Master MGH3000, Owner'S Operation And Installation Manual

Page 1: ... MGH6000 and MGH7000 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 F U E L F RE SE T 12 0 2 40 VO LT S 12 0 24 0V FU LL PO WE R SE LE CT OR 12 0 ON LY RE SE T TE ST RE SE T 120 VO LT S RE SE T ...

Page 2: ...MGH7000 Only 12 Generator Grounding 15 Extension Cords 16 Standby Installation To Home Or Building 16 Determining Electrical Load For Generator 16 Operation 18 General Information 18 Using Receptacle 18 Power Cord and Plug Requirements 19 Prestart 20 Starting 20 High Altitude Operation 22 Adding Electrical Loads 22 Disconnecting Electrical Loads 22 Stopping Engine 23 Maintenance and Repairs 24 Sto...

Page 3: ...fe and proper operation of this generator Safety information appears throughout these instructions Pay close attention to them Below are definitions for the safety information listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substantial property damage if you ignore warning WARNING indicates a hazard which can cause severe personal injury dea...

Page 4: ... or damage to generator may result Do not wear damp clothing or wet shoes when using generator 4 WARNING Guard against burns Hot engine parts can cause severe injury Use caution and remain alert when using generator Keep children and animals away from generator while it is running or hot Keep all covers and shields in place Keep them tightly secured The muffler becomes very hot during operation Th...

Page 5: ...e sure fuel tank is empty Never store with fuel in tank Vapors may reach an open flame or spark Fire or explosion may result 11 CAUTION Never operate generator if engine speed changes greatly if engine misfires often 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 12 CAUTION Keep gene...

Page 6: ...p Fuel Gage PRODUCT IDENTIFICATION Circuit Breaker 120 240 Volt Receptacle Roll Cage 120 Volt Receptacle GFCI Full Power Selector Switch 120 Volt Receptacle Run Lamp Provision for Auto Idle Switch Gas Tank Starter Grip Choke Lever Fuel Valve Lever Oil Dipstick Ground Lug Alternator Engine Engine ON OFF Switch Figure 1 Portable Generator Model MGH4000A Shown ...

Page 7: ...20 Volt Twist Lock No 30 Amp 30 Amp 30 Amp 30 Amp 120 240 Volt Twist Lock No 20 Amp 20 Amp 20 Amp 30 Amp 120 Volt Full Power Switch No Yes Yes Yes No General Specifications Honda Engine H P 5 5 8 9 11 13 Honda Model GX160K1VX GX240K1VA GX270VA GX340K1VA GX390K1VXE Fuel Type Gasoline Gasoline Gasoline Gasoline Gasoline Fuel Tank Capacity 3 9 qt 5 gal 5 gal 5 gal 5 gal Oil Alert System Yes Yes Yes Y...

Page 8: ...away from any object WARNING Do not use generator outdoors in rain or snow Do not use generator near standing water or snow Do not use if generator is wet or damp Operating generator in these conditions increases the risk of electrocution Severe injury or death can occur Do not use generator in extremely dusty or dirty conditions This will severely affect its life Keep generator clean Do not allow...

Page 9: ...l may flow away from the oil level sensing device This will cause the oil alert system to shut down engine See engine owner s manual for more information Figure 2 Engine Switch Location 120V ONLY 120 240V FULL POWER SELECTOR 120V ONLY 120 240V FULL POWER SELECTOR HONDA OFF ON START ENGINE SW CIRCUIT BREAKER FULL POWER SELECTOR SWITCH All models except MGH3000 and MGH7000 have a full power selector...

Page 10: ...his should trip GFCI resulting in no electrical power at receptacle Verify this by plugging test lamp with good bulb into receptacle If lamp does not work GFCI recep tacle is good WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a qualified electrician for repairs 2 If the GFCI receptacle tests okay restore power by pushing the RESET button back in The test lamp shou...

Page 11: ...ce the total generator load 20 20 Tripped Normal Figure 6 Receptacle Circuit Breaker Button ENGINE OIL 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 CHECKING OIL LEVEL AND ADDING OIL Follow steps below to check oil level Make sure engine is level and stopped 1 Remove dipstick see Figure 7 Wipe dipst...

Page 12: ...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 running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Always allow room for fuel to expand If you overfill tank fuel can over flow onto hot engine This can cause fire or explosion After refueling tig...

Page 13: ...y termi nals 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 CABLES TO ENGINE 1 Attach the red positive battery cable to the starter solenoid on engine see Figure 8 2 Attach the black negative battery cable to the engine block Use the bolt ...

Page 14: ...re 11 3 Locate the black negative battery cable attached to engine block Connect it to the negative battery terminal see Figure 11 4 Check battery before starting engine Make sure fluid levels are full Make sure battery is charged See engine owner s manual for more information Figure 10 Battery Hold Down System TO STARTER SOLENOID TO ENGINE BLOCK Figure 11 Connecting Positive and Negative Cables t...

Page 15: ...er 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 supply the ground wire and grounding point They 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 ...

Page 16: ...the generator will power selected items in a building Have generator and additional wiring installed by a skilled licensed electrician This is not a do it yourself job Follow all local codes WARNING The electrician must install a double throw transfer switch This isolates existing electrical circuits from the utility power line If not isolated generator output will back feed into utility power lin...

Page 17: ...l 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 DETERMINING ELECTRICAL LOAD FOR GENERATOR Continued Approximate Starting Watts Motor Approximate Universal Repulsion Split HP Running Motors Induction Capacitor Phase Rating Watts small appliance Motors Motors Motors 1 8 275 400 600 85...

Page 18: ...bon monoxide gas Overexposure will cause loss of consciousness and will lead to death WARNING Never connect generator to any existing electrical circuits The generator output will back feed into the utility power line This may electrocute a power company line repair person Also if generator is powering electrical circuits the chance of an electrical fire exists Note We supply the engine owner s ma...

Page 19: ...le NEMA L14 20P 20 amp or L14 30P 30 amp plug Four wire 20 amp or 30 amp cord W Neutral X Hot Ground Green 120 Volt 30 Amp G W X L5 30P Plug w G Y X w G Y X 120V 120V Neutral Ground Ground X Hot W Neutral Y Hot Ground Green L14 30P Plug L14 20P Plug 120V 120V Neutral 120 240 Volt 20 and 30 Amp Figure 14 Cord and Plug Configurations OPERATION Continued ...

Page 20: ...ine speed is preset The throttle is locked in preset posi tion Do not adjust throttle Preset position lets engine run at 3600 RPM under load The engine must maintain 3600 RPM for generator to create correct voltage Running engine at lower speeds will damage generator and powered items IMPORTANT Never start generator with electrical loads connected Start engine before adding electrical loads 1 Make...

Page 21: ...kcase Add oil as necessary Be sure engine is on a level surface See oil alert system page 9 B Electric Starter Model MGH7000 Only Turn the engine switch to the START position see Figure 17 Hold it there until engine starts When engine starts let switch return to the ON position IMPORTANT Do not use electric starter more than five seconds Starter motor damage may occur If engine fails to start rele...

Page 22: ... Only move switch to 120 240 VOLT position if powering 240V items 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 gene...

Page 23: ... for two or three minutes after removing electrical loads This lets engine cool slightly 3 Turn engine switch to the OFF position see Figure 19 4 Turn fuel valve lever off Do this by moving valve lever fully to the left see Figure 20 OPERATION Continued HONDA OFF ON START ENGINE SW CIRCUIT BREAKER ON push OFF Engine Switch For Model MGH7000 Engine Switch For All Models Except MGH7000 Figure 19 Eng...

Page 24: ...intenance 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 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...

Page 25: ...EMEDY 1 Replace capacitor 2 Checkresistanceofcoils see Electrical Component Speci fications below 3 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor terminals for 2 3 seconds 1 Set engine speed to 3720 RPM 62 Hz with no load 2 Replace both diodes on rotor 3 Checkresistanceofcoils see Electrical Component Speci fications below 4 Replace capacitor 1 Set engine speed to 3720 RPM 62 H...

Page 26: ... 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 Yellow Yellow Red Black Green White Diode Capacitor White White GFCI Black Black Run Light Circuit Breaker 20A LINE WHITE HOT T2 Stator 110 120V T1 T3 T2 T4 L2 L1 Rotor Stator White Brown Auxiliary Phase Green Red Black Yellow Main Windings T1 T3 T4 L1...

Page 27: ...ring Diagram Model MGH7000 Parts Company of America 1657 Shermer Road Northbrook IL 60062 1 800 323 0620 708 498 5900 Parts Department Portable Heater Parts 342 N County Road 400 East Valparaiso IN 46383 1 800 362 6951 219 462 7441 Parts Department Master Service Center 1184 Wilson NW Grand Rapids MI 49504 1 800 446 1446 616 791 4760 Mike Fowler MTA Distributors 2940 Foster Creighton Drive Nashvil...

Page 28: ...being used Reduces fuel consumption and engine noise Increases engine life Complete installation and operation instructions included Note Use only original replacement parts This will protect your warranty cover age for parts replaced under warranty Parts Under Warranty Contact authorized dealers of this product If they cannot supply original replace ment part s either contact your nearest Parts C...

Page 29: ...5 16 4 PARTS AVAILABLE NOT SHOWN 099866 03 Safety Information Decal 1 099866 04 Safety Information Decal 1 099867 02 Operation Decal 1 KEY PART NO NUMBER DESCRIPTION QTY 099722 02 Alternator Assembly 1 1 100074 01 Top Cover 1 2 100065 01 120V 15A Duplex GFCI Receptacle 1 3 22616009 Circuit Breaker 20 Amp 1 4 27002002S Capacitor 1 5 26333000 Screw M4 x 20 1 6 099863 01 Terminal Block 1 7 099701 01 ...

Page 30: ...6 M11084 26 M11084 26 Screw 10 16 x 3 8 1 8 099847 01 099847 02 099847 03 099847 04 Stator Bolt 4 9 WLE 5 WLE 5 WLE 5 WLE 5 Lock Washer 5 16 4 10 099843 01 099843 01 099843 01 099843 01 Bearing Housing 1 11 27004002S 27005003S 099845 01 27007004S Capacitor 1 12 100054 01 100054 01 Terminal Post 4 13 Stator 1 14 27003002 27003002 27003002 27003002 Fan Bracket 1 15 27003015S 27003015S 27003015S 2700...

Page 31: ...ne Spreader 1 3 NEC 5C Lock Nut 5 16 18 6 4 WP 5C Flat Washer 5 16 5 5 26020000 Shock Mount 3 6 04110002 Screw 5 16 18 x 1 1 2 2 7 14138000 Ground Strap 1 8 21834000 Washer 5 16 x 1 1 2 1 9 100406 01 Bolt 5 16 18 x 3 4 4 This list contains replaceable parts used in your generator When ordering parts follow the instructions listed under REPLACEMENT PARTS on page 28 of this manual ...

Page 32: ...LIST For Models MGH4000A MGH5000A MGH6000 and MGH7000 Fuel Tank and Roll Cage 9 10 11 12 13 15 15 15 13 13 17 17 18 11 11 11 16 11 16 21 20 19 16 14 23 14 23 16 16 16 16 14 23 22 F U E L F 1 3 2 4 24 7 8 6 6 7 27 24 26 5 25 ...

Page 33: ... Bolt 5 16 18 x 3 4 3 16 WP 5C Flat Washer 5 16 7 17 HC5 11C Bolt 5 16 18 x 1 3 4 2 18 099756 01 Engine Spreader 1 19 099750 01 Hook Bolt 5 16 18 2 20 099749 01 Battery Mounting Bracket 1 21 NEC 5C Lock Nut 5 16 18 2 22 100410 01 Sems Screw 8 18 x 1 2 4 23 M10908 74 Screw 1 4 20 x 1 2 3 24 WP 4C Washer 1 4 5 25 01076002 Washer 10 1 26 WLI 3 Lock Washer 10 1 27 099965 01 Linkage Cover 1 PARTS AVAIL...

Page 34: ... 120V 15A Duplex GFCI Receptacle 1 5 099956 01 099956 01 099956 01 Full Power Selector Switch 1 6 22616009 Circuit Breaker 20 Amp 2 22616011 Circuit Breaker 25 Amp 2 22616010 22616010 Circuit Breaker 30 Amp 2 7 099834 01 099834 01 099834 01 120 240V 20A Twist Lock Receptacle 1 099835 01 120 240V 30A Twist Lock Receptacle 1 8 26299000 26299000 26299000 26299000 Lamp 1 9 099760 01 099760 01 099760 0...

Page 35: ...35 NOTES ...

Page 36: ...er 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 ...