Honda Power Equipment EM5000SX User Manual

Thank you for purchasing a Honda generator. 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. This owner’s manual describes the operation and maintenance of the

EM5000SXKl Honda Generator. All information in this publication is based

on the latest product information available at the time of printing. Honda

Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.

This manual should be considered a permanent part of the generator and should remain with it if it is resold.

Safety Messages

Your safety and the safety of others is very important. We have provided

important safety messages in this manual and on the generator. Please read

these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol Lfi and one of three words: DANGER, WARNING, or CAUTION.

These mean

D ’

m You WILL be KILLED or SERIOUSLY HURT if you don’t

follow instructions.

L -

m You CAN be KILLED or SERIOUSLY HURT if you don’t

follow instructions.

9 *

r You CAN be HURT if you don’t follow instructions.

Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury.

Damage Prevention Messages

You will also see other important messages that are preceded by the word NOTICE.

This word means:

-1 Your generator or other property could be damaged if you don’t follow instructions.

The purpose of these messages is to help prevent damage to your generator, other property, or the environment.

SAFETY

Safety Label Locations Safety Information

COMPONENT IDENTIFICATION CONTROLS

Engine Switch Recoil Starter Fuel Valve Choke Rod Circuit Breaker

Grond Terminal ......................................................................

Oil Alert System Auto-throttle System Volt Meter Pilot Lamp Voltage Selector Switch (Dual voltage System) DC Terminals DC Circuit Protector

GENERATOR USE..

Connections to a Building’s Electrical System Generator Ground Circuit AC Applications.. AC Operation AC Receptacle Selection

DC Operation ......................................................................

Disconnecting the battery cables

Auto-throttle System

High Altitude Operation

PREOPERATION CHECK

Engine Oil

Fuel Recommendation STARTING THE ENGINE.. STOPPING THE ENGINE

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4 4 6

8 10 10

11 11

12 12 12

14 14

16 16

17 18

19 20 21

25 28

MAINTENANCE

Maintenance Schedule

Tool Kit

Engine Oil Change ................................................................ 31

Air Cleaner Service Fuel Sediment Cup Spark Plug

Spark Arrester Maintenance ................................................... 35

TRANSPORTING/STORAGE .................................................. 36

TROUBLESHOOTING

WIRING DIAGRAM.. .................................................................. 40

SPECIFICATIONS .................................................................. 41

INSTALLATION OF OPTIONAL PARTS ................................ 42

WARRANTY SERVICE.. .......................................................... 48

INDEX ...................................................................................... 49

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29 29 30

32 33 34

SAFETY

SAFETY LABEL LOCATION

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.

lCHfCK fOR SPIlltO fllfl OR flJf1 LfAKS.

STOP tW6INL BEDIRt RtWLlNG.

lCONlR6lfR NI’IL NY A NI Wt PI WINCE

RiPANDUf SUR L’APPARtlL. ARRhR Lt HOTtUR AVANI Dt RtlAlRt It PLtlN.

IINSPKiCIONAR PARA COMRUSTIRlt OfRRAMADO

0 ESCAPE. PARAR YOIOR ANKS Ot fCHAR.

WARNING DO NOT !JSE INDOORS. EXHAUST GAS CONTAINS POISONOUS

CARBON MONOXIDE.

ATTENTION NE PAS” UTILISER OANS UN ENDROIT FERME A CAUSE DU

RISOUE D’EMPOISONNEMENT DU GAZ.

ATENCl()N NO LO. USE’EN LUGARES CERRADOS’POROUE EL MONOXIDE

DE CARBON0 ES

VENENOSO.

ITOR CO.. LTD.

n BE SUR~fb?ILL CRANKCASE 11 VOLTAGE WITH RECOMMENDED OIL BEFORE USING~ FOR DETAILEO -___ -_ ____ __ _-..I

SEE THE OWNER’S MANUAL

CAUTION

. .---

_.---- -.-

~‘EXPLANATI~~U.

-.--- ~-- ~-~

FREQUENCY RATED OUTPUT

MAX. OUTPUT PHAsE

MADE IN JAPAN @i

AC II DC

120/24OV 11 VOLTAGE

60Hz

4.5kVA

CURRENT

II 5.OkVA -..-. -_--_ ___-

10/[ FUEL “;=J&~;j

ARA

12v

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

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

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 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’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 1 meter (3 feet) away from buildings and other equipment during operation.

- Do not enclose the generator in any structure.

Keep flammable materials away from the generator.

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 well-ventilated 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.

COMPONENT IDENTIFICATION

VOLT METER

ENGINE SWITCH

CHOKE ROD

RCUlT BREAKER

UN0 TERMINAL

ENGINE SERIAL NUMBER

FUEL TANK CAP

FUEL METER

-SPARK PLUG CAP

SERIAL NUMBER

MUFFLER

Record the engine and frame serial numbers for your future reference. Refer to these serial numbers when ordering parts, and when making

technical or warranty inquiries (see page 47)

Frame serial number: Engine serial number:

CONTROLS

Engine Switch

To start and stop the engine.

Key position: OFF:

ON:

START:

ENGINE

Return the key to the ON position once the engine has started. Do not use the starter for more than 5 seconds at a time. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.

To Stop the engine. Key can be removed/inserted. To run the engine after starting. To start the engine by turning the starter

motor.

Recoil Starter

To start the engine, pull the starter grip lightly until resistance is felt, then pull

briskly.

[I Do not allow the starter to snap back against the engine.

Return it gently to prevent damage to the starter.

Fuel Valve

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 lever to OFF after stopping the engine.

Choke Rod

The choke is used to provide proper starting mixture when the engine is cold.

It can be opened and closed by operating the choke rod manually. Pull the

rod out toward CLOSED to enrich the mixture.

Circuit Breaker

The circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle. If the circuit breaker is switched OFF automatically, check that the applicance is working properly

and does not exceed the rated load capacity of the circuit before switching the circuit breaker ON again. The circuit breaker may be used to switch the generator power on or off.

Ground Terminal

The gernerator ground terminal is connected to the frame of the generater, the metal non-current carrying parts of the generator, and the ground terminals of each receptacle.

AC CIRCUIT BREAKER

GROUND TERMINAL

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 shut down the engine (the engine switch will remain in the ON position). If the Oil Alert system shuts down the engine, the Oil Alert lamp will flash when you operate the starter, and the engine will not start. If this occurs, add engine oil

(P-24).

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.

AUTO:

OFF:

Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator.

The auto-throttle system does not operate.

SWITCH

Pilot Lamp

The pilot lamp is illuminated when the generator is operating normally. It

indicates that the generator is producing electrical power at the 120 or 120/ 240 volt receptacles. If the pilot light is illuminated, the volt meter should be displaying 120 or 240 volts depending on the position of the voltage selector switch.

When the auto-throttle is in the AUTO position, and there is no load connected to the generator, the engine will run slower and the pilot light will be dimmer than at normal operating speed.

Volt Meter

The volt meter,displays the voltage the generator is producing depending on the position of the voltage selector switch. If the voltage selector switch is in the “120/240 V” position, the volt meter will display 240 volts. If the voltage

selector switch is in the “120 V ONLY” position, the volt meter will display 120

volts.

Voltage Selector Switch (Dual voltage System)

The voltage selector switches the main power carrying windings of the

generator to produce “12OV ONLY” or “120/24OV”. If a 240V appliance is

connected to the 4-prong receptacle, the switch must be in the “120/24OV”

position. If a 120V appliance ONLY is being connected to any of the 120V

3-prong receptacles, select the “120V ONLY” position.

120/24OV: 12OV ONLY:

The 12OV and 120/24OV receptacles can be used simultaneously.

ONLY the 12OV receptacles can be used. Do not use the 120/24OV receptacle in this position. Rated power will be available at the 12OV twist lock receptacle.

PILOT LAF(P

VOLTAGE SELECTOR SWIT/CH

VOLT METER

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 generator is overloaded, when there is a problem with the battery or the connections between the battery and the generator are

improper.

DC CIR PROTE

NEGATliE TiRMINAL (BLACK)

POSlilVE TERMINAL (RED)

+ 39 hidden pages

Honda Power Equipment EM5000SX User Manual

CONTENTS

SAFETY

SAFETY INFORMATION

COMPONENT IDENTIFICATION

CONTROLS

Engine Switch

Recoil Starter

Fuel Valve

Choke Rod

Circuit Breaker

Ground Terminal

Oil Alert System

Auto-throttle System

Pilot Lamp

Volt Meter

Voltage Selector Switch (Dual voltage System)

DC Terminals

DC Circuit Protector