Master Lock Portable Generator MGH4000CI MGH5000CI MGH5000CIE MGH6000CI MGH7000CI User Manual

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PORTABLE GASOLINE  
GENERATORS  
OWNER’S OPERATION AND INSTALLATION MANUAL  
FUEL  
F
120 VOLTS  
RESET  
TEST  
FULL POWER  
SELECTOR  
120  
ONLY  
120  
240V  
1
2
0
/2  
4
0
V
O
L
ENM  
T
S
00000005  
HOURS  
1/10  
R
R
E
S
S
E
T
T
E
E
FUEL  
F
1
2
0
V
O
L
T
S
R
E
S
E
T
T
E
S
T
Auto-Idle  
ON  
OFF  
ENM  
00000005  
H
O
U
R
S
1
/
1
0
RESET  
RESET  
240 VOLTS  
Generator Models: HWI3000, MGH3000, MGH4000D, MGH4000DI, MGH5000D, MGH5000DI,  
MGH5000DIE, MGH6000D, MGH6000DI, MGH7000D, MGH7000DI, 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.  
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OWNER’S MANUAL  
SAFETY  
PRODUCT  
INFORMATION  
IDENTIFICATION  
Continued  
9. Only a qualified electrical service per-  
son should service and repair generator.  
• Generator produces high voltage.  
Use extreme caution when working  
on electrical parts.  
Gas Cap/Fuel Gauge  
Control  
Panel  
• Always remove spark plug wire from  
spark plug before servicing. This will  
prevent accidental starting.  
When working on generator, avoid hot  
muffler, exhaust manifold, and engine  
parts. Severe burns may occur.  
FUEL  
F
120 Volt  
Receptacle  
• Do not work on generator when tired.  
• Use only factory approved replace-  
ment parts.  
Full Power  
Selector Switch  
120 Volt  
Receptacle  
(GFCI)  
120 VOLTS  
10. Store generator in a well-vented area.  
Make sure fuel tank is empty. Never  
store with fuel in tank. Vapors may  
reach an open flame or spark. Fire or  
explosion may result.  
RESET  
TEST  
FULL POWER  
120  
ONLY  
120  
240V  
120/240 VOLTS  
ENM  
120 Volt  
Receptacle  
(Duplex)  
00000005  
HOURS  
1/10  
RESET  
RESET  
Provision for  
Auto-Idle Switch  
11. Never operate generator  
• if engine speed changes greatly  
• if engine misfires often  
Run Lamp  
Hour Meter  
• if powered items overheat  
• if electrical output drops  
• if it is sparking  
• if it produces smoke or flames  
• if it vibrates at high levels  
• if it has a damaged receptacle  
Roll Cage  
Gas Tank  
120/240 Volt  
Receptacle  
Circuit  
Breaker  
12. Keep generator and nearby areas clean.  
• Keep generator free of oil, mud, and  
other foreign matter.  
Choke  
Lever  
• Remove anything that creates slip-  
pery areas around generator.  
FUEL  
F
• Remove oily rags and other items  
that create fire hazards.  
Fuel  
Valve  
• Keep a fire extinguisher nearby.  
Make sure it is rated ABC by the  
NFPA. They are good for all uses.  
Consult your local fire department.  
• Keep fire extinguisher well main-  
tained. Be familiar with its use.  
Lever  
13. Know how to stop engine quickly.  
Know how to use all controls.  
Ground  
Lug  
14. Prolonged exposure to loud noise can  
cause hearing loss.  
Starter Grip  
• When working around generator,  
wear approved hearing protection.  
• Remember neighbors when using  
generator.  
Alternator  
Engine  
Engine ON/  
OFF Switch  
Oil Dipstick  
Figure 1 - Portable Generator (Model MGH4000D Shown)  
105202  
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PORTABLE GASOLINE GENERATORS  
HIGH AND LOW  
GENERAL  
VENTILATION  
TEMPERATURE  
OPERATION  
INFORMATION  
DANGER: Use only in well-  
ventedareas.Makesureareahas  
plenty of free-moving, fresh, out-  
side air. Never run generator in  
an enclosed or confined area.  
Never run generator inside occu-  
pied building. Engine exhaust  
containspoisonouscarbonmon-  
oxide gas. Overexposure will  
causelossofconsciousnessand  
will lead to death.  
Master portable generators are rugged and  
compact. These models provide depend-  
able, 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 perfor-  
mance 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.  
Air temperature affects generator output.  
Output drops 1% for each 10° temperature  
rise above 60° F. Very low temperatures may  
make the engine hard to start. See engine  
owner’s manual for more information.  
Thisgeneratorneedscoolingairtorunprop-  
erly. Never block free-flowing, cooling air  
to generator. Overheating will occur with-  
out cooling air. This will damage the gen-  
erator. Keep generator at least three feet  
away from any object.  
Additional Features  
• Circuit breaker protection  
• Spark-arresting muffler (except model  
MGH10000A)  
• Large fuel tank  
• Oil alert system  
DUST, DIRT, RAIN,  
AND SNOW  
WARNING: Do not use gen-  
erator outdoors in rain or snow.  
Do not use generator near stand-  
ing water or snow. Do not use if  
generator is wet or damp. Oper-  
ating generator in these condi-  
tions increases the risk of elec-  
trocution. Severe injury or death  
can occur.  
• Electric starter (models MGH5000DIE,  
MGH7000D, MGH7000DI, and  
MGH10000A only)  
• 15-Amp ground fault circuit interrupter  
(GFCI) receptacle (Except HWI3000  
Model)  
UNPACKING  
1. Remove generator from carton.  
2. Remove any protective packaging ap-  
plied to generator for shipment.  
Do not use generator in extremely dusty or  
dirtyconditions. Thiswillseverelyaffectits  
life. Keep generator clean. Do not allow  
dust, dirt, rain, or snow to collect on it.  
Protect generator from outdoor elements.  
3. Check for loose or missing parts. Check  
for shipping damage. If any parts are  
missing or damaged, promptly inform  
dealer where you bought generator.  
4. Battery cables are supplied for model  
MGH5000DIE,  
MGH7000D,  
MGH7000DI, and MGH10000A only.  
These cables are in a separate bag in-  
side generator carton. You must install  
these cables to engine. See Battery,  
page 8 for installation instructions.  
105202  
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OWNER’S MANUAL  
SPECIFICATIONS  
MGH5000D  
MGH4000D MGH5000DI MGH6000D  
MGH4000DI MGH5000DIE MGH6000DI MGH7000DI MGH10000A  
MGH7000D  
MODEL  
HWI3000 MGH3000  
Electrical  
Rated Wattage  
2500  
2500  
4000  
5000  
6000  
7000  
10,000  
Rated Amperage  
120 V  
20.8  
––  
20.8  
––  
33.3  
16.7  
41.7  
20.8  
50  
25  
57  
28.3  
83.3  
41.7  
240 V  
Receptacle  
120-V Duplex  
––  
Yes  
No  
No  
No  
––  
––  
Yes  
––  
Yes  
––  
Yes  
––  
Yes  
––  
Yes  
––  
120-V, 20-A Duplex  
120-V, 15-A GFCI  
120-V Twist-Lock  
120/240-V Twist-Lock  
Yes  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
30 Amp  
20 Amp  
Yes  
30 Amp  
20 Amp  
Yes  
30 Amp  
20 Amp  
Yes  
30 Amp  
30 Amp  
No  
30 Amp  
30 Amp  
No  
120-V Full-Power Switch No  
120/240-V, 50-A  
No  
5.5  
No  
No  
No  
No  
Yes  
General  
Honda Engine H.P.  
Honda Model  
Fuel Type  
5.5  
8
GX240K1VA  
Gasoline  
5 gal.  
9
11  
GX340K1VA  
Gasoline  
5 gal.  
13  
20  
GX160K1VX GX160K1VX  
GX270VA  
Gasoline  
5 gal.  
GX390K1VXE GX620VXA3  
Gasoline  
3.9 qt.  
Yes  
Gasoline  
3.9 qt.  
Yes  
Gasoline  
5 gal.  
Yes  
Gasoline  
5 gal.  
Yes  
Fuel Tank Capacity  
Oil Alert System  
Start Method  
Yes  
Yes  
Yes  
Recoil  
85.5  
Recoil  
85.5  
Recoil  
139  
Recoil/Elec.  
173  
Recoil  
Electric  
247  
Electric  
325  
Weight (pounds)  
191  
* Single-phase, 1.0 power factor  
Note: Ratings apply to SAE standard conditions. Reduce ratings 3 1/2% for each 1000 feet above sea level and 1% for each 10° Fahrenheit  
rise above 60°F.  
105202  
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PORTABLE GASOLINE GENERATORS  
120 VOLT ONLY: This position sends full  
GROUND FAULT CIRCUIT  
INTERRUPTER RECEPTACLE  
GENERATOR  
FEATURES  
power to the 120V receptacles only. 240V  
power is not available. Use this position  
when powering 120V items only.  
All models (Except HWI3000) 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 pro-  
tects you against hazardous electrical shock  
caused when your body becomes a path  
through which electricity travels to reach  
ground. This could happen when you touch  
an appliance or cord that is ‘live’ through  
faulty mechanism, damp or worn insula-  
tion, etc.  
OIL ALERT SYSTEM  
120/240 VOLT: This position sends full  
power to the 120/240V receptacle. It also  
powers the 120V receptacles at reduced  
wattage capacity.  
Theoilalertsystemprotectstheenginefrom  
low oil damage. This system automatically  
shuts down the engine and prevents engine  
restarting if the oil level falls too low.  
Full Pow er  
Note:Whenthishappens, theengineswitch  
remains in the ON position. The oil alert  
system is wired into the ON/OFF Switch.  
120 V  
ONLY  
120/  
240V  
Selector  
If this system shuts down the engine, the  
engine will not start until you add oil. Add  
oil to engine (see Engine Oil, page 7).  
When protected by the GFCI, you may still  
feel a shock, but the GFCI should cut it off  
quickly. A person in normal health should  
notreceiveseriousinjury. Note:Infantsand  
very small children may still be affected.  
Note: Operate generator on a level surface.  
If not level, the oil may flow away from the  
oil level sensing device. This will cause the  
oil alert system to shut down engine.  
120 VOLT ONLY Position  
Test Procedure  
See engine owner’s manual for more  
information.  
Full Pow er  
Check the GFCI receptacle every month.  
This insures it is working right.  
120 V  
ONLY  
120/  
240V  
ENGINE SW  
ON  
Selector  
1. Push black TEST button. Red RESET  
button should pop out. This should trip  
GFCI, resulting in no electrical power  
at receptacle. Verify this by plugging  
test lamp with good bulb into recep-  
tacle. If lamp does not work, GFCI re-  
ceptacle is good.  
OFF  
120/240 VOLT Position  
Models HWI3000, MGH3000, MGH4000D,  
MGH4000DI, MGH5000D, MGH5000DI,  
MGH6000D, and MGH6000DI  
Figure 3 - Full Power Selector Switch  
WARNING: If RESET button  
does not pop out, do not use the  
GFCI receptacle. Contact a quali-  
fied electrician for repairs.  
IMPORTANT: Do not move the full power  
selector switch while powering electrical  
items.Unplugallitemsbeforemovingswitch.  
Failure to do so can damage switch. Models  
HWI3000, MGH3000, MGH7000D,  
MGH7000DI,andMGH10000Adonothave  
thisswitch. Thesemodelsprovidefullpower  
to all receptacles.  
HONDA  
2. If the GFCI receptacle tests okay, re-  
store 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.  
Models  
MGH5000DIE,  
ON  
OFF  
START  
MGH7000D,  
MGH7000DI, and  
MGH10000A  
ENGINE SW  
ELECTRIC START  
(Models MGH5000DIE,  
MGH7000D, MGH7000DI, and  
MGH10000A)  
CIRCUIT  
BREAKER  
Figure 2 - Engine Switch Location  
FULL POWER SELECTOR  
SWITCH  
Models MGH5000DIE, MGH7000D,  
MGH7000DI, andMGH10000Ahaveelec-  
tric starters. A battery is not supplied with  
generator. You must provide a 12-volt, 32-  
amp-hour battery. For more battery infor-  
mation, see Battery, page 8.  
RESET  
TEST  
All models except HWI3000, MGH3000,  
MGH7000D,  
MGH7000DI,  
and  
MGH10000A have a full power selector  
switch on the control panel. The switch has  
two positions: 120 VOLT ONLY, and 120/  
240 VOLT.  
Figure 4 - GFCI Receptacle  
105202  
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OWNER’S MANUAL  
ENGINE OIL  
GENERATOR  
FUEL  
WARNING:Gasolinepresents  
a hazard of fire or explosion.  
Gasoline is flammable. Its vapor  
is explosive.  
FEATURES  
We ship the generator without oil in the  
engine crankcase. You must add oil before  
starting engine. See engine owner’s manual  
for specific oil type.  
Continued  
ENGINE CIRCUIT BREAKER  
(Models MGH5000DIE,  
MGH7000D, MGH7000DI, and  
MGH10000A)  
• Keep fuel out of children’s  
reach.  
CHECKING OIL LEVEL AND  
ADDING OIL  
Refuel generator in a well-  
ventedarea.Donotfillfueltank  
in the dark. Do not refuel while  
engine is running. Unhook all  
electrical loads and shut off  
engine before refueling.  
Follow steps below to check oil level. Make  
sure engine is level and stopped.  
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.  
1. Remove dipstick (see Figure 7). Wipe  
dipstick clean.  
2. Insert dipstick into oil filler neck. Do  
not screw it in. Oil level should be at  
top of filler neck. Oil should cover most  
of dipstick. For Model MGH10000A  
only, the oil should be between the two  
dots on dipstick.  
• Do not overfill fuel tank. Al-  
ways allow room for fuel to  
expand.Ifyouoverfilltank,fuel  
can overflow onto hot engine.  
This can cause fire or explo-  
sion. After refueling, tightly  
close fuel tank cap.  
• Do not spill fuel. Fuel or fuel  
vapor may ignite. If fuel spills,  
make sure area is dry before  
starting engine.  
ON  
OFF  
START  
ENGINE SW  
3. If level is low, fill to top of oil filler  
neck (see Figure 7). For Model  
MGH10000A only, fill to top dot on  
dipstick. Only use oil recommended in  
engine owner’s manual.  
Engine Circuit  
Breaker Button  
CIRCUIT  
BREAKER  
ON/push OFF  
• Never smoke in refueling area.  
Never allow open flames or  
sparks in area.  
• Store fuel in approved con-  
tainer. Store fuel in a well-  
ventedareafreeofopenflames  
or sparks.  
Note: If oil level is too low, oil alert system  
will shutdown engine and prevent engine  
from restarting.  
Figure 5 - Engine Circuit Breaker  
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 recep-  
tacle. Let circuit breaker cool down. Push  
circuit breaker button to reset.  
Use clean, fresh, unleaded gasoline. Use  
gasoline with octane rating of 86 or higher.  
Service station gasoline pumps should dis-  
play the octane rating. Using gasoline with  
lower octane level could damage engine.  
Avoid getting dirt, dust, or water in fuel  
tank. Do not mix oil with gasoline.  
Oil Level  
At Top Of  
Filler Neck  
Electricmotorsneedhigherstartingcurrent.  
They require up to three-times their rated  
wattage to start. The starting current needed  
may be too high. This can cause nuisance  
circuit breaker tripping. To help prevent  
this, start electric motors first. Connect ad-  
ditional items to generator after starting  
motors. If this continues to happen, reduce  
the total generator load.  
Dipstick  
Oil  
See engine owner’s manual for more  
information.  
Figure 7 - Checking Oil Level (Model  
MGH4000D Shown)  
20  
Normal  
20  
Tripped  
Figure 6 - Receptacle Circuit Breaker  
Button  
Note: High ambient temperature will cause  
nuisance tripping.  
105202  
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PORTABLE GASOLINE GENERATORS  
Always wear safety glasses when working  
with battery. Make sure battery terminals  
are clean. Make sure cable connections are  
tight.  
BATTERY  
(Models MGH5000DIE,  
MGH7000D, MGH7000DI, and  
MGH10000A)  
Always shut down engine before removing  
or attaching battery cables. Always remove  
the negative (–) cable first. Always attach  
negative (–) cable last.  
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.  
Black,  
Negative (–)  
Battery Cable  
INSTALLING BATTERY  
CABLES TO ENGINE  
1. Attach the red, positive (+) battery  
cable to the starter solenoid on engine  
(see Figure 8). The starter solenoid is  
located directly above the starter on  
Model MGH10000A. This cable is fac-  
tory installed.  
Figure 9 - Connecting Black, Negative (-)  
Battery Cable to Engine Block (Model  
MGH7000D Shown)  
WARNING: Battery contains  
sulfuric acid. Contact with skin  
or eyes may cause severe burns.  
Do not tilt generator with battery  
installed.Tiltingcouldcausebat-  
tery acid to spill. Wear protective  
clothing and face shield when  
servicing. Keep out of children’s  
reach.  
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).  
CAUTION:Donotovertighten  
positive terminal on starter sole-  
noid. Positive terminal could ro-  
tate and cut into negative termi-  
nal, causing a short.  
Note: Model MGH10000A battery is  
located on opposite side as shown (see  
Figure 11, page 9).  
• If battery acid gets on your  
skin, wash with water.  
2. Attach the black, negative (–) battery  
cable to the engine block. Use the bolt,  
nut, and two washers provided with the  
battery cables. Use long mounting hole  
on opposite side of engine from starter  
solenoid.Attach cable as shown in Fig-  
ure 9.  
• Ifbatteryacidgetsinyoureyes,  
flush with water at least 15  
minutes. Call a doctor at once.  
Battery acid is poisonous.  
• If swallowed, drink large  
amounts of water or milk. Fol-  
low with milk of magnesia or  
vegetable oil. Call a doctor at  
once.  
2. Locate the red, positive (+) battery  
cable from starter solenoid. Connect it  
to the positive (+) battery terminal (see  
Figures 12 and 13, page 9).  
3. Locate the black, negative (–) battery  
cable attached to engine block. Connect  
it to the negative (–) battery terminal  
(see Figures 12 and 13, page 9).  
4. Check battery before starting engine.  
Make sure fluid levels are full. Make  
sure battery is charged.  
CAUTION: If you remove bat-  
tery, insulate the red, positive (+)  
battery cable terminal. Insulate  
with electrical tape. Exposed ter-  
minal may spark when generator  
runs.  
See engine owner’s manual for more  
information.  
Starter  
Solenoid  
Battery  
Mounting  
Bracket  
IMPORTANT: Make sure battery connec-  
tions are the correct polarity. Electric start  
generatorsusenegativeground, 12-voltDC  
starting system.  
Red, Positive (+)  
Battery Cable  
Nut  
Figure 8 - Connecting Red, Positive (+)  
Battery Cable to Engine Starter Solenoid  
(Model MGH7000D Shown)  
FULL POWER  
120  
ONLY  
120  
240V  
ENM  
00000005  
H
O
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1
Models MGH5000DIE, MGH7000D,  
MGH7000DI, and MGH10000A have an  
electric starter. A battery is not supplied  
withgenerator. Youmustprovidea12-volt,  
32-amp-hourbattery.Thepositiveandnega-  
tivebatterycablesaresuppliedwithgenera-  
tor. You must install these cables before  
mounting battery.  
/10  
Battery  
Hook  
Bolt  
Figure 10 - Battery Hold-Down System  
(Model MGH7000D Shown)  
105202  
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OWNER’S MANUAL  
BATTERY  
GENERATOR  
GROUNDING  
EXTENSION  
CORDS  
Continued  
Only use grounded extension cords. Be sure  
touseextensioncordwithproperwiregauge  
size. See chart below.  
WARNING: You must prop-  
erly earth-ground generator be-  
fore starting. This will help guard  
against deadly electric shock.  
Only use grounded plugs with  
generator.Onlyusegroundedex-  
tension cords. Only use three-  
wire or double-insulated power  
tools.  
FUEL  
F
Nut  
Recommended Minimum Wire  
Gauges (AWG) for Extension  
Cords  
Battery  
Ampere  
Load  
AWG for Length of  
Cord in Feet  
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. Grounding point can be a  
stake, grounding rod, or pipe. Grounding  
point should be copper or brass. Attach  
ground wire to grounding point. You must  
supplythegroundwireandgroundingpoint.  
These do not come with generator. Follow  
the National Electrical Code and all state  
and local codes. Consult your power com-  
pany or a licensed electrician.  
50'  
100'  
150'  
Battery  
Mounting  
Bracket  
Hook  
Bolt  
2
3
4
5
6
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
Figure 11 - Battery Hold-Down System  
(Model MGH10000A Shown)  
8
10  
12  
14  
16  
20  
FULL POWER  
TO ENGINE  
BLOCK  
120  
ONLY  
120  
240V  
ENM  
00000005  
1/10  
HOURS  
TO STARTER  
SOLENOID  
WARNING: For a grounding  
point, do not use metal pipe be-  
ing used to carry combustible  
materials or gases.  
Figure 12 - Connecting Positive and  
Negative Cables to Battery  
(Model MGH7000D Shown)  
Ground Lug  
FUEL  
F
Copper or Brass  
Grounding Point  
FUEL  
F
TO  
STARTER  
SOLENOID  
TO  
ENGINE  
BLOCK  
Ground Wire  
Alternator  
Figure 14 - Grounding Generator  
(Model MGH4000DShown)  
Figure 13 - Connecting Positive and  
Negative Cables to Battery  
(Model MGH10000A Shown)  
105202  
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R
PORTABLE GASOLINE GENERATORS  
ent size motors. For example: an elec-  
1. Make two lists of items you want pow-  
ered 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.  
STANDBY  
tric motor nameplate states 5 amps at  
120 volts. 5 amps x 120 volts = 600  
watts running. Multiply this figure by  
3. This will show the starting watts  
needed. 600 watts x 3 = 1800 watts to  
start. When figuring the generator load  
for motors, you must use the starting  
watts figure. Do not use the running  
watts figure. Note: Some motors re-  
quire nearly the same wattage to run as  
to start. These items include saws,  
drills, hair dryers, and food mixers. See  
Chart 1 for typical appliance wattage  
examples.  
INSTALLATION TO  
HOME OR  
BUILDING  
2. Enter running watts of each item ex-  
cept motors. The light bulb or appli-  
ance nameplate lists its wattage. Re-  
member, 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.  
WARNING: Have standby in-  
stallation performed by a skilled,  
licensed electrician. Do not let  
anyone else wire into a utility  
circuit. Personal injury, equip-  
mentdamage,ordamagetohome  
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. Make  
sure total wattage of electrical load does not  
exceed rated wattage of generator.  
4. Add watts and starting watts of all  
items. This total must not be larger than  
the rated wattage of your generator. It  
is a good idea to have up to 25% extra  
capacity for future needs or extra  
equipment.  
3. Electric motors present a special prob-  
lem. They require up to three-times  
their rated wattage to start. Chart 2,  
below, shows starting watts for differ-  
You may need to use this generator as a  
standby power source. During a power out-  
age, the generator will power selected items  
in a building. Have generator and additional  
wiring installed by a skilled, licensed elec-  
trician. This is not a do-it-yourself job. Fol-  
low all local codes.  
Chart 1 - Typical Electric Appliance Wattages  
Running Starting  
Running Starting  
Equipment  
Watts  
Watts Equipment  
Watts  
Watts  
Light bulb (100W)  
Radio  
Fan  
100  
150  
200  
400  
100  
150  
600  
400  
1/2" Drill  
Toaster  
Coffee maker  
Skillet  
1000  
1200  
1200  
1200  
1200  
1250  
1200  
1200  
1200  
1500  
Television  
WARNING: The electrician  
mustinstalladouble-throwtrans-  
fer switch. This isolates existing  
electrical circuits from the utility  
power line. If not isolated, gen-  
erator output will back-feed into  
utility power line. This may elec-  
trocute a power company line  
repair person.  
Furnace fan (1/3 hp)  
with blower  
14" Chain saw  
Water well pump  
(1/2 hp)  
Hot plate/range  
(per burner)  
10" Table saw  
Water heater  
(storage-type)  
600  
600  
700  
800  
800  
1000  
1800  
750  
2100  
2400  
1000  
1000  
Vacuum cleaner  
Sump pump (1/3 hp)  
Refrigerator/freezer  
6" Circular saw  
Floodlight  
1000  
3000  
1500  
2000  
1500  
6000  
5000  
5000  
Chart 2  
Approximate Starting Watts*  
Repulsion  
DETERMINING  
Motor  
HP  
Rating  
Approximate  
Running  
Watts  
Universal  
Motors  
Split  
Phase  
Motors  
ELECTRICAL LOAD  
FOR GENERATOR  
Induction  
Motors  
Capacitor  
Motors  
(small appliance)  
1/8  
1/4  
1/3  
1/2  
3/4  
1
1 1/2  
2
3
275  
400  
450  
600  
850  
1000  
1600  
2000  
3000  
400  
500  
600  
750  
1000  
1250  
1750  
2350  
x
600  
850  
975  
1300  
1900  
2300  
3200  
3900  
5200  
850  
1200  
1700  
1950  
2600  
x
x
x
x
x
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 watt-  
age of generator. For rated wattage of your  
generator, see Specifications, page 5. Elec-  
tric motors present a special problem when  
figuring load. Read Step 3 carefully.  
1050  
1350  
1800  
2600  
3000  
4200  
5100  
6800  
* – Always use starting watts, not running watts, when figuring correct electrical load.  
x – Motors of higher horsepower are not generally used.  
105202  
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OWNER’S MANUAL  
Model MGH10000A also has a 120/240V,  
50-amp receptacle (see Figure 15).  
POWER CORD AND PLUG  
REQUIREMENTS  
OPERATION  
GENERAL INFORMATION  
Model HWI3000 has only the 120V, 20-  
amp duplex receptacle.  
120V, 30-amp twist-lock receptacle  
• NEMA L5-30P plug  
This generator is not large enough to power  
your entire home. Do not connect generator Model MGH3000 has only the 120V, 15-  
toanyexistingelectricalcircuits.Plugitems amp GFCI duplex receptacle.  
directly into generator receptacles. Do not  
• Three-wire, 30-amp cord  
120/240V, 20 or 30-amp twist-lock  
receptacle  
exceedamperageratingofreceptacles.Only  
120V, 15-Amp GFCI Duplex  
120V, 15-Amp Duplex  
120/240V, 20 or 30-  
use grounded cords.  
• NEMA L14-20P (20-amp) or L14-30P  
(30-amp) plug  
DANGER: Use only in well-  
• Four-wire, 20-amp or 30-amp cord  
ventedareas.Makesureareahas  
plenty of free-moving, fresh, out-  
side air. Never run generator in  
an enclosed or confined area.  
Never run generator inside occu-  
pied building. Engine exhaust  
containspoisonouscarbonmon-  
oxide gas. Overexposure will  
causelossofconsciousnessand  
will lead to death.  
120/240V, 50-amp receptacle  
• NEMA L14-50P  
Amp Twist-Lock  
120 VOLTS  
• Four-wire, 50-amp cord  
RESET  
TEST  
120/240 Volt  
20 Amp  
120  
ONLY  
Neutral  
120V  
120V  
120  
240V  
ENM  
00000005  
HOURS  
1/10  
RESET  
RESET  
w
G
L14-20P  
Plug  
X
(Hot)  
Ground  
(Green)  
Y
X
120V, 30-Amp  
Twist-Lock  
DANGER:Neverconnectgen-  
erator to any existing electrical  
circuits.Thegeneratoroutputwill  
back-feed into the utility power  
line.Thismayelectrocuteapower  
companylinerepairperson.Also,  
if generator is powering electri-  
calcircuits,thechanceofanelec-  
trical fire exists.  
Ground  
W
Y
(Hot)  
(Neutral)  
RESET  
RESET  
240 VOLTS  
Neutral  
120V 120V  
L14-20P  
Plug  
120/240 Volt  
20 and 30  
Amp  
RESET  
w
G
Y
X
Ground  
L14-50P  
Plug  
RESET  
Note:Wesupplytheengineowner’smanual  
with generator. Refer to that manual for  
questions concerning engine operation.  
Ground  
G
w
Y
X
X
(Hot)  
Ground  
(Green)  
Neutral  
120V  
120V  
120V  
120V  
w
USING RECEPTACLE  
Neutral  
Y
X
G
W
L14-30P  
Plug  
Note: Do not exceed amperage rating of  
receptacles. Exceeding rating will trip re-  
ceptacle circuit breaker.  
Y
(Hot)  
120/240V, 50-Amp  
(Model MGH10000A only)  
(Neutral)  
Ground  
Figure 16 - Cord and Plug Configurations  
Figure 15 - Receptacle Locations  
Usereceptaclesproperly.Improperusecould  
damage generator. Use only grounded ex-  
tension cords. Power only grounded or  
double-insulated items. Do not overload  
receptacles. All generators (except models  
HWI3000 and MGH3000) have the follow-  
ing receptacles (see Figure 15):  
• 120V, 15-amp GFCI duplex receptacle  
• 120V, 30-amp twist-lock receptacle  
• 120/240V, 20 or 30-amp twist-lock  
receptacle  
• 120V, 15-amp duplex receptacle  
Continued  
105202  
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PORTABLE GASOLINE GENERATORS  
4. Start the engine.  
OPERATION  
Choke Button  
Pulled Out  
(Closed Position)  
A. Recoil Starter  
Continued  
Turn engine switch to the ON position  
PRESTART  
(see Figures 19 and 20). Remove slack  
from starter rope by lightly pulling  
starter grip. Next, pull starter rope  
briskly.  
Operate generator on a firm, dry, and clean  
surface. The surface must be level. Protect  
generator from heavy dust, sand, dirt, rain,  
orsnow. Donotlocategeneratornearstand-  
ing water and snow. Make sure area is well-  
vented.  
IMPORTANT: Do not let starter grip  
snap back against engine. Return it gen-  
tly. This will prevent damage to starter.  
Figure 18 - Choke Button Closed (Model  
MGH10000A Only)  
Note: If engine does not start, check  
the oil in the crankcase.Add oil as nec-  
essary. Be sure engine is on a level sur-  
face. See Oil Alert System, page 6.  
WARNING: Only responsible  
adults should use generator.  
Neverletanyoneoperategenera-  
tor without proper instructions.  
ENGINE SW  
ON  
OFF  
B. Electric Starter (Models  
MGH5000DIE,  
MGH7000DI, and MGH10000A Only)  
MGH7000D,  
Note: If oil level is too low, oil alert system  
will keep engine from starting (see Oil Alert  
System, page 6). Make sure oil level is full  
before starting. See Engine Oil, page 7.  
Turn the engine switch to the START  
position (see Figure 20). Hold it there  
until engine starts. When engine starts,  
let switch return to the ON position.  
Figure 19 - Engine Switch In ON Position  
(All Models Except MGH5000DIE,  
MGH7000D, and MGH10000A)  
Before starting the engine, disconnect all  
electric loads from generator.  
IMPORTANT: Do not use electric  
starter more than five seconds. Starter  
motor damage may occur. If engine  
fails to start, release the switch and wait  
ten seconds.After ten seconds, try start-  
ing again.  
STARTING  
IMPORTANT: The engine speed is preset.  
The throttle is locked in preset position. Do  
not adjust throttle. Preset position lets en-  
gine run at 3600 RPM under load. The  
engine must maintain 3600 RPM for gen-  
erator to create correct voltage. Running  
engine at lower speeds will damage genera-  
tor and powered items.  
HONDA  
Note: If engine does not start, check  
the oil in the crankcase.Add oil as nec-  
essary. Be sure engine is on a level sur-  
face. See Oil Alert System, page 6.  
ON  
OFF  
START  
Engine  
Switch  
5. As engine warms up, slowly move  
choke lever fully to the right (see Fig-  
ure 21). This opens the choke. On  
Model MGH10000A, the choke will  
automatically open.  
ENGINE SW  
IMPORTANT: Never start generator with  
electrical loads connected. Start engine be-  
fore adding electrical loads.  
CIRCUIT  
BREAKER  
ON/push OFF  
1. Make sure gasoline tank is full. See  
Fuel, page 7 for fuel information.  
Figure 20 - Engine Switch (Models  
MGH5000DIE, MGH7000D, MGH7000DI,  
and MGH10000A Only)  
Choke Lever (Closed Position)  
2. Move fuel valve lever to the ON posi-  
tion (see Figure 17).  
3. Move choke lever fully to the left (see  
Figure 17) or pull choke button out  
(Model MGH10000A only, see Figure  
18). This closes the choke.  
Choke Lever (Open Position)  
Note:You may not need to close choke  
if engine is warm or air temperature is  
high.  
Fuel Valve Lever (ON Position)  
Figure 17 - Fuel Valve Lever On, Choke  
LeverClosed (ModelMGH4000DShown)  
Figure 21 - Choke Lever Opened (Model  
MGH7000D Shown)  
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OWNER’S MANUAL  
Fuel Valve Lever  
(Off Position)  
STOPPING ENGINE  
OPERATION  
IMPORTANT: The engine speed is preset.  
The throttle is locked in preset position. Do  
not adjust throttle.  
Continued  
HIGH ALTITUDE OPERATION  
Follow the steps below to stop engine.  
This generator will not perform well at high  
altitudes without proper adjustment. See  
engine owner’s manual for details.  
1. Remove all electrical loads from gen-  
erator (see Disconnecting Electrical  
Loads). Remove electrical loads one at  
a time.  
ADDING ELECTRICAL  
LOADS  
2. Let engine run for two or three min-  
utes after removing electrical loads.  
This lets engine cool slightly.  
IMPORTANT: Do not overload generator.  
Make sure total wattage of all electrical  
loads does not exceed rated wattage of gen-  
erator. Overloading may shorten generator  
life. It could also cause internal damage to  
generator. Overloading will trip circuit  
breaker.  
3. Turn engine switch to the OFF posi-  
tion (see Figure 22).  
Figure 23 - Fuel Valve Lever Off (Model  
MGH7000D Shown)  
4. Turn fuel valve lever off. Do this by  
moving valve lever fully to the left (see  
Figure 23).  
IMPORTANT: (All models except  
HWI3000, MGH3000, MGH7000D,  
MGH7000DI, andMGH10000A)Keepfull  
power selector switch in the 120 VOLT  
ONLYpositionifonlypowering120Vitems.  
Only move switch to 120/240 VOLT posi-  
tion if powering 240V items.  
ENGINE SW  
ON  
OFF  
1. 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 10.  
Models HWI3000, MGH3000, MGH4000D,  
MGH4000DI, MGH5000D, MGH5000DI,  
MGH6000D and MGH6000DI  
HONDA  
2. Start engine. Let engine reach full  
speed.  
3. Connect electrical loads one at a time.  
If the load consists of electric motors,  
start them first. Always start the larg-  
est first. Start each motor individually.  
ON  
OFF  
START  
ENGINE SW  
DISCONNECTING ELECTRIC  
LOADS  
CIRCUIT  
BREAKER  
Remove electrical loads one at a time. Re-  
move voltage sensitive items first. Voltage  
sensitive items include TVs, VCRs, and  
other home electronic items.  
ON/push OFF  
Models MGH5000DIE, MGH7000D,  
MGH7000DI, and MGH10000A  
Figure22-EngineSwitchInOFFPosition  
105202  
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PORTABLE GASOLINE GENERATORS  
IMPORTANT: Keep generator level when  
servicing.Neverturngeneratorupsidedown  
or stand it on end to service.  
MAINTENANCE  
WARNING: The muffler be-  
comesveryhotduringoperation.  
The muffler remains hot for a  
while after shutdown. Let engine  
cool before storing.  
AND REPAIRS  
Note:Wesupplytheengineowner’smanual  
with generator. Refer to that manual for  
questions concerning engine maintenance  
and repairs.  
WARNING: Only a qualified  
electrical service person should  
service and repair the alternator  
on this generator. Use only fac-  
toryapprovedreplacementparts.  
IMPORTANT: Keep generator level while  
in storage. Never store generator upside  
down or standing on end.  
Non-enginepartsrequirelittlemaintenance.  
Keep generator clean. Use a damp cloth to  
clean outside surfaces. Never use water to  
clean generator. Water can cause damage to  
internal parts. Use vacuum to clean air inlet  
and outlet louvers of alternator.  
Note:Wesupplytheengineowner’smanual  
with generator. Refer to that manual for  
questions concerning engine storage.  
Use a fuel additive, such as STA-BIL® or an  
equivalent,whenstoringgeneratorwithfuel  
in fuel tank. This will minimize fuel gum  
deposits from forming in engine.  
CAUTION: The engine speed  
is preset. The throttle is locked in  
preset position. Do not adjust  
throttle. Preset position lets en-  
gine run at 3600 RPM under load.  
The engine must maintain 3600  
RPM for generator to create cor-  
rect voltage. Running engine at  
lower speeds will damage gen-  
erator and powered items.  
STORAGE  
WARNING: Remove all fuel  
fromfueltankbeforestoringgen-  
erator.Storefuelinapprovedcon-  
tainer. Store fuel in a well-vented  
areafreeofopenflamesorsparks.  
Cover and store generator in a clean, dry  
place. Do not expose generator to extreme  
high or low temperatures during storage.  
CAUTION: Shut off generator  
before performing maintenance.  
TROUBLESHOOTING  
WARNING: Only a qualified electrical service person should service  
and repair generator. Use only factory approved replacement parts.  
Note: See engine owner’s manual for en-  
gine troubleshooting.  
OBSERVED PROBLEM  
POSSIBLE CAUSE  
REMEDY  
No voltage when starting generator with no  
electrical load  
1. Defective capacitor  
2. Winding short circuit or loose  
connections  
3. Defective rotor diode  
4. Loss of residual magnetism  
1. Replace capacitor  
2. Check resistance of coils (see Electri-  
cal Component Specifications, page 15)  
3. Replace both diodes on rotor  
4. Apply 12-volt battery to capacitor ter-  
minals for 2-3 seconds  
Voltage is less than normal voltage with no  
electrical load  
1. Set engine speed to 3720 RPM (62 Hz)  
with no load  
1. Engine speed too low  
2. Defective rotor diode  
3. Partial short circuit in winding  
2. Replace both diodes on rotor  
3. Check resistance of coils (see Electri-  
cal Component Specifications, page 15)  
4. Replace capacitor  
4. Defective capacitor  
Voltmeterreadingmorethan10%highwith  
no electrical load  
1. Set engine speed to 3720 RPM (62 Hz)  
with no load  
1. Engine speed too high  
Voltmeter reading correct with no electrical  
load, but more than 10% low when electri-  
cal load is added  
1. Replace both diodes on rotor  
2. Do not overload generator  
3. Contact an authorized engine service  
center  
1. Defective rotor diode  
2. Electrical load too high  
3. Engine not running properly  
105202  
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OWNER’S MANUAL  
ELECTRICAL  
COMPONENT  
SPECIFICATIONS  
Resistance in Ohms  
Stator  
Main  
Winding * Winding  
Stator  
Auxiliary  
Rotor  
Primary Secondary  
Winding † Winding †  
Rotor  
Capacitor,  
MFD  
450 Volt  
Diodes (2)  
800 Volt  
Model  
HWI3000  
MGH3000  
1.6  
1.6  
5.9  
5.9  
6.9  
6.9  
1.33  
1.33  
2.07  
2.29  
2.29  
2.57  
2.9  
16  
16  
40  
50  
50  
60  
70  
80  
6 Amp  
6 Amp  
MGH4000D, MGH4000DI  
MGH5000D, MGH5000DI  
MGH5000DIE  
MGH6000D, MGH6000DI  
MGH7000D, MGH7000DI  
MGH10000A  
0.71  
0.54  
0.54  
0.37  
0.28  
0.40  
2.17  
1.38  
1.38  
1.01  
0.78  
0.90  
0.54  
0.61  
0.61  
0.68  
0.77  
0.37  
70 Amp  
70 Amp  
70 Amp  
70 Amp  
70 Amp  
70 Amp  
0.50  
*
Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow).  
Resistance between brown and white leads.  
Remove diodes to check resistance.  
WIRING DIAGRAMS  
Stator  
Receptacle  
120V/15A  
(MGH3000)  
Black  
L1  
HOT  
GFCI  
Black  
20A  
WHITE  
Receptacle  
120V/20A  
(HWI3000)  
Circuit  
Breaker  
T1  
L1  
T3  
T2  
T4  
L2  
L2  
L2  
110/120V  
Yellow  
L1  
Rotor  
Stator  
White  
Auxiliary  
Phase  
C
D
Brown  
Black  
Main  
Windings  
T4  
T3  
Red  
T2  
T1  
Yellow  
Green  
Figure 24 - Wiring Diagram, Models HWI3000 and MGH3000  
Red  
Black  
White  
Green/Yellow  
Green  
White  
Red  
120V, 15A  
Receptacle  
120/240V 20A  
Receptacle  
120V, 15A  
Receptacle  
120V, 30A  
Receptacle  
Circuit  
Breaker  
20A  
White  
Circuit  
Duplex  
GFCI  
T1  
T2  
Breaker  
25A  
Circuit  
Breaker  
20A  
Full Pwr  
Selector  
Switch  
Red  
Black  
Black  
Circuit  
Breaker  
25A  
White  
T3  
LINE  
T4  
Yellow  
Black  
Hour  
Meter  
Green  
Black  
White  
Green  
Red  
Red  
Black  
Black  
Green  
Red  
Main  
Windings  
Auxiliary  
Phase  
Capacitor  
White  
Stator  
White  
T1 T4 T3 T2  
T2  
T1  
T4  
Rotor  
Diode  
Diode  
Stator  
White  
T3  
T1  
L1  
T2  
T3  
T4  
L2  
Green  
220/240V  
Red  
Black  
Yellow  
110/120V  
110/120V  
Brown  
Continued  
Figure 25 - Wiring Diagram, Models MGH4000D, MGH5000D, MGH5000DIE, and MGH6000D  
105202  
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PORTABLE GASOLINE GENERATORS  
WIRING DIAGRAMS  
at  
o
r
Continued  
Green/Yellow  
Green  
Black  
120/240V 30A  
Receptacle  
120V, 15A  
Receptacle  
120V, 15A  
Receptacle  
120V, 15A  
Receptacle  
Circuit  
Breaker  
20A  
White  
White  
Circuit  
Breaker  
30A  
Duplex  
GFCI  
T1  
Red  
T3  
White  
White  
Black  
T2  
Circuit  
Breaker  
20A  
Circuit  
Breaker  
30A  
LINE  
Hour  
Meter  
T4  
White  
Yellow  
Green  
Black  
Black  
Red  
ob  
Black  
Black  
Red  
Main  
Windings  
Auxiliary  
Phase  
Capacitor  
White  
d
n
Stator  
T2 T3  
220/240V  
110/120V  
White  
T1 T4 T3 T2  
Stator  
White  
T4  
Rotor  
T2  
T1  
T3  
T1  
L1  
T4  
L2  
Green  
Red  
Diode  
Diode  
Black  
Yellow  
110/120V  
Brown  
Figure 26 - Wiring Diagram, Model MGH7000D  
of  
White  
White  
Green  
Black  
Black  
Green  
125V, 30A  
Receptacle  
125V, 15A  
Receptacle  
GFCI 125V, 15A  
Receptacle  
250V 30A  
Auto-Idle  
Control Board  
Receptacle  
d
o
Red  
250V 50A  
Receptacle  
Circuit  
Breaker  
20A  
Circuit  
Breaker  
30A  
White White  
White  
Red  
Circuit  
Breaker  
45A  
White  
White  
Black  
To  
Auto-Idle  
Solenoid  
Black  
Black  
Run  
Circuit  
Breaker  
20A  
Light  
Circuit  
Breaker  
30A  
Yellow  
Circuit  
Breaker  
45A  
e
Hour Meter  
White  
Black  
Red  
Green  
Black  
Black  
Black  
Yellow  
Red  
Black  
White  
Black  
Black  
Red  
Main  
Windings  
Capacitor  
White  
Stator  
T4  
Rotor  
Diode  
T2  
T1  
T3  
Stator  
T1 T4 T3 T2  
T1  
L1  
T2  
T3  
T4  
L2  
Diode  
220/240V  
110/120V  
110/120V  
Figure 27 - Wiring Diagram, Model MGH10000A  
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OWNER’S MANUAL  
TECHNICAL  
SERVICE  
REPLACEMENT  
PARTS  
PARTS CENTRALS  
These Parts Centrals are privately owned  
businesses. Theyhaveagreedtosupportour  
You may have further questions about in- Note: Use only original replacement parts.  
customer’s needs by providing original re-  
placement parts and accessories.  
stallation, operation, or troubleshooting.  
Thiswillprotectyourwarrantycoveragefor  
parts replaced under warranty.  
If so, contact DESA International’s Techni-  
cal Service Department at 1-800-323-5190.  
Baltimore Electric  
1348 Dixwell Avenue  
Hamden, CT 06514  
1-800-397-7553  
PARTS UNDER WARRANTY  
Contactauthorizeddealersofthisproduct.If  
they cannot supply original replacement  
part(s), either contact your nearest Parts  
Central or call DESA International’s Tech-  
203-248-7553  
SERVICING THE  
ENGINE  
Parts Company of America  
nicalServiceDepartmentat1-800-323-5190. 1657 Shermer Road  
Honda parts and services should be handled  
by your nearest authorized engine service  
firm. Check the yellow pages of your tele-  
phone directory under the listing:  
Northbrook, IL 60062  
1-800-323-0620  
708-498-5900  
When calling DESA International, have  
ready  
• your name  
Portable Heater Parts  
342 N. County Road 400 East  
Valparaiso, IN 46383  
• your address  
Engines Gasoline, Honda  
• model number of your generator  
• how generator is malfunctioning  
• purchase date  
1-800-362-6951  
219-462-7441  
ACCESSORIES  
Heavy-Duty Wheel Kit – PA2020  
For models MGH4000D,  
MGH4000DI, MGH5000D,  
MGH5000DI, MGH5000DIE,  
MGH6000D, MGH6000DI,  
MGH7000D, and MGH7000DI  
F B D  
Usually, we will ask you to return the defec-  
tive part to the factory.  
1349 Adams Street  
Bowling Green, KY 42103  
502-846-1199  
PARTS NOT UNDER  
WARRANTY  
1-800-654-8534  
Master Parts Dist.  
1184 Wilson Ave. NW  
Grand Rapids, MI 49544-3458  
1-800-446-1446  
616-791-0505  
Fax: 616-791-8270  
Contact authorized dealers of this product.  
If they cannot supply original replacement  
part(s), either contact your nearest Parts  
Central or call DESA International’s Parts  
Department at 1-800-972-7879 for referral  
information.  
Wheelbarrow-style wheel kit. Makes gen-  
erator easy for one person to move.  
This kit includes:  
• Large 12-inch wheels for easy rolling  
When calling DESA International, have Four Flags Power Products  
• Powder coated tubing and plated hard-  
ware for long life  
ready  
1115 Stateline Road  
Niles, MI 49120-4728  
1-800-268-4983  
• model number of your generator  
• the replacement part number  
• Long handles with thick grips for greater  
comfort and control  
616-684-2697  
Completeinstallationinstructionsincluded.  
Laportes Parts & Service  
2444 N 5th Street  
Hartsville, SC 29550  
803-332-0191  
Automatic Idle Kit – PA2010  
For models MGH4000D,  
MGH5000D, MGH6000D, and  
MGH7000D  
MTA Distributors  
555 Hickory Hills Blvd.  
Nashville, TN 37189-9244  
1-800-264-0225  
Automatically reduces engine speed when  
no power is being used. Reduces fuel con-  
sumption and engine noise. Increases en-  
gine life.  
615-299-8777  
Tuco Industrial Products  
5223 18th Street SW  
Lynwood, WA 98037-4506  
425-743-9533  
Completeinstallationandoperationinstruc-  
tions included.  
1-800-735-1268  
105202  
17  
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R
PORTABLE GASOLINE GENERATORS  
1a  
ILLUSTRATED  
PARTS LIST  
2a  
For Models HWI3000 and  
MGH3000 Alternator Assembly  
1b  
7
This list contains replaceable parts used in  
your generator. When ordering parts, fol-  
low the instructions listed under Replace-  
ment Parts on page 17 of this manual.  
2b  
4
22  
5
6
3
14  
21  
20  
15  
19  
13  
17  
12  
16  
15  
13  
7
8
18  
9
7
10  
11  
7
KEY PART  
KEY PART  
NO.  
NUMBER  
DESCRIPTION  
QTY.  
NO.  
NUMBER  
DESCRIPTION  
QTY.  
099722-01  
Alternator Assembly  
(HWI3000)*  
Alternator Assembly  
(MGH3000)*  
Top Cover (HWI3000)  
Top Cover (MGH3000)  
120V, 20A Duplex  
Receptacle (HWI3000)†  
120V, 15A Duplex (GFCI)  
Receptacle (MGH3000)†  
Circuit Breaker, 20 Amp †  
Capacitor  
Screw, M4 x 20  
Terminal Block  
Screw, M5 x 13  
End Plate  
Ground Lug  
Flanged Nut, 8mm  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
099861-01  
099842-01  
26310000  
27001005S  
WLE-4  
Bottom Cover  
Draw Bolt  
Screw, M6 x 16  
Engine Flange  
Lock Washer, 1/4"  
Stator  
Bearing  
Diode  
Rotor  
Fan  
1
1
4
1
4
1
1
2
1
1
4
4
1
099722-02  
1
1
1
1a  
1b  
2a  
099849-01  
100074-01  
104201-01  
**  
27001002  
27001009S  
**  
27001006  
26327006  
WLE-5  
1
2b  
100445-01  
1
1
1
1
1
13  
1
1
3
4
5
6
7
8
9
10  
22616009  
27002002S  
26333000  
099863-01  
099701-01  
099848-01  
17587000  
099891-01  
Bolt, 5/16-24 x 5/8"  
Lock Washer, 5/16"  
PARTS AVAILABLE - NOT SHOWN  
099866-03  
099866-04  
099867-02  
Safety Information Decal  
Safety Information Decal  
Operation Decal  
1
1
1
1
† Includes fastening hardware.  
* Includes reference numbers 1 through 22.  
** Parts not available. Included in alternator assembly.  
105202  
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OWNER’S MANUAL  
23  
ILLUSTRATED  
PARTS LIST  
For Models MGH4000D,  
MGH4000DI, MGH5000D,  
MGH5000DI, MGH5000DIE,  
MGH6000D, MGH6000DI,  
MGH7000D, and MGH7000DI  
Alternator Assembly  
25  
24  
22  
9
15  
21  
20  
19  
9
10  
This list contains replaceable parts used  
in your generator. When ordering parts,  
follow the instructions listed under Re-  
placement Parts on page 17 of this  
manual.  
8
14  
7
18  
6
5
13  
16  
12  
4
1
17  
2
11  
3
PART NUMBER FOR MODEL  
MGH5000D  
KEY MGH4000D  
NO. MGH4000DI  
MGH5000DI  
MGH5000DIE MGH6000DI MGH7000DI  
MGH6000D  
MGH7000D  
DESCRIPTION  
QTY.  
099723-01  
099723-02  
099844-01  
099701-01  
099760-01  
099863-01  
099863-02  
17587000**  
M11084-26  
099847-02  
WLE-5  
099723-03  
099844-01  
099701-01  
099760-01  
——  
099863-02  
17587000**  
M11084-26  
099847-03  
WLE-5  
099723-04  
099844-01  
099701-01  
099760-01  
——  
099863-02  
17587000**  
M11084-26  
099847-04  
WLE-5  
Alternator Assembly  
End Cover  
Screw, M5 x 13  
Bushing  
Terminal Block (4-block)  
Terminal Block (2-block)  
Ground Lug  
Screw, #10-16 x 3/8"  
Stator Bolt  
Lock Washer, 5/16"  
Bearing Housing  
Capacitor  
Terminal Post  
Stator  
1
1
6
1
1
1
1
1
4
4
1
1
4
1
1
4
1
1
1
1
2
1
1
1
4
4
1
2
3
4
5
6
7
8
099844-01  
099701-01  
099760-01  
099863-01  
099863-02  
17587000**  
M11084-26  
099847-01  
WLE-5  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
099843-01  
27004002S  
——  
099843-01  
27005003S  
——  
099843-01  
099845-01  
100054-01  
*
099843-01  
27007004S  
100054-01  
*
*
*
27003002  
27003002  
27003002  
27003002  
Fan Bracket  
27003015S** 27003015S** 27003015S** 27003015S** Screw, M8 x 20  
099891-01  
099892-01  
099842-01  
27003003  
27003012S  
*
27003008  
27003007S  
26322004**  
WLE-6**  
099891-01  
099892-01  
099842-02  
27003003  
27003012S  
*
27003008  
27003007S  
26322004**  
WLE-6**  
099891-01  
099892-01  
099842-03  
27003003  
27003012S  
*
27003008  
27003007S  
26322004**  
WLE-6**  
099891-01  
099892-01  
099842-04  
27003003  
27003012S  
*
27003008  
27003007S  
26322004**  
WLE-6**  
Rotor Nut, Flanged 8mm  
Foam Pad  
Draw Bolt  
Bearing  
Diode  
Rotor  
Fan  
Engine Flange  
Bolt, 3/8-16 x 5/8"  
Lock Washer, 3/8"  
* Part not available by itself. Must purchase Alternator Assembly.  
**Available at your local hardware store.  
105202  
19  
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R
PORTABLE GASOLINE GENERATORS  
19  
ILLUSTRATED  
18  
PARTS LIST  
20  
For Model MGH10000A  
13  
17  
8
Alternator Assembly  
21  
15  
This list contains replaceable parts used in  
26  
yourgenerator.Whenorderingparts,follow  
the instructions listed under Replacement  
Parts on page 17 of this manual.  
10  
12  
24  
14  
5
11  
23  
25  
1
2
6
4
16  
22  
9
7
3
KEY  
NO.  
PART  
NUMBER  
DESCRIPTION  
QTY.  
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.E. Bracket  
N.D.E. Bracket  
Mounting Bolts  
Nuts  
*
*
1
1
1
1
1
2
1
1
4
4
1
6
1
1
1
2
1
1
1
1
1
1
4
1
2
1
1
103188-01  
103191-01  
103192-01  
103193-01  
103194-01  
103195-01  
099847-05  
270010105  
103189-01  
099701-01  
103198-01  
103199-01  
103200-01  
27003012S  
103201-01  
099845-02  
103204-01  
099892-02  
103202-01  
103190-01  
27003155  
103203-01  
WLE-5  
Top Box  
Screw and Washer  
Plastic Cap  
Bearing  
Borelly Washer  
Diode  
Terminal Block  
Capacitor  
Tie Wrap  
Foam Pad  
Capacitor Bracket  
Engine Flange  
Bolts  
'O' Ring  
Washer  
Hex Head Nut  
Alternator Assembly  
099891-01  
102938-01  
* Part not available by itself. Must purchase Alternator Assembly.  
105202  
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OWNER’S MANUAL  
ILLUSTRATED  
PARTS LIST  
For Models HWI3000 and  
MGH3000 Roll Cage  
This list contains replaceable parts used in  
yourgenerator.Whenorderingparts,follow  
the instructions listed under Replacement  
Parts on page 17 of this manual.  
1
3
4
3
4
2
3
4
7
3
3
4
5
6
6
8
5
5
9
4
3
4
7
3
4
3
3
KEY  
NO.  
PART  
NUMBER  
DESCRIPTION  
Roll Cage  
QTY.  
1
2
3
4
5
6
7
8
9
105155-01  
099754-01  
NEC-5C  
1
1
9
7
3
2
1
1
1
Engine Spreader  
Lock Nut, 5/16-18  
Flat Washer, 5/16"  
Shock Mount  
WP-5C  
099853-02  
04110002  
14138000  
21834000  
100406-01  
Screw, 5/16-18 x 1 1/2  
Ground Strap  
Washer, 5/16" x 1 1/2"  
Bolt, 5/16-18 x 3/4"  
105202  
21  
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R
PORTABLE GASOLINE GENERATORS  
ILLUSTRATED  
PARTS LIST  
For Models MGH4000D,  
MGH4000DI, MGH5000D,  
MGH5000DI, MGH5000DIE,  
MGH6000D, MGH6000DI,  
MGH7000D, and MGH7000DI  
Fuel Tank and Roll Cage  
3
FUEL  
F
5
1
2
4
15  
26  
24  
9
23  
25  
27  
8
6
7
7
6
11  
13  
10  
22  
11  
16  
21  
20  
14  
23  
23  
16  
11  
11  
11  
16  
14  
13  
16  
12  
18  
10  
16  
17  
19  
16  
17  
16  
11  
13  
16  
11  
16  
11  
105202  
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OWNER’S MANUAL  
ILLUSTRATED  
PARTS LIST  
For Models MGH4000D,  
MGH4000DI, MGH5000D,  
MGH5000DI, MGH5000DIE,  
MGH6000D, MGH6000DI,  
MGH7000D, and MGH7000DI  
Fuel Tank and Roll Cage  
KEY  
NO.  
PART  
NUMBER  
DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
8
9
25954000  
099832-01  
25978000  
M51043-01  
099701-01  
19508001  
25985005  
099743-01  
099752-01  
099752-02  
103880-01  
NEC-5C  
14138000  
099853-02  
WLE-5  
WLI-3  
WP-5C  
HC5-11C  
099756-01  
099750-01  
099749-01  
NEC-5C  
100410-01  
M10908-74**  
WP-4C  
Gas Cap/Fuel Gage  
Gas Tank (with 90° fitting)  
Breather Assembly  
Screw, 1/4-20 x 1"  
Screw, M5 x 10  
Gas Line Clamp  
Fuel Line  
Fuel Filter  
Roll Cage†  
Roll Cage∆  
Lock Nut, 1/4-20  
Lock Nut, 5/16-18  
Ground Strap  
1
1
1
4
1
2
1
1
1
1
5
8
1
3
3
1
9
2
1
2
1
2
4
3
5
1
1
1
This list contains replaceable parts used in  
your generator. When ordering parts, fol-  
low the instructions listed under Replace-  
ment Parts on page 17 of this manual.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
Shock Mounts  
Lock Washer, 5/16"  
Lock Washer, #10  
Flat Washer, 5/16"  
Bolt, 5/16-18 x 1 3/4"  
Engine Spreader  
Hook Bolt, 5/16-18 **  
Battery Mounting Bracket **  
Lock Nut, 5/16-18 **  
Sems Screw, #8-18 x 1/2"  
Screw, 1/4-20 x 1/2"  
Washer, 1/4"  
099965-01  
WP-3C  
099742-01  
Linkage Cover  
Washer, #10  
90° Fitting with barbs  
PARTS AVAILABLE - NOT SHOWN  
099866-01  
Safety Information Decal *  
Safety Information Decal **  
Operation Decal *  
1
1
1
1
1
1
3
099866-02  
100003-01  
100003-02  
099873-01  
099873-02  
03157000  
Operation Decal **  
Battery Cable (Positive, Red)**  
Battery Cable (Negative, Black)**  
Fuel Line Grommet  
*
For models MGH4000D, MGH5000D, MGH5000DIE, and MGH6000D only  
** For model MGH7000D only  
For models MGH4000D and MGH5000D only  
For models MGH6000D and MGH7000D only  
*** Available at your local hardware store  
105202  
23  
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R
PORTABLE GASOLINE GENERATORS  
ILLUSTRATED  
PARTS LIST  
For Model MGH10000A Fuel  
Tank and Roll Cage  
3
FUEL  
31  
F
1
30  
2
4
29  
26  
9
28  
24  
37  
6
7
11  
24  
10  
12  
8
25  
24  
13  
23  
22  
14  
5
11  
27  
11  
24  
11  
18  
20  
25  
24  
25  
24  
11  
32  
24  
17  
13  
16  
15  
11  
19  
24  
11  
21  
35  
34  
33  
34  
36  
105202  
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OWNER’S MANUAL  
KEY  
NO.  
PART  
NUMBER  
ILLUSTRATED  
PARTS LIST  
For Model MGH10000A Fuel  
Tank and Roll Cage  
DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
8
9
Gas Cap/Fuel Gage  
Gas Tank (with 90° fitting)  
Breather Assembly  
1/4-20 x 1" Screw  
1/2-20 x 1" Bolt  
Gas Line Clamp  
Fuel Line  
3/8 Lock Washer*  
Roll Cage  
1/4-20 Lock Nut  
5/16-18 Lock Nut  
Ground Strap  
25954000  
099832-01  
25978000  
M51043-01  
260302006  
19508001  
25985006  
WLE-6  
105111-01  
103880-01  
NEC-5C  
14138000  
17529000  
WLE-5  
1
1
1
1
2
2
1
1
1
4
18  
1
3
1
1
1
2
1
2
1
2
4
1
24  
10  
4
2
4
2
2
2
1
2
4
2
2
1
1
1
1
1
3
2
1
This list contains replaceable parts used in  
your generator. When ordering parts, fol-  
low the instructions listed under Replace-  
ment Parts on page 17 of this manual.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
Shock Mounts  
5/16" Lock Washer  
3/8-16 x 1-1/4" Screw*  
3/8" Flat Washer*  
5/16-18 x 1-3/4" Bolt  
Engine Spreader  
5/16-18 Hook Bolt  
Battery Mounting Bracket  
Axle  
#8-18 x 1/2" Sems Screw  
1/4-20 x 1/2" Screw*  
5/16" Washer  
5/16-18 x 3/4" Bolt  
1/4" Washer  
1/2" Lock Washer  
5/16-18 x 2.50 Screw  
Handle  
Handle Grip  
Handle Plug  
Stand  
U-Bolt  
Flat Washer  
Wheels  
HC6-10C  
WP-6C  
HC5-11C  
102962-01  
099750-01  
099749-01  
102933-01  
100410-01  
M10908-74  
WP-5C  
26007004  
WP-4C  
WLI-8  
H8C5-20C  
105035-01  
103046-01  
103057-01  
102936-02  
100135-01  
WP-16C  
102932-01  
C4-12C  
099742-01  
099866-02  
100003-04  
099873-04  
Cotter Pin  
90º Fitting with Barbs  
Safety Information Decal  
Operation Decal  
Red Battery Cable (Positive)  
Black Battery Cable (Negative) 099873-02  
Grommet  
Screw (.250 x .75)  
Wheel Kit Hardware  
03157000  
HC4-6C  
103818-01  
Not shown  
* Available at your local hardware store  
105202  
25  
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R
PORTABLE GASOLINE GENERATORS  
ILLUSTRATED  
2
12  
PARTS LIST  
2
For Models MGH4000D,  
MGH4000DI, MGH5000D,  
MGH5000DI, MGH5000DIE,  
MGH6000D, MGH6000DI,  
MGH7000D, and MGH7000DI  
Control Panel  
5
1
3
RESET  
TEST  
6
Reset  
Reset  
120 Volt  
7
4
This list contains replaceable parts used in  
your generator. When ordering parts, fol-  
low the instructions listed under Replace-  
ment Parts on page 17 of this manual.  
7
FULL POWER  
SELECTOR  
120 ONLY  
13  
13  
120/240V  
120/240 VOLTS  
7
RESET  
RESET  
14  
ENM  
00000005  
HOURS 1/10  
11  
9
10  
PART NUMBER FOR MODEL  
MGH5000D  
KEY MGH4000D MGH5000DI MGH6000D MGH7000D  
NO. MGH4000DI MGH5000DIE MGH6000DI MGH7000DI DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
103349-01  
22616009  
099833-01  
15324000  
100445-01  
099956-01  
22616009  
103349-02  
22616009  
099833-01  
15324000  
100445-01  
099956-01  
22616011  
099834-01  
103349-03  
22616009  
099833-01  
15324000  
100445-01  
099956-01  
103349-04  
22616009  
099833-01  
15324000  
100445-01  
Control Panel  
Circuit Breaker, 20 Amp *  
120V, 30A Twist-Lock Receptacle *  
120V, 15A Duplex Receptacle *  
120V, 15A Duplex (GFCI) Receptacle *  
Full Power Selector Switch *  
Circuit Breaker, 20 Amp *  
Circuit Breaker, 25 Amp *  
Circuit Breaker, 30 Amp *  
120/240V, 20A Twist-Lock Receptacle *  
1
2
1
1
1
1
2
2
2
1
22616010  
099834-01  
22616010  
8
099834-01  
099835-01  
101350-01  
099760-01  
100410-01  
100149-01  
22261000  
099997-01  
103348-04  
103348-08  
100177-07  
120/240V, 30A Twist-Lock Receptacle *  
Hour Meter  
Bushing  
Sems Screw, #8-18 x 1/2"  
Control Box  
U-Nut  
1
1
1
4
1
8
1
1
1
1
9
101350-01  
099760-01  
100410-01  
100149-01  
22261000  
099997-01  
103348-01  
103348-05  
100177-07  
101350-01  
099760-01  
100410-01  
100149-01  
22261000  
099997-01  
103348-02  
103348-06  
100177-07  
101350-01  
099760-01  
100410-01  
100149-01  
22261000  
099997-01  
103348-03  
103348-07  
100177-07  
10  
11  
12  
13  
14  
Switch Plug  
Control Panel Assembly  
Control Panel Assembly - Auto Idle Models  
Panel Schematic Decal  
* Includes fastening hardware  
Not shown  
† Includes reference numbers 1 through 13  
105202  
26  
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OWNER’S MANUAL  
ILLUSTRATED  
PARTS LIST  
For Model MGH10000A Control  
Panel  
2
2
14  
6
16  
1
RESET  
TEST  
3
11  
12  
Reset  
Reset  
120 Volt  
7
Auto Idle  
Selector  
5
Off  
4
5
On  
12  
200 Vp;t  
15  
Reset  
Reset  
5
8
9
Reset  
Reset  
ENM  
00000005  
HOURS  
1/10  
13  
10  
4
KEY  
NO.  
PART  
NUMBER  
DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
Control Panel  
20 Amp Circuit Breaker  
103182-01  
22616009  
099833-01  
100410-01  
22261000  
100445-01  
103183-01  
103184-01  
26299000  
101350-01  
099834-01  
22616010  
099760-01  
103185-01  
100366-01  
15324000  
102927-01  
100177-05  
103257-01  
103258-02  
1
2
1
16  
20  
1
1
2
1
1
1
2
1
1
1
1
1
1
120V, 30A Twist-Lock Receptacle  
#8-18 x 1/2" Sems Screw  
U-Nut  
120V, 15A Duplex (GFCI) Receptacle  
125/250V, 50A Receptacle  
45 Amp Circuit Breaker  
Run Light  
Hour Meter  
120/240V, 20A Twist-Lock Receptacle  
30 Amp Circuit Breaker  
Bushing  
Control Box  
Rocker Switch  
120V, 15A Duplex Receptacle  
Control Panel Assembly  
Panel Schematic Diagram  
Auto Idle PC Board Kit  
Solenoid Assembly Kit (With Bracket)  
1
1
† Includes reference numbers 1 through 16  
Not shown  
105202  
27  
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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.  
Note: The two-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda  
warrants the engine. See engine owner’s manual for engine warranty information.  
TWO-YEAR LIMITED WARRANTY  
GASOLINE PORTABLE GENERATORS  
DESA International warrants each alternator, generator, or electric product of its manufacture, to be free from defects  
in material and workmanship for two years from the date of first purchase from an authorized dealer, provided that the  
product has been properly installed, maintained, and operated in accordance with all applicable instructions. The bill  
of sale or proof of purchase must be presented at the time a claim is made under this warranty.  
This warranty is extended only to the original retail purchaser. This warranty covers only the parts and labor required  
to restore this unit to its proper operating condition. Warranty parts must be obtained through factory authorized  
dealers and service centers for this product. These dealers and service centers will provide original factory replace-  
ment parts. Failure to use original factory replacement parts voids this warranty.  
This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that  
fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration,  
modification, tampering, contaminated fuels, repair using improper parts, or repair by anyone other than an authorized  
dealer or service center. Routine maintenance is the responsibility of the owner. Travel, handling, transportation, and  
incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of  
the owner.  
DESA International makes no warranty with respect to the engine and engine components not of its manufacture.  
They are subject to warranties of their manufacturers.  
To the full extent allowed by the law of the jurisdiction that governs the sale of the product, this express warranty  
excludes any and all other expressed warranties and limits the duration of any and all implied warranties, including  
warranties of merchantability and fitness for a particular purpose to two years from the date of first purchase, and  
DESA International’s liability is hereby limited to the purchase price of the product and DESA International shall not  
be liable for any other damages whatsoever including indirect, incidental, or consequential damages.  
Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental  
or consequential damages, so the above limitation of damages may not apply to you.  
This warranty provides the original purchaser with specific rights. For information regarding those rights, please  
consult the applicable state laws.  
INTERNATIONAL  
2701 Industrial Drive  
P.O. Box 90004  
Bowling Green, KY 42102-9004  
105202 01  
105202-01  
REV. A  
09/98  
NOT A UPC  
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