The‘‘e-SPEC’’mark symbolizes environmentally
responsible technologies applied to Honda power
equipment, which contains our wish to ‘‘preserve
nature for generations to come.’’
Thank you for purchasing a Honda generator.
This manual covers operation and maintenance of the EM3100CX·
EM4500CX·EM5500CX·EM4500CXS·EM5500CXS generators.
All information in this publication is based on the latest product
information available at the time of approval for printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time
without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
This manual should be considered a permanent part of the generator
and should remain with it if it is resold.
Pay special attention to statements preceded by the following words:
Indicates a strong possibility of severe personal injury or
death if instructions are not followed.
Indicates a possibility of personal injury or equipment
damage if instructions are not followed.
Gives helpful information.
If a problem should arise, or if you have any questions about the
generator, consult an authorized Honda dealer.
Honda generator is designed to give safe and dependable service if
operated according to instructions. Read and understand the Owner’s
Manual before operating the generator. Failure to do so could result
in personal injury or equipment damage.
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.
Never attempt to modify the generator. It can cause an accident as
well as damage to the generator and appliances.
Do not connect an extension to the muffler.
Do not modify the intake system.
Do not adjust the governor.
Do not remove the control panel or do not change the wiring of the
control panel.
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.
Be sure to observe the instructions in this manual for how to use the
generator and maintenance information. Ignoring or improperly
following the instructions can cause an accident such as an electric
shock, and the condition of the exhaust gas may deteriorate.
Place the generator on a firm level place before operation.
Do not operate the generator with any cover removed. You may get
your hand or foot caught in the generator and it may cause accident.
Consult your authorized Honda dealer for disassembly and service of
the generator that are not covered in this manual.
3
Carbon Monoxide Hazards
Exhaust contains poisonous carbon monoxide, a colorless, odorless
gas. Breathing exhaust can cause loss of consciousness and may lead
to death.
If you run the generator in an area that is confined, or even partially
enclosed area, the air you breathe could contain dangerous amount of
exhaust gas.
Never run your generator inside a garage, house, or near open
windows or doors.
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.
If you get an electric shock, consult a doctor and have medical
treatment immediately.
Do not connect to a building’s electrical system unless an isolation
switch has been installed by a qualified electrician.
4
Fire and Burn Hazards
Do not use the generator in areas with a high risk of fire.
When installed in ventilated rooms, additional requirements for fire
and explosion protection shall be observed.
The exhaust system gets hot enough to ignite some materials.
−
Keep the generator at least 1 meter (3 feet) away from buildings and
other equipment during operation.
−
Do not enclose the generator in any structure.
−
Keep flammable materials away from the generator.
Some parts of the internal combustion engine are hot and may cause
burns. Pay attention to the warnings on 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.
Do not pour the water directly on the generator to put out the fire
when it occurs. Use an appropriate fire extinguisher specially
designed for electric fire or oil fire.
If you inhale fumes produced by an accidental fire with the generator,
consult a doctor and have medical treatment immediately.
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.
5
Disposal
To protect the environment, do not dispose of the used generator,
battery, engine oil, etc. carelessly by leaving them in the waste.
Observe the local laws or regulations or consult your authorized
Honda generator dealer to dispose of these parts.
Please dispose of used motor oil in a manner that is compatible with
the environment. We suggest you take it in a sealed container to your
local service station for reclamation. Do not throw it in the trash or
pour it on the ground.
An improperly disposed battery can hurt the environment. Always
confirm local regulations for battery disposal. Contact your Honda
servicing dealer for a replacement.
6
SAFETY LABEL LOCATIONS2.
These labels warn you of potential hazards that can cause serious
injury. Read the labels and safety notes and precautions described in
this manual carefully.
If a label comes off or becomes hard to read, contact your Honda
dealer for a replacement.
READ OWNER’S MANUALCONNECT CAUTIONFUEL CAUTION
EXHAUST CAUTION
HOT CAUTION
HOT CAUTION
7
Honda generator is designed to give safe and
dependable service if operated according to
instructions.
Read and understand the Owner’s Manual
before operating the generator. Failure to do
so could result in personal injury or equipment
damage.
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 partially 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.
Do not connect to a building’s electrical
system unless an isolation switch has been
installed by a qualified electrician.
Connections for standby power to a building’s
electrical system must be made by a qualified
electrician and mu st comply with all
applicable laws and electrical codes. Improper
connections can allow electrical current from
the generator to backfeed into the utility lines.
Such backfeed may electrocute utility
company workers or others who contact the
lines during a power outage, and when utility
power is restored, the generator may explode,
burn, or cause fires in the building’s electrical
system.
8
Stop the engine before refueling.
Gasoline is extremely flammable and
explosive under certain conditions.
Refuel in a well ventilated area with
the engine stopped.
Keep away from cigarette, smoke and
sparks when refueling the generator.
Always refuel in a well ventilated
location.
Wipe up spilled gasoline at once.
A hot exhaust system can cause serious burns.
Avoid contact if the engine has been running.
9
CE mark and noise label locations
NOISE LABEL AND CE MARK
NOISE LABEL
Performance class
IP code
Dry mass
[Example:EM5500CXS]
Year of manufacture
Manufacturer and address
10
CHOKE ROD
AIR CLEANER
FUEL VALVE LEVER
COMPONENT IDENTIFICATION3.
CONTROL PANEL
STARTER GRIP
ENGINE SERIAL NUMBER
FUEL TANK CAP
FUEL GAUGE
FUSE (CXS type)
OIL DRAIN BOLT
MUFFLER
OIL FILLER CAP
SPARK PLUG CAP
FRAME SERIAL NUMBER
Record the frame serial number and the engine serial number in the
spaces below. You will need these serial numbers when ordering parts.
The Auto Throttle 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 rated speed.
ON:
OFF:
Recommended to minimize fuel consumption and further
reduce noise levels when no load is applied to the generator.
The Auto Throttle system does not operate.
Recommended to minimize warm-up time when the generator
is started.
Leave the switch in the OFF position when using appliances that
require only momentary power, that have a power demand of
less than 1 ampere, or that have large startup power demands.
AUTO THROTTLE SWITCH
OFF
ON
OFF
14
ON
4.
PRE-OPERATION CHECK
Be sure to check the generator on a level surface with the engine
stopped.
Check the engine oil level before each use.
1.
Using non detergent oil or 2-stroke engine oil could shorten the
engine’s service life.
Use 4-stroke motor oil that meets or exceeds the requirements for API
service category SE or later (or equivalent). Always check the API
service label on the oil container to be sure it includes the letters SE or
later (or equivalent).
AMBIENT TEMPERATURE
SAE 10W-30 is recommended for general, all-temperature use. Other
viscosities shown in the chart may be used when the average
temperature in your area is within the indicated range.
Remove the oil filler cap and wipe the dipstick clean.
1.
Check the oil level by inserting the dipstick in the filler hole without
2.
screwing it in.
If the oil level is low, fill to the upper limit of the oil filler neck with
3.
the recommended oil.
Running the engine with insufficient oil can cause serious engine
damage.
The Oil Alert System will automatically stop the engine before the oil
level falls below the safe limit. However, to avoid the inconvenience of
an unexpected shutdown, it is still advisable to visually inspect the oil
level regularly.
OIL FILLER HOLE
OIL FILLER CAP
DIPSTICK
UPPER LIMIT
15
Check the fuel level.
2.
Check the fuel gauge. If the fuel level is low, refuel the fuel tank until
the level as specified.
After refueling, tighten the fuel tank cap securely.
Use automotive unleaded gasoline with a Research Octane Number of
91 or higher (a Pump Octane Number of 86 or higher).
Never use stale or contaminated gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
Gasoline is extremely flammable and is explosive under certain
conditions.
Refuel in a well ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
Do not overfill the fuel tank (there should be no fuel above the
upper level mark (red) on the fuel strainer). After refueling, make
sure the fuel tank cap is closed properly and securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
starting the engine.
Avoid repeated or prolonged contact with skin or breathing of
vapor.
KEEP OUT OF REACH OF CHILDREN.
UPPER LEVEL MARK (RED)
FUEL GAUGE
FULL
16
FUEL TANK CAP
EMPTY
FUEL STRAINER
UPPER
LEVEL
MARK (RED)
Gasoline spoils very quickly depending on factors such as light
exposure, temperature and time.
In worst cases, gasoline can be contaminated within 30 days.
Using contaminated gasoline can seriously damage the engine
(caburetor clogged, valve stuck).
Such damage due to spoiled fuel is disallowed from coverage by the
warrantry.
To avoid this please strictly follow these recommendations:
Only use specified gasoline (see page).
Use fresh and clean gasoline.
To slow deterioration, keep gasoline in a certified fuel container.
If long storage (more than 30 days) is foreseen, drain fuel tank and
carburetor (see page).
Gasolines Containing Alcohol
If you decide to use a gasoline containing alcohol (gasohol), be sure its
octane rating is at least as high as that recommended by Honda. There
are two types of ‘‘gasohol’’: one containing ethanol, and the other
containing methanol.
Do not use gasohol that contains more than 10% ethanol. Do not use
gasoline containing methanol (methyl or wood alcohol) that does not
also contain cosolvents and corrosion inhibitors for methanol. Never
use gasoline containing more than 5% methanol, even if it has
cosolvents and corrosion inhibitors.
47
16
Fuel system damage or engine performance problems resulting
from the use of fuels that contain alcohol is not covered under the
warranty.
Honda cannot endorse the use of fuels containing methanol since
evidence of their suitability is as yet incomplete.
Before buying fuel from an unfamiliar station, try to find out if the
fuel contains alcohol, if it does, confirm the type and percentage of
alcohol used.
If you notice any undesirable operating symptoms while using a
gasoline that contains alcohol, or one that you think contains
alcohol, switch to a gasoline that you know does not contain alcohol.
17
3.
Check the air cleaner.
Check the air cleaner element to be sure it is clean and in good
condition.
Unsnap the two air cleaner cover clips, remove the air cleaner cover,
and remove the air cleaner element.
Clean or replace the element if necessary (see page).
41
Never run the engine without the air cleaner element. Rapid engine
wear will result from contaminants, such as dust and dirt, being
drawn through the carburetor, into the engine.
AIR CLEANER COVER
18
CLIP
ELEMENT
STARTING THE ENGINE5.
Make sure that the circuit breaker is OFF.
The generator may be hard to start if a load is connected.
CIRCUIT BREAKER
OOFFFF
OOFFFF
19
Electric starting
(CXS type)
When starting the generator after adding fuel for the first time, after
long-term storage, or after running out of fuel, turn the fuel valve
lever to the ON position, then wait for 10 to 20 seconds before
starting the engine.
1.2.B type:
Set the Voltage Selector Switch to match the voltage requirements
for the application.
VOLTAGE SELECTOR SWITCH
230 V
115 V
Turn the fuel valve lever to the ON position.
OOFFFF
ON
FUEL VALVE LEVER
20
Make sure the auto throttle switch is in the OFF position, or more
3.
time will be required for warm up.
(F,G,GW,ITtypes)
AUTO THROTTLE SWITCH
OFF
OFF
(B type)
OFF
AUTO THROTTLE SWITCH
OOFFFF
21
Turn the engine switch to the START position and hold it there for 5
4.
seconds or until the engine starts.
After the engine starts, let the engine switch return to the ON
position.
OFF
ON
START
ENGINE SWITCH
OOFFFF
ON
START
Do not use the electric starter for more than 5 seconds at a time. If the
engine fails to start, release the switch and wait 10 seconds before
operating the starter again.
When the speed of the starter motor drops after a period of time, it is
an indication that the battery should be recharged.
22
If you wish to use the auto throttle system, turn the auto throttle
5.
switch to the ON position after the engine has warmed up for 2 or 3
minutes.
(F,G,GW,ITtypes)
AUTO THROTTLE SWITCH
ON
ON
(B type)
AUTO THROTTLE SWITCH
ON
OONN
23
Manual starting
When starting the generator after adding fuel for the first time, after
long-term storage, or after running out of fuel, turn the fuel valve
lever to the ON position, then wait for 10 to 20 seconds before
starting the engine.
1.2.B type:
Set the Voltage Selector Switch to match the voltage requirements
for the application.
VOLTAGE SELECTOR SWITCH
230 V
115 V
Turn the fuel valve lever to the ON position.
OOFFFF
ON
FUEL VALVE LEVER
24
CX type:
3.
Pull the choke rod to the CLOSED position to start a cold engine.
Push the choke rod in the OPEN position to start a warm engine.
CXS type:
The auto choke will be closed if the engine is cold. If you want to
operate the choke manually, pull the choke rod out to the CLOSED
position.
OPEN
CCLLOOSSEEDD
CCLLOOSSEEDD
CHOKE ROD
25
4. CXS type:
Make sure the auto throttle switch is in the OFF position, or more
time will be required for warm up.
(F,G,GW,ITtypes)
AUTO THROTTLE SWITCH
OFF
OFF
(B type)
AUTO THROTTLE SWITCH
26
OFF
OOFFFF
Turn the engine switch to the ON position.5.
(CX type)
(CXS type)
ENGINE SWITCH
ON
OOFFFF
ON
OOFFFF
OFF
ENGINE SWITCH
ON
OFF
ON
27
Pull the starter grip lightly until you feel resistance, then pull the
6.
starter grip briskly toward in the direction of the arrow as shown
below.
The starter grip can be drawn back very quickly before you release
it. This may pull your hand forcefully toward the engine and cause
an injury.
Do not allow the starter grip to snap back. Return it slowly by hand.
Do not let the starter rope rub against the generator body, or the
rope will wear out prematurely.
DDiirreeccttiioonn ttoo ppuullll
STARTER GRIP
Push the choke rod to the OPEN position as the engine warms up.
7.
OOPPEENN
CHOKE ROD
28
8. CXS type:
If you wish to use the auto throttle system, turn the auto throttle
switch to the ON position after the engine has warmed up for 2 or 3
minutes.
(F,G,GW,ITtypes)
AUTO THROTTLE SWITCH
ON
ON
(B type)
AUTO THROTTLE SWITCH
ON
OONN
29
High altitude operation
At high altitude, the standard carburetor air-fuel mixture will be
excessively rich. Performance will decrease, and fuel consumption will
increase.
High altitude performance can be improved by specific modifications
to the carburetor. If you always operate the generator at altitudes
higher than 1,500 meters (5,000 feet) above sea level, have your
authorized Honda dealer perform these carburetor modifications.
Even with suitable carburetor jetting, engine horsepower will decrease
approximately 3.5% for each 300 meter (1,000 foot) increase in altitude.
The affect of altitude on the horse power will be greater than this if no
carburetor modification is made.
Operation of the generator at an altitude lower than the carburetor is
jetted for may result in reduced performance, overheating, and
serious engine damage caused by an excessively lean air/fuel mixture.
30
6.
GENERATOR USE
Be sure to ground the generator when the connected equipment is
grounded.
Do not connect to a building’s electrical system unless an isolation
switch has been installed by a qualified electrician.
Connections for standby power to a building’s electrical system
must be made by a qualified electrician and must comply with all
applicable laws and electrical codes. Improper connections can
allow electrical current from the generator to back feed into the
utility lines. Such back feed may electrocute utility company
workers or others who contact the lines during a power outage,
and when utility power is restored, the generator may explode,
burn, or cause fires in the building’s electrical system.
Do not exceed the current limit specified for any one receptacle.
Do not connect the generator to a household circuit. This could
cause the damage to the generator or to electrical appliances in the
house.
Do not modify or use the generator for other purposes than it is
intended for. Also observe the following when using the generator.
Do not connect an extension to the exhaust pipe.
When an extension cable is required, be sure to use a tough rubber
sheathed flexible cable (IEC 245 or equivalent).
Limit length of extension cables; 60 m (200 feet) for cables of 1.5
(0.0023 in ) and 100 m (330 feet) for cables of 2.5 mm (0.0039
mm
). Long extension cables will lower usable power due to
in
resistance in the extension cable.
Keep the generator away from other electric cables or wires such as
commercial power supply lines.
31
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.
Substantial overloading will switc h OFF the circuit b reaker.
Exceeding the time limit for maximum power operation or slightly
overloading the generator may not switch the circuit breaker or DC
circuit protector OFF, but will shorten the service life of the
generator.
Limit operation requiring maximum power to 30 minutes.
Maximum power is:
EM3100CX:
EM4500CX·4500CXS:
EM5500CX·5500CXS:
For continuous operation, do not exceed the rated power.
Rated power is:
EM3100CX:
EM4500CX·4500CXS:
EM5500CX·5500CXS:
In either case, the total power requirements (VA) of all appliances
connected must be considered.
Most appliance motors require more than their rated wattage for
startup.
3.1 kVA
4.5 kVA
5.5 kVA
2.8 kVA
4.0 kVA
5.0 kVA
32
AC Applications
Be sure that all appliances are in good working order before
connecting them to the generator. Electrical equipment (including
lines and plug connections) should not be defective. If an appliance
begins to operate abnormally, becomes sluggish, or stops suddenly,
turn off the generator engine switch immediately. Then disconnect
the appliance, and examine it for signs of malfunction.
(B type only):1.
Set the Voltage Selector Switch to match the voltage
requirements for the appliance.
VOLTAGE SELECTOR SWITCH
Start the engine (see page).
2.
Switch the circuit breaker ON.
3.
ON
230 V
115V
19
CIRCUIT BREAKER
ON
Confirm that the appliance to be used is switched off, and plug in the
4.
appliance.
Most motorized appliances require more than their rated power for
startup.
33
AC Circuit Protector
(Except EM3100CX F, G types)
The AC circuit protectors will automatically switch OFF (push button
comes out) if there is a short circuit or a significant overload of the
generator at 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 c ircuit protector ON
(pushing the push button in).
Btype
ON
OFF
AC CIRCUIT PROTECTOR
(For 115 V receptacle No.1)
115 V RECEPTACLE
No.1
AC CIRCUIT PROTECTOR
(For 115 V receptacle No.2)
115 V RECEPTACLE
No.2
34
F, G, GW types
(Except EM3100CX)
AC CIRCUIT PROTECTOR
(For receptacle No.1)
IT type
AC CIRCUIT PROTECTOR
(For receptacle No.2)
RECEPTACLE No.1RECEPTACLE No.2
AC CIRCUIT PROTECTOR
(For receptacle No.1)
RECEPTACLE No.1
35
Oil Alert System
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 fall s below a safe limit, the Oil Alert system will
automatically shut down 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.15
36
STOPPING THE ENGINE7.
To stop the engine in an emergency, turn the engine switch to the OFF
position.
IN NORMAL USE:
Turn the circuit breaker to the OFF position.
1.
CIRCUIT BREAKER
ON
OFF
Turn the engine switch to the OFF position.
2.
(CX type)(CXS type)
ON
OOFFFF
ON
OOFFFF
OFF
OFF
ON
ON
OOFFFF
ENGINE SWITCH
37
Turn the fuel valve lever to the OFF position.3.
FUEL VALVE LEVER
OFF
ON
38
MAINTENANCE8.
The purpose of the maintenance and adjustment schedule is to keep
the generator in the best operating condition.
Inspect or service as scheduled in the table below.
Make sure the engine is off before you begin any maintenance or
repairs. This will eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is
adequate ventilation whenever you operate the engine.
Burns from hot parts. Let the engine and exhaust system cool
before touching.
Injury from moving parts. Do not run the engine unless instructed
to do so.
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 maintenance.
Use Honda Genuine parts or their equivalent. The use of replacement
parts which are not of equivalent quality may damage the generator.
Maintenance Schedule
REGULAR SERVICE PERIOD (3)
Performed at every indicated
month or operating hour interval,
whichever comes first.
ITEM
Engine oil
Air cleaner
Sediment cup
Spark plug
Valve clearance
Combustion
chamber
Fuel tank and filter
Fuel tube
(1)
Service more frequently when used in dusty areas.
(2)
These items should be serviced by your Honda servicing dealer, unless you have the
proper tools and are mechanically proficient. Refer to the Honda shop manual for service
procedures.
(3)
For commercial use, log hours of operation to determine proper maintenance intervals.
Drain the oil while the engine is still warm to assure rapid and
complete draining.
Remove the oil drain bolt and sealing washer, remove the oil filler
1.
cap, and drain the oil.
Reinstall the drain bolt and sealing washer. Tighten the bolt securely.
2.
Refill with the recommended oil (see page) and check the oil level.
3.15
Oil capacity:
1.1L(1.2USqt,1.0lmpqt)
SEALING WASHER
UPPER LIMIT
OIL DRAIN BOLTOIL FILLER CAP
Wash your hands with soap and water after handling used oil.
Please dispose of used motor oil in a manner that is compatible with
the environment. We suggest you take it in a sealed container to your
local service station for reclamation. Do not throw it in the trash or
pour it on the ground.
40
AIR CLEANER SERVICE
2.
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service more
frequently when operating the generator in extremely dusty areas.
Do not use gasoline or low flash point solvents for cleaning. They are
flammable and explosive under certain conditions.
Never run the engine without the air cleaner element. Rapid engine
wear will result.
Unsnap the two air cleaner cover clips, remove the air cleaner cover,
1.
and remove the air cleaner element.
CLIP
ELEMENT
AIR CLEANER COVER
Wash the air cleaner element in a solution of household detergent
2.
ELEMENT
and warm water, then rinse thoroughly, or wash in nonflammable or
high flashpoint solvent. Allow the air cleaner element to dry
thoroughly.
Soak the air cleaner element in clean engine oil and squeeze out the
3.
excess oil. The engine will smoke during initial startup if too much
oil is left in the air cleaner element.
Reinstall the air cleaner element and the cover.
4.
properly
hooked
improperly
hooked
CLIP
ELEMENT
AIR CLEANER COVER
41
FUEL SEDIMENT CUP SERVICE
3.
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
The sediment cup prevents dirt or water that may be in the fuel tank
from entering the carburetor. If the engine has not been run for a long
time, the sediment cup should be cleaned.
Turn the fuel valve lever to the OFF position. Remove the sediment
1.
cup, O-ring, and filter.
Clean the sediment cup and filter in nonflammable or high flash
2.
point solvent.
Reinstall the filter, O-ring, and sediment cup.
3.
Turn the fuel valve lever to the ON position and check for leaks.
4.
After installing the sediment cup, be sure to tighten it securely. Check
for fuel leaks and make sure the area is dry before starting the engine.
FUEL VALVE LEVER
FILTER
O-RING
SEDIMENT CUP
42
OFF
SPARK PLUG SERVICE
4.
Recommended spark plugs:
BPR5ES (NGK)
W16EPR-U (DENSO)
To ensure proper engine operation, the spark plug must be properly
gapped and free of deposits.
If the engine has been running, the muffler will be very hot. Be careful
not to touch the muffler.
Remove the spark plug cap.
1.
Clean any dirt from around the spark plug base.
2.
Use a spark plug wrench to remove the spark plug.
3.
SPARK PLUG WRENCH
SPARK PLUG CAP
Visually inspect the spark plug.
4.
Discard it if the insulator is
cracked, chipped, or fouled. Clean
the spark plug with a wire brush if
it is to be reused.
Measure the plug gap with a
5.
feeler gauge.
Correct as necessary by carefully
bending the side electrode.
The gap should be:
0.70.8 mm (0.0280.031 in)
−−
SIDE ELECTRODE
0.7 0.8 mm
−
(0.028 0.031 in)
−
SEALING WASHER
43
Make sure that the sealing washer is in good condition, and thread
6.
the spark plug in by hand to prevent cross-threading.
After the spark plug is seated, tighten with a spark plug wrench to
7.
compress the washer.
If installing a new spark plug, tighten 1/2 turn after the spark plug seats
to compress the washer. If reinstalling a used spark plug, tighten 1/8 to
1/4 turn after the spark plug seats.
Reinstall the spark plug cap on the spark plug securely.
8.
The spark plug must be securely tightened. An improperly
tightened plug can become very hot and possibly damage the
generator.
Never use a spark plug with an improper heat range.
44
FUSE REPLACEMENT
5.
(CXS type)
If the fuse is blown, the starter motor will not work until it is replaced.
Turn the engine switch to the OFF position.
1.
Remove the fuse holder cover and replace the fuse.
2.
The specified fuse is 10A.
FUSE HOLDER COVER
If frequent fuse failure occurs, determine the cause and correct the
problem before attempting to operate the generator further.
Never use a fuse with a different rating from that specified. Serious
damage to the electrical system or fire may result.
45
TRANSPORTING/STORAGE
9.
Transporting
To prevent fuel spillage when transporting or during temporary
storage, the generator should be secured upright in its normal
operating position, with the engine switch OFF.
The fuel valve lever should be turned OFF.
When transporting the generator:
Do not overfill the tank.
Do not operate the generator while it is on a vehicle. Take the
generator off the vehicle and use it in a well ventilated place.
Avoid a place exposed to direct sunlight when putting the
generator on a vehicle. If the generator is left in an enclosed
vehicle for many hours, high temperature inside the vehicle could
cause fuel to vaporize resulting in a possible explosion.
Do not drive on a rough road for an extended period with the
generator on board. If you must transport the generator on a
rough road, drain the fuel from the generator beforehand.
Take care not to drop or strike the generator when transporting.
Do not place heavy object on the generator.
When transporting the generator by loading it on to a vehicle, secure
to the generator frame as shown.
46
Storage
1.
Drain the carburetor by loosening the drain screw. Drain the
gasoline into a suitable container.
Gasoline is extremely flammable and is explosive under certain
conditions. Perform this task in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the area during
this procedure.
DRAIN SCREW
2.
Change the engine oil (refer to page).
3.
Remove the spark plug, and pour about a tablespoon of clean
40
engine oil into the cylinder. Turn the engine several revolutions
slowly with the recoil starter to distribute the oil, then reinstall the
spark plug.
4.
Slowly pull the starter grip until resistance is felt. At this point, the
piston is coming up on its compression stroke and both the intake
and exhaust valves are closed. Storing the engine in this position
will help to protect it from internal corrosion.
Align the notch on the starter pulley
with the hole at the top of recoil starter.
47
TROUBLESHOOTING10.
When the engine will not start:
Is there fuel in
the tank?
YES
Is the engine
switch ON?
YES
Is there enough
oil in the engine?
YES
Is the spark plug
in good
condition?
YES
NO
NO
NO
NO
Refill the fuel
tank (see page
).
16
Turn the engine
switch on (see
22
pagefor
electric starting
27
orfor manual
starting).
Add the
recommended
oil (see page).
Clean, readjust
gap and dry the
spark plug.
Replace it if
necessary (see
43
page).
15
Is the fuel
reaching the
carburetor?
If the engine still
does not start,
take the
generator to an
authorized
Honda dealer.
48
YES
NO
To check:
Turn off the engine switch and loosen the
1)
drain screw (see page).
Turn the fuel valve to ON. Fuel should flow
2)
from the drain when the fuel valve is
turned ON.
Clean the fuel
sediment cup
(see page).
47
42
[CXS Type]
Starter motor does not turn round;
Isthefuseblown?Replacethefuse(see
NO
Is the battery
discharged?
NO
If the starter motor
still does not turn
round, take the
generator to an
autorized Honda
dealer.
YES
YES
page).
45
Charge the battery.
49
No electricity at the AC receptacles:
Is the circuit
breaker ON?
YES
Is the AC circuit
protector ON?
YES
Check the electrical
appliance or
equipment for any
defects.
NO
NO
NO DEFECTS
DEFECTS
Turn the circuit
breaker ON (see
page).
33
Reset the AC
circuit protector
(see page).
Take the generator
to an authorized
Honda generator
dealer.
Replace the
electrical
appliance or
equipment.
Take the
electrical
appliance or
equipment to an
electrical shop
for repair.
34
50
Dimensions and Weight
Model
Description code
Length
Width
Height
Dry mass (weight)
Engine
Model
Engine type
Displacement
BoreStroke
×××
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
SPECIFICATIONS
11.
EM3100CX
EARC
681 mm (26.8 in)
530 mm (20.9 in)
546 mm (21.5 in)
74.5 kg (164.2 lbs)
GX240
4-stroke, overhead valve, single cylinder
242 cm
73.058.0 mm (2.87 in2.28 in)
Transistorized magneto
1.1L(1.2USqt,1.0lmpqt)
23.5 L (6.21 US gal, 5.17 lmp gal)
W16EPR-U (DENSO)
(14.8 cu-in)
8.2:1
3,000 rpm
Forced air
BPR5ES (NGK)
Generator
AC
output
Model
Type
Rated Voltage (V)
Rated Frequency (Hz)
Rated Ampere (A)
Rated Output (kVA)
Max. Output (kVA)
B
115/230
24.3/12.2
EM3100CX
F, G
230
50
12.2
2.8
3.1
51
Noise
Model
Type
Sound pressure level (Lp )
According to 98/37/EC
Microphone point
CONTROL
Center
PANEL
1.0 m
A
1.60 m
EM3100CX
B, F, G
78 dB
Guaranteed sound power level
WA
(L) Tested by 2000/14/EC
96 dB
‘‘the figures quoted are emission levels and are not necessarily safe
working levels. Whilst there is a correlation between the emission and
exposure levels, this cannot be used reliably to determine whether or
not further precautions are required. Factors that influence the actual
level of exposure of work-force include the characteristics of the work
room, the other sources of noise, etc. i.e. the number of machines and
other adjacent processes, and the length of time for which an operator
is exposed to the noise. Also the permissible exposure level can vary
from country. This information, however, will enable the user of the
machine to make a better evaluation of the hazard and risk’’.
Specifications are subject to change without notice.
52
Dimensions and Weight
Model
Description code
Length
Width
Height
Dry mass (weight)
Engine
Model
Engine type
Displacement
BoreStroke
×××
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
Generator
Model
Type
Rated Voltage (V)
AC
output
Rated Frequency (Hz)
Rated Ampere (A)
Rated Output (kVA)
Max. Output (kVA)
EM4500CXEM4500CXS
EASC
681 mm (26.8 in)
530 mm (20.9 in)
87.8 kg (193.6 lbs)
GX340
4-stroke, overhead valve, single cylinder
337 cm
82.064.0 mm (3.23 in2.52 in)
Transistorized magneto
1.1L(1.2USqt,1.0lmpqt)
23.5 L (6.21 US gal, 5.17 lmp gal)
W16EPR-U (DENSO)
EM4500CX·EM4500CXS
B
115/230
34.8/17.4
(20.6 cu-in)
8.0:1
3,000 rpm
Forced air
BPR5ES (NGK)
50
4.0
4.5
EATC
877 mm (34.5 in)
530 mm (20.9 in)
546 mm (21.5 in)546 mm (21.5 in)
95.3 kg (210.1 lbs)
F, G, GW
230
17.4
53
Noise
Model
Type
Sound pressure level (Lp )
According to 98/37/EC
Microphone point
CONTROL
Center
PANEL
1.0 m
A
1.60 m
EM4500CX·EM4500CXS
B, F, G, GW
80 dB
Guaranteed sound power level
WA
(L) Tested by 2000/14/EC
97 dB
‘‘the figures quoted are emission levels and are not necessarily safe
working levels. Whilst there is a correlation between the emission and
exposure levels, this cannot be used reliably to determine whether or
not further precautions are required. Factors that influence the actual
level of exposure of work-force include the characteristics of the work
room, the other sources of noise, etc. i.e. the number of machines and
other adjacent processes, and the length of time for which an operator
is exposed to the noise. Also the permissible exposure level can vary
from country. This information, however, will enable the user of the
machine to make a better evaluation of the hazard and risk’’.
Specifications are subject to change without notice.
54
Dimensions and Weight
Model
Description code
Length
Width
Height
Dry mass (weight)
Engine
Model
Engine type
Displacement
BoreStroke
×××
Compression ratio
Engine speed
Cooling system
Ignition system
Oil capacity
Fuel tank capacity
Spark plug
Generator
Model
Type
Rated Voltage (V)
AC
output
Rated Frequency (Hz)
Rated Ampere (A)
Rated Output (kVA)
Max. Output (kVA)
EM5500CX
EAUC
681 mm (26.8 in)
530 mm (20.9 in)
546 mm (21.5 in)
90.1 kg (198.6 lbs)
GX390
4-stroke, overhead valve, single cylinder
389 cm
88.064.0 mm (3.46 in2.52 in)
8.0:1
3,000 rpm
Forced air
Transistorized magneto
1.1L(1.2USqt,1.0lmpqt)
23.5 L (6.21 US gal, 5.17 lmp gal)
BPR5ES (NGK)
W16EPR-U (DENSO)
EM5500CX·EM5500CXS
B
115/230
43.5/21.7
EM5500CXS
EAVC
877 mm (34.5 in)
530 mm (20.9 in)
546 mm (21.5 in)
97.6 kg (215.2 lbs)
(23.7 cu-in)
F, G, GW, IT
230
50
21.7
5.0
5.5
55
Noise
Model
Type
Sound pressure level (Lp )
According to 98/37/EC
Microphone point
CONTROL
Center
PANEL
1.0 m
A
1.60 m
EM5500CX·EM5500CXS
B, F, G, GW, IT
80 dB
Guaranteed sound power level
WA
(L) Tested by 2000/14/EC
97 dB
‘‘the figures quoted are emission levels and are not necessarily safe
working levels. Whilst there is a correlation between the emission and
exposure levels, this cannot be used reliably to determine whether or
not further precautions are required. Factors that influence the actual
level of exposure of work-force include the characteristics of the work
room, the other sources of noise, etc. i.e. the number of machines and
other adjacent processes, and the length of time for which an operator
is exposed to the noise. Also the permissible exposure level can vary
from country. This information, however, will enable the user of the
machine to make a better evaluation of the hazard and risk’’.
Specifications are subject to change without notice.
56
12.
STANDARD KIT PARTS
Battery Tray Kit (CXS type)
INSTALLATION OF KIT PARTS
Unscrew the four 610 mm flange bolts, and remove the side
1.
×
panel.
Route the starter cable under the tank and connect it to the starter
2.
solenoid.
Connect the ground cable to the generator.
3.
Pass the starter cable and the ground cable through the slots on the
4.
side panel.
Reinstall the side panel using the four 610 mm flange bolts.
5.
STARTER SOLENOID
STARTER CABLE
(positive)
×
CABLE TIE
GROUND
CABLE
SIDE PANEL
SLOT
STARTER CABLE
GROUND CABLE
610 mm FLANGE BOLT (4)
×
57
Install the battery guards on the frame using the four 812 mm
6.
×
flange bolts.
Install the battery tray on the battery guards using the four 840
7.
mm flange bolts.
Set the battery on the battery tray and secure with the battery
8.
bracket.
Connect the starter cable to the battery positive () terminal first,
9.
then to the negative () terminal. When disconnecting, disconnect
at the battery negative () terminal first.
Install the battery guard plate using the four 840 mm flange bolts
10.
and two 812 mm flange bolts.
BATTERY
BRACKET
BATTERY
×
−
−
STARTER
CABLE
+
()
−
()
+
×
×
Use a battery rated at
−−
12V 18 30Ah or more
BATTERY
GUARD
×
840mm
FLANGE BOLT (4)
×
840mm
FLANGE BOLT (4)
BATTERY
GUARD PLATE
58
GROUND
CABLE
×
812mm
FLANGE BOLT (2)
BATTERY
TRAY
BATTERY
GUARD
×
812mm
FLANGE BOLT (4)
OPTIONAL KIT PARTS
2 Wheel Type
Handle Installation
Install the right and left handles on the generator upper frame using
the handle brackets and four flange bolts.
Wheel Kit Installation
Apply grease to the axle shaft as shown below, and install the two
1.
wheels on the axle shaft using the washers and split pins.
Install the axle assembly on the generator using four 816 mm
2.
×
flange bolts and 8 mm flange nuts.
Install the two stands on the under frame using four 816 mm
3.
×
flange bolts.
−− −
TORQUE:
LEFT UPPER HANDLE ASSY
LEFT HANDLE BRACKET
8 16 mm FLANGE BOLT (4)
×
20 mm PLAIN WASHER (2)
WHEEL (2)
2429 N·m (2.43.0 kgf·m , 1722 lbf·ft)
×
8 16 mm FLANGE BOLT (4)
RIGHT UPPER
HANDLE ASSY
LONGER
RIGHT HANDLE BRACKET
×
8 16 mm FLANGE BOLT (4)
AXLE
SHAFT
GENERATOR
SIDE
4.0 28 mm
×
SPLIT PIN (2)
STAND (2)
8 mm FLANGE NUT (4)
59
4 Wheel Type
Install the lock plate and four wheels on the wheel shaft using the
1.
washers and split pins.
Install the left wheel shaft on the left side nearest the engine.
Install the wheel shaft assembly on the generator using eight 816
2.
mm flange bolts and 8 mm flange nuts.
TORQUE:
−− −
2429 N·m (2.43.0 kgf·m , 1722 lbf·ft)
×
8 16 mm FLANGE BOLT (8)
LONGER
WHEEL (4)
RIGHT WHEEL SHAFT
LEFT WHEEL SHAFT
GENERATOR
SIDE
×
60
8 mm FLANGE NUT (8)
20mm PLAIN WASHER (4)
LOCK PLATE
4 28 mm SPLIT PIN (4)
×
Hanger Kit Installation
Position the hanger at the generator’s balance point as shown below.
1.
Fit the end tabs of the hanger through the bracket slots, and bolt the
2.
brackets to the hanger and tighten securely.
TORQUE:
8 16 mm FLANGE BOLT (4)
×
−− −
2429 N·m (2.43.0 kgf·m , 1722 lbf·ft)
HANGER
HANGER BRACKET (2)
280 mm (11 in)
HANGER
GENERATOR
SIDE
61
[CXS type]
Remote Control Kit
Unscrew the four 610 mm flange bolts, and remove the side
1.
×
panel.
Remove the plug from the 6-pin connector.
2.
Connect the remote control cable to the 6-pin connector.
3.
Pass the remote control cable through the cord grommet, and fit the
4.
grommet into the cutout.
Reinstall the side panel using the four 610 mm flange bolts.
5.
6-PIN CONNECTOR
REMOTE CONTROL CABLE
PLUG
CORD GROMMET
50 mm
×
CUTOUT
SIDE PANEL
REMOTE CONTROL BOX
62
610 mm FLANGE BOLT (4)
×
To avoid accidentally unplugging the remote control cable, secure
6.
the cable to the generator frame with the cable ties as shown.
CABLE TIES
REMOTE CONTROL CABLE
Connect the blind connector when not using the remote control.
Engine will not start unless the blind connector is connected.
PILOT LAMP
START SWITCH
STOP SWITCH
Starting the engine with remote control
Turn the fuel valve to the ON position.
1.
Turn the engine switch to the ON position.
2.
Press the start switch untill the pilot lamp comes on.
3.
Stopping the engine with remote control
Press the stop switch.
1.
Turn the engine switch to the OFF position.
2.
Turn the fuel valve lever to the OFF position.
3.
63
WIRING DIAGRAM13.
ACOR
ACCP
ACNF
ATS
ATSw
ATU
AVRe
BAT
CB
CBxB
ChC
D
DCW
EgB
EgCU
EgSw
Fu
ExW
FW
FLCS
GeB
GT
IgC
MW
OAU
OLSw
RCB
RCC
St
SP
SSw
STSw
SoV
T
VMe
VSSw
AC Output Receptacle
AC Circuit Protector
AC Noise Filter
Auto Throttle Solenoid
Auto Throttle Switch
Auto Throttle Unit
Auto Voltage Regulator
Battery
Circuit Breaker
Control Box Block
Charge Coil
Diode
DC Winding
Engine Block
Engine Control Unit
Engine Switch
Fuse
Exciter Winding
Field Winding
Fuel Cut Solenoid
Generator Block
Ground Terminal
Ignition Coil
Main Winding
Oil Alert Unit
Oil Level Switch
Remote Control Block
Remote Control Cable
Starter
Spark Plug
Start Switch
Stop Switch
Solenoid Valve
Thermistor
Volt Meter
Voltage Selector Switch
64
Bl
Y
Bu
G
R
W
Br
O
Lb
Lg
P
Gr
ENGINE SWITCH
EM3100CX·EM4500CX·EM5500CX
OFF
ON
EM4500CXS·EM5500CXS
OFF
ON
START
BLACK
YELLOW
BLUE
GREEN
RED
WHITE
BROWN
ORANGE
LIGHT BLUE
LIGHT GREEN
PINK
GRAY
IGEFSG
IGEFSGLOBATST
65
EM3100CX·EM4500CX·EM5500CX (B type)
66
EM4500CXS·EM5500CXS (B type)
67
EM3100CX·EM4500CX·EM5500CX (F, G, GW types)
68
EM4500CXS·EM5500CXS (F, G, GW, IT types)
69
MAJOR Honda DISTRIBUTOR ADDRESSES14.
For further information, please contact Honda Customer Information Centre
at the following address or telephone number: