HONDA EM5000is User Manual
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
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:
on the generator.
Safety Labels
Safety Messages
of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
−
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
Safety Headings
Safety Section
Instructions
This entire book is filled with important safety information please
read it carefully.
−
−
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
GEN ERAT OR SAFET Y .
−
2
.
CONTENTS
............................................................................................CONTROLS .12
........................................................................................Starter Grip .13
.............................................................................................FEATURES .16
............................................................................................i-Monitor .19
.........................................................................................Fuel Gauge .22
................................................................................GENERATOR SAFETY .6
..................................................IMPORTANT SAFETY INFORMATION .6
......................................................................Operator Responsibility .6
.................................................................Carbon Monoxide Hazards .6
.......................................................................Electric Shock Hazards .7
........................................................................Fire and Burn Hazards .7
.................................................................................Refuel With Care .8
.................................................................SAFETY LABEL LOCATIONS .9
........................................................................CONTROLS & FEATURES .10
...........................................COMPONENT & CONTROL LOCATIONS .10
................................................................................Fuel Valve Lever .12
....................................................................................Engine Switch .12
..........................................................................Eco-Throttle Switch .13
...................................................................Voltage Selector Switch .14
.........................................................................AC Circuit Protectors .14
..................................................................................Folding Handle .15
...............................................................................Ground Terminal .16
................................................................................Output Indicator .17
............................................................................Overload Indicator .17
..............................................................................Oil Alert Indicator .18
...............................................................................BEFORE OPERATION .23
................................................ARE YOU READY TO GET STARTED? .23
.........................................................................................Knowledge .23
..............................................IS YOUR GENERATOR READY TO GO? .24
...............................................................................Check the Engine .25
...........................................................................Maintenance Cover .25
3
CONTENTS
..............................................................................................OPERATION .26
......................................................................................................FUSE .59
.....................................................SAFE OPERATING PRECAUTIONS .26
......................................................................STARTING THE ENGINE .27
.............Starting the Engine with Remote Control (Optional Part) .30
......................................................................STOPPING THE ENGINE .31
...........Stopping the Engine with Remote Control (Optional Part) .32
.....................................................................................AC OPERATION .33
.................................................................................AC Applications .35
...................................................................AC Receptacle Selection .36
.................................................................Power Producing Circuits .36
...................................................................Voltage Selector Switch .37
....................................................................ECO-THROTTLE SYSTEM .38
................................................................................STANDBY POWER .39
...............................Connections to a Building’s Electrical System .39
.................................................................................System Ground .39
.......................................................................Special Requirements .40
.............................................................SERVICING YOUR GENERATOR .41
.............................................THE IMPORTANCE OF MAINTENANCE .41
......................................................................MAINTENANCE SAFETY .42
............................................................................Safety Precautions .42
................................................................MAINTENANCE SCHEDULE .43
...........................................................................................REFUELING .44
...............................................................FUEL RECOMMENDATIONS .45
..................................................................ENGINE OIL LEVEL CHECK .46
...........................................................................ENGINE OIL CHANGE .47
....................................................ENGINE OIL RECOMMENDATIONS .48
........................................................................AIR CLEANER SERVICE .49
.............................................................FOAM AIR FILTER CLEANING .50
.................................................................SEDIMENT CUP CLEANING .51
.........................................................................SPARK PLUG SERVICE .52
................................................................SPARK ARRESTER SERVICE .54
...............................................................................BATTERY SERVICE .56
4
..................................................................................................STORAGE .60
....................................................................STORAGE PREPARATION .60
.............................................................................................Cleaning .60
.....................................................................................................Fuel .60
..........................................................................................Engine Oil .63
...................................................................STORAGE PRECAUTIONS .64
................................................................REMOVAL FROM STORAGE .64
CONTENTS
......................................................................................TRANSPORTING .65
.......................................TAKING CARE OF UNEXPECTED PROBLEMS .66
.............................................................................ENGINE PROBLEMS .66
....................................................................GENERATOR PROBLEMS .68
..........................................TECHNICAL & CONSUMER INFORMATION .69
................................................................TECHNICAL INFORMATION .69
...................................................................Serial Number Location .69
....................Carburetor Modification for High Altitude Operation .70
............................................Emission Control System Information .71
.............................................................................................Air Index .74
....................................................................................Specifications .75
.................................................................................Wiring Diagram .77
...............................................................CONSUMER INFORMATION .78
...........................................................................Honda Publications .78
..............................................................Dealer Locator Information .79
.........................................................Customer Service Information .79
...............................................................................................ASSEMBLY .80
..................................................................................................SAFETY .80
..............................................The Importance of Proper Assembly .80
..........................................................Important Safety Precautions .81
............................................................................................ASSEMBLY .82
..........................................................................................Unpacking .82
........................................................................................Loose Parts .82
........................................................................Wheel Kit Installation .83
............................................................................Handle Installation .84
..........................................................................Rear Bar Installation .85
................................................................................................Battery .86
...........................................................................................Engine oil .88
.....................................................................................................Fuel .88
...........................................................................BEFORE OPERATION .89
....................................................................................OPTIONAL PARTS .90
............................................................................Remote Control Kit .90
..........................................................................................Hanger Kit .93
........................................................................................................INDEX .94
.............................QUICK REFERENCE INFORMATION .Inside back cover
5
GENERATOR SAFETY
IMPORTANT SAFETY INFORMATION
Honda generators are designed for use with electrical equipment that
has suitable power requirements. Other uses can result in injury to the
operator or damage to the generator and other property.
Most accidents can be prevented if you follow all instructions in this
manual and on the generator. The most common hazards are
discussed below, along with the best way to protect yourself and
others.
Operator Responsibility
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles,
and connections.
Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without
parental supervision.
Carbon Monoxide Hazards
Exhaust contains poisonous carbon monoxide, a colorless, odorless
gas. Breathing carbon monoxide can cause loss of consciousness
and may lead to death.
If you run the generator in a confined or even partly 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.
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 servicing dealer for a replacement.
9
CONTROLS & FEATURES
COMPONENT & CONTROL LOCATIONS
Use the illustrations on these pages to locate and identify the most
frequently used controls.
OVERLOAD
INDICATOR
OUTPUT
INDICATOR
i-MONITOR
ENGINE SWITCH
OIL ALERT
INDICATOR
i-MONITOR
BUTTON
FUEL VALVE
VOLTAGE SELECTOR SWITCH
CIRCUIT PROTECTORS
RECEPTACLES
ECO-THROTTLE SWITCH
10
CONTROL & FEATURES
FUEL TANK CAP
SPARK PLUG
INSPECTION COVER
WHEEL
STARTER GRIP
FUEL GAUGE
AIR CLEANER
FUSE (Inside maintenance cover)
HANDLE
BATTERY TRAY
(Inside maintenance cover)
STAND
GROUND TERMINAL
OIL DRAIN PLUG
OIL FILLER
CAP/DIPSTICK
MUFFLER TIP
11
CONTROL & FEATURES
CONTROLS
Fuel Valve Lever
The fuel valve lever is located on
the control panel.
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.
Engine Switch
The engine switch controls the
ignition system, and it operates
the electric starter.
OFF Stops the engine. The
−
engine switch key can be
removed/inserted.
ON Running position, and for
−
starting with the recoil starter.
START Operates the electric
−
starter.
OONN
FUEL VALVE LEVER
OONN
OOFFFF
ENGINE SWITCH
SSTTAARRTT
OOFFFF
REMOTE For using the remote
−
control kit (optional parts).
12
OOFFFF
RREEMMOOTTEE
ENGINE SWITCH
Starter Grip
Pulling the starter grip operates
the recoil starter to crank the
engine for starting.
Do not allow the starter grip to
snap back against the engine.
Return it gently to prevent
damage to the starter.
Do not let the starter rope rub
against the generator body, or
the rope will wear out
prematurely.
CONTROL & FEATURES
STARTER GRIP
Eco-Throttle Switch
TM
The Eco-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 proper speed to power the
electrical load.
If high electrical loads are connected simultaneously, turn the EcoÂThrottle switch to the OFF position to reduce voltage changes.
ON Recommended to minimize
−
ECO-THROTTLE SWITCH
fuel consumption and further
reduce noise levels when a
reduced load or no load is applied
to the generator.
OFF The Eco-Throttle system
−
does not operate. Generator
operates at full output.
ONOFF
13
CONTROL & FEATURES
Voltage Selector Switch
The voltage selector switch switches generator output to produce
‘‘120V ONLY’’ or ‘‘120/240V.’’ If a 240V appliance is connected to the 4Âprong receptacle, the switch must be in the ‘‘120/240V’’ 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
120/240V:
simultaneously.
120V ONLY:
120/240V receptacle in this position. The most power will be available
at the 30A 120V locking plug receptacle.
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.
The 120V and 120/240V receptacles can be used
ONLY the 120V receptacles can be used. Do not use the
VOLTAGE SELECTOR SWITCH
120V/240V
120V ONLY
CIRCUIT PROTECTOR
for Receptacle
CIRCUIT PROTECTOR
for Receptacle
120V 30A
120V 20A
14
CIRCUIT PROTECTOR
for Receptacle
120V 20A
CIRCUIT PROTECTOR
for Receptacle
AC CIRCUIT PROTECTOR
120/240V 30A
ON
OFF
PUSH
CONTROL & FEATURES
Folding Handle
The foldable handle is intended for ease of transportation and should
be folded when the generator is stationary. Do not rest objects on the
extended handle.
To Extend The Handle
Lift handle upward. Lock levers will lock and secure the handle into
place.
To Fold The Handle
Press both handle lock levers downward.
1.
Lower the handle.2.
HANDLE LOCK LEVER
HANDLE
Handle
transport
position
Generator
stationary
position
15
CONTROL & FEATURES
FEATURES
Ground Terminal
The ground terminal is connected to the frame of the generator, the
metal non-current-carrying parts of the generator, and the ground
terminals of each receptacle.
Before using the ground terminal, consult a qualified electrician,
electrical inspector, or local agency having jurisdiction for local codes
or ordinances that apply to the intended use of the generator.
GROUND TERMINAL
16
CONTROL & FEATURES
Output Indicator
The green output indicator is illuminated when the generator is
operating normally. It indicates that the generator is producing
electrical power at the receptacles.
OUTPUT
INDICATOR
(GREEN)
Overload Indicator
If the generator is overloaded, or if there is a short circuit in a
connected appliance, or if the inverter is overheated, the red overload
indicator will go ON. When the generator is operating overloaded, the
red overload indicator will stay ON and, after about five seconds,
current to the connected appliance(s) will shut off, and the green
output indicator will go OFF.
OVERLOAD
INDICATOR (RED)
17
CONTROL & FEATURES
Oil Alert Indicator
The Oil Alert system is designed to prevent engine damage caused by
an insufficient amount of oil in the crankcase. Before the oil level in the
crankcase can fall below a safe limit, the Oil Alert indicator comes on,
and the Oil Alert system automatically will stop the engine (the engine
switch will remain in the ON position).
The i-Monitor display will show ‘‘OIL’’ on the screen and the Oil Alert
indicator illuminates.
If the engine stops or the Oil Alert indicator comes on when you turn
the engine switch to START or pull the starter grip, check the engine
oil level (see page ) before troubleshooting in other areas.
Even when oil is added to the engine, the generator will not restart
until the Oil Alert indicator is reset. To reset the Oil Alert indicator, turn
the engine switch OFF, add the proper amount of oil (see page ),
and then turn the engine switch back ON.
46
OIL ALERT
(RED)
47
18
It blinks.
CONTROL & FEATURES
i-Monitor
TM
The i-Monitor is a user interface that allows the operator to view (when
the generator is running) total operating time in hours, generator
output, engine RPM, battery voltage, and error messages. The
different display modes are selected by pressing the i-Monitor button.
i-Monitor at Startup
During start up, the i-Monitor display and all three indicators will
simultaneously blink once. The condition of the i-Monitor display
andallthreeindicatorscanbecheckedwiththeaidofanobserver.
Once the generator is running, the Output indicator (green) and the
i-Monitor display will remain lit.
Display Backlight Flashes
If the key is left in the ON position for over 30 seconds without starting
the engine, the display will start to flash.
i-Monitor Display
The i-Monitor display is divided into two screens. The single-digit
screen displays the i-Monitor mode, which is represented by a number
1 through 4. The four-digit screen displays the four mode values or
any activated error messages.
i-Monitor Display Mode 1 Total Operating Hours
−
This mode displays the total operating hours of the generator. When
the generator is running, the total operating time accumulates. If the
total operating time is less than one hour, the numeric display will be
‘‘0.’’ When the operating time is one hour or greater, the display will
be ‘‘1’’ or ‘‘2’’ and so on. Base the generator’s maintenance schedule
on the accumulated time displayed.
SINGLE-DIGIT
SCREEN DISPLAY
i-MONITOR BUTTON
FOUR-DIGIT
SCREEN DISPLAY
19
CONTROL & FEATURES
i-Monitor Display Mode 2 Power Output
This mode displays an approximate generator output on the display
screen. The output is expressed in VA (volt-amperes). The output
value is not an exact measurement and should be regarded as a
reference only. Power output will not display until a load is connected
to the generator.
i-Monitor Display Mode 3 Engine RPM
When the i-Monitor is in this mode, the engine’s speed, expressed in
revolutions-per-minute (RPM) is displayed.
−
−
i-Monitor Display Mode 4 Battery Voltage
This mode displays the battery condition, expressed in Volts DC.
−
20
CONTROL & FEATURES
i-Monitor Low Battery Message
If the engine switch is turned to the START position and ‘‘batt’’ is
shown on the i-Monitor display, the battery voltage is too low to
operate the engine’s electric starter. Use the recoil starter to start the
generator. Have the battery recharged and checked (see page ).58
i-Monitor System Error Messages
If the generator has a system malfunction, it will show an error
message on the i-Monitor display. During remote control operation, an
E-01 error message may display if the starter button is pressed for
more than 10 seconds. With an E-01 error message, the engine will
stay running and the electrical output may stay constant.
Normal remote control operation will be restored after the E-01 error
message clears. If the E-01 error message will not clear or if any other
error message displays, contact an authorized Honda generator dealer.
OVERLOAD INDICATOR LIGHT
ERROR MESSAGE
(Example: E-01)
21
CONTROL & FEATURES
Fuel Gauge
The fuel gauge is a mechanical device that measures the fuel level in
the tank. The red indicator in the window will reference the level in
relation to full or empty. To provide increased operating time, start
with a full tank before beginning operation. Check the fuel level with
the generator on a level surface. Always refuel with the engine OFF
and cool.
FULL
FUEL GAUGE
EMPTY
22
FUEL TANK CAP
BEFORE OPERATION
ARE YOU READY TO GET STARTED?
Your safety is your responsibility. A little time spent in preparation will
significantly reduce your risk of injury.
Knowledge
Read and understand this manual. Know what the controls do and
how to operate them.
Familiarize yourself with the generator and its operation before you
begin using it. Know how to quickly shut off the generator in case of
an emergency.
If the generator is being used to power appliances, be sure that they
do not exceed the generator’s load rating (see page ).35
23
BEFORE OPERATION
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.
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.
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.
24
Check the Engine
BEFORE OPERATION
Check the oil level (see page ). A low oil level will cause the Oil Alert
system to shut down the engine.
Check the air filter (see page ). A dirty air filter 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.
Maintenance Cover
Never operate the generator without the maintenance cover in place,
as poor engine and generator performance will result.
46
49
44
MAINTENANCE COVER
25
OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the generator for the first time, please review the
GENERATOR SAFETY
BEFORE OPERATION
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 ) section and the chapter titled
(see page ).
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
23
Before connecting an AC appliance or power cord to the generator:
Use grounded 3-prong extension cords, tools, and appliances, or
double-insulated tools and appliances.
Inspect cords and plugs, and replace if damaged.
Make sure that the appliance is in good working order. Faulty
appliances or power cords can create a potential for electric shock.
Make sure the electrical rating of the tool or appliance does not
exceed that of the generator. Never exceed the maximum power
rating of the generator. Power levels between rated and maximum
may be used for no more than 30 minutes.
Operate the generator at least 3 feet (1 meter) away from buildings
and other equipment.
Do not operate the generator in an enclosed structure.
26
STARTING THE ENGINE
OPERATION
Refer to
SAFE OPERATING PRECAUTIONS
IS YOUR GENERATOR READY TO GO
Refer to
AC OPERATION
(see page ) for connecting loads to the
33
generator.
Make sure that all appliances
1.
connected to the generator are
turned off. The generator may
be hard to start if a load is
connected.
Set the Voltage Selector Switch
2.
to match the voltage
requirements for the
application.
Turn the fuel valve lever to the
3.
ON position.
on page and perform the
26
checks (see page ).
VOLTAGE SELECTOR SWITCH
FUEL VALVE LEVER
OONN
24
120V/
240V
120V
ONLY
Make sure the Eco-Throttle
4.
switch is in the OFF position, or
more time will be required for
warm-up.
IfyouwishtousetheEcoÂThrottle system, turn the EcoÂThrottle switch to the ON
position after the engine has
warmed up for 2 or 3 minutes.
OOFFFF
ECO-THROTTLE SWITCH
OONN
OOFFFF
27
OPERATION
5.
Start the engine.
Using the electric starter:
Turn the engine switch to the
START position, and hold it
there until the engine starts.
When the engine starts,
release the key, allowing the
switch to return to the ON
position.
If the engine fails to start
within 5 seconds, release the
key, and wait at least 10
ENGINE SWITCH
seconds before operating the
starter again.
Using the electric starter for more than 5 seconds at a time will
overheat the starter motor and can damage it.
OOFFFF
OONN
SSTTAARRTT
Do not leave the engine switch in the ON position when the
generator is not operating as the battery will be drained. Turn the
engine switch to the OFF position when not in use.
28
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