R PORTABLE GASOLINE GENERATORS F F U E L OWNER’S OPERATION AND INSTALLATION MANUAL 120 VOL TS RES ET TES T FUL 120 ON LY L SEL POW ECT ER OR 120 240 V 120 /240 VO LTS EN 000 M 000 HOU RS 05 1/10 RES ET F F U E L RES ET 120 VO LTS RES ET TES T Aut o-Id le ON OFF EN 000 M 000 05 HOU RS RES ET 1/10 240 VO LTS RES ET Generator Models: HWI3000, MGH3000, MGH4000D, MGH4000DI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, MGH7000DI, and MGH10000A IMPORTANT:
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 SAFETY INFORMATION PRODUCT IDENTIFICATION Continued 13. 14. E L U F 120 Volt Receptacle Full Power Selector Switch 120 Volt Receptacle (GFCI) 12 0 VO LT S RE SE TE T ST FU LL PO WE R 12 ON 0 LY 12 0 24 0V 120 Volt Receptacle (Duplex) 12 0/2 40 VO LT S EN 00 M 00 00 HO 05 UR RE SE S T 1/1 0 RE SE T Provision for Auto-Idle Switch Run Lamp Hour Meter Roll Cage 120/240 Volt Receptacle Circuit Breaker Gas Tank E L Choke Lever U 12. Control Panel F 11.
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.
OWNER’S MANUAL SPECIFICATIONS MGH5000D MGH4000D MGH5000DI MGH6000D MGH4000DI MGH5000DIE MGH6000DI MGH7000D MGH7000DI MGH10000A HWI3000 MGH3000 Rated Wattage 2500 2500 4000 5000 6000 7000 10,000 Rated Amperage 120 V 240 V 20.8 –– 20.8 –– 33.3 16.7 41.7 20.8 50 25 57 28.3 83.3 41.
R PORTABLE GASOLINE GENERATORS 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. 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.
OWNER’S MANUAL GENERATOR FEATURES Continued ENGINE CIRCUIT BREAKER (Models MGH5000DIE, MGH7000D, MGH7000DI, and MGH10000A) 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 MGH10000A, the fuse is located inside of the Keyswitch box.
R PORTABLE GASOLINE GENERATORS BATTERY (Models MGH5000DIE, MGH7000D, MGH7000DI, and MGH10000A) 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 BATTERY GENERATOR GROUNDING Continued E F FU L Nut 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.
R PORTABLE GASOLINE GENERATORS STANDBY INSTALLATION TO HOME OR BUILDING 1. 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. 2. 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.
OWNER’S MANUAL OPERATION Model MGH10000A also has a 120/240V, 50-amp receptacle (see Figure 15). POWER CORD AND PLUG REQUIREMENTS GENERAL INFORMATION Model HWI3000 has only the 120V, 20amp duplex receptacle. 120V, 30-amp twist-lock receptacle • NEMA L5-30P plug • Three-wire, 30-amp cord 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.
R PORTABLE GASOLINE GENERATORS OPERATION 4. 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.
OWNER’S MANUAL OPERATION STOPPING ENGINE Continued IMPORTANT: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle. 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.
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.
OWNER’S MANUAL ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Main Auxiliary Primary Secondary Winding * Winding ∆ Winding † Winding † Model HWI3000 MGH3000 MGH4000D, MGH4000DI MGH5000D, MGH5000DI MGH5000DIE MGH6000D, MGH6000DI MGH7000D, MGH7000DI MGH10000A 1.6 1.6 0.71 0.54 0.54 0.37 0.28 0.40 5.9 5.9 2.17 1.38 1.38 1.01 0.78 0.90 6.9 6.9 0.54 0.61 0.61 0.68 0.77 0.
PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued Green/Yellow Green Black o 120/240V 30A Receptacle 120V, 15A Receptacle 120V, 15A Receptacle 120V, 15A Receptacle Circuit Breaker 20A T2 Circuit Breaker 20A White White T1 Circuit Breaker 30A Circuit Breaker 30A Duplex Red GFCI White White Black HOT r T3 LINE Hour Meter T4 WHITE at R White Yellow Green Black Black ob Red Black Black Red d n White White T1 Auxiliary Phase Main Windings Capacitor T4 T3 T2 T2 T1
OWNER’S MANUAL TECHNICAL SERVICE REPLACEMENT PARTS You may have further questions about installation, operation, or troubleshooting. Note: Use only original replacement parts. This will protect your warranty coverage for parts replaced under warranty. 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.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 1a 2a For Models HWI3000 and MGH3000 Alternator Assembly 1b 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. 7 2b 4 22 5 6 3 20 15 14 21 19 13 17 16 7 8 13 15 12 18 9 7 10 11 7 KEY NO.
OWNER’S MANUAL ILLUSTRATED PARTS LIST 23 For Models MGH4000D, MGH4000DI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, and MGH7000DI Alternator Assembly 15 22 9 21 19 9 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. 20 10 8 14 7 18 6 5 13 16 12 4 1 17 2 11 3 KEY NO.
R PORTABLE GASOLINE GENERATORS 19 ILLUSTRATED PARTS LIST 18 20 For Model MGH10000A Alternator Assembly 13 17 8 21 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. 15 26 12 24 5 25 10 14 11 23 1 2 6 4 16 22 9 7 3 KEY NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 † DESCRIPTION Stator Rotor Draw Bolt Fan Balancing Disc Lifting Eyes D.E. Bracket N.
OWNER’S MANUAL 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. 1 3 4 2 3 4 3 7 4 3 3 4 5 6 6 8 5 5 9 4 3 3 4 4 7 3 3 105202 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000D, MGH4000DI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, and MGH7000DI Fuel Tank and Roll Cage F 2 15 26 F U E L 3 5 1 4 24 9 23 25 7 6 27 7 8 6 11 13 10 11 16 22 21 20 11 14 16 11 13 16 23 11 16 14 12 18 16 17 16 23 13 19 10 16 11 17 16 11 16 11 22 105202
OWNER’S MANUAL ILLUSTRATED PARTS LIST For Models MGH4000D, MGH4000DI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, and MGH7000DI Fuel Tank and 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. KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Model MGH10000A Fuel Tank and Roll Cage 2 29 F U E L 3 F 31 30 1 4 26 9 28 24 37 7 11 24 6 10 12 8 25 24 13 27 18 23 22 14 5 11 11 24 25 11 20 25 24 32 24 17 13 11 24 11 16 19 24 15 11 21 33 35 34 34 36 24 105202
OWNER’S MANUAL ILLUSTRATED PARTS LIST For Model MGH10000A Fuel Tank and 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. KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000D, MGH4000DI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, and MGH7000DI Control Panel 2 12 2 5 1 3 6 RE SE TE T ST Re se t 12 0 7 Vo lt 4 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 ILLUSTRATED PARTS LIST For Model MGH10000A Control Panel 2 14 2 6 16 1 3 Re 12 se 0 t RE SE TE T ST 11 Vo 12 lt Re 7 se t Au 4 to Off 5 Idle 5 On Se lect or 12 15 9 20 0V p;t Re 8 se t Re se t Re se t Re se E 00 NM 00 00 05 U HO t RS 1/10 13 10 4 KEY NO.
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.