Honda Power Equipment EM5000X User Manual

Thank you for purchasing a Honda generator. This manual covers operation and maintenance of EM5000SX/EM5000X gen-

erators. All information in this publication is based on the latest product

information available at the time of approval for 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 re

main with the generator when sold. Pay special attention to statements preceded by the following words:

ADANGER: structions are not followed.

m Indicates a strong possibility of severe personal injury or loss of

life if instructions are not followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed.

NOTE: Gives helpful information.

If a problem should arise, or if you have any questions about the generator,

consult an authorized Honda dealer.

m The Honda generator is designed to give safe and dependable serv-

ice if operated according to instructions. Read and understand this Owner’s Manual before operating the generator. Failure to do so could result in person-

al injury or equipment damage.

NOTE: This generator is equipped with a U.S.D.A. qualified spark arrester which requires periodic maintenance to ensure its effectiveness. It is illegal in some areas to operate an engine without a spark arrester. Check local laws

and regulations.

Indicates severe personal injury or death will result if in-

CONTENTS

GENERATOR’SAFETY:. COMPONENT IDENTIFICATION PRE-OPERATION CHECK

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

GENERATOR USE.

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

High altitude operation

MAINTENANCE..........................................2 7

TRANSPORTING/STORAGE

TROUBLESHOOTING.

10.

WIRING DIAGRAM.......................................4 0

11.

SPECIFICATIONS......‘..................................4 2

12.

INSTALLATION OF OPTIONAL PARTS

13..

WARRANTY FERVICE

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3 7

9 .13 .18 .25

.26

.36

~38’

.43 .49

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1. GENERATOR SAFETY

Place the generator on a firm, level surface; avoid loose sand or snow. If the generator is tilted or overturned, fuel spillage and a fire may result.

To prevent fire hazards and to provide adequate ventilation, keep the generator at least 1 meter (3 feet) -away from buildings and other equipment during operation. Do not place flammable objects close to the generator.

Children and pets must be kept away from the area of operation due to a possibility of electric shock or burns from hot components.

Know how to stop the generator quickly, and understand the operation of all the controls. Never permit anyone to operate the generator without proper instruction.

The generator is a potential source of electrical shocks if misused. Do not operate the generator in rain or snow. Do not let the generator get wet, and do not operate it with wet hands.

0 Gasoline is extremely flammable and is explosive under certain conditions.

Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the refueling area or where gasoline is stored.

Do not overfill the fuel tank. After refueling, make sure the tank cap is closed properly and securely.

Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may

ignite. If any fuel is spilled, make sure the area is dry before starting the

engine.

Never run the engine in an enclosed or confined area. Exhaust contains

poisonous carbon monoxide gas; exposure may cause loss of consciousness and may lead to death.

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.

Connections for standby power to a building’s electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to backfeed into the utility lines.

Such backfeed may electrocut6 utility company workers or others who contact the lines during a power outage, and when utility power is restored, the generator may explode, burn, or cause fires in the building’s electrical system.

CAUTION: Equipment damage and corrosion from sand, dirt, and water may

occur if the generator is overturned or sinks into a soft surface.

‘4

Read these labels before you operate the generator.

FWARNING DO NOT USE INDOORS. EXHAUST GAS CDNTAlNS>

POISONOUSCARBON MONOXIDE.

ATTENTION NE,PASUTlLlSERDANSUNENDROlT FERMEACAUSE

DU RISQUED'EMPOISONNEMENT DU GAZ.

ATENCl(')N NO LO USE EN LUGARES CERRADOS PORQUE EL

MONOXIDE DE CARBON0 ESVENENOSO.

? CO.. LTD.

MADE IN JAPAN Gl

EM5000X

CAUTLUN

IAl.

HONDA MOTOR CO., LTD.

MADE IN JAPAN

Ub II

2. COMPONENT IDENTIFICATION

ENGINE SWITCH (EM5000X)

PILOT LAMP

ENGINE SWITCH

CHOKE ROD

FUEL VALVE

AIR CLEANER

RECOIL STARTER GRIP

DC CIRCUIT PROTECTOR

VOLT R/lCl-CD

-. lYlL,Lrl

OIL ALERT LAMP

DC OUTPUT

TERMINAL

.‘\’

VOLTAGE SELECTOR SWITCH

:EPTACLES

TERMINAL

OIL FILLER CAP

SWITCH (EMSOOOSX)

OIL DRAIN PLUG

FUEL TANK CAP

FUEL METER

SPARK PLUG CAP

MUFFLER

3. PRE-OPERATION CHECK

Perform the pre-operation check with the generator on a level surface and the engine stopped.

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1. Engine Oil CAUTION: Engine oil is a major factor affecting engine performance and

service life. Non detergent oils, ‘castor-based oils, and 2-stroke engine dils are not recommended because they have inadequate lubrictitihg characteris!ics.

Use Honda 4-stroke oil an equivalent high-detergent, premium quality motor

oil certified to meet or exceed U.S. automobil manufacture’s.requirements

for Service Classification SG-SF/CC-CD. Motor oils classified SG.SF/CCCD

will show this designation on the container,

SAE lOW/30 is recommended for general, all-temperature use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

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1. Remove the oil filler cap and check the oil level.

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2. ,lf the. level is low, fill to the top of the oil filler,neck with the recornmel nded oil. .,

NOTE: The Oil Alert System will automatically stop the engine before the oil level fails below the safe limit. However,.to avoid the inconvenie,nce of an unexpected shutdown, it is advisable,to visually inspect the oil level regularly.

OIL FILLER CAP

OIL FILLER HOLE

-20 ,o 20 40 60 80 lOOoF

-30 -20 -10. 0 10 20 30 4o”c

Ambient temperature

2. Fuel

Check the fuel meter and refill the tank if the fuel level is low. Your engine is designed to use any gasoline that has a pump octane number (-1 of 86 or higher, or that has a research octane number of 91 or higher. Gasoline pumps at service station normally display the pump oc-

tane number. We recommend that you use unleaded fuel because it produces fewer engine and spark plug deposits and extends the life of exhaust system components.

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt, dust or water in the fuel tank. Use of a lower octane gasoline can cause persistent “pinging” or heavy “spark knock” (a metallic rapping noise) which, if severe, can lead to engine damage.

CAUTION: If “spark knock” or “pinging” occurs at a steady engine speed under normal load, change brands of gasoline. If spark-knock or

pinging persists, consult your authorized Honda dealer. Failure to do so

is considered misuse, and damage caused by misuse is not covered by

Honda’s Limited Warranty.

Occasionally you may exp’erience light spark knock while operating under heavy

loads. This is no cause for concern, it simply means your engine is operating

efficiently.

Fuel tank capacity: 17.0 II (4.5 US gal)

FUEL METER

FUEL FILLER CAP

‘m ,:

’ Gasoline is extremely .flammable and is explosive under certain

conditions.

Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refuel-’ ed- or where .gasoline is stored.

Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely.

Be careful not to,spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting, the engine.

0 Avoid repeated or prolonged contact with skin or breathing of vapor.

KEEP OUT OF .REACH OF CHILDREN.

GASOLINES CONTAINING ALCOHOL If you’decide to use a gasoline containing alcohol (gasohol), be sure it’s octane

rating is at least as high as that recommended by Honda. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol .(methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion’ inhibitors.

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NOTE:

Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their

suitability is as yet incomplete.

Before buying fuel from an unfamiliar station, try to find out if the fuel con-

tains alcohol, if it ,does, ‘confirm the type and percentage of alcohol used.

If you notice any undersirable operating symptoms while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

3. Air Cleaner Check the air cleaner elements to be sure they are clean and in good condi-

tion. Clean or replace the elements if necessary (page30).

CAUTION: Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, such as dust and dirt, being drawn through the

carburetor, into the engine.

ELEMENT

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4. STARTING THE ENGINE

1. Make sure that the AC circuit breaker is. in the OFF position, and that nothing is connected to the DC terminals.

The generator may be hard to start if a load is connected.

AC ClkUlT BREAKER

2. Turn the fuel valve to the ON position.

DC TERM’IidALS

FUEL VALVE

3. Pull the choke rod out td the CLOSE position.

CHOKE ROD

4. Make sure the auto-throttle switch is’ in the.O.FF position, or more time will be required for warm up. (ERi15000SX only)

‘14

AU’TO-TH ROTTLE SW I’TCH

5. Start the engine

With

recoil starter:

Turn the engine switch to the ON position.

ITCH

I, .,

ENGINE SWITCH

(EM5000X)

Pull the starter grip lightly until resistance is felt, then pull briskly. CAUTION: Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter or housing.

.STARTER GRIP

(EM5000SXI

With electric starter (EM5000SX only):

Turn the engine switch to the START position and hold it there until the engine starts.

NOTE:

Do not use the electric 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.

If the generator is equipped with a remote control kit, make sure the switch

on the relay box is turned off, or the engine will not start.

0 If the speed of the starter motor drops after a period of time, it is an indica-

tion that the battery.should be recharged.

,ENGlNE SWITCH

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6. When the engine starts, allow the engine switch to return to the ON position.

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