Owner’s Manual Generator EM500 l Q1997 American Honda Motor Co., Inc.
Thank you for purchasing a Honda generator. This manual covers operation and maintenance of the EM500 and EM600 generators. 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.
CONTENTS CONTENTS ................................... 1. GENERATOR SAFETY ........................... 2. COMPONENT IDENTIFICATION 3. PRE-OPERATION CHECK ................................. ................................. 4. STARTING THE ENGINE ....................................... 5. GENERATOR USE ................................. 6. STOPPING THE ENGINE ......................................... 7. MAINTENANCE ............................... 8. TRANSPORTING/STORAGE .................................... 9.
1. GENERATOR SAFETY E To ensure safe operation - Place the generator at least 1 m (3 ft) away from buildings or other equipment when operating the generator. Operate the generator on a level surface. If the generator is tilted, fuel spillage may resuit. Exhaust gas contains poisonous carbon monoxide. Never run the generator in an enclosed area. Be sure to provide adequate ventilation. Know how to stop the generator quickly and understand operation of all the controls.
2.
CARRYING HANDLE \ FUEL TANK / CAP THROTTL .
3. PRE-OPERATION CAUTION: stopped. CHECK Be sure to check the generator on a level surface with the engine, 1. Check the engine oil level. CAUTION: Engine oil is a major factor affecting engine performance service life. Non-detergent or vegetable oils are not recommended. and Use Honda 4.stroke oil, or an equivalent high detergent, premium quality motor’ oil certified to meet or exceed U.S. automobile manufacturer’s requirements for Service Classification SE or SF.
-20 -30 0 -20 20 -10 40 0 60 10 20 80 30 100°F 40°C NOTE: The oil alert lamp (EM600 only) will light during operation before the engine oil level becomes too low. If this occurs, stop the engine and fill to the top of the filler neck with the recommended oil (page 4). l The oil alert lamp should always light when starting, but should go out after the engine is running if there is sufficient oil. If the lamp does not light at all, replace the bulb.
2. Check the fuel level. Use low lead or unleaded 88 or higher. automotive Never use an oil/gasoline or water in the fuel tank. mixture gasoline with a pump octane rating of or dirty CAUTION: Gasoline substitutes are harmf.ul to the fuel system components. l l l l gasoline. not getting recommended; they dirt, dust may be Gasoline is extremely flammable and explosive under certain conditions. Refuel in a well ventilated area with the engine stopped.
4. 1. Disconnect STARTING THE ENGINE the load from the AC or DC receptacle. 2. Move the engine switch to “ON”. ENGINE 3. Pull the starter rope lightly until resistance is felt, then pull briskly. CAUTION: Do not allow the starter grip to snap back against the generator. Return it gently to prevent damage to the housing. NOTE: out. Make sure the pilot lamp comes on.
5. GENERATOR USE o prevent electrical shock from faulty appliances, the generator H?IlEQT should be grounded. Connect a length of heavy wire between the ground terminal and the ground source. GROUND TERMINAL CAUTION: l Limit operation requiring maximum power (EM500: 500VA, EM600: 600VA) to 30 minutes. For continuous operation, do not exceed the rated power of 4OOVA (EM5001 and 450VA (EM600). l Do not exceed the current limit specified for any one receptacle.
AC operation 1. Start the engine and make sure the pilot lamp comes on. If not, the filament may be burnt out. 2. Move the selector switch to the AC position. 3. Plug in the appliance. CAUTION: Be sure that appliances do not exceed the rated load for more than 30 minutes, and never exceed the maximum load. Substantial overloading will switch off the circuit breaker. Lesser overloading will not switch off the circuit breaker and will shorten the service life of the generator. 4.
DC operation Start the engine and move the selector switch to the DC position. The DC receptacle may be used for charging 12 volt automotive-type batteries only. m Batteries produce explosive gases. Keep sparks, flames, and cigarettes away. To prevent the possibility of creating a spark near the battery, connect the charging cord first to the battery, then to the generator, and disconnect the cord first at the generator.
6. To stop the engine in an emergency, In normal use: 1. Turn off the electrical appliance generator. 2. Move the engine switch to OFF. l High altitude STOPPING THE ENGINE move the engine switch to OFF. or disconnect the charging cord from the operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and feul consumption will increase.
7. MAINTENANCE The purpose of the maintenance schedule and adjustment generator in the best operating condition. Inspect or service as scheduled in the table on the next page. is to keep the m Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas. CAUTION: replacement generator, Use only genuine HONDA parts which are not of parts or their equivalent.
Maintenance Schedule REGULAR SERVICE Perform at every indicated month or operating hour interval, whichever occurs Inspection Engine oil Daily First month Every 3 months Every 6 months Every year 2O’Ars. 5O’irs. 1 OZ-irs. 3OCZirs.
Changing oil Drain the oil while draining. the engine is still warm to assure rapid and complete 1. Remove the oil filler cap, and drain the oil. 2. Refill with the recommended oil (see page 4) and check the level. OIL OIL CAPACITY: FILLER 0.35P (0.37 US qt) CA+ CAUTION: Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly (page 13). Service more frequently when operating the generator in extremely dusty areas. E I m Never use gasoline or low flash point cleaner element. A fire or explosion could result. CAUTION: Never wear may result. run the generator without solvents for cleaning the air cleaner. Rapid the air engine 1.
Spark plug service Recommended spark plug: BPMR4A-10 (NGK) W14MPR-UIO (ND) To ensure proper engine operation, and free of deposits. the spark plug must be properly gapped 1. Remove the spark plug cap. 2. Use the wrench supplied in the tool kit to remove the spark plug. 3. Visually chipped. 4. Measure The gap bending inspect the spark plug. Discard it if the insulator is cracked or Clean the spark plug with a wire brush if it is to be reused. the plug gap with a feeler gauge. should be 0.9-1.0 mm (0.
5. Attach the plug threading. washer. Thread the plug in by hand to prevent cross- 6. Tighten a new spark plug l/2 turn with the wrench to compress the washer. If you are reusing a plug, it should only take l/8-1/4 turn after the plug seats. CAUTION: The spark plug must be securely tightened. An improperly can become very hot and possibly damage the generator. l Never use a spark plug with an improper heat range.
Spark arrester B Allow maintenance If the generator has been running, it to cool before proceeding. CAUTION: The spark arrester its efficiency. must be serviced the muffler will be very hot. every 100 hours to maintain 1. Remove the four left side cover screws, and remove the cover. SCREW 2. Remove the mounting bolt for the muffler, the mounting bolt for the choke bimetal strip, and the two nuts that attach the exhaust pipe to the engine. Remove the muffler and exhaust pipe. 3.
MUFFLER HEAT SETTING BOLT SHIELD EXHAUST PIPE 5. Use a brush to remove carbon deposits from the spark arrester screen. 6. Check the exhaust pipe gaskets; replace if damaged. Reassemble the exhaust system. See next page. The automatic choke system needs adjustment, when reinstalling.
Automatic choke adjustment 1. Loosen the automatic choke setting bolt. 2. Push the choke valve arm at the carburetor so the choke valve is closed. 3. Adjust distance “A” to 3 mm (0.12 in) by relocating the bimetal strip. Retighten the bolt securely. NOTE: l Recheck distance A after tightening the bimetal strip. l Hard starting or lack of power will result if not adjusted CHOKE VALVE ARM SETTING properly.
8. TRANSPORTING/STORAGE B When transporting the generator, turn the engine switch OFF and keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. I ? Before storing the unit for an extended period: 1. Be sure the storage area is free of excessive humidity and dust. 2. Drain the fuel a. With the engine switch ON, remove the fuel filler cap. b. Loosen the drain screw and drain the fuel into a suitable Retighten the screw. c. Move the engine switch to OFF. container.
9. TROUBLESHOOTING A. When the engine will not start: 1. Is the engine switch ON? 2. Is there enough fuel? 3. Is nothing connected at the AC and DC receptacles? 4. Is gasoline reaching the carburetor? To check, remove the side cover and loosen the drain screw with fuel valve ON. m the spark ignite. If any fuel is spilled, make sure the area is dry before testing plug or starting the engine. Fuel vapor or spilled fuel may 5. Is there a spark at the spark plug? a. Remove the spark plug cap.
d. Grounding the side electrode to the cover, pull the recoil starter to see if sparks jump across the gap. SPARK PLUG e. If there are no sparks, replace the plug. If OK, try to start the engine according to the instructions. 6. If the engine still does not start, take the generator B. C. to the dealer. No electricity at the AC receptacles: 1. Is the AC circuit breaker on? 2. Check the electrical appliance or equipment for any defects. No electricity at the DC receptacles: 1.
10. SPECIFICATIONS Dimensions Length x Width x Height EM500: EM600: EM500: EM600: Dry Weight 355 x 250 x (14.0 x 9.84 365 x 250 x (14.4 x 9.84 325 mm x 12.8 in) 325 mm x 12.8 in) 18.0 kg (39.7 lb) 19.0 kg (41.9 lb) Engine Engine Type 4-stroke, Displacement [Bore x Stroke] Compression Ratio Engine Speed Cooling System Ignition System Oil Capacity Fuel Tank Capacity Spark Plug 59.8 cc (3.65 cu in) [46x 36 mm (1.81 x 1.42 in)] 5.5 : 1 3.600 r.p.m. Forced air cooling C.D.I. 0.35 c! (0.37 us qt) 2.
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~ Warranty Owner Service Satisfaction Your satisfaction and goodwill are important to your dealer and to us. All Honda warranty details are explained in the Distributor’s Limited Warranty. Normally, any problems concerning the product will be handled by your dealer’s service department. If you have a warranty problem that has not been handled to your satisfaction, we suggest you take the following action: l Discuss your problem with a member of dealership management.
Current customer service contact information: United States, Puerto Rico, and U.S. Virgin Islands: Honda Power Equipment dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership's management. The Service Manager or General Manager can help. Almost all problems are solved in this way.
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