Honda Power Equipment EU6500is User Manual

4.5 (2)

Owner’s Manual

GENERATOR

EU6500is

o2006 Honda Motor Co., Ltd.

See page 78 for instructions

-All Rights Reserved

on assembling your generator.

 

 

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the generator and should remain with the generator if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever.

INTRODUCTION

Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase of one of the finest generators on the market.

We want to help you get the best results from your new generator and to operate it safely. This manual contains all the information on how to do that; please read it carefully.

As you read this manual, you will find information preceded by a symbol. That information is intended to help you avoid

damage to your generator, other property, or the environment.

We suggest you read the Distributor’s Limited Warranty to fully understand its coverage and your responsibilities of ownership. The Distributor’s Limited Warranty is a separate document that should have been given to you by your dealer.

When your generator needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes,

Honda Motor Co., Ltd.

1

A FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this generator safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining a generator. You must use your own good judgement.

You will find important safety information in a variety of forms, including:

Safety Labels on the generator.

Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

Safety Headings such as IMPORTANT SAFETY INFORMATION.

Safety Section such as GENERAT OR SAF ET Y .

Instructions how to use this generator correctly and safely.

This entire book is filled with important safety information please read it carefully.

2

CONTENTS

 

GENERATOR SAFETY................................................................................

.6

IMPORTANT SAFETY INFORMATION ..................................................

.6

Operator Responsibility......................................................................

.6

Carbon Monoxide Hazards.................................................................

.6

Electric Shock Hazards .......................................................................

.7

Fire and Burn Hazards ........................................................................

.7

Refuel With Care .................................................................................

.8

SAFETY LABEL LOCATIONS .................................................................

.9

CONTROLS & FEATURES.........................................................................

10

COMPONENT & CONTROL LOCATIONS ............................................

10

CONTROLS.............................................................................................

12

Fuel Valve Lever .................................................................................

12

Engine Switch.....................................................................................

12

Recoil Starter ......................................................................................

13

EcoThrottleTM Switch..........................................................................

13

Voltage Selector Switch ....................................................................

14

AC Circuit Protectors..........................................................................

14

Folding Handle ...................................................................................

15

Maintenance Cover............................................................................

16

FEATURES..............................................................................................

17

Ground Terminal................................................................................

17

Output Indicator .................................................................................

18

Overload Indicator .............................................................................

18

Oil Alert Indicator .............................................................................

19

i-MonitorTM ..........................................................................................

20

Fuel Gauge..........................................................................................

23

BEFORE OPERATION ................................................................................

24

ARE YOU READY TO GET STARTED? .................................................

24

Knowledge..........................................................................................

24

IS YOUR GENERATOR READY TO GO?...............................................

24

Check the Engine................................................................................

25

Battery Maintenance Cover...............................................................

25

3

CONTENTS

 

OPERATION ...............................................................................................

26

SAFE OPERATING PRECAUTIONS ......................................................

26

STARTING THE ENGINE .......................................................................

27

Starting the engine with remote control (optional part) ....................

30

STOPPING THE ENGINE .......................................................................

31

Stopping the engine with remote control (optional part) ..................

32

AC OPERATION......................................................................................

33

AC Applications..................................................................................

35

AC Receptacle Selection....................................................................

36

ECOTHROTTLETM SYSTEM....................................................................

38

STAND BY POWER................................................................................

39

Connections to a Building’s Electrical System................................

39

System Ground ..................................................................................

39

Special Requirements........................................................................

40

SERVICING YOUR GENERATOR..............................................................

41

THE IMPORTANCE OF MAINTENANCE ..............................................

41

MAINTENANCE SAFETY.......................................................................

42

Safety Precautions .............................................................................

42

MAINTENANCE SCHEDULE .................................................................

43

REFUELING ............................................................................................

44

FUEL RECOMMENDATIONS ................................................................

45

ENGINE OIL LEVEL CHECK ...................................................................

46

ENGINE OIL CHANGE............................................................................

47

ENGINE OIL RECOMMENDATIONS.....................................................

48

AIR CLEANER SERVICE.........................................................................

49

FOAM AIR FILTER CLEANING ..............................................................

50

SEDIMENT CUP CLEANING..................................................................

51

SPARK PLUG SERVICE..........................................................................

52

SPARK ARRESTER SERVICE.................................................................

54

BATTERY SERVICE ................................................................................

55

FUSE .......................................................................................................

59

STORAGE...................................................................................................

60

STORAGE PREPARATION.....................................................................

60

Cleaning..............................................................................................

60

Fuel......................................................................................................

60

Engine Oil ...........................................................................................

63

STORAGE PRECAUTIONS ....................................................................

64

REMOVAL FROM STORAGE.................................................................

64

4

 

CONTENTS

TRANSPORTING ......................................................................................

 

.65

TAKING CARE OF UNEXPECTED PROBLEMS.......................................

.

66

ENGINE WILL NOT START...................................................................

.

66

ENGINE LACKS POWER.......................................................................

.

67

NO POWER AT THE RECEPTACLES....................................................

.

68

TECHNICAL & CONSUMER INFORMATION..........................................

.

69

TECHNICAL INFORMATION ................................................................

.

69

Serial Number Location ...................................................................

.

69

Carburetor Modification for High Altitude Operation.....................

70

Emission Control System Information............................................

.

71

Air Index.............................................................................................

.

73

Specifications ....................................................................................

.

74

Wiring Diagram .................................................................................

.

75

CONSUMER INFORMATION ...............................................................

.

76

Honda Publications...........................................................................

.

76

Customer Service Information.........................................................

.

77

ASSEMBLY ...............................................................................................

.

78

SAFETY..................................................................................................

.

78

The Importance of Proper Assembly ..............................................

.

78

Important Safety Precautions ..........................................................

.

79

ASSEMBLY............................................................................................

.

80

Unpacking..........................................................................................

.

80

Loose Parts ........................................................................................

.

80

Wheel Kit Installation........................................................................

.

81

Handle Installation ............................................................................

.

82

Rear Bar Installation..........................................................................

.

83

Engine oil ...........................................................................................

.

85

Fuel.....................................................................................................

.

85

Battery Voltage..................................................................................

.

86

BEFORE OPERATION ...........................................................................

.

86

OPTIONAL PARTS ....................................................................................

.

87

Remote Control Kit............................................................................

.

87

Hanger Kit ..........................................................................................

.

89

INDEX ........................................................................................................

.

90

QUICK REFERENCE INFORMATION ..............................

Inside back cover

5

GENERATOR SAFETY

IMPORTANT SAFETY INFORMATION

Honda generators are designed for use with electrical equipment that has suitable power requirements. Other uses can result in injury to the operator or damage to the generator and other property.

Most accidents can be prevented if you follow all instructions in this manual and on the generator. The most common hazards are discussed below, along with the best way to protect yourself and others.

Operator Responsibility

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles, and connections.

Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the generator without parental supervision.

Carbon Monoxide Hazards

Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death.

Operate outdoors away from buildings, open doors or windows.

Never run the generator in a closed or partially enclosed area.

6

GENERATOR SAFETY

Electric Shock Hazards

The generator produces enough electric power to cause a serious shock or electrocution if misused.

Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution. Keep the generator dry.

If the generator is stored outdoors, unprotected from the weather, check all of the electrical components on the control panel, before each use. Moisture or ice can cause a malfunction or short circuit in electrical components which could result in electrocution.

Do not connect to a building electrical system unless an isolation switch has been installed by a qualified electrician.

Fire and Burn Hazards

The exhaust system gets hot enough to ignite some materials.Keep the generator at least 3 feet (1 meter) away from buildings

and other equipment during operation.

Do not enclose the generator in any structure.Keep flammable materials away from the generator.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors.

7

GENERATOR SAFETY

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode. Allow the engine to cool if the generator has been in operation. Refuel only outdoors in a well-ventilated area with the engine OFF. Do not overfill the fuel tank. Never smoke near gasoline, and keep other flames and sparks away. Always store gasoline in an approved container. Make sure that any spilled fuel has been wiped up before starting the engine.

8

Honda Power Equipment EU6500is User Manual

GENERATOR SAFETY

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda servicing dealer for a replacement.

9

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

Use the two illustrations on these pages to locate and identify the most frequently used controls.

OVERLOAD

OIL ALERT

i-MONITOR

ECOTHROTTLE SWITCH

INDICATOR

INDICATOR

BUTTON

 

 

 

 

CIRCUIT PROTECTORS

OUTPUT

 

 

 

INDICATOR

 

 

 

i-MONITOR

ENGINE SWITCH

RECEPTACLES

VOLTAGE SELECTOR SWITCH

FUEL VALVE LEVER

10

 

CONTROL & FEATURES

FUEL GAUGE

FUEL TANK CAP

FUSE

STARTER GRIP

(inside battery maintenance cover)

 

BATTERY

 

(inside battery

 

maintenance cover)

 

OIL FILLER CAP/DIPSTICK

HANDLE

OIL DRAIN PLUG

STAND

RIGHT MAINTENANCE GROUND TERMINAL COVER

SPARK PLUG

INSPECTION COVER

MUFFLER TIP

WHEEL

AIR CLEANER

LEFT MAINTENANCE COVER

11

CONTROL & FEATURES

CONTROLS

Fuel Valve Lever

The fuel valve lever is located on the control panel.

The fuel valve must be in the ON position for the engine to run.

After stopping the engine, turn the fuel valve to the OFF position.

Engine Switch

The engine switch controls the ignition system, and it operates the electric starter.

OFF Stops the engine. The engine switch key can be removed/inserted.

ON Running position, and for starting with the recoil starter.

START Operates the electric starter.

REMOTE For using the remote control kit (optional parts).

ON

OFF

 

FUEL VALVE LEVER

 

ON

OFF

START

ENGINE SWITCH

OFF

REMOTE

ENGINE SWITCH

12

CONTROL & FEATURES

Recoil Starter

Used when the battery voltage is too low to turn the starter motor. Pulling the starter grip operates the recoil starter to crank the engine for starting.

STARTER GRIP

20°

Do not exceed 20 degrees from horizontal when pulling the starter grip.

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

Do not let the starter rope rub against the generator body or the rope will wear out prematurely.

EcoThrottleTM Switch

The EcoThrottle system automatically reduces engine speed when all loads are turned off or disconnected. When appliances are turned on or reconnected, the engine returns to the proper speed to power the electrical load.

If high electrical loads are connected simultaneously, turn the EcoThrottle switch to the OFF position to reduce voltage changes.

ON Recommended to minimize fuel consumption and further reduce noise levels when a reduced load or no load is applied to the generator.

OFF The EcoThrottle system does not operate. Generator operates at full speed.

ECOTHROTTLE SWITCH

OFF ON

13

CONTROL & FEATURES

Voltage Selector Switch

The voltage selector switch changes generator output to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4- prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only the 120V 3-prong receptacles are being used, select the ‘‘120V ONLY’’ position.

Select the voltage before starting the engine.

Switch Position

120/240V: The 120V and 120/240V receptacles can be used simultaneously.

120V ONLY: ONLY the 120V receptacles can be used. Do not use the 120/240V receptacle in this position. The most power will be available at the 30A 120V locking plug receptacle.

VOLTAGE SELECTOR SWITCH

120V/240V

120V ONLY

AC Circuit Protectors

The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at each receptacle. If an AC circuit protector switches OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before resetting the AC circuit protector ON.

CIRCUIT PROTECTOR

CIRCUIT PROTECTOR

CIRCUIT PROTECTOR

 

for Receptacle

for Receptacle

for Receptacle

 

 

 

AC CIRCUIT PROTECTOR

CIRCUIT PROTECTOR

 

ON

 

for Receptacle

 

 

 

 

 

120V 30A

 

OFF

PUSH

 

 

 

120V 20A

120V 20A

120/240V 30A

14

CONTROL & FEATURES

Folding Handle

The foldable handle is intended for ease of transportation and should be folded when the generator is stationary. Do not rest objects on the extended the handle.

To Extend The Handle

Lift handle upward. Lock levers will lock and secure the handle into place.

To Fold The Handle

1.Press both handle lock levers downward.

2.Lower the handle.

HANDLE

HANDLE LOCK LEVER

Handle transport position

Generator stationary position

15

CONTROL & FEATURES

Maintenance Cover

Open and close the maintenance cover for maintenance of the

EU6500is.

Open the maintenance cover, too, to use the recoil starter when the battery is discharged. Be sure to close the maintenance cover while the generator is running.

Work made with the right maintenance cover open:

Engine oil inspection/replacement

Work made with the left maintenance cover open:

Spark plug inspection/replacement

Air cleaner inspection/cleaning Sediment cup cleaning

To open:

Turn the ratch 90° to unlock and open the maintenance cover.

To close:

Turn the ratch 90° to lock while pushing the cover.

RATCH

RATCH

RIGHT MAINTENANCE

LEFT MAINTENANCE

COVER

COVER

RATCH

Close the cover and push.

16

CONTROL & FEATURES

FEATURES

Ground Terminal

The ground terminal is connected to the frame of the generator, the metal non-current-carrying parts of the generator, and the ground terminals of each receptacle.

Before using the ground terminal, consult a qualified electrician, electrical inspector or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator.

GROUND TERMINAL

17

CONTROL & FEATURES

Output Indicator

The output indicator (green) is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the receptacles.

OUTPUT INDICATOR (GREEN)

Overload Indicator

If the generator is overloaded, or if there is a short circuit in a connected appliance, or if the inverter is overheated, the overload indicator (red) will go ON. When the generator is operating overloaded, the overload indicator (red) will stay ON, and after about five seconds, current to the connected appliance(s) will shut off, and the output indicator (green) will go OFF.

OVERLOAD

INDICATOR (RED)

18

CONTROL & FEATURES

Oil Alert Indicator

The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert indicator comes on and the Oil Alert system automatically stops engine (the engine switch will remains the ON position).

The i-Monitor display will shows ‘‘OIL’’ on the screen and the Oil Alert indicator illuminats.

If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to START or pull the starter grip, check the engine oil level (see page 46 ) before troubleshooting in other areas.

Even when oil is added to the engine, the generator will not restart until the Oil Alert indicator is reset. To reset the Oil Alert indicator, turn the engine switch OFF, add the proper amount of oil (see page 47 ), and then turn the engine switch back ON.

OIL ALERT (RED)

It blinks.

19

CONTROL & FEATURES

i-MonitorTM

The i-Monitor is a user interface that allows the operator to view (when the generator is running) total operating time in hours, generator output, engine RPM, battery voltage and error messages. The different display modes are selected by pressing the i-Monitor button.

i-Monitor at Startup

During start up, the i-Monitor display and all three indicators will simultaneously blink once. The condition of the i-Monitor display and all three indicators can be checked. Once the generator is running, the Output indicator (green) and the i-Monitor display will remain lit.

Display Backlight Flashes

If the key is left in the ON position for over 30 seconds without starting the engine, the display will start to flash.

i-Monitor Display

The i-Monitor display is divided into two screens. The single-digit screen displays the i-Monitor mode which is represented by a number 1 through 4. The four-digit screen displays the four mode values or any activated error messages.

i-Monitor Display Mode 1 Total Operating Hours

This mode displays the total operating hours of the generator. When the generator is running, the total operating time accumulates. If the total operating time is less than one hour, the numeric display will be ‘‘0.’’ When the operating time is one hour or greater, the display will be ‘‘1’’ or ‘‘2’’ and so on. Base the generator’s maintenance schedule on the accumulated time displayed.

i-MONITOR BUTTON

SINGLE-DIGIT SCREEN DISPLAY

FOUR-DIGIT

SCREEN DISPLAY

20

CONTROL & FEATURES

i-Monitor Display Mode 2 Power Output

This mode displays an approximate generator output on the display screen. The output is expressed in VA (volt-amperes). The output value is not an exact measurement and should be regarded as a reference only. Power output will not display until a load is connected to the generator.

i-Monitor Display Mode 3 Engine RPM

When the i-Monitor is in this mode, the engine’s speed, expressed in revolutions-per-minute (RPM) is displayed.

i-Monitor Display Mode 4 Battery Voltage

This mode displays the battery condition, expressed in Volts DC.

21

CONTROL & FEATURES

i-Monitor Low Battery Message

If the engine switch is turned to the START position and ‘‘batt’’ is shown on the i-Monitor display, the battery voltage is too low to operate the engine’s electric starter. Use the recoil starter to start the generator. Have the battery recharged and checked (see page 58 ).

i-Monitor System Error Messages

If the generator has a system malfunction, it will show an error message on the i-Monitor display. During remote control operation, an E-01 error message may display if the starter button is pressed for more than 10 seconds. With an E-01 error message, the engine will stay running and the electrical output may stay constant.

Normal remote control operation will be restored after the E-01 error message clears. If the E-01 error message will not clear or if any other error message displays, contact an authorized Honda generator dealer.

OVERLOAD INDICATOR LIGHT

ERROR MESSAGE

(Example: E-01)

22

CONTROL & FEATURES

Fuel Gauge

The fuel gauge is a mechanical device that measures the fuel level in the tank. The red indicator in the window will reference the level in relation to full or empty. To provide increased operating time, start with a full tank before beginning operation. Check the fuel level with the generator on a level surface. Always refuel with the engine OFF and cool.

FULL

FUEL GAUGE

EMPTY

FUEL TANK CAP

23

BEFORE OPERATION

ARE YOU READY TO GET STARTED?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual. Know what the controls do and how to operate them.

Familiarize yourself with the generator and its operation before you begin using it. Know how to quickly shut off the generator in case of an emergency.

If the generator is being used to power appliances, be sure that they do not exceed the generator’s load rating (see page 35 ).

IS YOUR GENERATOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the generator to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the generator.

Improperly maintaining this generator, or failing to correct a problem before operation, could cause a malfunction in which you could be seriously injured.

Always perform a preoperation inspection before each operation, and correct any problem.

To prevent a possible fire, keep the generator at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects close to the engine.

Before beginning your preoperation checks, be sure the generator is on a level surface and the engine switch is in the OFF position.

24

BEFORE OPERATION

Check the Engine

Check the oil level (see page 46 ). A low oil level will cause the Oil Alert system to shut down the engine.

Check the air filter (see page 49 ). A dirty air filter will restrict air flow to the carburetor, reducing engine and generator performance.

Check the fuel level (see page 44 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

Battery Maintenance Cover

Never operate the generator without the battery maintenance cover in place, as poor engine and generator performance will result.

BATTERY MAINTENANCE COVER

25

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, please review the GENERATOR SAFETY section and the chapter titled BEFORE OPERATION.

For your safety, avoid starting or operating the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you.

Avoid any enclosed areas or activities that expose you to carbon monoxide.

Before connecting an AC appliance or power cord to the generator:

Use grounded 3-prong extension cords, tools, and appliances, or double-insulated tools and appliances.

Inspect cords and plugs, and replace if damaged.

Make sure that the appliance is in good working order. Faulty appliances or power cords can create a potential for electric shock.

Make sure the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

Operate the generator at least 3 feet (1 meter) away from buildings and other equipment.

Do not operate the generator in an enclosed structure.

26

OPERATION

STARTING THE ENGINE

Refer to Safe Operating Precautions on page 25 .

1.Make sure that all appliances are disconnected from the AC receptacles. The generator may be hard to start if a load is connected.

2. Set the Voltage Selector Switch

VOLTAGE SELECTOR SWITCH

to match the voltage

 

requirements for the

 

application.

 

3. Turn the fuel valve lever to the

FUEL VALVE LEVER

ON position.

ON

OFF

4. Make sure the EcoThrottle

switch is in the OFF position, or ECOTHROTTLE SWITCH more time will be required for

warm up.

120V/

240V

120V ONLY

OFF ON

27

OPERATION

5.Turn the engine switch to the START position, and hold it there until the engine starts. When the engine starts, release the key, allowing the switch to return to the ON position.

If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again.

ON

OFF

START

ENGINE SWITCH

Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

28

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