EM4000-6500SX Cover.ai 2/8/2011 11:12:32 AM Owner’s Manual GENERATOR EM4000SX • EM5000SX • EM6500SX C M Y CM MY CY CMY K 31Z23600 00X31-Z23-6000 Printed on Recycled Paper AHM.35.2011.02 PRINTED IN U.S.A. © 2011 Honda Motor Co., Ltd.
10/10/12 14:15:12 31Z23600_001 The engine exhaust from this product contains 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 partly closed area where people may be present. Keep this owner’s manual handy so that you can refer to it at any time.
10/10/12 14:15:18 31Z23600_002 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.
10/10/12 14:15:27 31Z23600_003 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.
10/10/12 14:15:31 31Z23600_004 CONTENTS GENERATOR SAFETY .................................................................................6 IMPORTANT SAFETY INFORMATION ...................................................6 Operator Responsibility.......................................................................6 Carbon Monoxide Hazards..................................................................6 Electric Shock Hazards ........................................................................
10/10/12 14:15:35 31Z23600_005 CONTENTS OPERATION ...............................................................................................23 SAFE OPERATING PRECAUTIONS ......................................................23 STARTING THE ENGINE .......................................................................24 STOPPING THE ENGINE .......................................................................27 AC OPERATION...............................................................................
10/10/12 14:15:38 31Z23600_006 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 ......................
10/10/12 14:15:45 31Z23600_007 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.
10/10/12 14:15:53 31Z23600_008 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.
/10/12 14:15:56 31Z23600_009 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.
10/10/12 14:16:09 31Z23600_010 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.
10/10/12 14:16:14 31Z23600_011 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the illustrations on these pages to locate and identify the most frequently used controls.
10/10/12 14:16:20 31Z23600_012 CONTROLS & FEATURES CONTROL PANEL AIR CLEANER BATTERY COVER FUEL VALVE LEVER SEDIMENT CUP OIL FILLER CAP/DIPSTICK STARTER GRIP OIL DRAIN PLUG HANDLE FUEL TANK CAP FUEL GAUGE SPARK PLUG STAND MUFFLER MANUAL CHOKE LEVER WHEEL 11
10/10/12 14:16:30 31Z23600_013 CONTROLS & FEATURES CONTROLS Engine Switch The engine switch controls the ignition system, and it operates the electric starter. ON START OFF 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. ENGINE SWITCH Starter Grip Used when the battery voltage is too low to turn the starter motor.
10/10/12 14:16:39 31Z23600_014 CONTROLS & FEATURES Fuel Valve Lever ON The fuel valve lever is located between the fuel tank and carburetor. The fuel valve must be in the ON position for the engine to run. OFF After stopping the engine, turn the fuel valve to the OFF position. FUEL VALVE LEVER Voltage Selector Switch The voltage selector switch switches generator output to produce ‘‘120V ONLY’’ or ‘‘120V/240V.
10/10/12 14:16:48 31Z23600_015 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: 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.
10/10/12 14:16:53 31Z23600_016 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.
10/10/12 14:17:00 31Z23600_017 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).
10/10/12 14:17:07 31Z23600_018 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 1. Press handle lock lever downward. 2. Lower the handle.
10/10/12 14:17:15 31Z23600_019 CONTROLS & FEATURES FEATURES 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 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 43 ) before troubleshooting in other areas.
10/10/12 14:17:22 31Z23600_020 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.
10/10/12 14:17:29 31Z23600_021 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.
10/10/12 14:17:37 31Z23600_022 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.
10/10/12 14:17:43 31Z23600_023 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 43 ).
10/10/12 14:17:52 31Z23600_024 OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time, review chapters GENERATOR SAFETY (see page 6 ) and BEFORE OPERATION (see page 21 ). 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.
10/10/12 14:17:59 31Z23600_025 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.
10/10/12 14:18:08 31Z23600_026 OPERATION 3. Make sure the Auto Throttle switch is in the OFF position, or more time will be required for warm up. AUTO THROTTLE SWITCH OFF 4. Start the engine. ON Using the electric starter: Turn the engine switch to the 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.
10/10/12 14:18:16 31Z23600_027 OPERATION Using the recoil starter: ON a. Turn the engine switch to the ON position. ENGINE SWITCH b. 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.
10/10/12 14:18:24 31Z23600_028 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. 1. Turn off or disconnect all appliances that are connected to the generator. 2. Move the AC circuit breaker to the OFF position. AC CIRCUIT BREAKER OFF 3. Turn the engine switch to the OFF position. OFF ENGINE SWITCH 4. Turn the fuel valve lever to the OFF position.
10/11/04 13:05:17 31Z23600_029 OPERATION AC OPERATION If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is in the appliance or the rated load capacity of the generator has been exceeded. Substantial overloading may damage the generator. Marginal overloading may shorten the service life of the generator. 1. Turn the voltage selector switch to either position.
10/10/12 14:18:45 31Z23600_030 OPERATION AC Applications Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. A faulty appliance or power cord can create a potential for electrical shock. If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance or the rated load capacity of the generator has been exceeded.
10/10/12 14:18:53 31Z23600_031 OPERATION AC Receptacle Selection The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. 4B ○ 4A ○ 120 V 30 A 120 V 20 A 120 V 20 A 4A & ○ 4B 120 V/240 V 20 A (EM4000SX) ○ 120 V/240 V 30 A (EM5000SX, EM6500SX) Power Producing Circuits This generator is equipped with two power generating circuits.
10/10/12 14:19:02 31Z23600_032 OPERATION Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle 120V ONLY 1 30A at 120V 30A at 120V 30A at 120V 2 20A at 120V 20A at 120V 20A at 120V 3 20A at 120V 20A at 120V 20A at 120V 4A 20A at 120V 30A at 120V 30A at 120V 4B None None None 120V/240V EM4000SX Available Power EM5000SX EM6500SX 1 15.0A at 120V 18.8A at 120V 22.9A at 120V 2 15.
10/10/12 14:19:09 31Z23600_033 OPERATION 120V/240V Position When the voltage selector switch is in the 120V/240V position, you must balance the load. Divide the load between the two sets of receptacles shown below. Balancing is necessary because each set of receptacles is powered by only one power producing circuit that can produce a maximum of amps(＊). ＊: 15.0 A (EM4000SX) 18.8 A (EM5000SX) 22.
10/10/12 14:19:18 31Z23600_034 OPERATION DC OPERATION The DC receptacle should ONLY be used for charging 12-volt automotive type batteries. The DC charging output is not regulated. Connecting the battery charging cable (optional equipment): 1. Before connecting the battery charging cable (optional equipment) to a battery that is installed in a vehicle, disconnect the vehicle battery ground cable from the negative (−) battery terminal. The battery gives off explosive hydrogen gas during normal operation.
10/10/12 14:19:28 31Z23600_035 OPERATION 3. Connect the black lead of battery charging cable into the negative (−) DC terminal of the generator. 4. Connect the red lead of the battery charging cable to the positive (＋) battery terminal and the black lead to the negative (−) battery terminal. 5. Start the generator. Do not start the vehicle while the battery charging cable is connected and the generator is running. The vehicle or the generator may be damaged.
10/10/12 14:19:34 31Z23600_036 OPERATION AUTO THROTTLE SYSTEM With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the Auto Throttle system does not operate. The Auto Throttle system will not respond to electrical loads of less than 1 ampere or intermittent loads such as a staple gun.
10/10/14 10:10:38 31Z23600_037 OPERATION STANDBY POWER Connections to a Building’s Electrical System Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. Improper connections to a building’s electrical system can allow current from the generator to backfeed into the utility lines.
10/10/12 14:19:44 31Z23600_038 OPERATION Special Requirements There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction. In some areas, generators are required to be registered with local utility companies.
10/10/12 14:19:51 31Z23600_039 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble free operation. It will also help reduce air pollution. To help you properly care for your generator, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools.
10/10/12 14:19:59 31Z23600_040 SERVICING YOUR GENERATOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in the owner’s manual.
10/10/12 14:20:12 31Z23600_041 SERVICING YOUR GENERATOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first.
10/10/12 14:20:19 31Z23600_042 SERVICING YOUR GENERATOR REFUELING With the engine stopped, check the fuel gauge. Refill the fuel tank if the fuel level is low. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank.
10/10/12 14:20:28 31Z23600_043 SERVICING YOUR GENERATOR UPPER LEVEL MARK (RED) FUEL TANK CAP FUEL GAUGE FUEL STRAINER FULL EMPTY UPPER LEVEL MARK (RED) After refueling, reinstall the fuel tank cap securely. FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
10/10/12 14:20:37 31Z23600_044 SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped. 1. Remove the oil filler cap/dipstick and wipe it clean. 2. Insert and remove the dipstick without screwing it into the oil filler hole. Check the oil level shown on the dipstick. 3. If the oil level is low, fill with the recommended oil to the upper limit on the oil filler cap/dipstick (see page 45 ). 4.
10/10/12 14:20:46 31Z23600_045 SERVICING YOUR GENERATOR ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap/dipstick, 12 × 15 mm drain plug, and sealing washer. 2. Allow the used oil to drain completely, and then reinstall the 12 × 15 mm drain plug and a new sealing washer. Tighten the plug securely. 3.
10/10/12 14:20:51 31Z23600_046 SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 10W−30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range. AMBIENT TEMPERATURE The SAE oil viscosity and service category are in the API label on the oil container.
10/10/12 14:20:59 31Z23600_047 SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1. Unsnap the air cleaner cover clips and open the air cleaner cover. 2. Free the hooks from the setting pins on the air cleaner case and remove the air cleaner cover to the right side of the frame pipe, taking care not to damage the air cleaner cover. 3. Remove the air cleaner element from the air cleaner case. 4. Check the air cleaner element to be sure it is clean and in good condition.
10/10/12 14:21:05 31Z23600_048 SERVICING YOUR GENERATOR 5. Reinstall the air cleaner element in the air cleaner case. 6. Set the hooks of the air cleaner cover to the setting pins securely, and then push the air cleaner cover to lock the clips. Be sure that the cover is set securely. There must be no clearance between the air cleaner cover and air cleaner case. Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid engine wear.
10/10/12 14:21:12 31Z23600_049 SERVICING YOUR GENERATOR AIR CLEANER ELEMENT CLEANING A dirty air cleaner element will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in very dusty areas, clean the air cleaner element more frequently than specified in the Maintenance Schedule. 1. Wash the air cleaner element in a solution of household detergent and warm water and rinse thoroughly, or wash in nonflammable or high flashpoint solvent.
10/10/12 14:21:20 31Z23600_050 SERVICING YOUR GENERATOR SPARK PLUG SERVICE In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. An incorrect spark plug can cause engine damage. If the engine is hot, allow it to cool before servicing the spark plug. 1.
10/10/12 14:21:28 31Z23600_051 SERVICING YOUR GENERATOR 3. Visually inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked, chipped, or fouled. 4. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.028−0.031 in (0.7−0.8 mm) SIDE ELECTRODE 0.028−0.031 in (0.7−0.8 mm) SEALING WASHER 5.
10/10/12 14:21:37 31Z23600_052 SERVICING YOUR GENERATOR SPARK ARRESTER SERVICE The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester. Clean the spark arrester as follows: 1. Remove the two 5 mm screws, and remove the spark arrester. 5 mm SCREWS SPARK ARRESTER 2. Use a brush to remove carbon deposits from the spark arrester screen.
10/10/12 14:21:46 31Z23600_053 SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING The sediment cup prevents dirt or water that may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1. Turn the engine switch to the OFF position and remove the key. KEY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away.
10/10/12 14:21:54 31Z23600_054 SERVICING YOUR GENERATOR BATTERY SERVICE Your generator’s engine charging system charges the battery while the engine is running. However, if the generator is only used periodically, the battery must be charged monthly to maintain the battery service life. The battery contains sulfuric acid (electrolyte), which is highly corrosive and poisonous. Getting electrolyte in your eyes or on your skin can cause serious burns.
10/10/12 14:22:02 31Z23600_055 SERVICING YOUR GENERATOR Battery Removal WARNING: Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling. 1. Loosen the cover screw and remove the battery cover. COVER SCREW BATTERY COVER 2. Remove the negative (−) cable from the battery negative (−) terminal, and then remove the positive (＋) cable from the battery positive (＋) terminal. 3. Remove the battery holder band.
10/10/12 14:22:08 31Z23600_056 SERVICING YOUR GENERATOR Battery Charging The battery will expel explosive hydrogen gas when overcharged. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Always use a regulated charger that provides the correct charging current to prevent overcharging. Wear protective clothing and a face shield, or have a skilled mechanic perform the battery maintenance. The battery is rated at 11.2 Ah (ampere-hours).
10/10/12 14:22:17 31Z23600_057 SERVICING YOUR GENERATOR Battery Installation 1. Install the battery in the generator. 2. Connect the battery positive (＋) cable to the battery positive (＋) terminal first and tighten the bolt securely. 3. Slide the battery boot over the positive (＋) cable and terminal. 4. Connect the battery negative (−) cable to the battery negative (−) terminal, and tighten the bolt securely. 5. Install the battery holder band. 6.
10/10/12 14:22:25 31Z23600_058 SERVICING YOUR GENERATOR FUSE If the fuse is blown, the starter motor won’t operate. In the event of fuse failure, locate the cause of failure and repair it before you continue operation. If the fuse continues to fail, discontinue generator use and consult an authorized Honda generator dealer. 1. Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse. 2. Remove the fuse holder cover and pull the fuse out.
10/10/12 14:22:33 31Z23600_059 STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your generator’s function and appearance, and will make the engine easier to start when you use the generator again. Cleaning Wipe the generator with a moist cloth.
10/10/12 14:22:38 31Z23600_060 STORAGE Service according to the table below: STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasoline stabilizer ＊. Fill with fresh gasoline and add gasoline 2 months to 1 year stabilizer ＊. Drain the carburetor float bowl (page 60 ). Drain the fuel sediment cup (page 54 ). Fill with fresh gasoline and add gasoline stabilizer ＊.
10/10/12 14:22:44 31Z23600_061 STORAGE Draining the Fuel Tank and Carburetor Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 1. Turn the fuel valve lever to the OFF position. 2. Place a suitable gasoline container below the carburetor, and use a funnel to avoid spilling fuel. 3.
10/10/12 14:22:53 31Z23600_062 STORAGE 4. After all the gasoline has drained into the container, tighten the drain screw securely. 5. Place a suitable gasoline container below the sediment cup, and use a funnel to avoid spilling gasoline. 6. Remove the sediment cup (see page 52 ), and then turn the fuel valve lever to the ON position. 7. Allow the gasoline to drain completely, and then install the sediment cup (see page 52 ). FUEL VALVE LEVER ON Engine Oil 1. Change the engine oil (see page 44). 2.
10/10/12 14:23:02 31Z23600_063 STORAGE STORAGE PRECAUTIONS If your generator will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark-producing electric motor, or where power tools are operated.
10/10/12 14:23:07 31Z23600_064 TRANSPORTING Do not lay the generator on its side when moving, storing, or operating it. Oil or fuel may leak and damage the engine or your property. If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the generator level when transporting to reduce the possibility of fuel leakage.
10/11/04 13:05:28 31Z23600_065 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Fuel valve lever OFF. Turn lever ON (p. 24). Engine switch OFF. Turn engine switch to ON (p. 25). Out of fuel. Refuel (p. 41). Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline. Drain fuel tank and carburetor (p. 60). Refuel with fresh gasoline (p. 41). Low oil level caused Oil Alert to stop engine. Add oil (p. 43).
10/11/04 13:10:17 31Z23600_066 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE LACKS POWER Possible cause Correction Air filter restricted. Clean or replace air filter (p. 46−48). Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline. Drain fuel tank and carburetor (p. 60). Refuel with fresh gasoline (p. 41). Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.
10/11/04 13:05:48 31Z23600_067 TAKING CARE OF UNEXPECTED PROBLEMS NO POWER AT THE AC RECEPTACLES Possible Cause Correction AC circuit breaker left in the OFF position after starting. Switch AC circuit breaker ON. AC circuit protector tripped. Check AC load and reset AC circuit protector (p. 15). Faulty power tool or appliance. Replace or repair power tool or appliance. Stop and restart the engine. Internal circuit overheated. Stop the engine. Reduce the electrical load.
10/10/12 14:23:29 31Z23600_068 TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER FRAME SERIAL NUMBER Record the frame serial number and date purchased in the spaces below. You will need this information when ordering parts and when making technical or warranty inquiries.
10/10/12 14:23:33 31Z23600_069 TECHNICAL INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
10/10/12 14:23:40 31Z23600_070 TECHNICAL INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
10/10/12 14:23:46 31Z23600_071 TECHNICAL INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your authorized Honda servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
10/10/12 14:23:54 31Z23600_072 TECHNICAL INFORMATION Air Index An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.
10/10/12 14:24:17 31Z23600_073 TECHNICAL INFORMATION Specifications Dimensions Model Type Description code Length Width Height Dry mass [weight] EM5000SX AT type EBMC EBRC 41.1 in (1,043 mm) 27.8 in (706 mm) 28.3 in (719 mm) EM4000SX 203.9 lbs (92.5 kg) EM6500SX EBJC 41.4 in (1,051 mm) 228.2 lbs (103.5 kg) 233.7 lbs (106.
10/10/12 14:24:26 31Z23600_074 TECHNICAL INFORMATION Wiring Diagram Abbreviations Symbol AC O AC CB Au Sw BAT CBB ChC CT D1 D2 D-AVR D-CDI DC D DC CP DC T DC W ECU ESw EgB EX W FrB Fu FW GeB GND GT J/B MW OLSw OP PoC RCBB RCBX RCCa SP SSw St Stp Sw VSSw Part name AC Outlet AC Circuit Breaker Auto Throttle Switch Battery Control Box Block Charge Coil Current Transformer Diode (MMB) Diode (196) Digital-Automatic Voltage Regulator Digital-CDI DC Diode DC Circuit Protector DC Terminal DC Winding Engine Contro
10/10/12 14:24:38 31Z23600_075 TECHNICAL INFORMATION EM4000SX: ＊1 · EM5000SX, EM6500SX: ＊2 74
10/10/12 14:24:46 31Z23600_076 CONSUMER INFORMATION Dealer Locator Information To find an authorized Honda Servicing Dealer anywhere in the United States, visit our website: www.hondapowerequipment.com/ dealerlocator/ Honda Publications Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Available through your Honda dealer or through Helm Inc. at 1 (888) 292-5395 or visit www.hondapowerequipment.
10/10/12 14:24:52 31Z23600_077 CONSUMER INFORMATION Customer Service Information 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.
10/10/12 14:24:58 31Z23600_078 ASSEMBLY SAFETY The Importance of Proper Assembly Proper assembly is essential to operator safety and the reliability of the machine. Any error or oversight made by the person assembling and servicing a unit can easily result in faulty operation, damage to the machine, or injury to the operator. Improper assembly can cause an unsafe condition that can lead to serious injury or death. Follow the procedures and precautions in the assembly instructions carefully.
10/10/12 14:25:05 31Z23600_079 ASSEMBLY Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing this assembly, be especially careful of the following: □ Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely. Make sure the engine is off before you begin any assembly, maintenance, or repairs.
10/10/12 14:25:15 31Z23600_080 ASSEMBLY ASSEMBLY Unpacking 1. Remove the generator and loose parts box from the carton. 2. Compare the loose parts with the inventory list below. Tools Required: 12 mm wrench (2), pliers Loose Parts (Wheel kit and handle) Check all loose parts against the following list. Contact your dealer if any of the loose parts shown below are not included with your generator. Ref. No.
10/10/12 14:25:22 31Z23600_081 ASSEMBLY Wheel Kit Installation 1. Install the two wheels on the axle shaft using the plain washers and split pins. 2. Install the axle assembly on the generator using four 8 × 16 mm flange bolts and 8 mm flange nuts. 3. Install the two stands on the under frame using four 8 × 16 mm flange bolts. TORQUE: 17−22 lbf·ft (24−29 N·m , 2.4−3.0 kgf·m) 8 × 16 mm FLANGE BOLT (8) GENERATOR SIDE SHORTER UNDER FRAME AXLE SHAFT 20 mm PLAIN WASHER (2) 4.
10/10/12 14:25:32 31Z23600_082 ASSEMBLY Handle Installation 1. Install the handle folder assembly on the generator upper frame using the 8 × 18 mm flange bolts. 2. Install the handle assembly on the generator upper frame pipe using the 8 × 16 mm flange bolts, handle bush A, handle bush B, and handle lower bracket. TORQUE: 17−22 lbf·ft (24−29 N·m , 2.4−3.
10/10/12 14:25:40 31Z23600_083 INITIAL USE INSTRUCTIONS ENGINE OIL The generator is shipped WITHOUT OIL in the engine. 1. Place the generator on a level surface. 2. Remove the oil filler cap/dipstick. 3. Add enough SAE 10W-30 API service category SJ or later (or equivalent) oil to bring the oil level to the upper limit on the oil filler cap/dipstick. SAE 10W-30 oil is recommended for general use; for additional recommendations, see page 45. Do not overfill the engine with oil.
10/10/12 14:25:49 31Z23600_084 INITIAL USE INSTRUCTIONS FUEL Add fuel to the generator in a well-ventilated area. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately. This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher.
10/10/12 14:26:00 31Z23600_085 INITIAL USE INSTRUCTIONS Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty. Move the generator at least 10 feet (3 meters) away from the fueling source and site before starting the engine. BATTERY WARNING: Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling. The battery is disconnected for shipment. 1.
10/10/12 14:26:06 31Z23600_086 INITIAL USE INSTRUCTIONS BEFORE OPERATION Before using the generator, all generator operators must read the following chapters and sections: GENERATOR SAFETY (pages 6 − 9 ) CONTROLS & FEATURES (pages 10 − 20 ) BEFORE OPERATION (pages 21 − 22 ) OPERATION (page 23 ) STARTING THE ENGINE (pages 24 − 26 ) STOPPING THE ENGINE (page 27 ) MAINTENANCE SCHEDULE (page 40 ) REGISTRATION Please Register Your Generator If your dealer did not collect registration information from you, pleas
10/10/12 14:26:12 31Z23600_087 OPTIONAL PARTS Remote Control Kit 1. Remove the plug from the 6-pin connector. PLUG 2. Connect the remote control cable to the back of the control panel and remote control box. REMOTE CONTROL CABLE REMOTE CONTROL CABLE REMOTE CONTROL BOX When the remote control is not being used, replace it with the plug on the connector.
10/10/12 14:26:20 31Z23600_088 OPTIONAL PARTS Remote Control Box PILOT LAMP START BUTTON STOP BUTTON Starting the engine with remote control 1. Turn the fuel valve on the generator to the ON position. 2. Turn the Auto Throttle switch on the generator to the OFF position. 3. Turn the engine switch on the generator to the ON position. 4. Press the start button until engine starts and the pilot lamp comes on. Stopping the engine with remote control 1. Press the stop button. 2.
10/10/12 14:26:27 31Z23600_089 OPTIONAL PARTS Hanger Kit 1. Position the hanger at the generator’s balance point as shown below. 2. Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely. TORQUE: 17−22 lbf·ft (24−29 N·m , 2.4−3.
10/10/12 14:26:32 31Z23600_090 INDEX A Abnormal Voltage Detection Function ............................................... 18 AC Applications .................................................................................... 29 AC Circuit Protectors ........................................................................... 15 AC Circuit Breaker ................................................................................ 14 AC OPERATION ................................................................
10/11/11 13:00:35 31Z23600_091 INDEX E Electric Shock Hazards .......................................................................... 7 Emission Control System Information ............................................... 69 ENGINE LACKS POWER ...................................................................... 65 Engine Oil ....................................................................................... 61, 82 ENGINE OIL CHANGE ....................................................................
10/10/12 14:26:45 31Z23600_092 INDEX K Knowledge ............................................................................................ 21 L Loose Parts ........................................................................................... 79 M MAINTENANCE SAFETY ..................................................................... 39 MAINTENANCE SCHEDULE ............................................................... 40 N NO POWER AT THE AC RECEPTACLES ..........................................
10/10/12 14:26:50 31Z23600_093 INDEX S SAFE OPERATING PRECAUTIONS .................................................... 23 SAFETY ................................................................................................. 77 SAFETY LABEL LOCATIONS ................................................................. 9 Safety Precautions ............................................................................... 39 SEDIMENT CUP CLEANING ................................................................
10/10/12 14:26:55 31Z23600_094 QUICK REFERENCE INFORMATION Fuel Type Engine Oil Type Spark Plug Type Maintenance Electrode Gap Before each use First 20 hours Subsequent Regular unleaded gasoline with a pump octane rating of 86 or higher SAE 10W-30, API SJ or later (or equivalent), for general use (page 45) BPR5ES (NGK) W16EPR-U (DENSO) 0.028−0.031 in (0.7−0.8 mm) Check engine oil level. Check air filter. Change engine oil.
EM4000-6500SX Cover.ai 2/8/2011 11:12:32 AM Owner’s Manual GENERATOR EM4000SX • EM5000SX • EM6500SX C M Y CM MY CY CMY K 31Z23600 00X31-Z23-6000 Printed on Recycled Paper AHM.35.2011.02 PRINTED IN U.S.A. © 2011 Honda Motor Co., Ltd.
