Honda EG5000CL, EG4000CL, EG6500CL Owner's Manual

Owner’s Manual

GENERATOR

EG4000CL • EG5000CL • EG6500CL

	See page 67 for
© 2011 Honda Motor Co., Ltd.—All Rights Reserved	Initial Use Instructions

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

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 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.........................................................................	11
COMPONENT & CONTROL LOCATIONS ............................................	11
CONTROLS.............................................................................................	13
Engine Switch.....................................................................................	13
Starter Grip .........................................................................................	13
Fuel Valve Lever .................................................................................	14
Choke Lever ........................................................................................	14
Voltage Selector Switch ....................................................................	15
AC Circuit Breaker ..............................................................................	15
AC Circuit Protectors..........................................................................	16
FEATURES..............................................................................................	17
Oil Alert System ...............................................................................	17
Automatic Engine Stop Function......................................................	17
Oil Alert Function ...............................................................................	17
Overspeed Detection Function .........................................................	17
Abnormal Voltage Detection Function.............................................	17
Fuel Gauge..........................................................................................	18
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
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
Tools....................................................................................................	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
STORAGE...................................................................................................	48
STORAGE PREPARATION.....................................................................	48
Cleaning..............................................................................................	48
Fuel......................................................................................................	48
Engine Oil ...........................................................................................	51
STORAGE PRECAUTIONS ....................................................................	52
REMOVAL FROM STORAGE.................................................................	52

4

	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
	RECEPTACLE

120V RECEPTACLES

GROUND TERMINAL

: Except EG4000CL

11

CONTROLS & FEATURES

FUEL GAUGE

CHOKE LEVER

FUEL VALVE LEVER

OIL FILLER CAP/

DIPSTICK

STARTER GRIP

AIR CLEANER

SEDIMENT CUP

OIL DRAIN PLUG

FUEL TANK CAP

SPARK PLUG

MUFFLER

12

CONTROLS & FEATURES

CONTROLS

Engine Switch

The engine switch controls the ignition system.

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.

OFF

ON

ENGINE SWITCH

Direction to pull

STARTER 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.

ON

OFF

FUEL VALVE LEVER

Choke Lever

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 CLOSED

starting.

OPEN

14

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

AC CIRCUIT BREAKER

OFF

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	AC CIRCUIT PROTECTOR
for Receptacle	for Receptacle

AC CIRCUIT PROTECTOR

for Receptacle

120V 30A
120V 20A
120V 20A
: Except EG4000CL	120V/240V 20A	(EG4000CL)
	120V/240V 30A	(EG5000CL, EG6500CL)
AC CIRCUIT PROTECTOR
ON
OFF	PUSH

16

CONTROLS & FEATURES

FEATURES

Oil AlertSystem

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 38 ) 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.

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 TANK CAP

FUEL GAUGE

FULL EMPTY

Ground Terminal

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 38 ). 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 41 ). A dirty air cleaner element will restrict air flow to the carburetor, reducing engine and generator performance.

Check the fuel level (see page 36 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

20

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, review chapters

GENERATOR SAFETY (see page 6 ) and BEFORE OPERATION (see 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.

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.

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 on page 21 and perform the IS YOUR GENERATOR READY TO GO checks (see page 19 ). Refer to AC OPERATION (see page 26 ) for connecting loads to the generator.

1.Make sure that the AC circuit breaker is in the OFF position. The generator may be hard to start if a load is connected.

2.Turn the fuel valve lever to the ON position.

OFF

AC CIRCUIT BREAKER

FUEL VALVE LEVER

ON

22