00X31-ZC2-7710 EG5000X BK Owner’s Manual GENERATOR EG5000X 31ZC2771 00X31-ZC2-7710 K 2eY1400.2009.03 " Printed in Japan o2001-2009 Honda Motor Co., Ltd.
09/03/03 15:44:42 31ZC2770_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. The generator is a potential source of electrical shock if misused.
09/03/03 15:44:48 31ZC2770_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 the information on how to do that; please read it carefully. As you read this manual, you will find information preceded by a symbol.
09/03/03 15:44:57 31ZC2770_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.
09/03/03 15:45:01 31ZC2770_004 CONTENTS GENERATOR SAFETY ............................................................................... 5 Safety Label Locations ........................................................................ 5 Important Safety Information ............................................................. 6 COMPONENT IDENTIFICATION ............................................................... 8 CONTROLS .................................................................................
09/03/03 15:45:03 31ZC2770_005 MAINTENANCE ....................................................................................... 26 The Importance of Maintenance ....................................................... 26 Maintenance Safety ........................................................................... 27 Maintenance Schedule ...................................................................... 28 Engine Oil Change .............................................................................
09/03/03 15:45:16 31ZC2770_006 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.
09/03/03 15:45:23 31ZC2770_007 IMPORTANT SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls and by observing safe operating procedures. Operator Responsibility Know how to stop the generator quickly in case of emergency.
09/03/03 15:45:30 31ZC2770_008 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.
09/03/03 15:45:35 31ZC2770_009 COMPONENT IDENTIFICATION VOLTAGE SELECTOR SWITCH ENGINE SWITCH CHOKE LEVER AC CIRCUIT BREAKER FUEL VALVE LEVER CIRCUIT PROTECTORS AC RECEPTACLES CARBURETOR DRAIN SCREW OIL FILLER CAP SEDIMENT CUP OIL DRAIN PLUG STARTER GRIP ENGINE SERIAL NUMBER 8
09/03/03 15:45:40 31ZC2770_010 FUEL TANK CAP GROUND TERMINAL MUFFLER AIR CLEANER SPARK PLUG CAP FRAME SERIAL NUMBER Record the engine and frame serial numbers and date of purchase for your future reference. Refer to these serial numbers when ordering parts and when making technical or warranty inquiries (see page 47 ).
09/03/03 15:45:48 31ZC2770_011 CONTROLS ENGINE SWITCH To start and stop the engine. Switch position: OFF: To stop the engine. ON: To start and run the engine. ENGINE SWITCH OFF ON STARTER GRIP To start the engine, pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
09/03/03 15:45:55 31ZC2770_012 FUEL VALVE LEVER The fuel valve is located on the carburetor. When the fuel valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the OFF position after stopping the engine. FUEL VALVE LEVER ON OFF CHOKE LEVER The choke is used to provide proper starting mixture when the engine is cold. It can be opened and closed by operating the choke lever manually.
09/03/03 15:46:01 31ZC2770_013 CIRCUIT BREAKER The AC circuit breaker will automatically switch OFF if there is a short circuit or an overload of the generator at the AC receptacle. If the AC circuit breaker is switched OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the AC circuit before switching the AC circuit breaker ON again. The AC circuit breaker may be used to switch the generator AC power ON or OFF.
09/03/03 15:46:09 31ZC2770_014 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.
09/03/03 15:46:14 31ZC2770_015 VOLTAGE SELECTOR SWITCH (DUAL VOLTAGE SYSTEM) The voltage selector switches the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120/ 240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position. 120/240V: 120V ONLY: The 120V and 120/240V receptacles can be used simultaneously.
09/03/03 15:46:21 31ZC2770_016 GENERATOR USE CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM Connections for standby power to a building 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. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers (see page 47 ).
09/03/03 15:46:27 31ZC2770_017 AC APPLICATIONS Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords 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.
09/03/03 15:46:35 31ZC2770_018 AC OPERATION 1. Start the engine (see page 24 ). 2. Turn the voltage selector switch to either position. With the voltage selector switch in the ‘‘120/240V’’ position, you can use the 120V and 120/240V receptacles simultaneously. If you are NOT using the 120/240V receptacle, then select the ‘‘120V ONLY’’ position. 3. Switch ON the AC circuit breaker. 4. Plug in the appliance. Most motorized appliances require more than their rated wattage for startup.
09/03/03 15:46:41 31ZC2770_019 AC RECEPTACLE SELECTION The control panel, shown below, has a voltage selector switch and five receptacles. Receptacle ＃4 and ＃5 comprise one 240-volt receptacle with two powered terminals. RECEPTACLE ＃1 RECEPTACLE ＃2 RECEPTACLE ＃5 RECEPTACLE ＃3 RECEPTACLE ＃4 Power Producing Circuits This generator is equipped with two power generating circuits.
09/03/03 15:46:48 31ZC2770_020 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 1 30A at 120V 2 20A at 120V 3 20A at 120V 4 20A at 120V 5 None 1 18.8A at 120V 2 18.8A at 120V 3 18.8A at 120V 4-5 18.8A at 240V 120V ONLY 120V/240V 120V ONLY Position When the voltage selector switch is in the 120V ONLY position, you do not need to spread the load over the receptacles.
09/03/03 15:46:53 31ZC2770_021 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. High altitude performance can be improved by specific modifications to the carburetor.
09/03/03 15:47:04 31ZC2770_022 PRE-OPERATION CHECK Before beginning your pre-operation checks, be sure the generator is on a level surface and the engine switch is in the OFF position. ENGINE OIL Engine oil is a major factor affecting engine performance and service life. Non-detergent and 2-stroke engine oils will damage the engine and are not recommended. Check the oil level EACH USE with the generator on a level surface and the engine stopped.
09/03/03 15:47:11 31ZC2770_023 REFUELING With the engine stopped, remove the fuel tank cap and check the fuel level. 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. Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first.
09/03/03 15:47:16 31ZC2770_024 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. You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors.
09/03/03 15:47:27 31ZC2770_025 STARTING THE ENGINE STARTING THE ENGINE 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. Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death.
09/03/03 15:47:33 31ZC2770_026 STOPPING THE ENGINE STOPPING THE ENGINE In an emergency: 1. To stop the engine in an emergency, turn the engine switch to the OFF position. In normal use: 1. Turn the AC circuit breaker to the OFF position. 2. Turn the engine switch to the OFF position. 3. Turn the fuel valve lever to the OFF position.
09/03/03 15:47:40 31ZC2770_027 MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble free operation. It will also help reduce air pollution. Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
09/03/03 15:47:47 31ZC2770_028 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.
09/03/03 15:47:58 31ZC2770_029 MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Check level Change Air cleaner Check Clean Sediment Cup Clean Spark pulg Check-adjust Replace Spark arrester Clean Valve clearance Check-adjust Combustion Clean chamber Fuel tank and filter Clean Fuel tube Check Each use First month or 20 Hrs. Every Every 3 months 6 months or or 50 Hrs. 100 Hrs. Every year or 300 Hrs.
09/03/03 15:48:06 31ZC2770_030 ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the drain plug and sealing washer, remove the oil filler cap, and drain the oil. 2. Reinstall the drain plug and sealing washer. Tighten the plug securely. 3. Refill with the recommended oil (see page 21 ) and check the oil level. OIL DRAIN PLUG UPPER LEVEL Wash your hands with soap and water after handling used oil.
09/03/03 15:48:16 31ZC2770_031 AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. Using gasoline or flammable solvent to clean the air filter can cause a fire or explosion. Use only soapy water or non-flammable solvent.
09/03/03 15:48:24 31ZC2770_032 FUEL 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 fuel valve lever to the OFF position. Remove the sediment cup, O-ring, and filter. 2. Clean the sediment cup, O-ring, and filter in non-flammable or high flash point solvent. 3. Reinstall the filter, O-ring, and sediment cup. 4.
09/03/03 15:48:34 31ZC2770_033 SPARK PLUG SERVICE Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler. 1. Remove the spark plug cap. 2. Clean any dirt from around the spark plug base. 3. Use a spark plug wrench to remove the spark plug. PLUG WRENCH 4. Inspect the spark plug.
09/03/03 15:48:47 31ZC2770_034 6. Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent cross-threading. 7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. −If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten 1/8−1/4 turn after the spark plug seats to compress the washer. The spark plug must be securely tightened.
09/03/03 15:48:54 31ZC2770_035 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.
09/03/03 15:48:58 31ZC2770_036 Use the following table to determine the appropriate storage procedure. 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 36 ). Drain the fuel sediment cup. (page 31 ). Fill with fresh gasoline and add gasoline stabilizer *.
09/03/03 15:49:06 31ZC2770_037 Draining the Carburetor Float Bowl 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. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. DRAIN SCREW Draining the Fuel Tank 1.
09/03/03 15:49:14 31ZC2770_038 Coating the Engine Cylinder with Oil 1. Remove the spark plug (see page 32 ). 2. Pour a teaspoon (5 cc) of clean engine oil into the cylinder. 3. Pull the starter grip several times to distribute the oil in the cylinder. 4. Reinstall the spark plug. 5. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed.
09/03/03 15:49:22 31ZC2770_039 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.
09/03/03 15:49:26 31ZC2770_040 TRANSPORTING TRANSPORTING When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite.
09/03/03 15:49:33 31ZC2770_041 TROUBLESHOOTING When the engine will not start: Is there fuel in the tank? NO Refill the fuel tank (see page 22). NO Add the recommended oil (see page 21). NO Adjust the gap and dry the spark plug. Replace it if necessary (see page 32). NO Clean the fuel sediment cup. YES Is there enough oil in the engine? YES Is the spark plug in good condition? YES Is fuel reaching the carburetor? To check: 1. Turn the fuel valve lever OFF and loosen the drain screw. 2.
09/03/03 15:49:36 31ZC2770_042 No electricity at the AC receptacles: Is the AC circuit breaker ON? YES NO Turn the AC circuit breaker ON (see page 17). NO DEFECTS Check the electrical appliance or equipment for any defects. DEFECTS Take the generator to an authorized Honda generator dealer. Replace the electrical appliance or equipment. Take the electrical appliance or equipment to an electrical shop for repair.
09/03/03 15:49:43 31ZC2770_043 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 are 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.
09/03/03 15:49:47 31ZC2770_044 Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
09/03/03 15:49:51 31ZC2770_045 Replacement Parts The emission control systems on your new Honda engine were designed, built, and certified to conform with applicable emission regulations. We recommend the use of Honda Genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.
09/03/03 15:49:59 31ZC2770_046 AIR INDEX (Models certified for sale in California) 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.
09/03/03 15:50:14 31ZC2770_047 SPECIFICATIONS Dimensions Model Type Power product description code Length Width Height Dry mass [weight] EG5000X Non-California type (AN type) EA7 25.7 in (653 mm) 18.9 in (480 mm) 19.1 in (485 mm) 146.6 lbs (66.5 kg) California type (AC type) 19.6 in (497 mm) Engine Model Engine type Displacement 〔Bore x stroke〕 Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug GX340K1 4-stroke, overhead valve, single cylinder 20.
09/03/03 15:50:22 31ZC2770_048 CONSUMER INFORMATION Dealer Locator Information To find an authorized Honda Servicing Dealer anywhere in the United States: Call (800) 426-7701 or visit our web site: www.hondapowerequipment.com/dealerlocator/ Customer Service Information Servicing dealership personnel are trained professionals. They should be able to answer most questions you may have.
09/03/03 15:50:28 31ZC2770_049 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 888292-5395 or visit www.hondapowerequipment.com/own.htm Parts Catalog This manual provides complete, illustrated parts lists. Available through your Honda dealer.
09/03/03 15:50:37 31ZC2770_050 WIRING DIAGRAM 49
09/03/03 15:50:40 31ZC2770_051 INDEX COMPONENT IDENTIFICATION ............................................................... 8 CONTROLS ............................................................................................... 10 Choke Lever ........................................................................................ 11 Circuit Breaker .................................................................................... 12 Circuit Protector .................................................
09/03/03 15:50:43 31ZC2770_052 PRE-OPERATION CHECK ........................................................................ 21 Engine Oil ........................................................................................... 21 Fuel Recommendations ..................................................................... 23 Refueling ............................................................................................. 22 GENERATOR SAFETY ............................................................
09/03/03 15:50:45 31ZC2770_053 MEMO 52
00X31-ZC2-7710 EG5000X BK Owner’s Manual GENERATOR EG5000X 31ZC2771 00X31-ZC2-7710 K 2eY1400.2009.03 " Printed in Japan o2001-2009 Honda Motor Co., Ltd.
