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Master Lock MGH3000G manual

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Table of contents for the manual

  • Page 1

    POR T ABLE GASOLINE GENER A T OR S OWNER’S OPERA TION AND INST ALLA TION MANUAL R 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. Generator Models: HWI3000, MGH3000G, MGH3000, MGH3000PR, MGH4000C , MGH4000CI, MGH5000D, MG[...]

  • Page 2

    2 106813 POR T ABLE GASOLINE GENERA TORS R 1. Gasoline presents a hazard of fire or e x- plosion. Gasoline is flammable. Its va- por is explosi ve. •K eep fuel out of children’ s reach. • Refuel generator in a well-vented area. Do not fill fuel tank in the dark. Do not refuel while engine is run- ning. Unhook all electrical loads and shut of [...]

  • Page 3

    3 106813 OWNER’S MANUAL F U E L F FUEL F 120 ONLY 120 240V R E S E T T E S T 1 2 0 V O L T S 120/240 VOLTS RESET RESET E N M 0 0 0 0 0 0 0 5 HO UR S 1/10 F U L L P O W E R 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[...]

  • Page 4

    4 106813 POR T ABLE GASOLINE GENERA TORS R VENTILA TION DUST , DIRT , RAIN, AND SNOW HIGH AND LOW TEMPERA TURE OPERA TION 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. GENERAL INFORMA [...]

  • Page 5

    5 106813 OWNER’S MANUAL SPECIFICA TIONS MGH5000D MGH4000C MGH5000DI MODEL HWI3000 MGH3000G MGH3000 MGH3000PR MGH4000CI MGH5000DIE Electrical Rated Wattage 2500 2500 2500 2500 4000 5000 Rated Amperage 120 V 20.8 20.8 20.8 20.8 33.3 41.7 240 V –– –– –– –– 16.7 20.8 Receptacle 120-V Duplex –– –– –– –– Yes Yes 120-V, 2[...]

  • Page 6

    6 106813 POR T ABLE GASOLINE GENERA TORS R GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE 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 (mod- els MGH3000G, MGH3000, and MGH3000PR only). The GFCI protects you against hazardous elect[...]

  • Page 7

    7 106813 OWNER’S MANUAL ENGINE CIRCUIT BREAKER (Models MGH5000DIE, MGH6500IE, 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 loc[...]

  • Page 8

    8 106813 POR T ABLE GASOLINE GENERA TORS R Always wear safety glasses when working with battery. Make sure battery terminals are clean. Make sure cable connections are tight. Always shut down engine before removing or attaching battery cables. Always remove the negative (–) cable first. Always attach negative (–) cable last. INSTALLING BATTERY [...]

  • Page 9

    9 106813 OWNER’S MANUAL Ampere AWG for Length of Load Cord in Feet 50' 100' 150' 21 8 1 8 1 8 31 8 1 8 1 8 41 6 1 6 1 6 51 6 1 6 1 6 61 6 1 6 1 4 81 6 1 4 1 2 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8 FUE L F F F U E L Figure 12 - Battery Hold-Down System (Model MGH6500IE Shown) TO STARTER SOLENOID TO ENGINE BLOCK [...]

  • Page 10

    10 106813 POR T ABLE GASOLINE GENERA TORS R Running Starting Equipment Watts Watts 1/2" Drill 1000 1250 Toaster 1200 1200 Coffee maker 1200 1200 Skillet 1200 1200 14" Chain saw 1200 1500 Water well pump (1/2 hp) 1000 3000 Hot plate/range (per burner) 1500 1500 10" Table saw 2000 6000 Water heater (storage-type) 5000 5000 Running Star[...]

  • Page 11

    11 106813 OWNER’S MANUAL RESET 240 VO LTS RESET RESET RESET RESET TEST 120 VOLTS R E SE T R E SE T EN M 0 00 00 0 05 H O U R S 1 /1 0 120 ONLY 120 240V OPERA TION GENERAL INFORMATION This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator recept[...]

  • Page 12

    12 106813 POR T ABLE GASOLINE GENERA TORS R Figure 23 - Engine Switch In ON Position (All Models Except MGH5000DIE, MGH6500IE, MGH10000A, and MGH3000PR) ENGINE SW ON OFF OPERA TION Continued Fuel Valve Lever (ON Position) Choke Lever (Closed Position) Figure 19 - Fuel Valve Lever On, Choke Lever Closed (Model MGH4000C Shown) Figure 21 - Choke Butto[...]

  • Page 13

    13 106813 OWNER’S MANUAL RESET TEST 120 VO LTS R E S E T 2 4 0 V O L T S O F F A u to - Id le O N R E S E T R E S E T R E S E T E N M 0 0 0 0 0 0 0 5 HOURS 1/10 Choke Lever (Open Position) Figure 25 - Choke Lever Opened (Model MGH6500IE Shown) OPERA TION Continued HONDA OFF ON START ENGINE SW CIRCUIT BREAKER ON/push OFF Figure 24 - Engine Switch [...]

  • Page 14

    14 106813 POR T ABLE GASOLINE GENERA TORS R MAINTENANCE AND REP AIRS WARNING: Only a qualified electrical service person should service and repair the alternator on this generator. Use only fac- tory approved replacement parts. HIGH ALTITUDE OPERATION This generator will not perform well at high altitudes without proper adjustment. See engine owner[...]

  • Page 15

    15 106813 OWNER’S MANUAL TROUBLESHOOTING WARNING: Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts. POSSIBLE CAUSE 1. Defecti ve capacitor 2. W inding short circuit or loose connections 3. Defective rotor diode 4. Loss of residual magnetism 1. Engine speed too low 2. Defec[...]

  • Page 16

    16 106813 POR T ABLE GASOLINE GENERA TORS R WIRING DIAGRAMS Figure 31 - Wiring Diagram, Models HWI3000, MGH3000G, MGH3000, and MGH3000PR Resistance in Ohms Stator Stator Rotor Rotor Capacitor, Main Auxiliary Primary Secondary MFD Diodes (2) Model Winding * Winding ∆ Winding † Winding † 450 Volt 800 Volt HWI3000 1.6 5.9 6.9 1.33 16 6 Amp MGH30[...]

  • Page 17

    17 106813 OWNER’S MANUAL Circuit Breaker 25A 120/240V 20A Receptacle T4 120V, 15A Receptacle 120V, 30A Receptacle White White Green Black Red Black Red Black White T3 Red Green Stator 110/120V T1 T2 T3 T4 L2 L1 110/120V 220/240V Rotor Stator White Brown Auxiliary Phase Diode T2 Green Red Black Yellow Main Windings T1 T3 T4 T1 T1 T2 T3 T4 Green/Ye[...]

  • Page 18

    18 106813 POR T ABLE GASOLINE GENERA TORS R 250V 30A Receptacle 250V 50A Receptacle 125V, 15A Receptacle GFCI 125V, 15A Receptacle 125V, 30A Receptacle Circuit Breaker 20A Circuit Breaker 20A Green Green Black Black White Black Red Black Black Black Black Black White White White Green Black Black Black Red Red Red Red Yellow Yellow White White Auto[...]

  • Page 19

    19 106813 OWNER’S MANUAL 9 17587000 Ground Lug 1 10 099891-01 Flanged Nut, 8mm 1 11 099861-01 Bottom Cover 1 12 099842-01 Draw Bolt 1 13 26310000 Screw, M6 x 16 4 14 27001005S Engine Flange 1 15 WLE-4 Lock Washer, 1/4" 4 16 ** Stator 1 17 27001002 Bearing 1 18 27001009S Diode 2 19 ** Rotor 1 20 27001006 Fan 1 21 26327006 Bolt, 5/16-24 x 5/8&[...]

  • Page 20

    20 106813 POR T ABLE GASOLINE GENERA TORS R PART NUMBER FOR MODEL MGH5000D KEY MGH4000C MGH5000DI MGH6000D NO. MGH4000CI MGH5000DIE MGH6000DI MGH6500IE DESCRIPTION QTY. 099723-01 099723-02 099723-03 099723-04 Alternator Assembly 1 1 099844-01 099844-01 099844-01 099844-01 End Cover 1 2 099701-01 099701-01 099701-01 099701-01 Screw, M5 x 13 6 3 0997[...]

  • Page 21

    21 106813 OWNER’S MANUAL 1 5 16 14 24 10 26 18 19 6 2 11 12 9 3 7 4 22 23 25 17 21 8 20 15 13 ILLUSTRA TED PA R TS LIST For Model MGH10000A 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. * Part not available by [...]

  • Page 22

    22 106813 POR T ABLE GASOLINE GENERA TORS R KEY PART NO. NUMBER DESCRIPTION QTY. 1 099831-01 Handle (includes 2 spacers) 1 2 WLE-4 1/4" Lock Washer 2 3 099769-01 M6 x 35 Screw 2 4 NEC-5C 5/16-18 Nut 3 5 099754-01 Engine Spreader 1 6 13401000 Rubber Bumper 3 7 WP-5C 5/16" Flat Washer 2 8 19165004 5/16-18 x 1" Screw 1 9 04110002 5/16-1[...]

  • Page 23

    23 106813 OWNER’S MANUAL ILLUSTRA TED PA R TS 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 32 of this manual. 1 2 3 4 5 3 4 3 4 5 3 4 3 6 6 7 9 3 3 3 7 4 4 3 4 5 8 KEY PART NO. NUMBER DESCRI[...]

  • Page 24

    24 106813 POR T ABLE GASOLINE GENERA TORS R 9 10 11 12 13 11 16 13 13 17 17 18 11 11 16 11 16 21 20 19 14 23 14 23 23 16 16 16 10 11 16 11 16 22 FUEL F 1 3 2 4 24 7 8 6 6 27 7 25 15 5 26 FUEL F 10 10 29 24 1 2 24 29 24 28 9 24 28 ILLUSTRA TED PA R TS LIST For Models MGH4000C, MGH4000CI, MGH5000D, MGH5000DI, MGH5000DIE, MGH6000D, MGH6000DI, and MGH6[...]

  • Page 25

    25 106813 OWNER’S MANUAL KEY MGH4000C MGH5000D MGH6000D NO. MGH4000CI MGH5000DI MGH6000DI MGH6500IE DESCRIPTION QTY. MGH5000DIE 1 25954000 25954001 25954001 25954001 Gas Cap/Fuel Gage 1 2 099832-01 107021-01 107021-01 107021-01 Gas Tank (with 90 ° fitting) 1 3 25978000 — — — Breather Assembly 1 4 HC4-8C — — — Screw, 1/4-20 x 1" [...]

  • Page 26

    26 106813 POR T ABLE GASOLINE GENERA TORS R 23 37 29 36 26 10 37 28 12 10 16 27 2 37 10 10 25 10 9 35 1 7 3 6 5 6 9 10 4 9 10 36 9 24 22 8 12 11 25 37 10 10 21 21 20 20 19 19 18 32 9 31 34 30 33 18 FUEL F 17 10 9 15 14 13 ILLUSTRA TED PA R TS LIST For Model MGH10000A Fuel Tank and Roll Cage[...]

  • Page 27

    27 106813 OWNER’S MANUAL ILLUSTRA TED PA R TS LIST For Model MGH10000A Fuel Tank and Roll Cage This list contains replaceable parts used in your generator. When ordering parts, fol- low the instructions listed under Replace- ment Parts on page 32 of this manual. KEY PART NO. NUMBER DESCRIPTION QTY. 1 079503-25AA Gas T ank Assembly 1 2 105905-01 R[...]

  • Page 28

    28 106813 POR T ABLE GASOLINE GENERA TORS R PART NUMBER FOR MODEL MGH5000D KEY MGH4000C MGH5000DI MGH6000D NO. MGH4000CI MGH5000DIE MGH6000DI MGH6500IE DESCRIPTION QTY. 1 103349-01 103349-02 103349-03 103349-05 Control Panel 1 2 22616009 22616009 22616009 22616009 Circuit Breaker, 20 Amp * 2 3 099833-01 099833-01 099833-01 099833-01 120V, 30A Twist[...]

  • Page 29

    29 106813 OWNER’S MANUAL † Includes reference numbers 1 through 16 ∆ Not shown KEY PART NO. NUMBER DESCRIPTION QTY. 1 103182-01 Control Panel 1 2 22616009 Circuit Breaker , 20 Amp 2 3 099833-01 120V , 30A T wist-Lock Receptacle 1 4 100410-01 Sems Screw , #8-18 x 1/2" 16 5 22261000 U-Nut 20 6 100445-01 20V , 15A Duplex (GFCI) Receptacle 1[...]

  • Page 30

    30 106813 POR T ABLE GASOLINE GENERA TORS R D E S A IN T E R N A T IO N A L S2 S1 L1 L2 1 2 4 5 3 8 7 14 13 10 12 11 9 8 10 6 Control Board Assembly and Mounting Solenoid Assembly and Mounting ILLUSTRA TED PA R TS LIST For Solenoid and Control Board Assemblies and Mounting[...]

  • Page 31

    31 106813 OWNER’S MANUAL ILLUSTRA TED PA R TS LIST For Solenoid and Control Board Assemblies and Mounting This list contains replaceable parts used in your generator. When ordering parts, fol- low the instructions listed under Replace- ment Parts on page 32 of this manual. * Model MGH10000A Only † All Models Except MGH10000A KEY PART NO. NUMBER[...]

  • Page 32

    32 106813 POR T ABLE GASOLINE GENERA TORS R PA R TS CENTRALS These Parts Centrals are privately owned businesses. They have agreed to support our customer’s needs by providing original re- placement parts and accessories. Tool & Equipment 5 Manila Drive Hamden, CT 06514-0322 203-248-7553 1-800-397-7553 Grainger Parts Operations 1657 Shermer R[...]

  • Page 33

    33 106813 OWNER’S MANUAL NOTES _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _____________________________[...]

  • Page 34

    34 106813 POR T ABLE GASOLINE GENERA TORS R NOTES _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ ____________[...]

  • Page 35

    35 106813 OWNER’S MANUAL NOTES _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _____________________________[...]

  • Page 36

    KEEP THIS WARRANTY W ARRANTY INFORMA TION FIVE-YEAR LIMITED WARRANTY GASOLINE PORTABLE GENERATORS DESA Specialty Products™ makes no warranty with respect to the engine and engine components not of its manufac- ture. They are subject to warranties of their manufacturers. Honda warrants the engine. See engine owner’s manual for engine warranty in[...]