Honda Power Equipment EM6500SX, EM5000SX, EM4000SX User Manual 2

Owner’s Manual

GENERATOR

EM4000SX • EM5000SX • EM6500SX

See page 82 for Initial Use Instructions

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductiveharm.

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.

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.

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 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 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.

Distributor’s Limited Warranty

is a separate document that should

to fully

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:

Safety Labels

Safety Messages

of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

Safety Headings

Safety Section

Instructions

This entire book is filled with important safety information please read it carefully.

−

on the generator.

−

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

−

how to use this generator correctly and safely.

−

be or if

be if you don’t follow

IMPORTANT SAFETY INFORMATION

GENE R ATOR SAFE TY.

−

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

........................................................................................Starter Grip .12

.............................................................................................FEATURES .18

System .18

.........................................................................................Fuel Gauge .20

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

....................................................................................Engine Switch .12

................................................................................Fuel Valve Lever .13

...................................................................Voltage Selector Switch .13

System .14

.....................................................................................DC Terminals .16

..................................................................................Folding Handle .17

......................................................................Auto Throttle

.............................................................................AC Circuit Breaker .14

.........................................................................AC Circuit Protectors .15

..........................................................................DC Circuit Protector .16

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

.....................................................Automatic Engine Stop Function .18

..............................................................................Oil Alert Function .18

........................................................Overspeed Detection Function .18

............................................Abnormal Voltage Detection Function .18

.......................................Auto Choke and Throttle Control System .19

......................................iAVR (Intelligent Auto Voltage Regulator) .19

...............................................................................Ground Terminal .20

...............................................................................BEFORE OPERATION .21

................................................ARE YOU READY TO GET STARTED? .21

.........................................................................................Knowledge .21

..............................................IS YOUR GENERATOR READY TO GO? .21

...............................................................................Check the Engine .22

CONTENTS

..............................................................................................OPERATION .23

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

.....................................................SAFE OPERATING PRECAUTIONS .23

......................................................................STARTING THE ENGINE .24

......................................................................STOPPING THE ENGINE .27

.....................................................................................AC OPERATION .28

.................................................................................AC Applications .29

...................................................................AC Receptacle Selection .30

.................................................................Power Producing Circuits .30

...................................................................Voltage Selector Switch .31

.....................................................................................DC OPERATION .33

SYSTEM .35

................................................................................STANDBY POWER .36

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

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

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

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

...............................................................................BATTERY SERVICE .53

................................................................AUTO THROTTLE

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

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

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

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

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

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

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

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

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

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

..................................................AIR CLEANER ELEMENT CLEANING .48

.........................................................................SPARK PLUG SERVICE .49

................................................................SPARK ARRESTER SERVICE .51

.................................................................SEDIMENT CUP CLEANING .52

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

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

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

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

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

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

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

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

CONTENTS

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

...................................................................ENGINE WILL NOT START .64

.......................................................................ENGINE LACKS POWER .65

..............................................NO POWER AT THE AC RECEPTACLES .66

..................................................NO POWER AT THE DC TERMINALS .66

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

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

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

...............................................Emission Control System Information .69

................................................................................................Air Index .71

........................................................................................Specifications .72

.....................................................................................Wiring Diagram .73

...................................................................CONSUMER INFORMATION .75

..................................................................Dealer Locator Information .75

..............................................................................Honda Publications .75

............................................................Customer Service Information .76

...............................................................................................ASSEMBLY .77

..................................................................................................SAFETY .77

..............................................The Importance of Proper Assembly .77

..........................................................Important Safety Precautions .78

............................................................................................ASSEMBLY .79

..........................................................................................Unpacking .79

........................................................................................Loose Parts .79

........................................................................Wheel Kit Installation .80

............................................................................Handle Installation .81

..................................................................INITIAL USE INSTRUCTIONS .82

...........................................................................................ENGINE OIL .82

.......................................................................................................FUEL .83

...............................................................................................BATTERY .84

...........................................................................BEFORE OPERATION .85

.....................................................................................REGISTRATION .85

....................................................................................OPTIONAL PARTS .86

...............................................................................Remote Control Kit .86

.............................................................................Remote Control Box .87

..............................................................................................Hanger Kit .88

........................................................................................................INDEX .89

.............................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 injuries or property damage 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 carbon monoxide can cause loss of consciousness and may lead to death.

If you run the generator in an area that is confined, or even partly enclosed area, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your generator inside a garage, house, or near open windows or doors.

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 that 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 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 generator dealer for a replacement.

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

Use the illustrations on these pages to locate and identify the most frequently used controls.

AC CIRCUIT PROTECTORS

VOLTAGE SELECTOR SWITCH

AC CIRCUIT BREAKER

DC CIRCUIT PROTECTOR

ENGINE SWITCH

DC TERMINALS

＊

GROUND TERMINAL

AUTO THROTTLE SWITCH

120 V/240 V AC RECEPTACLE

120 V RECEPTACLES

: Except EM4000SX

＊

CONTROLS & FEATURES

CONTROL PANEL

AIR CLEANER

FUEL VALVE LEVER

SEDIMENT CUP

STARTER GRIP

FUEL TANK CAP

FUEL GAUGE

BATTERY COVER

OIL FILLER CAP/DIPSTICK

OIL DRAIN PLUG

HANDLE

SPARK PLUG

WHEEL

STAND

MUFFLER

MANUAL CHOKE LEVER

CONTROLS & FEATURES

CONTROLS

Engine Switch

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

OFF Stops the engine. The

−

engine switch key can be removed/inserted.

ON Running position, and for

−

starting with the recoil starter.

START Operates the electric

−

starter.

Starter Grip

Used when the battery voltage is too low to turn the starter motor. 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.

OOFFFF

ENGINE SWITCH

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OONN

SSTTAARRTT

S GRIP

TARTER

Fuel Valve Lever

The fuel valve lever is located between the fuel tank and carburetor.

CONTROLS & FEATURES

OONN

The fuel valve must be in the ON

OOFFFF

position for the engine to run.

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

EL VALVE LEVER

Voltage Selector Switch

The voltage selector switch switches generator output to produce ‘‘120V ONLY’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the 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.

Switch Position

120V/240V:

The 120V 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.

VOLTAGE SELECTOR SWITCH

120 V/240 V

120 V ONLY

CONTROLS & FEATURES

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:

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. Recommended to minimize warm-up time when the generator is started and when starting a load with large startup power equipments.

TO THROTTLE SWITCH

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OONN

OOFFFF

OONN

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.

OONN

CIRCUIT BREAKER

OOFFFF

CONTROLS & FEATURES

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.

AC CIRCUIT PROTECTOR for Receptacle

＊

120 V 30 A

: Except EM4000SX

＊

AC CIRCUIT PROTECTOR for Receptacle

120 V 20 A

AC CIRCUIT PROTECTOR for Receptacle

120 V/240 V 20 A (EM4000SX)

V/240 V 30 A (EM5000SX,

120 EM6500SX)

OFF

112200 VV 2200 AA

PUSH

CONTROLS & FEATURES

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

POSITIVE DC TERMINAL (RED)

NEGATIVE DC TERMINAL

OFF

(BLACK)

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. However, the DC circuit protector does not prevent overcharging.

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 the extended handle.

To Extend The Handle

Lift handle upward. Lock lever will lock and secure the handle into place.

To Fold The Handle

Press handle lock lever downward.

Lower the handle.

HANDLE

Handle transport position

Generator stationary position

HANDLE LOCK LEVER

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 ) before troubleshooting in other areas.

Automatic Engine Stop Function

Oil Alert Function

During operation, the engine will automatically stop if there is not enough oil in the tank. Moreover, if the generator is on a slope, the oil alert function may operate and stop the engine.

Overspeed Detection Function

To protect the engine from exceeding the engine load, the engine will automatically stop if the engine speed becomes abnormal.

Abnormal Voltage Detection Function

The engine will automatically stop during generation when it detects abnormal voltage.

System

If the engine stops, make sure the oil level is correct. Wait a few minutes, and then try to restart the engine. If the engine still won’t start, take the generator to your authorized servicing Honda power equipment dealer.

CONTROLS & FEATURES

Auto Choke and Throttle Control System

The ECM of this engine controls the choke valve and throttle automatically.

When starting and warming up the engine, you do not need to operate the choke lever unless the engine is hard to start using the normal starting procedure.

＊

ECM

MANUAL CHOKE LEVER

＊

ECM: Engine Control Module

iAVR (Intelligent Auto Voltage Regulator)

This generator is equipped with an intelligent, automatic voltage regulator. The 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 EM5000SX EM6500SX

5,000 watts for up to 10 seconds

7,000 watts for up to 10 seconds

CONTROLS & 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.

FUEL GAUGE FUEL TANK CAP

EMPTYFULL

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.

GROUND TERMINAL

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 ).29

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 pre-operation inspection before each operation, and correct any problem.

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 and the engine switch is in the OFF position.

Check the Engine

Check the oil level (see page ). 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 ). A dirty air cleaner element 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.

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the generator for the first time, review chapters

GENERATOR SAFETY

page ).621

For your safety, do not operate the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

(see page ) and

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.

BEFORE OPERATION

(see

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

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

SAFE OPERATING PRECAUTIONS IS YOUR GENERATOR READY TO GO AC OPERATION

(see page ) or

28 33

DC OPERATION

connecting loads to the generator.

Make sure that the AC circuit

breaker is in the OFF position. The generator may be hard to start if a load is connected.

Turn the fuel valve lever to the

ON position.

on page and perform the

checks (see page ). Refer to

(see page ) for

CIRCUIT BREAKER

OOFFFF

FUEL VALVE LEVER

OONN

Make sure the Auto Throttle

switch is in the OFF position, or more time will be required for warm up.

Start the engine.

Using the electric starter:

OPERATION

TO THROTTLE SWITCH

OFF

SSTTAARRTT

OONN

Turn the engine switch to the

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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

ENGINE SWITCH

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.

OPERATION

Using the recoil starter:

Turn the engine switch to the

ON position.

Pull the starter grip lightly until

you feel resistance; then pull briskly in the direction of the arrow as shown.

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. Be careful not to hit your hand against the handle when pulling the starter grip.

OONN

DDiirreeccttiioonn ttoo ppuullll

ENGINE SWITCH

TARTER

S GRIP

IfyouwishtousetheAuto

Throttle system, turn the Auto Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes.

AUTO THROTTLE SWITCH

OONN

OPERATION

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 procedure.

Turn off or disconnect all appliances that are connected to the

generator.

Move the AC circuit breaker to

the OFF position.

AC CIRCUIT BREAKER

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Turn the engine switch to the

OFF position.

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Turn the fuel valve lever to the

OFF position.

NGINE SWITCH

EL VALVE LEVER

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+ 67 hidden pages