EM5000SX
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EM3800SX•EM5000SX•EM6500SX
See page 57 for instructions
on assembling your generator.
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
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.
The generator is a potential source of electrical shock if misused. Do
not expose the generator to moisture, rain or snow. Do not let the
generator get wet, and do not operate it with wet hands.
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. No part of this publication may be reproduced without
written permission.
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 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 warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty policy
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. Your authorized 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 yourown 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.
GEN E RATOR SAF E T Y.
be or if
be or if
be if you don’t follow
IMPORTANT SAFETY INFORMATION
−
.
2
CONTENTS
..............................................................................GENERATOR SAFETY . 5
.......................................................................Safety Label Locations . 5
............................................................Important Safety Information . 6
..............................................................COMPONENT IDENTIFICATION . 8
..............................................................................................CONTROLS . 10
....................................................................................Engine Switch . 10
........................................................................................Starter Grip . 10
................................................................................Fuel Valve Lever . 11
..........................................................................................Choke Rod . 11
............................Voltage Selector Switch (Dual Voltage System) . 12
...............................................................................Ground Terminal . 12
.......................................................................................DC Terminal . 13
..........................................................................DC Circuit Protector . 13
System . 14
..........................................................................................Engine Oil . 30
............................................................................................Refueling . 31
..............................................................................Oil Alert
System . 14
...................................................................................GENERATOR USE . 17
..................................................................................Ground System .17
.................................................................................AC Applications . 18
.....................................................................................AC Operation . 19
.....................................................................................DC Operation . 26
System . 28
......................................................................Auto Throttle
.............................................................................AC Circuit Breaker . 15
..........................................................................AC Circuit Protector . 16
...............................Connections to a Building’s Electrical System . 17
.......................................................................Special Requirements . 17
...................................................................AC Receptacle Selection . 20
......................................................................Auto Throttle
....................................................................High Altitude Operation . 29
.......................................................................PRE-OPERATION CHECK . 30
....................................................................Fuel Recommendations . 32
..............................STARTING THE ENGINE/STOPPING THE ENGINE . 33
3
......................................................................................MAINTENANCE . 35
......................................................The Importance of Maintenance . 35
..........................................................................Maintenance Safety . 36
.....................................................................Maintenance Schedule . 37
............................................................................Engine Oil Change . 38
...........................................................................Air Cleaner Service . 39
...........................................................Fuel Sediment Cup Cleaning . 40
............................................................................Spark Plug Service . 41
............................................................Spark Arrester Maintenance . 42
.............................................................................Fuse Replacement .43
..................................................................TRANSPORTING/STORAGE . 44
.............................................................................TROUBLESHOOTING . 47
..................................................................TECHNICAL INFORMATION . 49
............................................Emission Control SystemInformation . 49
.............................................................................................Air Index . 51
.................................................................................WIRING DIAGRAM . 52
....................................................................................SPECIFICATIONS . 54
..............................................................................................ASSEMBLY . 57
.................................................WARRANTY SERVICE INFORMATION . 69
.................................................DEALER LOCATOR INFORMATION . 69
............................................CUSTOMER SERVICE INFORMATION . 69
.....................................................................Honda PUBLICATIONS . 70
......................................................................................................INDEX . 71
4
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.
5
IMPORTANT SAFETY INFORMATION
Honda generators are designed to give safe and dependable service if
operated according to instructions. Read and understand this owner’s
manual before operating your generator. You can help prevent
accidents by being familiar with your generator’s controls, and by
observing safe operating procedures.
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 and
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 amountof exhaust gas.
Never run your generator inside a garage, house, or near open
windows or doors.
6
Electric Shock Hazards
The generator produces enough electric power to cause a serious
shock or electrocutionif 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 thatcould 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 ignitesome 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 materialsaway 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.
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks where the
generator is refueled or where gasoline is stored. Refuel in a wellventilated area with the engine stopped.
Fuel vapors are extremely flammable and may ignite after the
engine has started. Make sure that any spilled fuel has been wiped
up before starting the generator.
7
COMPONENT IDENTIFICATION
CHOKE ROD
AIR CLEANER
FUEL VALVE LEVER
STARTER GRIP
ENGINE SERIAL NUMBER
CONTROL PANEL
＊
1:Except EM3800SX
ENGINE SWITCH
AC CIRCUIT PROTECTORS
OIL DRAIN PLUG
120 ONLY 120/240
VOLTAGE SELECTOR SWITCH
CONTROL PANEL
OIL FILLER CAP/DIPSTICK
FUSE
−
DC CIRCUIT
PROTECTOR
DC OUTPUT
TERMINAL
8
AC CIRCUIT BREAKER
AUTO THROTTLE
SWITCH
＊
1
120V AC RECEPTACLES
120/240V AC
RECEPTACLE
GROUND TERMINAL
FUEL TANK CAP
FUEL GAUGE
TRANSPORT HANDLE
SPARK PLUG CAP
FRAME SERIAL NUMBER
STAND
WHEEL
Record the engine and frame serial numbers and date of purchase
*
MUFFLER
for your future reference. Refer to these serial numbers when
ordering parts and when making technical or warranty inquiries (see
page ).
69
Engine serial number:
Frame serial number:
Date of purchase:
9
CONTROLS
Engine Switch
To start and stop the engine.
Key position:
OFF:
ON:
START:
Starter Grip
To start the engine, pull the starter grip lightly until resistance is felt,
and then pull briskly.
To stop the engine. Key can be removed/inserted.
To run the engine after starting.
To start the engine by operating the startermotor.
ON
OOFFFF
SSTTAARRTT
ENGINE SWITCH
Do not allow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter.
The recoil starter is used to start the engine if the generator is not
equipped with a 12-volt battery to operate the starter motor, or if the
battery does not contain adequate charge to operate the starter motor.
RECOIL STARTER
STARTER GRIP
10
Fuel Valve Lever
The fuel valve is located between the fuel tank and carburetor. When
the valve lever is in the ON position, fuel is allowed to flow from the
fuel tank to the carburetor. Be sure to return the fuel valve lever to the
OFF position after stopping the engine.
FUEL VALVE LEVER
OFF
Choke Rod
ON
The choke is used to provide an enriched fuel mixture when starting a
cold engine. It can be opened and closed by operating the choke rod
manually. Pull the rod out toward CLOSED to enrich the mixture for
cold starting.
OPEN
CCLLOOSSEEDD
CHOKE ROD
11
Voltage Selector Switch (Dual Voltage System)
The voltage selector switch switches the main power carrying
windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a
240V appliance is connected to the 4-prong receptacle, the switch
must be in the ‘‘120/240V’’ position. If only a 120V appliance is being
connected to any of the 120V 3-prong receptacles, select the ‘‘120V
ONLY’’ position.
Switch Position
120/240V:
The 120V and 120/240V receptacles can be used
simultaneously.
120V ONLY:
ONLY the 120V receptacles can be used. Do not use the
120/240V receptacle in this position. The most power
will be available at the 30A 120V locking plug
receptacle.
VOLTAGE SELECTOR SWITCH
120/240V
112200//224400VV
112200VV OONNLLYY
120V ONLY
GROUND TERMINAL
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.
12
DC Terminals
The DC terminals may ONLY be used for charging 12-volt automotive
type batteries.
The terminals are colored red to identify the positive ( ) terminal and
black to identify the negative ( ) terminal. The battery must be
−
＋
connected to the generator DC terminals with the proper polarity
(battery positive to generator red terminal and battery negative to the
generator black terminal).
DC Circuit Protector
The DC circuit protector automatically shuts off the DC battery
charging circuit when the DC charging circuit is overloaded, when
there is a problem with the battery, or when the connections between
the battery and the generator are improper.
DC CIRCUIT
PROTECTOR
NEGATIVE TERMINAL
(BLACK)
POSITIVE TERMINAL
(RED)
13
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 can fall below a safe limit, the Oil Alert system will
automatically stop the engine (the engine switch will remain in the ON
position). The Oil Alert system should not take the place of checking
the oil level before each use.
If the engine stops and will not restart, check the engine oil level (see
page )before troubleshooting in other areas.
30
Auto Throttle
The Auto Throttle
System
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.
Switch Position
AUTO:
Recommended to minimize fuel consumption and further
reduce noise levels when no load is applied to the generator.
OFF:
The Auto Throttle system does not operate.
Recommended to minimize warm-up time when the
generator is started and when starting a load with large startup power equipments.
AUTO THROTTLE SWITCH
OFF
ON
OFF
14
ON
AC Circuit Breaker
The AC circuit breaker will automatically switch OFF if there is a short
circuit or a significant overload of the generator at the receptacle. If the
AC circuit breaker is switched OFF automatically, check that the
appliance is working properly and does not exceed the rated load
capacity of the circuit before switching the AC circuit breaker ON again.
The AC circuit breaker may be used to switch the generator power ON
or OFF.
ON
OFF
AC CIRCUIT BREAKER
15
AC Circuit Protector
The AC circuit protectors will automatically switch OFF if there is a
short circuit or a significant overload of the generator at the 20A 120V,
30A 120V locking plug, or 120/240V locking plug 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 PROTECTORS
ON
＊
1
OFF
＊
1:Except EM3800SX
16
GENERATOR USE
Connections to a Building’s Electrical System
Connections for standby power to a building’s electrical system must
be made by a qualified electrician. The connection must isolate the
generator power from utility power, and must comply with all
applicable laws and electrical codes. A transfer switch, which isolates
generator power from utility power, is available through authorized
Honda generator dealers.
Improper connections to a building’s electrical system 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 the generator may
explode, burn, or cause fires when utility power is restored. Consult
the utility company or a qualified electrician.
Ground System
Honda portable generators have a system ground that connects
generator frame components to the ground terminals in the AC output
receptacles. The system ground is not connected to the AC neutral
wire. If the generator is tested by a receptacle tester, it will show the
same ground circuitcondition as for a homereceptacle.
Special Requirements
There may be Federal or State Occupational Safety and Health
Administration (OSHA) regulations, local codes, or ordinances that
apply to the intended use of the generator. Please consult a qualified
electrician, electrical inspector, or the localagency having jurisdiction.
In some areas, generators are required to be registered with local
utility companies.
17
AC Applications
Before connecting an appliance or power cord to the generator:
Make sure that it is in good working order. Faulty appliances or
power cords can create a potential for electrical shock.
If an appliance begins to operate abnormally, becomes sluggish, or
stops suddenly, turn it off immediately. Disconnect the appliance,
and determine whether the problem is the appliance or the rated
load capacity of the generator has been exceeded.
Make sure that 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 open the circuit breaker. Exceeding the
time limit for maximum power operation or slightly overloading the
generator may not switch the circuit breaker or circuit protector OFF,
but will shorten the service life of the generator.
Limit operation requiring maximum power to 30 minutes.
Maximum power is:
EM3800SX:
EM5000SX:
EM6500SX:
For continuous operation (longer than 30 minutes), do not exceed the
rated power.
Rated power is:
EM3800SX:
EM5000SX:
EM6500SX:
The total power requirements (VA) of all appliances connected must
be considered. Appliance and power tool manufacturers usually list
rating information near the model number or serial number.
3.8 kVA
5.0 kVA
6.5 kVA
3.3 kVA
4.5 kVA
5.5 kVA
18
AC Operation
1.
Start the engine (see page ).
2.
Turn the voltage selector switch to either position.
33
With the voltage selector switch in the ‘‘120/240V’’ position, you can
use the 120V and 120/240V receptacles simultaneously. If you are
NOT using the 120/240V receptacle but require more powerfrom the
120V locking plug receptacle, then select the ‘‘120V ONLY’’ position.
Switch the AC circuit breaker ON.
3.
Plug in the appliance.
4.
Be sure that all appliances are in good working order before
connecting them to the generator. If an appliance begins to operate
abnormally, becomes sluggish, or stops suddenly, turn off the ignition
switch lever immediately. Then disconnect the appliance and examine
it for signs of malfunction.
Most motorized appliances require more than their rated power for
startup.
Do not exceed the current limit specified for any one receptacle. If an
overloaded circuit causes the AC circuit breaker or AC circuit protector
to switch OFF, reduce the electrical load on the circuit, wait a few
minutes and then reset the AC circuit breaker or AC circuit protector.
AC CIRCUIT PROTECTORS
＊
1:Except EM3800SX
AC CIRCUIT BREAKER
VOLTAGE SELECTOR SWITCH
＊
1
19
AC Receptacle Selection
The control panel, shown below, has a voltage selector switch and
four receptacles. Receptacle 4, the 240-volt receptacle, has two
＃
powered terminals, 4A and 4B.
EM3800SX:
4A
○
4B
○
120V 30A
120V 20A (in total)
120V 20A (in total)
4A 4B
& 120/240V 20A
○
○
Power Producing Circuits
This generator is equipped with two power generating circuits. When
the voltage selector switch is in the 120V/240V position, each of the
two power producing circuits supplies power to specific receptacles.
When the voltage selector switch is in the 120V ONLY position, the
power producing circuits operate in parallel, sharing the total load
connected to terminal 4A and receptacles 1, 2, and 3.
POWER
CIRCUIT 1
POWER
CIRCUIT 2
20
120V/240V 120V ONLY
POWER CIRCUIT 2
POWER CIRCUIT 1
Voltage Selector Switch
The power available to each receptacle depends on the position of the
voltage selector switch.
Available Power
27.5A at 120V
20A at 120V
20A at 120V
20A at 120V
None
13.8A at 120V
13.8A at 120V
13.8A at 120V
13.8A at 240V
120V ONLY
120V/240V
ReceptacleSwitch Position
1
2
3
4A
4B
1
2
3
4A-4B
120V ONLY Position
When the voltage selector switch is in the 120V ONLY position, you
do not need to spread the load over the receptacles. You must,
however, make sure the load on any receptacle does not exceed its
available power shown in the preceding table and the total load does
not exceed 27.5 amps.
120V/240V Position
When the voltage selector switch is in the 120V/240V position, you
must balance the load. Divide the load between the two sets of
receptacles shown below. Balancing is necessary because each set of
receptacles is powered by only one power producing circuit that can
produce a maximumof 13.8 amps.
Set of
Receptacles
134B
＋＋
24A
＋
Total Current
Available
13.8A
13.8A
Power Producing
Circuit
1
2
21
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