 2 1 4 24 Fuel Tank and Roll Cage 5 7 26 25 6 7 6 8 14 27 23 9 24 11 13 10 11 16 22 21 20 11 14 16 11 13 16 23 11 16 14 12 18 16 17 16 19 13 16 15 17 15 15 32 23
ILLUSTRATED PARTS LIST This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual. KEY NO.
This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual. ILLUSTRATED PARTS LIST For Models MGH4000A, MGH5000A, MGH6000, and MGH7000 Control Panel 11 2 1 3 RE SE TE T ST 7 12 RE SE T 0V 4 OL TS 5 6 12 12 FU LL SE PO LE WE CT R OR 12 0/2 40 6 VO LT S 12 ON 0 LY RE SE T 12 0 24 0V RE SE T 8 13 10 9 KEY NO.
NOTES 35
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.
