Page 2 - PORTABLE GASOLINE GENERATORS; SAFETY; WARNINGS
2 118683 PORTABLE GASOLINE GENERATORS R 1. Gasoline presents a hazard of fire or explosion. Gasoline is flammable. Its vapor is explosive.• Keep 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 e...
Page 3 - OWNER’S MANUAL; PRODUCT; Continued
3 118683 OWNER’S MANUAL FUEL F FUE L F 120 ONLY 120 240V RES ET TES T 120 V OLT S 120/2 40 V OLT S RES ET RES ET ENM 00000 005 HOU RS 1/10 FULL PO WER 9. Only a qualified electrical service person should service and repair generator. • Generator produces high voltage. Use extreme caution when working...
Page 4 - Additional Features; • 15-Amp ground fault circuit interrupter
4 118683 PORTABLE GASOLINE GENERATORS R VENTILATION DUST, DIRT, RAIN, AND SNOW HIGH AND LOW TEMPERATURE OPERATION 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 fo...
Page 5 - MODEL; Electrical; Ratings apply to SAE standard; SPECIFICATIONS
5 118683 OWNER’S MANUAL MGH5000E MGH4000D MGH5000EI MODEL HWI3000A MGH3000GA MGH3000A MGH4000DI MGH5000EIE MGH6500AIE Electrical Rated Wattage 2500 2500 2500 4000 5000 6500 Rated Amperage 120 V 20.8 20.8 20.8 33.3 41.7 57 240 V –– –– –– 16.7 20.8 28.3 Receptacle 120-V Duplex –– –– –– Yes Yes Yes 120...
Page 6 - Test Procedure; Position; GENERATOR; Figure 2 - Engine Switch Location; Models; WARNING: If RESET button
6 118683 PORTABLE GASOLINE GENERATORS R GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE All models (Except HWI3000A) 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 MGH3000GA and MGH3000A only). The GFCI ...
Page 7 - ENGINE CIRCUIT BREAKER; Figure 5 - Engine Circuit Breaker; Figure 4 - GFCI Receptacle; RECEPTACLE CIRCUIT; Normal; Figure 6 - Receptacle Circuit Breaker; ENGINE OIL; CHECKING OIL LEVEL AND; Figure 7 - Checking Oil Level (Model
7 118683 OWNER’S MANUAL ENGINE CIRCUIT BREAKER (Models MGH5000EIE and MGH6500AIE) 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...
Page 8 - Figure 10 - Battery Hold-Down System; Figure 11 - Connecting Positive and; MOUNTING BATTERY TO; Secure battery to generator by battery; INSTALLING BATTERY; Battery Cable to Engine Starter Solenoid; Make sure battery connec-; BATTERY
8 118683 PORTABLE GASOLINE GENERATORS R Figure 10 - Battery Hold-Down System (Model MGH6500AIE Shown) TO STARTER SOLENOID TO ENGINE BLOCK 120 ONLY 120 240V ENM 000 0000 5 HOU RS 1/10 FUL L PO WER Figure 11 - Connecting Positive and Negative Cables to Battery (Model MGH6500AIE Shown) MOUNTING BATTERY...
Page 9 - F i g u r e 1 2 - G ro u n d i n g G e n e r a t o r; Recommended Minimum Wire; National Electrical Code
9 118683 OWNER’S MANUAL OFF ENGINE FUEL F Ampere AWG for Length of Load Cord in Feet 50' 100' 150' 2 18 18 18 3 18 18 18 4 16 16 16 5 16 16 16 6 16 16 14 8 16 14 12 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8 GENERATOR GROUNDING Ground Lug Ground Wire Alternator Copper or Brass Ground...
Page 10 - Typical Electric Appliance Wattages; DETERMINING; Chart 1
10 118683 PORTABLE GASOLINE GENERATORS R Do not use the running watts figure. Note: Some motors require 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. 4. Add watts and starting watts of al...
Page 11 - OPERATION; GENERAL INFORMATION; Figure 13 - Receptacle Locations; POWER CORD AND PLUG; Figure 14 - Cord and Plug Configurations; We supply the engine owner’s manual; USING RECEPTACLE; Do not exceed amperage rating of
11 118683 OWNER’S MANUAL RES ET TES T 120 V OLT S RES ET 240 VO LTS RES ET RES ET RES ET ENM 0000 0005 HOU RS 1/1 0 120 ONL Y 120 240V OPERATION GENERAL INFORMATION This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items ...
Page 12 - Engine; Figure 15 - Fuel Valve Lever On, Choke Lever; Oil Alert; STARTING; WARNING: Only responsible; PRESTART
12 118683 PORTABLE GASOLINE GENERATORS R RES ET TES T 120 V OLT S RES ET 240 VO LTS OFF Auto -Idle ON RES ET RES ET RES ET ENM 0000 0005 HOU RS 1/1 0 Choke Lever (Open Position) Figure 18 - Choke Lever Opened (Model MGH6500AIE Shown) HONDA OFF ON START ENGINE SW CIRCUIT BREAKER ON/push OFF Figure 17...
Page 13 - Solenoid Mounting Bracket; Adjusting the Idle Speed; HIGH ALTITUDE OPERATION; Determining Electrical Load For; DISCONNECTING ELECTRIC
13 118683 OWNER’S MANUAL OPERATION Continued WARNING: Always set the idle speed before turning on the Auto- Idle. If idle speed is not set, the larger resistor on the control board may become hot. Heat from the resistor may damage the protective coating on the control board. OFF ENG INE Solenoid Mou...
Page 14 - STORAGE; STOPPING ENGINE; Disconnecting Electrical; Figure 21 - Engine Switch In OFF Position
14 118683 PORTABLE GASOLINE GENERATORS R STORAGE 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. Refer to that manual for questions concerning engine storage. Use a fuel additive, such a...
Page 15 - TROUBLESHOOTING; POSSIBLE CAUSE; SERVICING THE; Engines Gasoline, Honda; or call Honda direct:; TECHNICAL
15 118683 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. Defective capacitor2. W i n d i n g s h o r t c i r c u i t o r l o o s e connections 3. Defective rotor dio...
Page 16 - ELECTRICAL; Resistance between brown and white leads.
16 118683 PORTABLE GASOLINE GENERATORS R ELECTRICAL COMPONENT SPECIFICATIONS * Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow). Δ Resistance between brown and white leads. † Remove diodes to check resistance. Model Resistance in Ohms Capacitor, MFD 450 Volt Dio...
Page 17 - WIRING DIAGRAMS
17 118683 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 Yello...
Page 18 - Figure 26 - Wiring Diagram, Model MGH6500AIE
18 118683 PORTABLE GASOLINE GENERATORS R WIRING DIAGRAMS Continued Figure 26 - Wiring Diagram, Model MGH6500AIE 120/240V 30A Receptacle T4 120V, 15A Receptacle Circuit Breaker 20A Green Black Black Black Red Black T3 White White Green Red T1 T2 White Circuit Breaker 30A Circuit Breaker 30A Black Red...
Page 19 - DESCRIPTION; ILLUSTRATED; Alternator Assembly; Replacement
19 118683 OWNER’S MANUAL † Includes fastening hardware.* Includes reference numbers 1 through 22.** Parts not available. Included in alternator assembly. KEY PARTNO. NUMBER DESCRIPTION QTY. 118054-01 Alternator Assembly* 1 118703-01 End Cover 1 2a 100445-01 120V, 15A Duplex (GFCI) Receptacle (MGH300...
Page 20 - PART NUMBER FOR MODEL; Assembly; Replacement Parts
20 118683 PORTABLE GASOLINE GENERATORS R PART NUMBER FOR MODEL MGH5000E KEY MGH4000D MGH5000EI NO. MGH4000DI MGH5000EIE MGH6500AIE DESCRIPTION QTY. 118055-01 118055-02 118055-03 Alternator Assembly 1 1 118782-01 118782-01 118782-01 End Cover 1 2 118714-01 118714-01 118714-01 Shaft End Cap 1 3 118712...
Page 21 - KEY; Engine Spreader
21 118683 OWNER’S MANUAL KEY PART NO. NUMBER DESCRIPTION QTY. 1 118669-01 Handle (includes 2 spacers) 1 2 WLE-4 1/4" Lock Washer 2 3 099769-01 M6 x 35 Bolt 2 4 NEC-5C 5/16-18 Nut 1 5 099754-01 Engine Spreader 1 6 118821-02 Rubber Bumper 2 7 WP-5C 5/16" Flat Washer 1 8 50009402 5/16-18 x 1/2&...
Page 23 - Roll Cage
23 118683 OWNER’S MANUAL KEY PART NO. NUMBER DESCRIPTION QTY. 1 118916-02 Roll Cage 1 2 NEC-5C Lock Nut, 5/16-18 7 3 099853-03 Shock Mount 2 4 * Bolt, 5/16-18 x 1/2" 1 5 WLE-5 Lock Washer, 5/16" 1 6 14138002 Grounding Strap 1 7 099853-02 Shock Mount 1 * Available at any hardware store. ILLUS...
Page 24 - Fuel Tank and Roll Cage
24 118683 PORTABLE GASOLINE GENERATORS 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 30 11 16 11 16 22 FU EL F 1 3 2 4 24 7 8 6 6 27 7 25 15 5 26 FU EL F 10 10 29 24 1 2 24 29 24 28 9 24 28 ILLUSTRATED PARTS LIST For Models MGH4000D, MGH4000DI, MGH5000E, MGH...
Page 25 - Replacement Parts
25 118683 OWNER’S MANUAL ILLUSTRATED PARTS LIST * Only on MGH5000EIE electric start models 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 MGH4000D, MGH4000DI, MGH5000E,MGH5...
Page 26 - For Solenoid and Control Board
26 118683 PORTABLE GASOLINE GENERATORS R DESA IN TERNA TIO NAL S2 S1 L1 L2 1 2 4 5 3 7 12 11 9 10 8 6 Control Board Assembly and Mounting Solenoid Assembly and Mounting ILLUSTRATED PARTS LIST For Solenoid and Control Board Assemblies and Mounting
Page 29 - PARTS CENTRALS; Manila Drive; REPLACEMENT; Heavy-Duty Wheel Kit – PA2022; REPAIR SERVICE; WARRANTY SERVICE
29 118683 OWNER’S MANUAL PARTS CENTRALS These Parts Centrals are privately owned businesses. They have agreed to support our customer’s needs by providing original replacement parts and accessories. Tool & Equipment 5 Manila Drive Hamden, CT 06514-0322 203-248-7553 1-800-397-7553 Grainger Parts ...
Page 30 - NOTES
30 118683 PORTABLE GASOLINE GENERATORS R NOTES ________________________________________________________________________________________________ ________________________________________________________________________________________________ ___________________________________________________________...
Page 32 - KEEP THIS WARRANTY; WARRANTY INFORMATION; FIVE-YEAR LIMITED WARRANTY; Model
KEEP THIS WARRANTY WARRANTY INFORMATION 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 e...
