R PORTABLE GASOLINE GENERATORS OWNER’S OPERATION AND INSTALLATION MANUAL Generator Models: HWI3000, MGH3000G, MGH3000, MGH3000PR, MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE, and MGH10000A 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. 106813 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 12 ON 0 LY 120 Volt Receptacle (Duplex) R 12 0 24 0V 12 0/2 EN 00 M 00 00 HO 05 UR S 1/1 40 VO LT S 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 E L Choke Lever U 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 MODEL Electrical Rated Wattage Rated Amperage 120 V 240 V Receptacle 120-V Duplex 120-V, 20-A Duplex 120-V, 15-A GFCI 120-V Twist-Lock 120/240-V Twist-Lock 120-V Full-Power Switch 120/240-V, 50-A HWI3000 MGH3000G MGH3000 MGH3000PR 2500 2500 2500 2500 4000 5000 20.8 –– 20.8 –– 20.8 –– 20.8 –– 33.3 16.7 41.7 20.
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 HANDLES AND TOP BATTERY (Models MGH5000DIE, COVER MGH6500IE, and MGH10000A) Always wear safety glasses when working with battery. Make sure battery terminals are clean. Make sure cable connections are tight. Follow the steps below to attach the handles and top cover to Model MGH10000A: 1. Remove the two bolts, lock nuts, and washers holding side panels to control panel end of roll cage.
OWNER’S MANUAL BATTERY Continued FUL MOUNTING BATTERY TO GENERATOR 4. See engine owner’s manual for more information. Battery Mounting Bracket Nut FULL POW ER 120 ONL Y 120 240V ENM 000 000 05 RS HOU TO STARTER SOLENOID Figure 14 - Connecting Positive and Negative Cables to Battery (Model MGH6500IE Shown) To Starter Solenoid To Engine Block Figure 15 - Connecting Positive and Negative Cables to Battery (Model MGH10000A Shown) EXTENSION CORDS Battery Only use grounded extension cords.
R PORTABLE GASOLINE GENERATORS STANDBY INSTALLATION TO HOME OR BUILDING 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. 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 17). GENERAL INFORMATION POWER CORD AND PLUG REQUIREMENTS Model HWI3000 has only the 120V, 20-amp 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 well-vented. WARNING: Only responsible adults should use generator. Never let anyone operate generator without proper instructions.
OWNER’S MANUAL OPERATION Continued HONDA 6. Engine Switch Adjusting the Idle Speed ON OFF START ENGINE SW CIRCUIT BREAKER Figure 24 - Engine Switch (Models MGH5000DIE, MGH6500IE, and MGH10000A Only) ON/push OFF Choke Lever (Open Position) 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.
R PORTABLE GASOLINE GENERATORS OPERATION Continued 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.
OWNER’S MANUAL 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. Note: We supply the engine owner’s manual with generator.
R PORTABLE GASOLINE GENERATORS ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Capacitor, Main Auxiliary Primary Secondary MFD 450 Volt Winding * Winding Δ Winding † Winding † Model HWI3000 MGH3000G MGH3000, MGH3000PR MGH4000C, MGH4000CI MGH5000D, MGH5000DI MGH5000DIE MGH6000D, MGH6000DI MGH6500IE MGH10000A 1.6 1.95 1.6 0.71 0.54 0.54 0.37 0.28 0.40 5.9 5.2 5.9 2.17 1.38 1.38 1.01 0.78 0.90 6.9 6.79 6.9 0.54 0.61 0.61 0.68 0.77 0.37 1.33 1.31 1.33 2.07 2.29 2.29 2.
OWNER’S MANUAL WIRING DIAGRAMS Continued Red Black Red 120/240V 20A Receptacle T1 White Circuit Breaker 25A White T4 Yellow White Black Circuit Breaker 20A HOT Hour Meter Green Black Green Main Windings White T1 T4 T3 T2 Green Red Capacitor White White LINE Black Black Circuit Breaker 20A Red Red Red 120V, 30A Receptacle GFCI Black T3 ck Bla Circuit Breaker 25A Duplex T2 Full Pwr Selector Switch Black Green White 120V, 15A Receptacle White 120V, 15A Receptacle WHITE
R PORTABLE GASOLINE GENERATORS WIRING DIAGRAMS Continued White Green Green/Yellow Black • 120V, 15A Receptacle 120V, 15A Receptacle Duplex GFCI White Circuit Breaker 30A Red Circuit Breaker 30A Black T3 120V, 15A Receptacle Circuit Breaker 20A T2 Circuit Breaker 20A White White HOT T1 To Solenoid White WHITE s1 s2 120/240V 30A Receptacle Switch LINE Hour Meter T4 Yellow White Green Black Black Red Black Black Red White White T1 Auxiliary Phase Main Windings Capacito
OWNER’S MANUAL ILLUSTRATED PARTS LIST 1a 2a For Models HWI3000, MGH3000G, 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 32 of this manual. 7 2b 4 22 5 6 3 20 13 15 14 21 19 17 16 7 8 13 15 12 9 7 18 10 11 7 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 23 For Models MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE Alternator Assembly 15 21 20 8 14 7 18 6 5 13 16 4 1 17 2 3 PART NUMBER FOR MODEL MGH5000D KEY MGH4000C MGH5000DI MGH6000D NO.
OWNER’S MANUAL ILLUSTRATED PARTS LIST 19 18 For Model MGH10000A Alternator Assembly 20 8 17 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. 15 21 26 10 12 5 25 23 11 1 2 6 4 16 22 9 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 † 7 DESCRIPTION Stator Rotor Draw Bolt Fan Balancing Disc Lifting Eyes D.E. Bracket N.D.E.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 1 For Model MGH3000G 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 3 4 7 4 7 4 6 5 10 11 6 9 6 12 8 12 KEY NO.
OWNER’S MANUAL ILLUSTRATED PARTS LIST 1 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 32 of this manual. 2 3 4 3 4 3 7 4 3 3 4 5 6 6 8 5 5 9 4 3 4 3 4 7 3 3 106813 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, and MGH6500IE 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 12 E L 2 U F 24 22 14 11 16 18 13 10 F 13 29 10 23 23 14 10 24 29 10 16 11 28 17 24 16 11 24 28 9 24 106813
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 MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, MGH6500IE Fuel Tank and Roll Cage KEY MGH4000C NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST 36 For Model MGH10000A Fuel Tank and Roll Cage 35 33 9 9 10 23 20 20 10 25 10 36 10 24 22 32 9 28 29 31 30 2 26 27 18 19 12 10 9 18 20 10 25 20 34 10 9 10 21 19 16 17 15 14 E L 10 F U 1 F 21 13 10 4 9 6 3 5 6 12 8 7 11 26 106813
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 32 of this manual. KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Models MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, and MGH6500IE Control Panel 2 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 ILLUSTRATED PARTS LIST For Model MGH10000A Control Panel 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 14 2 6 16 1 3 Re se t 12 0 Vo RE SE TE T ST 11 12 lt 7 Re se t 4 Off Au to 5 Idle Se lect or 5 On 12 15 9 20 Re Re se se 0V p;t 8 t t Re Re E 00 N M 00 se se t t 00 HO 05 UR S 1/10 13 10 4 KEY NO.
R PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting 12 10 13 6 14 7 8 10 11 9 8 Solenoid Assembly and Mounting 3 DE TE RN AT IO NA L L2 L1 S2 IN S1 SA 4 5 2 1 Control Board Assembly and Mounting 30 106813
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.
R PORTABLE GASOLINE GENERATORS 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 below. Each Authorized Dealer, Authorized Service Center, and Parts Central is independently owned and operated. See pages 19 through 31 for an Illustrated Parts List.
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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.
