Honda Automobiles EM3800SX manual

EM3800SX•EM5000SX•EM6500SX K2:EM5000SX See page 54 f or instructions on assembling y our generator . 31Z21600 00X31-Z21-6000[...]

The generator is a pot ential source of electri cal shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the genera tor get wet, a nd do n ot opera te it with wet ha nds. Keep this owner’s manual handy, so you ca n refer to it at any time. This owner’s manual is considered a permane nt part of the generator and sh[...]

1 Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase o f one of the f inest generators on the market. We want to help you get the bes t 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 thi[...]

− − − − − − 2 A FEW WORDS ABOUT SAFETY Safety Labels Safety Messages Safety Headings Safety Section Instructio ns 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 po tential hazards that could hurt you or others. Of [...]

3 CONTENTS ...................................................................................................... SAFETY . 5 ....................................................................... Safety Label Locations . 5 .............................................................................. Safety Infor mati on . 6 ......................[...]

4 .................................................................. TRANSPORTING/ STORAGE . 44 ............................................................................. TROUBLESHOOTING . 47 ................................................................................. WIRING DIAGRAM . 49 .....................................................[...]

5 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. 03/11/17 18:39:14 31Z21600_006[...]

6 SAFETY INFORMATION Operator Responsibility Carbon Monoxide Hazards Honda generators are designed to give safe and depend able 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[...]

− − − 7 Electric Shock Hazar ds Fire and Burn Hazards The generator produces enough electric power to cause a ser ious 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 whe n your hands are wet, could result in electr ocution. Keep the g[...]

− ＊ ＊ 8 COMPONENT IDENTIFICATION CONTROL PANEL CHOKE ROD ENGINE SWITCH CONTROL PANEL AIR CLEANER FUEL VALVE LEVER RECOIL STARTE R GRIP ENGINE SERIAL NUMBER OIL FILTER C AP/DIP STICK AC CIRC UIT PROTEC TORS 120/240 AC RECEPTACLE GROUND TERMINAL AUTO THROTTLE SWITCH 120 ONLY 120/240 VOLTAGE SELECTO R SWITCH AC RECEPTACLES DC CIRCUIT PROTECTOR D[...]

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10 CONTROLS Engine Switch Recoil Starter Key position: OFF: ON: START: STARTER GRIP ENGINE SWITCH ON O O F F F F S S T T A A R R T T RECOIL STARTER To start and stop the engine. To start the engine, pull the star ter grip lightly until resistance is felt, then pull briskly. Do not allow the starter gr ip to snap back against the engine. Return it g[...]

11 Fuel Valve Lever Choke Rod OPEN CHOKE ROD OFF ON FUEL VALVE LEVER C C L L O O S S E E D D The choke is used to provide an e nriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually. Pull the rod out toward CLOSED to enrich the mixture for cold starti ng. The fuel valve is located between t[...]

12 Voltage Selector Swi tch (Dual Voltage System) Ground Terminal Switch Position 120/240V: 120V ONLY: GROUND TERMINAL VOLTAGE SELECTO R SWITCH 120V ONLY 120/240V 1 1 2 2 0 0 / / 2 2 4 4 0 0 V V 1 1 2 2 0 0 V V O O N N L L Y Y The voltage selector switch switc hes the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or[...]

＋ − 13 DC Terminals DC Circuit Prote ctor DC CIRCUIT PROTECTOR NEGATIVE T ERMINAL (BLACK) POSITIVE TER MINAL (RED) The DC terminals may ONLY be used f or charging 12 volt automotive type batteries. The terminals are colored red to identif y the positive ( ) terminal and black to identify the negative ( ) term inal. The battery must be connected[...]

14 Oil Alert System Auto Throttle System Switch Position AUTO: OFF: OFF ON OFF ON AUTO THROTTLE SWITCH If the en gine stops and wi ll not restart, check the engine oil level (see page ) before tr oubleshooting in other areas. The auto throttle system automatically reduces engine speed when all loads are turned off or disconnected. When appliances a[...]

15 AC Circuit Breaker OFF ON AC CIRCUIT BREAKER The AC circuit breaker will automatic ally switch OFF if there is a s hort circuit or a significant overloa d of the gen erator at the receptacle. If the AC circuit break er is switched OFF automatically, c heck that the appliance is working properly and does not exceed the rated load capacity o f the[...]

＊ ＊ 16 AC Circuit Prote ctor ON OFF AC CIRC UIT PROTEC TORS 1 1:Except EM3800SX The AC circuit protectors will automatically switch OFF if there is a short circuit or a significant overload o f the generator at th e 20A 120V, 30A 120V locking plug, or 120/240V locking plug receptacle. If a AC circuit protector switches OFF automatically, check [...]

17 GENERATOR USE Improper connections to a building electrical system can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocu te utility company workers or others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored. Co[...]

18 AC Applications Before connecting an appliance or power cord to the generator: Make sure that it is in good wo rking order. Faulty applia nces 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 determi[...]

＊ ＊ 19 AC Operation VOLTAGE SELECTO R SWITCH 1 AC CIRC UIT PROTEC TORS AC CIRCUIT BREAKER 1:Except EM3800SX Start the engine (see page ). Turn the voltage selector switch to either position. With the voltage selector switch in th e ‘‘120/ 240V’’ position, you can use the 120V and 120/ 240V receptacles simultaneously. If you are NOT usin[...]

＋ ＋＋ 20 AC Receptacle Selection Main power circuit Main Circuit I Main Circuit II Receptacles powered by each main circuit Power distribut ion EM3800SX: 120V 30A 120V 20A 120/240V 20A The generator has two separate main power producing circuits. These two circuits supply eq ual power to different receptacles shown when the voltage selector sw[...]

＋ ＋＋ 21 Main power circuit Main Circuit I Main Circuit II Receptacles powered by each main circuit Power distribut ion EM5000SXK2: 120V 30A 120V 20A 120/240V 30A The table shows the specifications when the 120/ 240V locking plug receptacle is used for 120V. When two or more receptacles are used; prevent overloading by dividing the load betwee[...]

＋ ＋＋ 22 Main power circuit Main Circuit I Main Circuit II Receptacles powered by each main circuit Power distribut ion EM6500SX: 120V 30A 120V 20A 120/240V 30A The table shows the specifications when the 120/ 240V locking plug receptacle is used for 120V. When two or more receptacles are used; prevent overloading by dividing the load between [...]

＋＋ ＋ ＋ −− − − − 23 The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilati on when charging or using ba tteries. Battery posts, t erminals and related accessories contain lead and lead compounds. Wash hands after handling. DC Operation Connecting the batter y cables: POSITIVE TER [...]

− − − − ＋ ＋ ＋ ＋ − 24 Disconnecting the batter y cables: NE GATI VE TERM INA L (BLACK) POSITIVE TER MINAL (RED) DC CIRCUIT PROTECTOR Stop the engine. An overloaded DC circuit, excessive c urrent 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[...]

25 Auto Throttle System OFF ON OFF ON AUTO THROTTLE S WITCH With the switch in the AUTO position, engine spe ed 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 oper ate. The auto throttle sy[...]

26 High Altitude Operation At high altitude, the standard carburetor air/ fu el 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 a ltitude that dif fers f rom that at which this en gine was certified, for extended perio[...]

27 PRE-OPERATION CHECK Engine Oil UPPER LEVEL OIL FILLER CAP OIL FILLER HOLE SAE Viscosity Grad es AMBIENT TEMPERATU RE Engine oil is a major factor affecting engine performance and service life. Non detergent and 2-stroke engine oils will da mage the engine and are not recommended. SAE 10W-30 is recommended for general, all-temperature use. Other [...]

28 Fuel Gasoline is highly flammable and e xplosive, and you can be b urned or seriously injured when refueling. Stop engine and keep heat, sparks, and f lame away. Refuel only outdoors. Wipe up spills immediately. Fuel tank capacity: FUEL FILLER CAP FUEL GAUGE FUEL STRAINER SHOULD ER Check the fuel gauge, and refill the tank if the fuel level is l[...]

29 Oxygenated Fuels ETHANOL MTBE METHANOL Occasion ally you may hear a li ght ‘ ‘spark knock ’’ or ‘‘p inging’ ’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging oc curs at a steady engine spee d, under normal load, change brands of gas oline. If spark knock or pingi[...]

30 STARTING THE ENGINE/STOPPING THE ENGINE Starting the Engine Stopping the Engine In normal use: In an emergency: Make sure tha t the AC circu it breaker is in the OFF positio n. The generator may be hard to start i f a load is connected. Turn the fuel valve lever to the ON position. The automatic choke wil l be closed if the engin e is cold. If y[...]

31 MAINTENANCE Improper maintenance, or failur e to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and m aintenance recommendat ions and schedules in this owner’s manual. Maintenance, replacement, or r epair of the emission control devices and systems may be p[...]

− − − 32 Failure to properl y follow maintenance instr uctions and precautions can cause you to be seriously hurt or killed. Always follow the procedur es and precautions in the owner ’s manual. Safety Precautions Carbon monoxide poisoning from engine exhaust . Injury from moving parts. Burns from h ot parts. Maintenance Safety Some of the [...]

33 Source of Emissions Tampering and Altering The U.S. and California Clean Air Acts Emission Control System Inform ation EPA and California regulations require all manufacturers to furnish written ins tructions d escribi ng the opera tion and ma intenanc e of e mis- sion control systems. The following instructions and pro cedures must be followed [...]

34 Problems That May Affect Emissions If you are aware of any of the follow ing 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 c onsumption. 03/11/17 18:43:28 31Z21600_035[...]

35 Maintenance Replacement Parts The emission control systems on your Honda engine wer e designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine Honda part s whenever you have m aintenance done. These original-desi gn replacement par ts are manufactured to the same standards as the ori[...]

− − − 36 Air Index 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 pro vide you with information relating to the engine’s emission durability period. The descriptive term indic[...]

37 Maintenance Schedule Performed at every indicated month or opera ting hour i nterval, whichever comes first. ITEM First month or 20 Hrs. Every 3 months or 50 Hrs. (1) Engine oil Air cleaner Sediment cup Spark plug Spark arrester Idle speed Valve clearance Combustion chamb er Fuel tank and filter Fuel tube Check Change Check Clean Clean Clean-Adu[...]

38 Oil capacity: Engine Oil Change UPPER LEVEL OIL DRAIN PLUG Drain the oil while the engine is warm to assure rapid and complete draining. Remove the drain plug and sealing washer, remove the oil filler cap, and drain the oil. Reinstall the drain plug and sealing washer. Tighten the plug securely. Refill with the recommended oil (see page ) and ch[...]

39 Air Cleaner Service AIR CLEANER COVER CLIP CLIP ELEMENT ELEMENT A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Se rvice more frequently when operating the generator in extr emely dusty areas. Never run the generator without the air filter. Rap id engine wear wil[...]

40 Fuel Sediment Cup Cleaning SEDIMENT CUP O-RING FUEL FILTER OFF FUEL VALVE LEVER 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 f or a long time, the sediment cup should be cleaned. Clean the se diment cup, O-ring, and filter in nonf lammable or high flash point s[...]

−− − − 41 Recommended spark plugs: Spark Plug Service The gap should be: PLUG CAP SPARK PLUG WRENCH 0.028 0.031 in (0.70 0.80 mm) In or der to se rvice t he spark plu g, you will need a spark pl ug wren ch (commercially available). Use a spark plug wrench to remove the spark plug. Remove the spark plug cap. Clean any dirt from around the sp[...]

− − 42 Spark Arres ter Maintena nce SPARK ARRESTER SPARK ARRESTER SCRE EN SCREW Check that the spark plug washer i s in good condition, and thread the spark plug in by hand to prevent cross-threading. A f t e rt h es p a r kp l u gi ss e a t e d ,t i g h t e nw i t has p a r kp l u gw r e n c ht o compress the w asher. If installing a new sp ar[...]

43 Fuse Replacement FUSE HOLDER If the fuse is blown, the starter motor won’t oper ate. Turn the engine switch to the OFF position. Remove the fuse holder cover and replace the fuse. The specified fuse is 10A. If frequent fuse fa ilure occurs, determine the cause and correct the problem before attempting to operate the generator further. Never us[...]

44 TRANSPORTING/STORAGE Contact with a hot en gine or exhaust system can cause serious burns or fires. Let the engin e cool before transporting or storing the genera tor. When transporting the generator, turn t he engine switch and the fuel valve OFF. Keep the generator level to pr event fuel spi llage. Fuel vapor or spilled fuel may ignite. Take c[...]

45 STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING Before storing the unit for an extended period: 1. Be sure the storage area is free of excessive humidity and dust. 2. Service according to the table below: Less than 1 month 1 to 2 months 2 months to 1 year 1 year or more Use gasoline conditioners that are formulated to exten d[...]

46 Gasoline is extremely flammable and is explosive unde r certain conditions. Perform this task in a well-ventilated ar ea with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure. Storage DRAIN SCREW Align the not ch on t he star ter pul ley with th e hole at the to p of recoi l starte r. Drain the carbure[...]

47 TROUBLESHOOTING When the engine will not start: Is there fuel in the tank? Is there enough oil in the engine? Is the spark plug in good condition? Is the fuel reaching the carburetor? If the engine still does not start, take the generator to an authorized Honda generator dealer. Clean t he fuel sediment cup. Refill the fuel tank. Add th e reco m[...]

48 Is the AC circuit breaker ON. Check the e lectrical ap- pliance or equipment for any defects. Turn the AC circuit breaker ON. Take t he gener ato r to an authorized Honda generator dealer. Replace the elect rical ap- pliance or equipment. Take the electri cal ap- pliance or equipment to an electrical shop for repair. No electricity at the AC rec[...]

49 WIRING DIAGRAM EM3800SX 03/11/17 18:45:59 31Z21600_050[...]

50 EM5000SX, EM6500SX 03/11/17 18:46:27 31Z21600_051[...]

×× × ± ± −− 51 SPECIFICATIONS Dimensions Engine Generator ITEM MAINTEN ANCE SPECIFICAT ION Tune-up Specifications EAMC GX240 2.9 2.3 in (73 58 mm) 27.2 in (690 mm) 28.3 in (720 mm) 192 lbs (87 kg) 14.8 cu-in (243 cm ) 6.6 US gal (25 ) 1.2 US qt (1.1 ) Transistorized magneto Forced air cooling 3,600 rpm 8.2 : 1 3,800 VA 60 Hz 120/ 240 V 3,3[...]

×× × ± ± −− 52 Dimensions Engine Generator ITEM MAINTEN ANCE SPECIFICAT ION Tune-up Specifications Model Power product description code Length Width Height Dry weight Model Engine Type Displaceme nt Bore Stroke Compressio n Ratio Engine Speed Cooling System Ignition System Oil Capacity Fuel Tank Capacity Spark Plug Model Type Rated voltage[...]

×× × ± ± −− 53 Dimensions Engine Generator ITEM SPECIFICATION MA INTENANCE Tune-up Specifications Model Power product description code Length Width Height Dry weight Model Engine Type Displaceme nt Bore Stroke Compressio n Ratio Engine Speed Cooling System Ignition System Oil Capacity Fuel Tank Capacity Spark Plug Model Type Rated voltage [...]

54 ASSEMBLY The Importance of Proper Assembly Improper assembly can cause an unsafe condi tion that can lead to serious injury or death. Follow the procedures and pr ecautions in the assembly instruct ions carefully. Failure to properl y follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and prec[...]

□ □ □ □ 55 Important Safety Precauti ons Carbon monoxide poisoning from engine exhaust . Injury from moving parts. Burns from h ot parts. Make sure you have a clear understanding of all basic sh op safety practices and that you are wearing appropriate clo thing and safety equipment. When performing this assembly, be especially careful of th[...]

× × 56 Loose Parts (Wheel kit and handle) Unpacking Remove the generator and loose par ts box from the carton. Compare the loose parts with the inventory list below. Tools Required: Check all loose parts a gainst the fol lowing list. C ontact your dealer if any of the loose parts shown below are not included with your generator. 1. 2. 14 mm wrenc[...]

−− − × 57 Handle Installation TORQUE: RIGHT HANDLE BRACKET LEFT HANDLE BRACKET 8 16 mm FLANGE BOLT (4) LEFT UPPER HANDLE ASSY RIGHT UPPER HANDLE ASSY Install the right and l eft handles on the generator upper frame using the brackets and 4 flange bolts. 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf ·m) 03/11/17 18:47:48 31Z21600_058[...]

× × −− − × × × 58 Wheel Kit In stallation TORQUE: AXLE WHEEL (2) 8 16 mm FLANGE BOLT (4) GENERATOR SIDE 8 16 mm FLANGE BOLT (4) 4.0 30 mm COTTER PI N (2) STAND (2) 20 mm WASHER ( 2) LONGER 8 mm FLANGE NUT (4) Install the two wheels on the ax le shaft using the washers and cotter pins. Install the axle assembly on the generator using four[...]

−− − × 59 Hanger Kit Installation (optional) TORQUE: HANGER HANGER GENERATOR SIDE HANGER BRACKET (2) 8 16 mm FLANGE BOLT (4) 280 mm (11 in) Posi tion the hang er at the gene rator’s ba lanc e point as sho wn below. Fit the end tabs of the hanger through the bracke t slots, and bolt the brackets to the hanger and tighten securely. 17 22 lbf[...]

60 Remote Control Kit (optional) REMOTE CONTROL CABLE REMOTE CONTROL BOX REMOTE CONTROL CABLE CABLE TIES Remove the blind 6-P connector from the back of the control panel. Connect the remote control cable to the back of the control panel and remote control box. Connect the blind connector when not using the remote contr ol. Engine will not start un[...]

61 Remote Contro l Box PILOT LAMP START SWI TCH STOP SWI TCH Turn the auto-throttle switch to the OFF position. Turn the fuel valve to the ON position. Starting the engine with remote control Turn the engine switch to the ON position. Press the start switch untill the pilot lamp comes on. Stopping the engine with remote control Press the stop swit [...]

＋ − − 62 Battery posts, t erminals and relat ed accessories contain lead and lead compounds. Wash hands after handling. Battery Tray Kit ( optional) Install the battery guard on the frame. Set the battery tray on the battery guar d and tighten the bolts. Route the starter cable under the tank and connect it to the starter solenoid. Connect th[...]

○ ○ ○ ○ ＋ ＋ − − 63 BATTERY TRAY BATTERY GUARD PLATE STARTER CABLE (positive) BATTERY BRACKET BATTERY GUARD STARTER SOLE NOID GROUND CABLE BATTERY GUARD BATTERY Use a battery rated at 51R STARTER CABLE CABLE TIE CABLE TIE GROUND CABLE 03/11/17 19:47:49 31Z21600_064[...]

64 Engine Oil WITHOUT OIL Fuel SAE Viscosity Grad es AMBIENT TEMPERATU RE OIL FILLER HOLE FILLER CAP/DIPSTICK UPPER LIMIT The generator is shipped in the engine. Place the generator on a level surface. Add enough of the recommen ded o il to bring the oil level to the top of the oil filler neck. Use a 4-stroke motor oil that meets the requirements f[...]

65 BEFORE OPERATION SAFETY CONTROLS GENERATOR USE STARTING THE ENGINE STOPPING THE ENGINE Before using your generator, y ou should become familiar with information contained in the following chapters and sections: (page ) (page ) (page ) (page ) (page ) 5 10 17 30 30 03/11/17 18:48:51 31Z21600_066[...]

66 WARRANTY SERVICE INFORMATION Servicing dealership personnel are trained pr ofessionals. They should be able to answer any qu estions you may have. If you encoun ter 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 prob[...]

67 INDEX .............................................................................................. ASSEMBLY . 54 .............................................................. COMPONENT IDENTIFICATION . 8 ................................................................................................ CONTENTS . 3 ..............................[...]

68 ....................................................................... PRE-OPERATION CHECK . 27 .......................................................................................... Engine Oil . 27 ..................................................................................................... Fuel . 28 ...............................[...]

EM3800SX•EM5000SX•EM6500SX K2:EM5000SX See page 54 f or instructions on assembling y our generator . 31Z21600 00X31-Z21-6000[...]