Honda Automobiles 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.

Keep this owner’s manual handy, so 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 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 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.

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 if you don’t follow

IMPORTANT SAFETY INFORMATION

GEN ERAT OR SAFET Y .

−

............................................................................................CONTROLS .12

.............................................................................................FEATURES .16

Indicator Light .18

.........................................................................................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

.....................................................................................Recoil Starter .13

.........................................................................Eco-throttle Switch .13

...................................................................Voltage Selector Switch .14

.........................................................................AC Circuit Protectors .14

..................................................................................Folding Handle .15

...............................................................................Ground Terminal .16

.......................................................................Output Indicator Light .17

...................................................................Overload Indicator Light .17

...................................................................Oil Alert

...............................................................................BEFORE OPERATION .23

................................................ARE YOU READY TO GET STARTED? .23

.........................................................................................Knowledge .23

..............................................IS YOUR GENERATOR READY TO GO? .23

...............................................................................Check the Engine .24

CONTENTS

..............................................................................................OPERATION .25

......................................................................................................FUSE .57

.....................................................SAFE OPERATING PRECAUTIONS .25

......................................................................STARTING THE ENGINE .26

......................................................................STOPPING THE ENGINE .29

.....................................................................................AC OPERATION .30

.................................................................................AC Applications .32

...............................................................................STAND BY POWER .36

.................................................................................System Ground .36

...........................................................................................REFUELING .41

...............................................................................BATTERY SERVICE .54

...................................................................AC Receptacle Selection .33

.................................................................ECO-THROTTLE SYSTEM .35

...............................Connections to a Building’s Electrical System .36

.......................................................................Special Requirements .37

.............................................................SERVICING YOUR GENERATOR .38

.............................................THE IMPORTANCE OF MAINTENANCE .38

......................................................................MAINTENANCE SAFETY .39

............................................................................Safety Precautions .39

................................................................MAINTENANCE SCHEDULE .40

...............................................................FUEL RECOMMENDATIONS .42

..................................................................ENGINE OIL LEVEL CHECK .43

...........................................................................ENGINE OIL CHANGE .44

....................................................ENGINE OIL RECOMMENDATIONS .45

........................................................................AIR CLEANER SERVICE .46

.............................................................FOAM AIR FILTER CLEANING .48

.................................................................SEDIMENT CUP CLEANING .49

.........................................................................SPARK PLUG SERVICE .50

................................................................SPARK ARRESTER SERVICE .52

..................................................................................................STORAGE .58

....................................................................STORAGE PREPARATION .58

.............................................................................................Cleaning .58

.....................................................................................................Fuel .58

..........................................................................................Engine Oil .61

...................................................................STORAGE PRECAUTIONS .62

................................................................REMOVAL FROM STORAGE .62

CONTENTS

......................................................................................TRANSPORTING .63

.......................................TAKING CARE OF UNEXPECTED PROBLEMS .64

.............................................................................ENGINE PROBLEMS .64

....................................................................GENERATOR PROBLEMS .66

..........................................TECHNICAL & CONSUMER INFORMATION .67

................................................................TECHNICAL INFORMATION .67

...................................................................Serial Number Location .67

....................Carburetor Modification for High Altitude Operation .68

.............................................................................Oxygenated Fuels .69

............................................Emission Control System Information .70

.............................................................................................Air Index .72

....................................................................................Specifications .73

.................................................................................Wiring Diagram .75

...............................................................CONSUMER INFORMATION .76

...........................................................................Honda Publications .76

.........................................................Customer Service Information .77

................................................................INSTALLATION OF KIT PARTS .78

..................................................................................................SAFETY .78

..............................................The Importance of Proper Assembly .78

..........................................................Important Safety Precautions .79

........................................................................STANDARD KIT PARTS .80

..........................................................................................Unpacking .80

........................................................................................Loose Parts .80

........................................................................Wheel Kit Installation .81

............................................................................Handle Installation .82

..........................................................................Rear Bar Installation .83

................................................................................................Battery .84

..........................................................................OPTIONAL KIT PARTS .85

............................................................................Remote Control Kit .85

......................................................................Hanger Kit Installation .89

........................................................................................................INDEX .90

.............................QUICK REFERENCE INFORMATION .Inside back cover

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 exhaust can cause loss of consciousness and may lead to death.

If you run the generator in a confined or even partially enclosed area, the air you breathe could contain dangerous amounts of exhaust gas. To keep exhaust gas from building up, provide adequate ventilation.

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 which could result in electrocution.

Do not connect to a building 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.

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.

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.

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

Use the two 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

VOLTAGE SELECTOR SWITCH

FUEL VALVE

CIRCUIT PROTECTORS

RECEPTACLES

ECO-THROTTLE SWITCH

CONTROL & FEATURES

SPARK PLUG INSPECTION COVER

STARTER GRIP

FUSE(Inside the maintenance cover)

HANDLE

AIR CLEANER

FUEL TANK CAP

GROUND TERMINAL

STAND

OIL DRAIN PLUG

OIL FILLER CAP/DIPSTICK

MUFFLER TIP

WHEEL

CONTROL & FEATURES

CONTROLS

Fuel Valve Lever

The fuel valve lever is located on the control panel.

The fuel valve must be in the ON position for the engine to run.

After stopping the engine, turn the fuel valve to the OFF position.

Engine Switch

The engine switch controls the ignition system, and it operates the electric starter.

OFF Stops the engine. 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).

OOFFFF

RREEMMOOTTEE

ENGINE SWITCH

Recoil Starter

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

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 ecothrottle 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

CONTROL & FEATURES

Voltage Selector Switch

The voltage selector switch is used to select generator AC voltage; either 120 V or 120/240 V. Select the voltage before starting the engine.

VOLTAGE SELECTOR SWITCH

120V/240V

120V ONLY

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 the each receptacles. 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.

CIRCUIT PROTECTOR

CIRCUIT PROTECTOR for Receptacle

for Receptacle

CIRCUIT PROTECTOR for Receptacle

AC CIRCUIT PROTECTOR

CIRCUIT PROTECTOR for Receptacle

120V 30A

120V 20A

OFF PUSH

120/240V 30A

120V 20A

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 extended handle.

To Extend Handle

Lift handle upward. Lock levers will lock and secure handle into place.

To Fold Handle

Press both handle lock levers downward.

1. Lower handle.

HANDLE LEVER

HANDLE

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

CONTROL & FEATURES

Output Indicator Light

The output indicator light (green) is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the receptacles.

OUTPUT INDICATOR LIGHT (GREEN)

Overload Indicator Light

If the generator is overloaded, or if there is a short circuit in a connected appliance, or if the inverter is overheated, the overload indicator light (red) will go ON. When the generator is operating overloaded, the overload indicator light (red) will stay ON, and after about five seconds, current to the connected appliance(s) will shut off, and the output indicator light (green) will go OFF.

OVERLOAD INDICATOR LIGHT (RED)

CONTROL & FEATURES

Oil Alert Indicator Light

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 comes on and the Oil Alert

system automatically will stop the engine (the engine switch will remain in the ON position). If the engine stops or the Oil Alert

indicator light 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.

43 Even when oil is added to the engine, the generator will not restart until the Oil Alert

indicator light is reset. To reset the Oil Alert indicator light, turn the engine switch OFF, add the proper amount of oil (see page ), and then turn engine switch back ON. The i-Monitor display will show ‘‘OIL’’ on the screen and the Oil Alert

indicator lamp will illuminate.

OIL ALERT (RED)

indicator light

It blinks.

CONTROL & FEATURES

i-Monitor

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 Start Up

When the engine switch is turned to the ON position, the i-Monitor

display and all indicator lights will blink once.

Backlight Time Out

Once the engine switch has been turned to the ON position, the engine must be started within 30 seconds, otherwise the display backlight will turn off. This time out feature is designed to protect the battery from unnecessary drain. To reset the time out i-Monitor backlight feature,

the engine switch must be turned OFF and then back ON.

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.

NUMBER DISPLAY PORTION

i-MONITOR BUTTON

NUMERIC VALUE DISPLAY PORTION

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.

CONTROL & FEATURES

i-Monitor Low Battery Message

If the engine switch is turned ON 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 ).

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 is cleared. 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

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

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 ).32

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 preoperation 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 preoperation checks, be sure the generator is on a level surface and the engine switch is in the OFF position.

BEFORE OPERATION

Check the Engine

Check the oil level (see page ). A low oil level will cause the Oil Alert

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.

system to shut down the engine.

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, please review the

GENERATOR SAFETY OPERATION

For your safety, avoid starting or operating the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death.

section and the chapter titled

Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you.

Avoid any enclosed areas or activities that expose you to carbon monoxide.

BEFORE

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.

OPERATION

STARTING THE ENGINE

Refer to Safe Operating Precautions on page .

Make sure that all appliances

are disconnected from the AC receptacles. The generator may be hard to start if a load is connected.

Set the Voltage Selector Switch

VOLTAGE SELECTOR SWITCH

to match the voltage requirements for the application.

Turn the fuel valve lever to the

FUEL VALVE LEVER

ON position.

OONN

OOFFFF

120V/ 240V

120V ONLY

OPERATION

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 seconds before operating the starter again.

ENGINE SWITCH

Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

OOFFFF

OONN

SSTTAARRTT

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