See page 81 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.
California Proposition 65
This product contains or emits
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
people may be present.
partly closed area where
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
reserves the right, however, to discontinue or change specifications or
design at any time without notice and without incurring any obligation
whatsoever.
of approval for printing. Honda Motor Co., Ltd.
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. Th
to do that; please read it carefully.
is manual contains all the information on how
As you read this manual, you will find info
symbol.
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 de
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.
That information is intended to help you avoid
Distributor’s Limited Warranty
is a separate document that should
aler is specially trained in servicing
rmation preceded by a
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 pr
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 asso
must use your own good judgment.
You will find important safety information in a variety of forms,
uding:
incl
ocedures and other information on labels and in this
ciated with operating or maintaining a generator. You
• Safety Labels — on
• Safety Messages — prece
of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
• Safety Headings — su
• Safety Section — suc
• Instructions — how to use this g
This entire book is filled with important safety information — please
read it carefully.
INDEX .......................................................................................................93
QUICK REFERENCE INFORMATION ............................ Inside back cover
5
GENERATOR SAFETY
IMPORTANT SAFETY INFORMATION
Honda generators are designed for use with electrical equipment that
has suitable p
operator or damage to the generator and other property.
Most injuries or property damage can be prevented if you follow all
instructions in this m
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 co
• Be sure that anyone who operates the generator receives proper
nstruction
i
parental supervision.
Carbon Monoxide Hazards
A generator's exhaust contains toxic carbon monoxide, which you
not se
can
MINUTES. To avoid carbon monoxide poisoning, follow these
instructions when operating a generator:
• Only run a generator OUTSIDE, far away from windows, doors, and
ven
ts.
• Never operate a generator inside a house, garage, basement, crawl
space, or any en
• Never operate a generator near open doors or windows.
• Get fresh air and seek medical attention immediately if you suspect
you have
Early symptoms of carbon monoxide exposure include headache,
fatigue, shor
exposure to carbon monoxide can cause loss of muscular
coordination, loss of consciousness, and then death.
ower requirements. Other uses can result in injury to the
anual and on the generator. The most common
nnections.
. Do not let children operate the generator without
e or smell. Breathing carbon monoxide can KILL YOU IN
closed or partially enclosed space.
inhaled carbon monoxide.
tness of breath, nausea, and dizziness. Continued
To alert you to potentially dangerous levels of carbon monoxide coming
from a generator o
battery operated carbon monoxide alarms or plug-in carbon monoxide
alarms with battery back-up on every level of the home and outside
sleeping areas in accordance with the manufacturer's instructions.
perating outside, or from other sources, install
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
hands are wet, could result in electrocution. Keep the generator dry.
• If the generator is stored outdoors, unprotected from the weather,
check the Ground Fa
other 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
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 equip
– Do not enclose the generator in any structure.
– Keep flammable materials away from the generator.
, or near a pool or sprinkler system, or when your
ult Circuit Interrupter (GFCI) receptacle and all
instal
led by a qualified electrician.
ment during operation.
• The muffler becomes very hot during operation and remains hot for
a while
while it is hot. Let the engine cool before storing the generator
indoors.
after stopping the engine. Be careful not to touch the muffler
7
GENERATOR SAFETY
Refuel With Care
Gasoline is extremely flammable, and gasoline vapor can explode.
Do not refuel during operation.
Allow the engine to cool if it has been in operation.
Refuel only outdoors in a well-ventilated area and on a level surface.
Never smok
Do not overfill the fuel tank.
Make sure that any spilled fuel has been wiped up before starting the
engine.
Always store gasoline in an approved container.
e near gasoline, and keep other flames and sparks away.
8
GENERATOR SAFETY
SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause serious
injury. Read them carefully.
If a label comes off or becomes hard to read, contact your Honda
generator de
aler for a replacement.
9
CONTROLS & FEATURES
VOLTAGE SELECTOR SWITCH
AC CIRCUIT BREAKER
DC CIRCUIT
PROTECTOR
ENGINE SWITCH
DC TERMINALS
AUTO THROTTLE SWITCH
GROUND
TERMINAL
*: Except EM4000SX
*
<EM4000SX>
RECEPTACLES
GFCI RECEPTACLES
AC CIRCUIT PROTECTORS
COMPONENT & CONTROL LOCATIONS
Use the illustrations on these pages to locate and identify the most
frequently used controls.
10
CONTROLS & FEATURES
AIR CLEANER
FUEL VALVE LEVER
SEDIMENT CUP
STARTER GRIP
OIL DRAIN PLUG
OIL FILLER CAP/DIPSTICK
BATTERY COVER
CONTROL PANEL
HANDLE
SPARK PLUG
FUEL TANK CAP
FUEL GAUGE
WHEEL
MUFFLER
STAND
MANUAL CHOKE LEVER
11
CONTROLS & FEATURES
ENGINE SWITCH
OFF
ON
STARTER
GRIP
START
Direction to pull
CONTROLS
Engine Switch
The engine switch controls the
ignition system, and it operates
the ele
ctric starter.
OFF – Stops the engine. The
engine
switch k
ey can be
removed/inserted.
ON – Running position, and for
starting w
ith the recoil starter.
START – Operates the electric
star
ter
.
Starter Grip
Used when the battery voltage is
too low to turn the
ter motor.
star
Pulling the starter grip operates
the recoil starter to crank the
engine
•
.
Do not allow the starter grip to
snap back against the
generator. Return it gently to
prevent damage to the starter.
•
Do not let the starter rope rub
against the generator body, or
the rope will wear out
prematurely.
•
Be careful not to hit your hand
against the handle when pulling
the starter grip.
12
CONTROLS & FEATURES
ON
OFF
FUEL VALVE LEVER
VOLTAGE SELECTOR SWITCH
120 V/240 V
120 V ONLY
Fuel Valve Lever
The fuel valve lever is located
between the fuel tank and
carburetor.
The fuel valve must be in the ON
posit
ion for the engine to run.
After stopping the engine, turn
the fuel
valve t
Voltage Selector Switch
The voltage selector switch switches generator output to produce
‘‘120V ONL
4-prong receptacle, the switch must be in the ‘‘120V/240V’’ position. If
only a 120V appliance is being connected to any of the 120V 3-prong
receptacles, select the ‘‘120V ONLY’’ position.
Select the voltage before starting the engine.
o the OFF position.
Y’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the
Switch Position
20
120V/240V: The 1
V and 120V/240V receptacles can be used
simultaneously.
120V ONLY: ONLY
120 volts is available in this position; 240 volts is
not available. The most power will be available at the 30A 120V
locking plug receptacle.
13
CONTROLS & FEATURES
AUTO THROTTLE SWITCH
OFF
ON
OFF
ON
AC CIRCUIT BREAKER
ON
OFF
Auto Throttle® System
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.
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.
R
ecommended to minimize warm-up time when the generator
is started and when star
ting a load with large start-up power
requirements.
AC Circuit Breaker
The AC circuit breaker will automatically switch OFF if there is a short
circuit or a significant overload
at the receptacles.
The AC circuit breaker may be used to switch the generator power ON
or OFF.
14
CONTROLS & FEATURES
*
*: Except EM4000SX
AC CIRCUIT PROTECTOR for Receptacle ④
AC CIRCUIT PROTECTOR
for Receptacle ③
AC CIRCUIT PROTECTOR
for Receptacle ②
AC CIRCUIT PROTECTOR
for Receptacle ①
① 120 V 30 A
④ 120/240 V 30 A
<EM4000SX>
② GFCI RECEPTACLE
(120 V 20 A DUPLEX RECEPTACLE)
③ GFCI RECEPTACLE
(120 V 20 A DUPLEX RECEPTACLE)
OFF
ON
PUSH
AC CIRCUIT PROTECTOR
④ 120/240 V 20 A
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.
15
CONTROLS & FEATURES
GFCI TEST BUTTON
GFCI RESET BUTTON
GFCI RECEPTACLES
(120 V 20 A DUPLEX RECEPTACLES)
Each 120 V 20 A duplex receptacle is protected by a Ground Fault
Circuit Inter
ground-fault currents.
An example of ground-fault current is the current that would flow
through a p
at the same time, is in contact with an electrical ground such as a
plumbing fixture, wet floor, or earth. The GFCI will protect against
current flowing through that person.
The GFCI will not protect against short circuit or overloads.
GFCIs can be expected to interrupt power supply if there are ground
faults
devices, wiring, or equipment. Due to the risk of a power interruption,
this generator is not recommended for powering medical or life
support equipment.
rupter (GFCI) for protection against the shock hazard of
erson who is using an appliance with faulty insulation and,
stray current imposed on the wiring by other electrical
or
16
CONTROLS & FEATURES
DC CIRCUIT PROTECTOR
POSITIVE DC TERMINAL
(RED)
NEGATIVE DC TERMINAL
(BLACK)
OFF
ON
DC Terminals
The DC terminals may ONLY be used for charging 12-volt automotive
type batteries.
The terminals are colored red to identi
fy 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
r
ging circuit when the DC charging circuit is overloaded, when
cha
there is a problem with the battery, or when the connections between
the battery and the generator are improper. However, the DC circuit
protector does not prevent overcharging.
17
CONTROL & FEATURES
HANDLE LOCK LEVER
HANDLE
Handle
transport
position
Generator
stationary
position
Folding Handle
The foldable handle is intended for ease of transportation and should
be folded wh
extended handle.
To Extend The Handle
Lift handle upward. Lock lever will lock and secure the handle into
place.
To Fold The Handle
1. Press handle lock lever downward.
2. Lower the handle.
en the generator is stationary. Do not rest objects on the
18
CONTROLS & FEATURES
FEATURES
®
Oil Alert
The Oil Alert system is designed to prevent engine damage caused by
an insufficient amount of oil in the crankcase. Before the oil level in
the crankcase can fall below a safe limit, the Oil Alert system will
automatically stop the engine (the engine switch will remain in the ON
position).
If the engine stops and will not restart, check the engine oil level (see
page 47) before troubleshooting in other areas.
Automatic Engine Stop Function
Ale
Oil
During operation, the engine will automatically stop if there is not
enough
alert function may operate and stop the engine.
Overspeed Detection Function
To protect the engine from exceeding the engine load, the engine will
automa
System
rt Function
in the tank. Moreover, if the generator is on a slope, the oil
oil
ti
cally stop if the engine speed becomes abnormal.
Abnormal Voltage Detection Function
The engine will automatically stop during generation when it detects
abnormal
If the engine stops, make sure the oil level is correct. Wait a few
minutes, and t
start, take the generator to your authorized servicing Honda power
equipment dealer.
v
oltage.
hen try to restart the engine. If the engine still won’t
19
CONTROLS & FEATURES
MANUAL CHOKE LEVER
* ECM
* ECM: Engine Control Module
Auto Choke and Throttle Control System
The ECM of this engine controls the choke valve and throttle
automati
When starting and warming up the engine, you do not need to operate
the chok
starting procedure.
cally.
e lever unless the engine is hard to start using the normal
iAVR (Intelligent Auto Voltage Regulator)
This generator is equipped with an intelligent, automatic voltage
regulator. T
he iAVR provides power in excess of the maximum rating
for up to ten seconds to start appliances that require high startup
current.
The total amount of power available for each generator model is:
EM4000SX 5,000 watts for up to 10 seconds
EM5000SX 7,000 watts for up to 10 seconds
EM6500SX 7,000 watts for up to 10 seconds
20
CONTROLS & FEATURES
FUEL GAUGEFUEL TANK CAP
FULLEMPTY
GROUND TERMINAL
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.
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,
electric
al inspector, or local agency having jurisdiction for local codes
or ordinances that apply to the intended use of the generator.
21
BEFORE OPERATION
ARE YOU READY TO GET STARTED?
Your safety is your responsibility.
significantly reduce your risk of injury.
Knowledge
Read and understand this manual. Know what the controls do and
how to
Familiarize yourself with the generator and its operation before you
begin
an emergency.
If the generator is being used to power appliances, be sure that they
do not ex
IS YOUR GENERATOR READY TO GO?
For your safety, to ensure compliance with environmental regulations,
and to
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.
operate the
using
it. Know how to quickly shut off the generator in case of
ceed the generator’s load rating (see page 33).
maximiz
m.
e the service life of your equipment, it is very
A little time spent in preparation will
22
Failure to properly maintain this
generator, or failing to correct a
problem before operation, could
result in a significant malfunction.
Some malfunctions can seriously
hurt or kill
Always perform a pre-operation
inspection before each operation
and correct any problems.
you.
BEFORE OPERATION
To prevent a possible fire, keep the generator at least 3 feet (1 meter)
away from building walls and other equipment during operation. Do
not place flammable objects close to the engine.
Before beginning your pre-operation checks, be sure the generator is
on a level surface
Check the Engine
• Before each use, look around and underneath the engine for signs
of oil or gasoline leaks.
•
Check the oil level (see page 47). A low oil level will cause the Oil
Alert system to shut down the engine or prevent it from starting.
• Check the air cleaner (see page 50). A dirty air cleaner element will
restrict air flow to the carburetor, reducing engine and generator
p
erform
• Check the fuel level (see page 45). Starting with a full tank will help
to eliminate or reduce operating interruptions for refueling.
Check the GFCI
ance.
and the engine switch is in the OFF position.
Check the GFCI operation (see page 29) after starting the engine.
23
OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the generator for the fir
GENERATOR SAFETY
page 22).
For your safety, do not operate the generator in an enclosed area such
as
a garage.
monoxide gas that can collect rapidly in an enclosed area and cause
illness or death.
Before connecting an AC appliance or power cord to the generator:
Your generator’s exhaust contains poisonous carbon
(see page 6) and
Exhaust contains poisonous carbon
monoxide gas that can build up to
dangerous levels in closed areas.
Breathing carbon monoxide can
s
e unconsciousness or death.
cau
Never run the generator in a closed,
or even par
people may be present.
tly closed area where
st time, review chapters
BEFORE OPERATION
(see
• Use grounded 3-prong extension cords, tools, and appliances, or
double-insulated
• Inspect cords and plugs, and replace if damaged.
• Do not use cord lengths greater than 164 feet (50 meters), and do
ot
use multiple tools and appliances with built-in noise filters. Such
n
use may activate the GFCI.
• Make sure that the appliance is in good working order. Faulty
ppliances or po
a
• Make sure the electrical rating of the tool or appliance does not
ceed the rated power of the generator or the receptacle being used.
ex
• Operate the generator at least 3 feet (1 meter) away from buildings
nd other equ
a
• Do not operate the generator in an enclosed structure.
• Do not place flammable objects close to the engine or locate the
e
nerator near flammable materials.
g
tools and appliances.
wer cords can create a potential for electric shock.
ipment.
24
OPERATION
OFF
AC CIRCUIT BREAKER
FUEL VALVE LEVER
ON
STARTING THE ENGINE
To prevent a possible fire, keep the generator at least 3 feet (1 meter)
away from building walls and other equipment during operation. Do
not place flammable objects close to the engine.
Operating this generator less than 3 feet (1 meter) from a building or
other obstruction can cause overheating and damage the generator.
For proper cooling, allow at least 3 feet (1 meter) of empty space
above and around the generator.
Refer to
the
AC OPERATION
to
connecting loads to the generator.
1. Make sure that all appliances
are disconne
receptacle.
2. Make sure that the AC circuit
breaker is
3. Turn the fuel valve lever to the
ON position.
SAFE OPERATING PRECAUTIONS
IS YOUR GENERATOR REA DY TO GO
(see page 31) or
cted from
in the OFF position.
the AC
on page 24 and perform
checks (see page 22). Refer
DC OPERATION
(see page 37) for
25
OPERATION
AUTO THROTTLE SWITCH
OFF
ON
START
OFF
ENGINE SWITCH
4. Make sure the Auto Throttle
switch is in the OFF position, or
more time will be required for
warm up.
5. Start the engine.
• Using the electric starter:
Turn the engine switch to the
ST
ART 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 second
s, release the key, and
wait at least 10 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.
Do not leave the engine switch in the ON position when the
generator is not operating as the battery will discharge. Turn the
engine switch to
the OFF position when not in use.
26
• Using the recoil starter:
ENGINE SWITCH
ON
STARTER
GRIP
Direction to pull
AUTO THROTTLE SWITCH
ON
a. Turn the engine switch to the
ON position.
b. Pull the starter grip lightly
until you feel resistance; then
pull briskly in the direction of
the ar
Do not allow the starter
•
row as shown.
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.
•
Be careful not to hit your
hand against the handle
when pulling the starter
grip.
OPERATION
6. If you wish to use the Auto
Throttle system, turn the Auto
Throttle switch to the ON
position after the engine has
rmed up for 2 or 3 minutes.
wa
27
OPERATION
AC CIRCUIT BREAKER
OFF
OFF
ENGINE SWITCH
OFF
FUEL VALVE LEVER
STOPPING THE ENGINE
To stop the engine in an emergency, simply turn the engine switch to
the OFF position. Under normal conditions, use the following
proced
1. Turn off or disconnect all appliances that are connected to the
2. Move the AC circuit breaker to
3. Turn the engine switch to the
ure.
generator.
the OFF position.
OF
F posi
tion.
4. Turn the fuel valve lever to the
OFF posi
28
tion.
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