R PORTABLE GASOLINE GENERATORS F F U E L OWNER’S OPERATION AND INSTALLATION MANUAL 120 VOL TS RES ET TES T FUL L SEL POW ECT ER OR 120 ON LY 120 240 V EN 000 M 000 HOU RS 120 /240 VOL TS 05 1/10 RES ET F F U E L RES ET 120 VO LTS RES ET TES T Aut o-Id ON le OFF EN 000 M 000 05 HOU RS RES ET 1/10 240 VO LTS RES ET Generator Models: HWI3000, MGH3000, MGH3000PR, MGH4000C, MGH4000CI, MGH5000C, MGH5000CI, MGH5000CIE, MGH6000C, MGH6000CI, MGH7000C, MGH7000CI, and MGH10000 IMPORTA
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. F U E L 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 120 Volt Receptacle (Duplex) 12 0 24 0V 12 0/2 40 EN 00 M 00 00 HO 05 UR 1/1 VO LT S RE SE T S 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 MODEL HWI3000 MGH4000C MGH3000 MGH3000PR MGH4000CI MGH5000C MGH5000CI MGH5000CIE MGH6000C MGH6000CI MGH7000C MGH7000CI MGH10000 Electrical Rated Wattage 2500 2500 2500 4000 5000 6000 7000 10,000 Rated Amperage 120 V 240 V 20.8 –– 20.8 –– 20.8 –– 33.3 16.7 41.7 20.8 50 25 57 28.3 83.3 41.
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 FUEL 20 Continued 20 Normal Tripped Figure 6 - Receptacle Circuit Breaker Button Note: High ambient temperature will cause nuisance tripping. RE SE TE T ST ENGINE OIL Figure 4 - GFCI Receptacle 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.
R PORTABLE GASOLINE GENERATORS BATTERY Continued 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.
OWNER’S MANUAL BATTERY Continued TO ENGINE BLOCK FUL L PO WE 120 ON LY R 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.
R PORTABLE GASOLINE GENERATORS 3. DETERMINING ELECTRICAL LOAD FOR GENERATOR Continued 1. 2. 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. 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.
OWNER’S MANUAL POWER CORD AND PLUG REQUIREMENTS OPERATION Continued Model MGH10000 also has a 120/240V, 50-amp receptacle (see Figure 15). Model HWI3000 has only the 120V, 20amp duplex receptacle. Models MGH3000 and MGH3000PR have only the 120V, 15-amp GFCI duplex receptacle.
R PORTABLE GASOLINE GENERATORS Choke Button Pulled Out (Closed Position) OPERATION Continued 4. 5. Start the engine. A. Recoil Starter Move engine lever or turn engine switch to on position (see Figures 20 and 21). 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.
OWNER’S MANUAL OPERATION MAINTENANCE AND REPAIRS Continued 1. 2. 3. Check items to be powered. Their nameplate lists their wattage ratings. Note: The wattage ratings for some 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 9. Start engine.
R PORTABLE GASOLINE GENERATORS 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: Keep generator level while in storage. Never store generator upside down or standing on end.
OWNER’S MANUAL ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Main Auxiliary Primary Secondary Winding * Winding ∆ Winding † Winding † Model HWI3000 MGH3000, MGH3000PR MGH4000C, MGH4000CI MGH5000C, MGH5000CI MGH5000CIE MGH6000C, MGH6000CI MGH7000C, MGH7000CI MGH10000 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.
R PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued Green Green/Yellow Black 120/240V 30A Receptacle 120V, 15A Receptacle 120V, 15A Receptacle 120V, 15A Receptacle Circuit Breaker 20A T2 Circuit Breaker 20A White White Circuit Breaker 30A Duplex Red GFCI White White Black HOT Circuit Breaker 30A T3 LINE Hour Meter T4 WHITE T1 White Yellow Green Black Black Red Black Black Red White White T1 Auxiliary Phase Main Windings Capacitor T4 T3 T2 T2 T1 T4 T3 Stator St
OWNER’S MANUAL REPLACEMENT PARTS AND ACCESSORIES 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 on page 17. Each Authorized Dealer, Authorized Service Center, and Parts Central is independently owned and operated. See pages 18 through 27 for an Illustrated Parts List.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 1a 2a For Models HWI3000, MGH3000, and MGH3000PR 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 MGH4000C, MGH4000CI, MGH5000C, MGH5000CI, MGH5000CIE, MGH6000C, MGH6000CI, MGH7000C, and MGH7000CI 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 PART NUMBER FOR MODEL MGH5000C KEY MGH4000C MGH5000CI MGH6000C NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 19 18 For Model MGH10000 Alternator Assembly 20 13 17 8 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. 21 15 26 12 24 5 25 10 14 11 23 1 2 6 4 16 22 9 7 3 KEY NO. DESCRIPTION PART NUMBER 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 † Stator Rotor Draw Bolt Fan Balancing Disc Lifting Eyes D.
OWNER’S MANUAL ILLUSTRATED PARTS LIST For Models HWI3000, MGH3000, and MGH3000PR 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 105420 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C, MGH4000CI, MGH5000C, MGH5000CI, MGH5000CIE, MGH6000C, MGH6000CI, MGH7000C, and MGH7000CÎ Fuel Tank and Roll Cage F U E L 2 15 26 F 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 105420
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 Replacement Parts on page 17 of this manual. KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Model MGH10000 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 11 24 25 22 11 25 20 24 11 32 24 23 14 11 5 17 13 11 24 16 19 24 15 11 21 33 35 34 34 36 24 105420
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 Replacement Parts on page 17 of this manual. KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C, MGH4000CI, MGH5000C, MGH5000CI, MGH5000CIE, MGH6000C, MGH6000CI, MGH7000C, and MGH7000CI 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 MGH10000 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 4 Off Au to 5 Idle Se lect or 5 On 12 20 0V p;t 15 9 Re 8 se Re se t t Re se Re t se E 00 NM 00 00 05 U HO t RS 1/10 13 10 4 KEY NO. DESCRIPTION PART NUMBER QTY.
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 five-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda warrants the engine.