Honda EG5000CL, EG4000CL, EG6500CL Owner's Manual
Owner’s Manual
GENERATOR
EG4000CL • EG5000CL • EG6500CL
© 2011 Honda Motor Co., Ltd.—All Rights Reserved
See page 67 for
Initial Use Instructions
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductiveharm.
Exhaust contains poisonous carbon
monoxide gas that can build up to
dangerous levels in closed areas.
Breathing carbon monoxide can
cause unconsciousness or death.
Never run the generator in a closed,
or even partly closed area where
people may be present.
Keep this owner’s manual handy so that 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
understand its coverage and your responsibilities of ownership. The
Distributor’s Limited Warranty
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.
Distributor’s Limited Warranty
is a separate document that should
to fully
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
Safety Messages
of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
Safety Headings
Safety Section
Instructions
This entire book is filled with important safety information please
read it carefully.
−
on the generator.
−
preceded by a safety alert symbol and one
You WILL KILLED SERIOUSLY HURT
you don’t follow instructions.
You CAN KILLED SERIOUSLY HURT
you don’t follow instructions.
You CAN HURT
instructions.
−
such as
such as
−
how to use this generator correctly and safely.
−
be or if
be or if
be if you don’t follow
IMPORTANT SAFETY INFORMATION
GENE R ATOR SAFE TY.
−
.
2
CONTENTS
............................................................................................CONTROLS .13
........................................................................................Starter Grip .13
.......................................................................................Choke Lever .14
.............................................................................................FEATURES .17
System .17
.........................................................................................Fuel Gauge .18
................................................................................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 .11
...........................................COMPONENT & CONTROL LOCATIONS .11
....................................................................................Engine Switch .13
................................................................................Fuel Valve Lever .14
...................................................................Voltage Selector Switch .15
.............................................................................AC Circuit Breaker .15
.........................................................................AC Circuit Protectors .16
..............................................................................Oil Alert
.....................................................Automatic Engine Stop Function .17
..............................................................................Oil Alert Function .17
........................................................Overspeed Detection Function .17
............................................Abnormal Voltage Detection Function .17
...............................................................................Ground Terminal .18
...............................................................................BEFORE OPERATION .19
................................................ARE YOU READY TO GET STARTED? .19
.........................................................................................Knowledge .19
..............................................IS YOUR GENERATOR READY TO GO? .19
...............................................................................Check the Engine .20
3
CONTENTS
..............................................................................................OPERATION .21
...................................................................................................Tools .35
.....................................................SAFE OPERATING PRECAUTIONS .21
......................................................................STARTING THE ENGINE .22
......................................................................STOPPING THE ENGINE .25
.....................................................................................AC OPERATION .26
.................................................................................AC Applications .27
...................................................................AC Receptacle Selection .28
.................................................................Power Producing Circuits .28
...................................................................Voltage Selector Switch .29
................................................................................STANDBY POWER .31
...............................Connections to a Building’s Electrical System .31
.................................................................................System Ground .31
.......................................................................Special Requirements .32
.............................................................SERVICING YOUR GENERATOR .33
.............................................THE IMPORTANCE OF MAINTENANCE .33
......................................................................MAINTENANCE SAFETY .34
............................................................................Safety Precautions .34
................................................................MAINTENANCE SCHEDULE .35
...........................................................................................REFUELING .36
...............................................................FUEL RECOMMENDATIONS .37
..................................................................ENGINE OIL LEVEL CHECK .38
...........................................................................ENGINE OIL CHANGE .39
....................................................ENGINE OIL RECOMMENDATIONS .40
........................................................................AIR CLEANER SERVICE .41
..................................................AIR CLEANER ELEMENT CLEANING .43
.........................................................................SPARK PLUG SERVICE .44
................................................................SPARK ARRESTER SERVICE .46
.................................................................SEDIMENT CUP CLEANING .47
4
..................................................................................................STORAGE .48
....................................................................STORAGE PREPARATION .48
.............................................................................................Cleaning .48
.....................................................................................................Fuel .48
..........................................................................................Engine Oil .51
...................................................................STORAGE PRECAUTIONS .52
................................................................REMOVAL FROM STORAGE .52
CONTENTS
......................................................................................TRANSPORTING .53
.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54
...................................................................ENGINE WILL NOT START .54
.......................................................................ENGINE LACKS POWER .55
..............................................NO POWER AT THE AC RECEPTACLES .56
..........................................TECHNICAL & CONSUMER INFORMATION .57
................................................................TECHNICAL INFORMATION .57
...................................................................Serial Number Location .57
....................Carburetor Modification for High Altitude Operation .58
............................................Emission Control System Information .59
.............................................................................................Air Index .61
....................................................................................Specifications .62
.................................................................................Wiring Diagram .63
...............................................................CONSUMER INFORMATION .65
..............................................................Dealer Locator Information .65
...........................................................................Honda Publications .65
.........................................................Customer Service Information .66
..................................................................INITIAL USE INSTRUCTIONS .67
...........................................................................................ENGINE OIL .67
.......................................................................................................FUEL .68
...........................................................................BEFORE OPERATION .69
.....................................................................................REGISTRATION .69
....................................................................................OPTIONAL PARTS .70
.....................................................................HANDLE INSTALLATION .70
.................................................................WHEEL KIT INSTALLATION .71
........................................................................................................INDEX .72
.............................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 injuries or property damage 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 carbon monoxide can cause loss of consciousness
and may lead to death.
If you run the generator in an area that is confined, or even partly
enclosed area, the air you breathe could contain a dangerous
amount of exhaust gas.
Never run your generator inside a garage, house, or near open
windows or doors.
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 that could result in electrocution.
Do not connect to a building’s 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
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
generator dealer for a replacement.
9
GENERATOR SAFETY
10
CONTROLS & FEATURES
COMPONENT & CONTROL LOCATIONS
Use the illustrations on these pages to locate and identify the most
frequently used controls.
ENGINE SWITCH
AC CIRCUIT BREAKER
VOLTAGE SELECTOR SWITCH
AC CIRCUIT PROTECTORS
120V/240V AC
＊
112200VV RREECCEEPPTTAACCLLEESS
RECEPTACLE
GROUND TERMINAL
＊
:
Except EG4000CL
11
CONTROLS & FEATURES
CHOKE LEVER
FUEL VALVE LEVER
AIR CLEANER
SEDIMENT CUP
FUEL GAUGE
STARTER GRIP
OIL DRAIN PLUG
OIL FILLER CAP/
DIPSTICK
12
FUEL TANK CAP
SPARK PLUG
MUFFLER
CONTROLS
Engine Switch
The engine switch controls the
ignition system.
CONTROLS & FEATURES
OOFFFF
−
OFF Stops the engine.
−
ON Running position, and for
starting.
Starter Grip
Pulling the starter grip operates
the recoil starter to crank the
engine.
Do not allow the starter grip to
snap back against the generator.
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.
ENGINE SWITCH
DDiirreeccttiioonn ttoo ppuullll
OONN
ST
ARTER GRIP
13
CONTROLS & FEATURES
Fuel Valve Lever
The fuel valve lever is located
between the fuel tank and
carburetor.
The fuel valve lever must be in the
ON position for the engine to run.
After stopping the engine, turn
the fuel valve lever to the OFF
position.
Choke Lever
The choke is used to provide
proper starting mixture when the
engine is cold. It can be opened
and closed by operating the choke
lever manually. Move the choke
lever to the CLOSED position to
enrich the mixture for cold
starting.
CCLLOOSSEEDD
OONN
FU
EL VALVE LEVER
OOFFFF
CHOKE LEVER
14
O
PEN
CONTROLS & FEATURES
Voltage Selector Switch
The voltage selector switch switches generator output to produce
‘‘120V ONLY’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the
4-prong receptacle, the switch must be in the ‘‘120V/240V’’ position. If
only a 120V appliance is being connected to any of the 120V 3-prong
receptacles, select the ‘‘120V ONLY’’ position.
Select the voltage before starting the engine.
Switch Position
120V/240V:
The 120V and 120V/240V receptacles can be used
simultaneously.
120V ONLY:
ONLY the 120V receptacles can be used. Do not use the
120V/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 Breaker
The AC circuit breaker will automatically switch OFF if there is a short
circuit or a significant overload at the receptacles.
The AC circuit breaker may be used to switch the generator power ON
or OFF.
ON
OFF
AC CIRCUIT BREAKER
15
CONTROLS & FEATURES
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.
AC CIRCUIT PROTECTOR
for Receptacle
AC CIRCUIT PROTECTOR
for Receptacle
＊
120V 30A
AC CIRCUIT PROTECTOR
for Receptacle
AC CIRCUIT PROTECTOR
for Receptacle
16
120V 20A
120V 20A
＊
: Except EG4000CL
120V/240V 20A (EG4000CL)
120V/240V 30A (EG5000CL, EG6500CL)
AC CIRCUIT PROTECTOR
ON
OFF
PUSH
FEATURES
CONTROLS & FEATURES
Oil Alert
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 system will
automatically stop the engine (the engine switch will remain in the ON
position).
If the engine stops and will not restart, check the engine oil level (see
page ) before troubleshooting in other areas.
Automatic Engine Stop Function
Oil Alert Function
During operation, the engine will automatically stop if there is not
enough oil in the tank. Moreover, if the generator is on a slope, the oil
alert function may operate and stop the engine.
Overspeed Detection Function
To protect the engine from exceeding the engine load, the engine will
automatically stop if the engine speed becomes abnormal.
Abnormal Voltage Detection Function
The engine will automatically stop during generation when it detects
abnormal voltage.
System
38
If the engine stops, make sure the oil level is correct. Wait a few
minutes, and then try to restart the engine. If the engine still won’t
start, take the generator to your authorized servicing Honda power
equipment dealer.
17
CONTROLS & 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.
FUEL GAUGE
FULL EMPTY
Ground Terminal
FUEL TANK CAP
The generator 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
18
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 ).27
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 pre-operation
inspection before each operation,
and correct any problem.
19
BEFORE OPERATION
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 pre-operation checks, be sure the generator is
on a level surface and the engine switch is in the OFF position.
Check the Engine
Check the oil level (see page ). A low oil level will cause the Oil Alert
system to shut down the engine or prevent it from starting.
Check the air cleaner (see page ). A dirty air cleaner element will
restrict air flow to the carburetor, reducing engine and generator
performance.
Check the fuel level (see page ). Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.
38
41
36
20
OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the generator for the first time, review chapters
GENERATOR SAFETY
page ).
19
For your safety, do not operate 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.
(see page ) and
Exhaust contains poisonous carbon
monoxide gas that can build up to
dangerous levels in closed areas.
Breathing carbon monoxide can
cause unconsciousness or death.
Never run the generator in a closed,
or even partly closed area where
people may be present.
6
BEFORE OPERATION
(see
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.
21
OPERATION
STARTING THE ENGINE
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.
Operating this generator less than 3 feet (1 meter) from a building or
other obstruction can cause overheating and damage the generator.
For proper cooling, allow at least 3 feet (1 meter) of empty space
above and around the generator.
Refer to
SAFE OPERATING PRECAUTIONS
IS YOUR GENERATOR READY TO GO
AC OPERATION
Make sure that the AC circuit
1.
(see page ) for connecting loads to the generator.
26
breaker is in the OFF position.
The generator may be hard to
start if a load is connected.
Turn the fuel valve lever to the
2.
ON position.
on page and perform the
checks (see page ). Refer to
CIRCUIT BREAKER
AC
FUEL VALVE LEVER
21
19
OFF
OONN
22
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