01/07/23 12:05:54 31ZB4800_001 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the generator get wet, and do not operate it with wet hands. Keep this owner’s manual handy, so you can refer to it at any time.
01/07/23 12:06:00 31ZB4800_002 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.
01/07/23 12:06:13 31ZB4800_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.
01/07/23 12:06:18 31ZB4800_004 CONTENTS SAFETY ....................................................................................................... 5 SAFETY LABEL LOCATIONS ............................................................... 5 SAFETY INFORMATION ...................................................................... 7 COMPONENT IDENTIFICATION ............................................................... 9 CONTROLS .............................................................................
01/07/23 12:06:21 31ZB4800_005 MAINTENANCE ....................................................................................... 31 The Importance of Maintenance ....................................................... 31 Maintenance Safety ........................................................................... 32 Emission Control System Information ............................................. 33 Air Index ..............................................................................................
01/07/23 12:06:50 31ZB4800_006 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.
01/07/23 12:07:04 31ZB4800_007 6
01/07/23 12:07:12 31ZB4800_008 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.
01/07/23 12:07:23 31ZB4800_009 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 electrical components on the control panel, before each use.
01/07/23 12:07:38 31ZB4800_010 COMPONENT IDENTIFICATION VOLT METER PILOT LAMP VOLTAGE SELECTOR SWITCH ENGINE SWITCH AC CIRCUIT BREAKER CHOKE ROD FUEL VALVE LEVER AC CIRCUIT PROTECTOR AIR CLEANER AC RECEPTACLES RECOIL STARTER GRIP GROUND TERMINAL OIL FILLER CAP DC CIRCUIT PROTECTOR AUTO-THROTTLE SWITCH DC OUTPUT TERMINAL OIL DRAIN PLUG ENGINE SERIAL NUMBER 9
01/07/23 12:07:47 31ZB4800_011 FUEL TANK CAP FUEL METER SPARK PLUG CAP FRAME SERIAL NUMBER MUFFLER * Record the engine and frame serial numbers for your future reference. Refer to these serial numbers when ordering parts, and when making technical or warranty inquiries (see page 55 ).
01/07/23 12:08:00 31ZB4800_012 CONTROLS ENGINE SWITCH To start and stop the engine. Key position: OFF: To stop the engine. Key can be removed/inserted. ON: To run the engine after starting. START: To start the engine by operating the starter motor. ON OFF START ENGINE SWITCH Return the key to the ON position once the engine has started. Do not use the starter for more than 5 seconds at a time. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.
01/07/23 12:08:09 31ZB4800_013 FUEL VALVE LEVER The fuel valve is located between the fuel tank and carburetor. When the 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 OFF ON CHOKE ROD The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually.
01/07/23 12:08:20 31ZB4800_014 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.
01/07/23 12:08:33 31ZB4800_015 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 25 ) before troubleshooting in other areas.
01/07/23 12:08:42 31ZB4800_016 Pilot Lamp The pilot lamp is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the 120 or 120/240 volt receptacles. If the pilot light is illuminated, the volt meter should be displaying 120 or 240 volts depending on the position of the voltage selector switch.
01/07/23 12:08:50 31ZB4800_017 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).
01/07/23 12:08:58 31ZB4800_018 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.
01/07/23 12:09:08 31ZB4800_019 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 if the rated load capacity of the generator has been exceeded.
01/07/23 12:09:18 31ZB4800_020 AC OPERATION 1. Start the engine (see page 29 ). 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, but require more power from the 120V locking plug receptacle, then select the ‘‘120V ONLY’’ position. 3. Switch ON the AC circuit breaker. 4. Plug in the appliance.
01/07/23 12:09:27 31ZB4800_021 AC RECEPTACLE SELECTION The generator has two separate main power producing circuits. These two circuits supply equal power to different receptacles shown when the voltage selector switch is in the 120/240V position. When two or more receptacles are used; prevent overloading by dividing the load between the two power circuits. The chart below shows the rated load in amperes that can be connected to each receptacle to balance the generator. The total rated ampere draw is 25.
01/07/23 12:09:38 31ZB4800_022 DC OPERATION The DC terminals may ONLY be used for charging 12 volt automotive type batteries. Connecting the battery cables: 1. Before connecting the battery charging cable to a battery that is installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( ) terminal. The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using batteries.
01/07/23 12:09:47 31ZB4800_023 An overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit protector (PUSH button extends out). If this happens, wait a few minutes before pushing in the circuit protector to resume operation. If the circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer. Disconnecting the battery cables: 1. Stop the engine. 2.
01/07/23 12:09:56 31ZB4800_024 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. Turn the auto-throttle to the OFF position to operate loads of less than 1 amp.
01/07/23 12:10:02 31ZB4800_025 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.
01/07/23 12:10:14 31ZB4800_026 PRE-OPERATION CHECK 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. SAE Viscosity Grades Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ.
01/07/23 12:10:28 31ZB4800_027 FUEL RECOMMENDATION 1. Check the fuel level gauge. 2. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored. Do not overfill the fuel tank (there should be no fuel in the filler neck).
01/07/23 12:10:34 31ZB4800_028 Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda generator dealer. Running the engine with persistent spark knock or pinging can cause engine damage.
01/07/23 12:10:44 31ZB4800_029 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement. Before using an oxygenated fuel, try to confirm the fuel’s contents.
01/07/23 12:10:59 31ZB4800_030 STARTING THE ENGINE 1. Make sure that the AC circuit breaker is in the OFF position. The generator may be hard to start if a load is connected. 2. Turn the fuel valve lever to the ON position. 3. The automatic choke will be closed if the engine is cold. If you want to operate the choke manually, pull the choke rod out to the CLOSED position. 4. Make sure the auto-throttle switch is in the OFF position, or more time will be required for warm up. 5.
01/07/23 12:11:06 31ZB4800_031 STOPPING THE ENGINE In an emergency: 1. To stop the engine in an emergency, move the engine switch to the OFF position. In normal use: 1. Turn the AC circuit breaker to the OFF position. Disconnect DC battery charging cables. 2. Turn the engine switch to the OFF position. 3. Turn the fuel valve lever to the OFF position.
01/07/23 12:11:14 31ZB4800_032 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.
01/07/23 12:11:25 31ZB4800_033 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.
01/07/23 12:11:34 31ZB4800_034 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.
01/07/23 12:11:38 31ZB4800_035 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.
01/07/23 12:11:43 31ZB4800_036 Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine Honda 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.
01/07/23 12:11:54 31ZB4800_037 AIR INDEX An Air Index Information hang tag/label was applied to this engine 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. The durability description is intended to provide you with information relating to the engine’s emission durability period.
01/07/23 12:12:09 31ZB4800_038 MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Performed at every indicated month or operating hour interval, whichever comes first. Engine oil Air cleaner Sediment Cup Spark pulg Spark arrester Idle speed Valve clearance Combustion chamber Fuel tank and filter Fuel tube Check Change Check Clean Clean Clean-Adjust Replace Clean Clean-Adjust Check-Adjust Clean Clean Check Before each use First month or 20 Hrs. Every Every 3 months 6 months or or 50 Hrs. 100 Hrs.
01/07/23 12:12:21 31ZB4800_039 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 25 ) and check the oil level. Oil capacity: 1.2 US qt (1.1 , 1.0 Imp qt) OIL DRAIN PLUG UPPER LEVEL Wash your hands with soap and water after handling used oil.
01/07/23 12:12:35 31ZB4800_040 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. Never run the generator without the air filter. Rapid engine wear will result. AIR CLEANER COVER 1. Unsnap the air cleaner cover clips, remove the air cleaner cover, and remove the element. CLIP 2.
01/07/23 12:12:46 31ZB4800_041 FUEL SEDIMENT CUP CLEANING The sediment cup prevents dirt or water which 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 nonflammable or high flash point solvent. 3. Reinstall the filter, O-ring, and sediment cup. 4.
01/07/23 12:12:58 31ZB4800_042 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. 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.
01/07/23 12:13:13 31ZB4800_043 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.
01/07/23 12:13:21 31ZB4800_044 TRANSPORTING/STORAGE 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. Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator. Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator. Before storing the unit for an extended period: 1.
01/07/23 12:13:32 31ZB4800_045 1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure. DRAIN SCREW 2. Change the engine oil. (page 38 ) 3. Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder.
01/07/23 12:13:45 31ZB4800_046 TROUBLESHOOTING When the engine will not start: Is there fuel in the tank? NO Refill the fuel tank. YES Is there enough oil in the engine? NO YES Add the recommended oil. Still NO spark Is there a spark NO R e p l a c e t h e spark plug. f rom the spark plug? Be sure there is no spilled fuel around the spark plug. Spilled fuel may ignite.
01/07/23 12:13:50 31ZB4800_047 No electricity at the AC receptacles: Is the AC circuit breaker ON. YES Turn the AC circuit breaker ON. NO DEFECTS Check the electrical appliance or equipment for any defects. DEFECTS 46 NO 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.
01/07/23 12:14:07 31ZB4800_048 WIRING DIAGRAM 47
01/07/23 12:14:23 31ZB4800_049 SPECIFICATIONS Dimensions Model Power product description code Length Width Height Dry weight EM3500SX EA6 23.8 in (605 mm) 19.5 in (495 mm) 19.1 in (485 mm) 143.3 lbs (65.0 kg) Engine Model Engine type Displacement Bore x Stroke Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug GX240K1 4-stroke, overhead valve, single cylinder 14.8 cu-in (242 cm ) [2.9 2.3 in (73 58 mm)] 8.2 : 1 3,600 r.p.m.
01/07/23 12:14:32 31ZB4800_050 INSTALLATION OF OPTIONAL PARTS Remote Control Kit 1. Install the relay box on the right side of the generator. 2. Remove the blind 8 P connector from the back of the control box and connect the relay box connector instead. 3. Connect the remote control cable to the remote control and relay box. REMOTE CONTROL CABLE RELAY BOX REMOTE CONTROL BOX Connect the blind connector when not using the remote control. Engine will not start unless the blind connector is connected.
01/07/23 12:14:41 31ZB4800_051 Remote Control Box PILOT LAMP ENGINE SWITCH STARTER BUTTON Starting the engine with remote control 1. Turn the fuel valve to the ON position. 2. Turn the auto-throttle switch to the OFF position. 3. Turn off the engine switch at the generator and remove the key. 4. Turn the relay box switch to the ON position.
01/07/23 12:14:45 31ZB4800_052 5. Turn the engine switch at the remote control box to the ON position. 6. Press the starter button untill the pilot lamp comes on. Stopping the engine 1. Turn the engine switch at the remote control box to the OFF position. 2. Turn the relay box switch to the OFF position. 3. Turn the fuel valve to the OFF position.
01/07/23 12:14:58 31ZB4800_053 4 Wheel Kit Installation 1. Install the four wheels on the axle shaft. 2. Install the axle assembly on the generator using two bolts and nuts. Install the shaft with wheel stopper facing engine side.
01/07/23 12:15:02 31ZB4800_054 BATTERY TRAY KIT 1. Install the battery guard on the frame. Set the battery tray on the battery guard and tighten the bolts. 2. Route the starter cable under the tank and connect it to the starter solenoid. 3. Connect the ground cable to the generator rear housing. 4. Set the battery on the battery tray and secure with the battery bracket. Connect the starter cable to the battery positive ( ) terminal first, then to the negative ( ) terminal.
01/07/23 12:15:13 31ZB4800_055 STARTER SOLENOID STARTER CABLE (positive) STARTER CABLE BATTERY GUARD GROUND CABLE BATTERY Use a battery rated at 12V-18-35AH or more BATTERY BRACKET BATTERY GUARD BATTERY GUARD PLATE 54 BATTERY TRAY
01/07/23 12:15:21 31ZB4800_056 WARRANTY SERVICE INFORMATION Servicing 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.
01/07/23 12:15:25 31ZB4800_057 INDEX COMPONENT IDENTIFICATION ............................................................... 9 CONTROLS ............................................................................................... 11 Auto-throttle System ......................................................................... 14 Choke Rod ........................................................................................... 12 Circuit Breaker ........................................................
01/07/23 12:15:28 31ZB4800_058 SAFETY ....................................................................................................... 5 SAFETY INFORMATION ...................................................................... 7 SAFETY LABEL LOCATIONS ............................................................... 5 SPECIFICATIONS ..................................................................................... 48 STARTING THE ENGINE ..............................................................
01/07/23 12:15:30 31ZB4800_059 MEMO 58
01/07/23 12:15:33 31ZB4800_060 MEMO 59
01/07/23 12:15:35 31ZB4800_061 MEMO 60