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HONDA EB3000 EB4000 GENERATOR user manual

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2. 42 SEDIMENT CUP CLEANING gt 51 Serial Number Location 65 SERVICING YOUR GENERATOR 41 SPARK ARRESTER SERVICE 54 SPARK PLUG SERVICE teen a 52 Spe cial 6 40 SGC IC 71 STANDBY POWER 40 STARTING THE ENGINE 28 STOPPING THE ENGINE 31 STORAGE 25 56 STORAGE PRECAUTIONS 60 02 05 56 Systemi gt 40 TAKING CARE OF UNEXPECTED PROBLEMS 62 TECHNICAL amp CONSUMER INFORMATION 65 TECHNICAL INFORMATION
3. 65 THE IMPORTANCE OF MAINTENANCE 41 The Importance of Proper Assembly 76 TRANPORTING mitresna a 61 U 78 Voltage Selector Switch 14 Wheel Kit Installation 79 Wiring 73 88 QUICK REFERENCE INFORMATION Fuel Type Unleaded gasoline with a pump octane rating of 86 or higher Spark Plug Type NGK BPR5ES DENSO W16EPR U Electrode Gap 0 028 0 031 in 0 70 0 80 mm Maintenance Before each use Check engine oil level Check air filter First 20 hours Change engine oil Subsequent See Maintenance Schedule HONDA The Power of Dreams 31Z12602 220 2 1000 2008 12 00 31 212 6020 J 9 Printedin Japan
4. 47 ENGINE OIL RECOMIMENDA 48 AIR CLEANER ii adiis 49 5 50 SEDIMENT CUP CE ANG 51 SPARK PLUG 52 SPARK ARRESTER SERVICE iaaa 54 Engine Oil 55 6 59 STORAGE PRECAUTION 60 REMOVAL FROM STORAGE 4 60 5 Serial Number 65 Carburetor Modification for High Altitude 66 Fuels aa 67 Emission Control System Information 68 70 71 Wining 73 CONSUMER INFORMATION
5. 74 Honda 74 Customer Service 75 The Importance of Proper Assembly 2 76 Important Safety Precautions 77 ASSEMBLY ARNEE R 78 lt 78 Loose 78 Wheel Kit 79 Handle 80 Rear Bar Installato Ninis 81 Hanger Kit 82 Engine Oilarra 83 83 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 accidents 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 pr
6. YOLVYSNSD a 1 0 9 1 2 5 7 eee is 9 OIA volves A Ma poet HOLIMS 0123136 JOVILIOA ng 000 KINO NOZI AObzIAOZL 105 Lino dv A H 461 1000583 of 1 tres oaol y J oA 5 7 ng a 4 r Wi 39 op oy 9 1 mtn Sept 8 Tr ESH ng 1026 A pj xt H 1 NIVA FS 1 TI W N39 M want 132018 10 8 018 LINN 73 TECHNICAL amp CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your generator You may order them from your Honda generator dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Parts Catalog This manual provides complete illustrated parts lists 74 TECHNICAL amp CONSUMER INFORMATION Customer Service Information
7. EB5000i Dimensions Model Type EB5000i Power product description code EALJ Length 31 9 in 810 mm Handle in up position 45 5 in 1 155 mm Width 26 4 in 670 mm Height 30 7 in 780 mm Dry weight 198 165 90 kg Engine Model GX340K1 Engine Type 4 stroke overhead valve single cylinder Displacement 20 6 338 Bore x Stroke 3 2 2 5 in 82 X 64 mm Compression Ratio 8 0 1 Engine Speed 2 400 3 600 rpm lt EcoThrottle ON gt Cooling System Forced air Ignition System Full transistor Oil Capacity 1 16 US qt 1 10 2 Fuel Tank Capacity 4 49 US gal 17 0 2 Spark Plug BPR5ES NGK W16EPR U DENSO Generator Type A Rated voltage 120 240 V Rated frequency 60 Hz AC output Rated Ampere 37 5 18 8 Rated Output 4 5 kVA Maximum Output 5 0 kVA Tuneup Specifications ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 0 70 0 80 mm Refer to Valve clearance cold 0 15 0 02 mm See your authorized EX 0 20 0 02 mm Honda dealer Other specifications No other adjustments needed Specifications may vary according to the types and are subject to change without notice 71 TECHNICAL amp CONSUMER INFORMATION 700015 Dimensions Model Type EB7000i Power product description code EAKJ Length Handle in up position 31 9 in 810 mm 45 5 in 1 155 mm Width 26 4 in 670 mm Height 30 7 in 780 mm Dry weight 198
8. 13 13 Voltage Selector SWC 14 AC Circuit 14 AC Circuit Bre Aken 15 Ground Fault Circuit 16 Folding 17 FEATURE Sorena 18 Ground 18 O tp t MEG ANON 19 INGICAON 19 Ol Alerte __ _6_ _ _ 20 he A 21 Fuel GaU ia a 24 ARE YOU READY GET STARTED 25 ae 25 IS YOUR GENERATOR READY TO 0 25 Check the ENGINE 26 26 Maintenance 26
9. 5 Plug in the appliance Most motorized appliances require more than their rated wattage for startup If the generator is overloaded or if there is a short circuit a connected appliance or if the inverter is overheated the overload indicator red will come ON The overload indicator red will stay ON and after about five seconds current to the connected appliance s will shut off and the output indicator green will go OFF Stop the engine and investigate the problem Determine if the cause is a short circuit in a connected appliance an overload or an overheated inverter Correct the problem and restart the generator Before connecting an appliance to the generator make sure that it is in good order and that its electrical rating does not exceed that of the generator Then start the generator and connect the appliance power cord When an electric motor is started the overload indicator red may come on This is normal if the overload indicator red goes off after about five seconds If the overload indicator red stays on consult an authorized Honda generator dealer 35 OPERATION AC Applications Before connecting an appliance or power cord to the generator Make sure that it is in good working order Faulty appliances power cords can create a potential for electrical shock f an appliance begins to operate abnormally becomes sluggish stops suddenly turn it off immediately
10. 26 MAINTENANCE SAFETY 42 MAINTENANCE SCHEDULE _ 43 Alert Indicator Light 2 20 OPERATION 27 Operator 6 O tp t 19 Overload Indicator aaraa 19 Fuels a i E REE 67 QUICK REFERENCE INFORMATION Inside back cover R 81 13 44 Refuel With Care 8 REMOVAL FROM STORAGE 60 87 5 SAFE OPERATING PRECAUTIONS 27 SAFETY ONES 76 SAFETY LABEL LOCATIONS 9 Salty Precautions
11. 5 OPERATION SAFE OPERATING PRECAUTIONS ccceieseccciacenvcocsusesvcustuvavnctsntiucenioxtizes 27 STARTING ENGINE sasasieoeduicaneiendieastaysvdsiaceuteduens 28 STOPPING THE ENGINE 31 ISP Cl OPERA TION a EEE a aa 32 AG OPERA PION uusissa arieni eainiie 34 AC Applications nesinnes aE a Taia 36 AC Receptacle 37 ECOTHROTTLE SYSTEM 39 STAND BY POWER cease anacnceanaceasassanamacasseandacusesaasaaactcaxsacs 40 Connections Building s Electrical System 40 Systemi 2 2 40 ctanntaseitaveteriuentenatedvedinstuamtelteoniuseteceuael 40 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE 41 MAINTENANCE SAFE UY siccssasssscensatacticienssatiansqanstnausaseatsancentsccsuecanexctacs 42 Safety Preca tiONS 42 MAINTENANCE SCHEDULE icant isiticendcasddesasecsstnchsnectanuadgcatacaxdacasaesetees 43 REFUELING 44 FUEL RECOMMENDATIONS 45 ENGINE OIL LEVEL CHECK 46
12. 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures 3 For commercial use log hours of operation to determine proper maintenance intervals 43 SERVICING YOUR GENERATOR REFUELING With the engine stopped check the fuel level gauge Refill the fuel tank if the fuel level is low AWARNING 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 FULL FUEL GAUGE 60 MAXIMUM FUEL LEVEL FUEL STRAINER SHOULDER FUEL TANK CAP Refuel in a well ventilated area before starting the engine If the engine has been running allow it to cool Refuel carefully to avoid spilling fuel Do not fill the fuel tank above the fuel strainer shoulder 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 44 SERVICING YOUR GENERATOR FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or high
13. Circuit Breaker niaaa 15 Circ it Protectors 14 AC OPERATION 34 Receptacle 37 AIR CLEANER SERVICE 49 creer rrr yer ter 70 ARE YOU READY GET 5 gt 25 Pet errr Prem sper 76 78 BEFORE OPERATION pindaan dia 25 Carbon Monoxide hazardS 6 Carburetor Modification for High Altitude Operation 66 Check the ENGINE cnccacanedeaseaseausesoasecniarane 26 th 26 12 19
14. 56 COMPONENT amp CONTROL LOCATIONS sccciscsicccossosiaserscnsiesanscasisoanens 10 Connections Building s Electrical System 40 CONSUMER INFORMATION 74 INT 12 CONTROLS amp FEATURES 10 Customer Service Information 75 Eco Throttle discesi 13 EGCGOTHROTTLE 39 Electrice Shock Hazards 7 Emission Control System Information 68 59 ENGINE OIL CHANGE 47 EINGINE LEVEE CHECK 46 ENGINE OIL RECOMMENDATIONS 48 ENGINE PROBLEMS 62 iandae dini ean i AAAA E A 12 INDEX F FEATURE 18 Fire and 7 FOAM AIR FILTER CLEANING 50 Folding nusa naye aeaeaei eaaa 17
15. Fuel aa a a a a a a 56 Fuel Gauge 24 FUEL RECOMMENDATIONS 45 Fuel Valve Lever 12 GENERATOR PROBLEMS 1 1 0 64 GENERATOR 2 55 5564 6 32 Ground Fault Circuit Interrupter 2 22 16 Ground Terminal 18 H Handle Installation sunina aeaa aaiae eaaa 80 Hanger Kit Installation aiani 82 Honda tevesedvdecevecevexeesadevesvenededeveevadeceveew 74 21 IMPORTANT SAFETY 10 6 Important Safety PreCa cncxaczecsascncasaccacecxcecstenaccccscssctccadesdst 77 a 85 IS YOUR GENERATOR READY QO 25 K Knowledge spesie a a EE a 25 L Loose 78 86 INDEX M Maintenance
16. GFCI fails the test the generator must be repaired by an authorized Honda servicing dealer before use 1 Unplug all tools and appliances from the generator 2 Start the engine 3 Turn the AC circuit breaker to the ON position 4 Press the TEST button The RESET button should extend and the AC circuit breaker should switch to the OFF position If the and AC circuit breaker do not function as described take the generator to an authorized Honda generator dealer for repair TEST BUTTON GFCI RESET BUTTON AC CIRCUIT BREAKER 32 OPERATION 5 Press the RESET button The RESET button should stay in flush with its base plate With the RESET button in and the engine running turn the AC circuit breaker to the ON position The AC circuit breaker should remain in the ON position The AC circuit breaker will not remain in the ON position if the RESET button is extended If the and AC circuit breaker do not function as described take the generator to an authorized Honda generator dealer for repair RESET BUTTON Pp AC CIRCUIT BREAKER During generator use if the RESET button extends and the AC circuit breaker trips this usually indicates a faulty power tool appliance or cord If that occurs perform test steps 1 through 5 to verify that the AC circuit breaker are in proper working order If
17. soapy water rinse and allow to dry thoroughly or clean in nonflammable solvent and allow to dry 2 Dip the foam air filter in clean engine oil then squeeze out all excess oil The engine will smoke when started if too much oil is left in the filter 1 Soak 2 Squeeze 3 Oil 4 Squeeze Do not twist Do not twist DABA 3 Wipe dirt from the air cleaner housing and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor 50 SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING 1 Turn the fuel valve lever to the OFF position FUEL VALVE LEVER 2 Remove the sediment cup by turning it counterclockwise AWARNING 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 3 Wash the sediment cup and O ring in nonflammable solvent and dry them thoroughly 4 Reinstall the O ring and sediment cup O RING SEDIMENT CUP 51 SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs BPR5ES NGK W16EPR U DENSO NOTICE Incorrect spark plugs can cause engine damage 1 Loosen the cover screw and remove the spark plug inspection cover SPARK PLUG INSPECTION COVER COVER SCREW 2 Disco
18. you operate your generator under unusual conditions such as sustained high load or high temperature operation or use it in dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use AWARNING 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 Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to EPA standards 41 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 AWARNING 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 Safety Precautions Make s
19. BE BURNED OR SERIOUSLY INJURED IF THE GASOLINE 15 IGNITED BEFORE REFUELING STOP THE ENGINE AND KEEP HEAT SPARKS AND FLAME AWAY HANDLE FUEL ONLY OUTDOORS 00 NOT FILL THE FUEL TANK ABOVE THE UPPER LIMIT LINE UP SPILLS IMMEDIATELY IMPROPER CONNECTIONS TO A BUILDING CAN ALLOW ELECTRICAL CURRENT TO BACKFEED INTO UTILITY LINES CREATING AN ELECTROCUTION HAZARD 1045 TO A BUILDING MUST ISOLATE GENERATOR POWAR FROM UTILITY POWER AND COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS 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 THAT CAN BUILD UP DANGEROUS LEVELS IN CLOSED AREAS THE GENERATOR 15 A POTENTIAL SOURCE OF ELECTRICAL SHOCK IF NOT KEPT DRY BDO NOT EXPOSE THE GENERATOR MOISTURE RAIN OR SNOW 00 NOT OPERATE THE GENERATOR WITH WET HANDS READ OWNER S MANUAL CAREFULLY BEFORE OPERATION gt A CAUTION gt A EXHAUST SYSTEM CAN CAUSE SERIOUS BURNS 010 CONTACT IF THE ENGINE HAS BEEN RUNNING CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS Use the two illustrations on these pages to locate and identify the most frequently used controls OIL ALERT INDICATOR i MONITOR TEST BUTTON B
20. Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded Make sure that the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes NOTICE Substantial overloading will open the circuit breaker Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF but will shorten the service life of the generator Limit operation requiring maximum power to 30 minutes Maximum power is EB5000i 5 000 VA EB7000i 6 500 VA For continuous operation longer than 30 minutes do not exceed the rated power Rated power is EB5000i 4 500 VA EB7000i 5 500 VA The total power requirements VA of all appliances connected must be considered Appliance and power tool manufacturers usually list rating information near the model number or serial number 36 OPERATION AC Receptacle Selection The generator has separate main power producing circuits These two circuits supply power to different receptacles shown when the voltage selector switch is in the 120 240 V position When two or more receptacles are used prevent overloading by dividing the load between the two power circuits The chart
21. and cotter pins 2 Install the axle assembly on the generator using four 8 16mm flange bolts 3 Install the two stands on the under frame using four 8 X 16 mm flange bolts TORQUE 17 22 24 29 N m 2 4 3 0 kgf m 8 16 FLANGE BOLT 4 STAND 2 AXLE WHEEL 2 20 mm WASHER 2 S 8X16 mm FLANGE BOLT 4 4 0 28 mm COTTER PIN 2 79 ASSEMBLY Handle Installation Install the handle assembly on the generator upper frame using the 12 mm washers spring washers and handle holder bolts TORQUE 17 22 24 29 2 4 3 0 kgf m HANDLE HOLDER BOLT 2 SPRING WASHER 2 a 12 mm WASHER 2 Operation must be checked after attaching a handle To Extend Handle Raise handle to horizontal position The handle will click into place when locked HANDLE LEVER HANDLE 80 ASSEMBLY Rear Bar Installation Install the rear bar on the generator frame using the two 8 45mm flange bolts TORQUE 17 22 24 29 2 4 3 0 kgf m 8 45mm FLANGE BOLT 2 REAR BAR 81 ASSEMBLY Hanger Kit Installation 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 secu
22. below shows the rated load in amperes that can be connected to each receptacle to balance the generator when the 120 240 V locking plug receptacle is used for 120 V The total rated ampere draw is EB5000i 37 5 EB7000i 45 8 EB5000i Main power circuit Receptacles powered by each main circuit Power distribution Main Circuit 1 3 and 4 1 3 4 18 8 rated Main Circuit 11 2and5 2 5 18 8A rated EB7000i Main power circuit Receptacles powered by each main circuit Power distribution Main Circuit 1 3 and 4 1 3 4 22 9 rated Main Circuit 2and5 2 5 22 9A rated 37 OPERATION Example EB5000i Receptacle 1 has a 15A load connected to it Receptacle 3 has a 10A load connected to it Both receptacles are powered by main power circuit The equation tells us that the total power draw on circuit is 25A This is a substantial overload of this circuit To eliminate the excess power draw on circuit the load from receptacle 3 should be switched to receptacle 2 Now circuit is powering the 15A load less than 18 8A and circuit Il is powering the 10A load less than 18 8A 120V 30A 8 120V 20A 2 120V 20A 5 120 240V 30A 4 120 240 30A 38 OPERATION ECOTHROTTLE SYSTEM With the switch in the ON position engine speed is automatically lowered when loads are reduced turned OFF or disconnected When applianc
23. do not use multiple tools and appliances with built in noise filters Such use may activate the and trip the circuit breaker e Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for electric shock e Make sure the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes Operate the generator at least 3 feet 1 meter away from buildings and other equipment Do not operate the generator in an enclosed structure 27 OPERATION STARTING THE ENGINE Refer to Safe Operating Precautions page 27 Make sure that the AC circuit breaker is in the OFF position The generator may be hard to start if a load is connected CIRCUIT BREAKER 2 Set the Voltage Selector Switch to match the voltage requirements for the application 3 Turn the fuel valve lever to the ON position FUEL VALVE LEVER 4 Turn the choke lever to the CHOKE LEVER CLOSED position to start a cold engine Leave the choke lever in the OPEN position to start a warm engine 28 OPERATION 5 Make sure the EcoThrottle switch is in the OFF position or more time will be required for warm up mee ON 6 Turn the engine switch to the ON position ENGINE SWITCH 7 Pull the start
24. generator has dried touch up any damaged paint and coat other areas that may rust with a light film of oil Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your generator deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank The Distributor s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor 56 STORAGE Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will
25. the and AC circuit breaker do test correctly then the fault is likely to be in the power tool appliance or cord Repair or replace the faulty power tool appliance or cord before further use 33 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 if the rated load capacity of the generator has been exceeded NOTICE Substantial overloading that continuously lights the overload indicator red may damage the generator Marginal overloading that temporarily lights the overload indicator red may shorten the service life of the generator 1 Turn the voltage selector switch to either position With the voltage selector switch in the 120 240 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 120 ONLY position VOLTAGE SELECTOR SWITCH 120V ONLY t 2 Start the engine and make sure the output indicator green comes on see pages GREEN 26 28 228 OVERLOAD INDICATOR RED 34 OPERATION 3 Make sure that the GFCI RESET BUTTON RESET button is pushed in flush with its base plate ae 270 4 Switch ON the AC circuit breaker
26. very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the two 8 mm flange bolts and remove the rear bar 2 Remove the six 6 mm flange nuts and remove the muffler protector 8 mm FLANGE BOLT 2 MUFFLER PROTECTOR 6 mm FLANGE NUT 6 REAR BAR 54 SERVICING YOUR GENERATOR 3 Remove the three 6 mm flange bolts and remove the exhaust tail pipe and the spark arrester 6 mm FLANGE BOLTS EXHAUST TAIL PIPE 2 TN SPARK ARRESTER ip AS 6 mm FLANGE BOLT 4 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the screen The spark arrester must be free of breaks and holes Replace the spark arrester if it is damaged 5 Inspect the screen for breaks or tears and replace it if necessary 6 Install the spark arrester and the exhaust tail pipe in the reverse order of removal TORQUE 8 Ibf ft 11 1 1 kgf m 7 Install the muffler protector and the rear in the reverse order of removal TORQUE 6 3 8 5 N m 0 87 kgf m 55 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 After the
27. Check your generator as described in the BEFORE OPERATION chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinder was coated with oil during storage preparation the engine may smoke briefly at startup This is normal 60 TRANSPORTING 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 Move the fuel valve to the OFF position When using ropes or tie down straps to secure the generator for transportation be sure to only use the frame bars as attachment points Do not fasten ropes or straps to any portions of the generator body or the folding transport handle 61 TAKING OF UNEXPECTED PROBLEMS ENGINE PROBLEMS Engine Will Not Start Possible Cause Correction 1 Check control Fuel valve lever Turn lever ON positions OFF Choke lever OPEN Move to CLOSED unless engine is warm Engine switch OFF Turn engine switch to ON 2 Check fuel Out of fuel Refuel Bad fuel generator stored wit
28. EMS No Power at the AC Receptacles Possible Cause Correction 1 Check circuit breaker and GFCI RESET button Circuit breaker left in the OFF position after starting Switch AC circuit breaker ON RESET button is not extended Check ac load and Switch AC circuit breaker ON activated RESET button extended and AC circuit breaker OFF Test 32 replace faulty power tool appliance or Push RESET button and switch AC circuit breaker ON 2 Check output and overload indicators Output indicator is OFF and overload indicator is ON Check AC load Stop and restart the engine Check the cooling air inlet Stop and restart the engine 3 Check circuit protectors Circuit protector s tripped Check AC load and reset circuit protector s 14 4 Check the power tool or appliance Faulty power tool or appliance Replace or repair power tool or known appliance good AC power Stop and restart source the engine 5 Take generator to an authorized Honda servicing dealer or refer to shop manual Faulty generator Replace or repair faulty components as necessary 64 TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location Se FRAME SERIAL NUMBER 7 IES Record the frame serial number in the space below You will need this serial number wh
29. 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 If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information Model and serial numbers see page 65 Name of the dealer who sold the generator to you Name and address of the dealer who services your generator Date of purchase e Your name address and telephone number A detailed description of the problem 75 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 AWARNING Improper assembly can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in t
30. Ibs 90 kg Engine Model GX390K1 Engine Type 4 stroke overhead valve single cylinder Displacement 23 75 cu in 389 3 Bore x Stroke 3 5 2 5 88 X 64 mm Compression Ratio 8 0 1 Engine Speed 2 400 3 600 rpm lt EcoThrottle ON gt Cooling System Forced air Ignition System Full transistor Oil Capacity 1 16 US qt 1 10 2 Fuel Tank Capacity 4 49 US gal 17 0 2 Spark Plug BPR5ES NGK W16EPR U DENSO Generator Type A Rated voltage 120 240 V Rated frequency 60 Hz AC output Rated Ampere 45 8 22 9A Rated Output 5 5 kVA Maximum Output 6 5 kVA Tuneup Specifications ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in 0 70 0 80 mm Refer to Valve clearance cold 0 15 0 02 mm EX 0 20 0 02 mm See your authorized Honda dealer Other specifications Specifications may vary change without notice 72 No other adjustments needed according to the types and are subject to TECHNICAL amp CONSUMER INFORMATION
31. NLY 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 CIRCUIT PROTECTOR CIRCUIT PROTECTOR CIRCUIT PROTECTOR for Receptacle 2 for Receptacle 3 for Receptacle AC CIRCUIT PROTECTOR PUSH CIRCUIT PROTECTOR for Receptacle 1 23 0120 30A 120V 20A 120V 20 0120 240 30A 14 CONTROL amp FEATURES AC Circuit Breaker The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload at the receptacles or if the ground fault circuit interrupter detects a ground fault current The AC circuit breaker may be used to switch the generator power ON or OFF AC CIRCUIT BREAKER 15 CONTROL amp FEATURES Ground Fault Circuit Interrupter All receptacles on the generator are protected by a Ground Fault Circuit Interrupter GFCI for protection against the shock hazard of ground fault current The has a TEST and RESET button and 15 connected to the AC circuit breaker An example of ground fault current is the current which would flow through a person who is using an appliance w
32. Owner s Manual GENERATOR EB5000i 70001 2004 Honda Motor Co Ltd See page 76 for instructions All Rights Reserved on assembling your generator WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the generator and should remain with the generator if resold The information and specifications included in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever 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 NOTICE symbol That information is intended to help you avoid damage to your generator other property or the environment We suggest you read the Distributor s Limited Warrantyto fully understand its coverage an
33. UTTON OVERLOAD INDICATOR OUTPUT INDICATOR i MONITOR ENGINE SWITCH 10 AC CIRCUIT PROTECTORS RECEPTACLES AC CIRCUIT BREAKER ECOTHROTTLE SWITCH FUEL VALVE LEVER CONTROL amp FEATURES HANGER FUEL GAUGE SPARK PLUG INSPECTION COVER OIL DRAIN PLUG MUFFLER OIL FILLER CAP DIPSTICK 11 CONTROL amp FEATURES CONTROLS Fuel Valve Lever The fuel valve lever is located on the control panel The fuel valve must be in the ON position for the engine to run After stopping the engine turn the fuel valve to the OFF position Engine Switch The engine switch controls the ignition system OFF Stops the engine ON Running position and for starting with the recoil starter Choke Lever The choke lever opens and closes the choke valve in the carburetor The CLOSED position enriches the fuel mixture for starting a cold engine The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm engine 12 FUEL VALVE LEVER ENGINE SWITCH CHOKE LEVER CONTROL amp FEATURES Recoil Starter STARTER GRIP Pulling the starter grip operates the recoil starter to crank the engine for starting NOTICE 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 w
34. assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in dusty conditions will require more frequent service 69 TECHNICAL amp CONSUMER INFORMATION Air Index An Air Index Information hang tag 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 The durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine s emission control system See your Emission Control System Warranty for additional information Descriptive Term Applicable to Emissions Durability Period Moderate 50 hours 0 65 cc 125 hours greater than 65 cc Intermediate 125 hours 0 65 cc 250 hours greater than 65 cc Extended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index Information hang tag must remain on the generator until it is sold Remove the hang tag before operating the generator 70 TECHNICAL amp CONSUMER INFORMATION Specifications
35. ator to view when the generator is running total operating time in hours generator output engine RPM and error messages The different display modes are selected by pressing the i Monitor button i Monitor at Start Up During start up the i Monitor display and all three indicators will simultaneously blink once The condition of the i Monitor display and all three indicators can be checked with the aid of an observer Once the generator is running the Output indicator green and the i Monitor display will remain lit i Monitor Display The i Monitor display is divided into two screens The single digit screen displays the i Monitor mode which is represented by a number 1 through 3 The four digit screen displays the three mode values total operating hours power output and engine RPM or any activated error messages i Monitor Display Mode 1 Total Operating Hours This mode displays the total operating hours of the generator When the generator is running the total operating time accumulates If the total operating time is less than one hour the numeric display will be 70 When the operating time is one hour or greater the display will 1 or 2 and so on Base the generator s maintenance schedule on the accumulated time displayed i MONITOR BUTTON SINGLE DIGIT SCREEN DISPLAY FOUR DIGIT SCREEN DISPLAY 21 CONTROL amp FEATURES i Monitor Display Mode 2 Power Out
36. d your responsibilities of ownership The Distributor s Limited Warranty is a separate document that should have been given to you by your dealer When your generator needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd 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 Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining a generator You must use your own good judgement You will find important safety information in a variety of forms including Safety Labels on the generator Safety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if A DANGER you don t follow instructions A WARNING You CAN be KILLED or SERIOUSLY HURT i
37. eat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications 66 TECHNICAL amp CONSUMER INFORMATION 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 Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE gt Methyl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of yo
38. en ordering parts and when making technical or warranty inquiries Frame serial number Date purchased 65 TECHNICAL amp CONSUMER 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 High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 5 000 feet 1 500 meters have your authorized Honda servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overh
39. engine oil into the cylinder 4 Pull the starter rope several times to distribute the oil in the cylinder 5 Reinstall the spark plug 6 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 Storing the engine in this position will help to protect it from internal corrosion Return the starter grip gently 59 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 If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of leakage Place the generator on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the generator to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the generator promoting rust and corrosion REMOVAL FROM STORAGE
40. er This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock 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 a Honda servicing dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 45 SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the engine oil level 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 filler neck Check the oil level shown on the dipstick 3 If the oil level is low fill to the top of the oil filler neck with the recommended oil see page 48 4 Screw in the oil filler cap dipstick securely DIPSTICK OIL FILLER CAP UPPER LIMIT ios The Oil Alert system will automatically s
41. er grip lightly until resistance is felt then pull briskly NOTICE 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 STARTER GRIP 29 OPERATION 8 If the choke lever was turned to CHOKE LEVER the CLOSED position to start the engine gradually turn it to the OPEN position as the engine warms up 9 If you wish to use the EcoThrottle system turn the EcoThrottle switch to the ON position after the engine has warmed up for 2 or 3 minutes ECOTHROTTLE SWITCH 10 Refer to AC 34 before moving the AC circuit breaker to the ON position 30 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 Switch 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 FUEL VALVE LEVER 31 OPERATION OPERATION CHECK Always check operation before using the generator AWARNING A faulty can cause electric shock which can seriously injury or kill you Always perform the GFCI inspection before using the generator If the
42. es are turned ON or reconnected the engine returns to the proper speed to power the electrical load In the OFF position the EcoThrottle system does not operate Appliances with large start up power demands may not allow the engine to reach normal operating rom when they are connected to the generator Turn the EcoThrottle to the OFF position and connect the appliance to the generator If the engine still will not reach normal operating speed check that the appliance does not exceed the rated load capacity of the generator If high electrical loads are connected simultaneously turn the EcoThrottle switch to the OFF position to reduce voltage changes The EcoThrottle system is not effective for use with appliances that require only momentary power If the tool or appliance will be turned ON and OFF quickly the EcoThrottle switch should be in the OFF position ECOTHROTTLE SWITCH 39 OPERATION STAND BY POWER Connections to a Building s Electrical System Do not connect 5000 EB7000i generator to home building s electrical system Honda EB5000i EB7000i generators are designed for construction job site use and cannot be connected to a building s electrical system These generators have the neutral bonded to ground to comply with OSHA job site temporary power regulation Building main breaker boxes also have the neutral bonded to ground so if an EB5000i or EB 7000 generator is con
43. f you don t follow instructions You be HURT if you don t follow A CAUTION instructions Safety Headings such as IMPORTANT SAFETY INFORMATION Safety Section such as GENERATOR SAFETY e Instructions how to use this generator correctly and safely This entire book is filled with important safety information please read it carefully 2 5 GENERATOR SAFETY IMPORTANT SAFETY 11 21 6 Operator dcddencevaudacdsndasddedsasaadendsssscdeataraiadenteed 6 Carbon Monoxide 6 Electric SHOCK 4 7 Fire and Burn 7 With 8 SAFETY LABEL 5 1 9 CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS 20 10 CONTRO U O 2546 12 Fuel Valve 12 Engine 12 CHOKE MGV GF ceeds vctawadeacwecdedeauaedivduinwesiedatavadandosnseecdds 12 State
44. he assembly instructions carefully Some of the most important safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing this assembly Only you can decide whether or not you should perform a given task AWARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this manual carefully 76 ASSEMBLY Important Safety Precautions Make sure you have 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 e Make sure the engine is off before you begin any maintenance or repairs This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away Do not run the engine when any protective guard or shield is removed To reduce the pos
45. he generator is producing electrical power at the receptacles OUTPUT INDICATOR GREEN NN 7 ms 0 Overload Indicator If the generator is overloaded or if there is a short circuit in a connected appliance or if the inverter is overheated the overload indicator red will go ON When the generator is operating overloaded the overload indicator red will stay ON and after about five seconds current to the connected appliance s will shut off and the output indicator green will go OFF OVERLOAD INDICATOR RED 19 CONTROL amp FEATURES Oil Alert Indicator 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 indicator comes on and the Oil Alert system automatically will stop the engine the engine switch will remain in the ON position The i Monitor display will show on the screen and the Oil Alert indicator will illuminate If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to ON and pull the starter grip check the engine oil level see page 46 before troubleshooting in other areas OIL ALERT RED OUTPUT OVERLOAD OIL INDICATOR ALARM ALERT It blinks 20 CONTROL amp FEATURES i Monitor The i Monitor is a user interface that allows the oper
46. hout treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor p 58 Refuel with fresh gasoline p 44 3 Check engine oil Low oil level Add oill p 46 level caused Oil Alert Turn engine switch to stop engine to OFF and restart the engine 4 Remove and Spark plug faulty Gap or replace inspect fouled or spark plug p 52 spark plug improperly gapped Spark plug wet Dry and reinstall with fuel flooded spark plug engine 5 Take generator to Fuel filter Replace or repair an authorized restricted faulty components Honda servicing carburetor as necessary dealer or refer to malfunction shop manual ignition malfunction valves stuck etc 62 TAKING CARE OF UNEXPECTED PROBLEMS Engine Lacks Power Possible cause Correction 1 Check air filter Air filter restricted Clean air filter 49 2 Check fuel Bad fuel generator stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor p 58 Refuel with fresh gasoline p 44 3 Take generator to an authorized Honda servicing dealer or refer to shop manual Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary 63 TAKING CARE OF UNEXPECTED PROBLEMS GENERATOR PROBL
47. ill wear out prematurely EcoThrottle Switch The EcoThrottle 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 proper speed to power the electrical load If high electrical loads are connected simultaneously turn the EcoThrottle switch to the OFF position to reduce voltage changes ON Recommended to minimize ECOTHROTTLE SWITCH fuel consumption and further reduce noise levels when a reduced load or no load is applied to the generator OFF EcoThrottle system does not operate Generator operates at full output 13 CONTROL amp FEATURES Voltage Selector Switch The voltage selector switch switches generator output to produce 120 V ONLY or 120 240 If a 240V appliance is connected to the 4 prong receptacle the switch must be the 120 240V position If only a 120V appliance is being connected to any of the 120V 3 prong receptacles select the 120 ONLY position Select the voltage before starting the engine Switch Position 120 240V The 120V and 120 240V receptacles can be used simultaneously 120V ONLY ONLY the 120V receptacles can be used Do not use the 120 240V receptacle in this position The most power will be available at the 120V locking plug receptacle VOLTAGE SELECTOR SWITCH 120V 240V 120V O
48. ith faulty insulation and at the same time is in contact with an electrical ground such as a plumbing fixture wet floor or earth The GFCI will not protect against short circuits or overloads The AC circuit breaker and AC circuit protectors provide that protection see pages 14 and 15 GFCI RESET BUTTON GFCI TEST BUTTON Gi 16 CONTROL amp 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 extended handle To Extend Handle Lift handle upward Lock levers will lock and secure handle into place To Fold Handle 1 Press both handle lock levers downward 2 Lower handle HANDLE LEVER HANDLE used position Generator opelation position 17 CONTROL amp FEATURES FEATURES Ground Terminal The 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 GROUND TERMINAL 18 CONTROL amp FEATURES Output Indicator The output indicator green is illuminated when the generator is operating normally It indicates that t
49. ms e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 68 TECHNICAL amp CONSUMER 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 e Hard starting or stalling after starting e Rough idle Misfiring or backfiring under load e Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your new 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 The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the Maintenance Schedule 43 Remember that this schedule is based on the
50. nected to a home or building electrical system the relay will trip the generator s main circuit breaker System Ground Honda EB5000i EB7000i generators have a system ground that connects generator frame components to the ground terminals at the AC output receptacles The system ground is connected to the AC neutral wire 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 be registered with local utility companies e If the generator is used at a construction site there may additional regulations which must be observed 40 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 Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If
51. ngine Check the air filter see page 49 A dirty air filter will restrict air flow to the carburetor reducing engine and generator performance Check the fuel level see page 44 Starting with full tank will help to eliminate or reduce operating interruptions for refueling Check the Check the GFCI operation after starting the engine Maintenance Cover Never operate the generator without the maintenance cover in place Poor engine and generator performance will result if the maintenance cover is not installed MAINTENANCE COVER 26 OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time please review the GENERATOR SAFETYsection and the chapter titled BEFORE OPERATION For your safety avoid starting or operating the generator in an enclosed area such as a garage Your generator s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death AWARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you Avoid any enclosed areas or activities that expose you to carbon monoxide Before connecting an AC appliance or power cord to the generator e Use grounded 3 prong extension cords tools and appliances or double insulated tools and appliances e Inspect cords and plugs and replace if damaged Do not use cord lengths greater than 164 feet 50 meters and
52. nnect the spark plug cap and remove any dirt from around the spark plug area 3 Remove the spark plug with a 13 16 inch spark plug wrench commercially available SPARK PLUG WRENCH 52 SERVICING YOUR GENERATOR 4 Inspect the spark plug Replace it if the electrodes are worn or if the insulator is cracked chipped or fouled 0 028 0 031 in 0 70 0 80 mm 5 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode SEALING WASHER The gap should be 0 028 0 031 in 0 70 0 80 mm 6 Make sure that the spark plug sealing washer is in good condition and thread the spark plug in by hand prevent cross threading 7 After the spark plug seats tighten with a 13 16 inch spark plug wrench to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats NOTICE A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 8 Attach the spark plug cap 9 Reinstall the spark plug inspection cover and tighten the cover screw 53 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
53. otect yourself and others Operator Responsibility Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output receptacles and connections Be sure that anyone who operates the generator receives proper instruction Do not let children operate the generator without parental supervision Do not operate within 3 feet 0 9 meter of any walls Do not operate in any enclosure Carbon Monoxide Hazards Exhaust contains poisonous carbon monoxide a colorless odorless gas Breathing exhaust can cause loss of consciousness and may lead to death If you run the generator in a confined or even partially enclosed area the air you breathe could contain dangerous amounts of exhaust gas To keep exhaust gas from building up provide adequate ventilation GENERATOR SAFETY Electric Shock Hazards The generator produces enough electric power to cause a serious shock or electrocution if misused e 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 the Ground Fault Circuit Interrupter and all other electrical components on the control panel before each use Moisture or ice can cause a malfunction or short circuit in elec
54. promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add fuel stabilizer following manufacturer s instructions 2 After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and turn the fuel valve lever to the OFF position 57 STORAGE Draining the Fuel Tank and Carburetor AWARNING 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 e Handle fuel only outdoors e Wipe up spills immediately DRAIN SCREW Place a suitable gasoline container below the carburetor drain hose 2 Loosen the carburetor drain screw and drain the gasoline from the carburetor 3 After all the fuel has drained into the container tighten the drain screw securely 4 Place an approved gasoline container below the sediment cup and use a funnel to avoid spilling fuel Remove the sediment cup then move the fuel valve lever to the ON position see page 51 5 Allow the fuel to drain completely then reinstall the sediment see page 51 58 STORAGE Engine Oil 1 Change the engine oill see page 471 2 Remove the spark plug page 52 3 Pour a tablespoon 5 10 of clean
55. put This mode displays an approximate generator output on the display screen The output is expressed in VA volt amperes The output value is not an exact measurement and should be regarded as a reference only Power output will not display until a load is connected to the generator ii 5 i Monitor Display 3 Engine RPM When the i Monitor is in this mode the engine s speed expressed in revolutions per minute RPM is displayed ii 5 rpm 22 CONTROL amp FEATURES i Monitor System Error Messages If the generator has a system malfunction it will show an error message on the i Monitor display If an error message display contact an authorized Honda generator dealer OVERLOAD INDICATOR OUTPUT OVERLOAD OIL INDICATOR ALARM ALERT ERROR MESSAGE Example E 01 23 CONTROL amp 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 aa FUEL GAUGE EMPTY FUEL TANK CAP 24 BEFORE OPERATION ARE YOU READY TO GET STARTED Your safety is your responsibility A little time spent in preparation will significantly reduce yo
56. rely TORQUE 17 22 24 29 2 4 3 0 kgf m HANGER BRACKET 2 8 16 mm FLANGE BOLT 4 HANGER FUEL TANK GENERATOR SIDE RIB 82 Engine Oil The generator is shipped WITHOUT OIL in the engine Place the generator on a level surface Add enough of the recommended oil to bring the oil level to the top of the oil filler neck Use a 4 stroke motor oil that meets the requirements for API service classification SJ SAE 10W 30 is recommended for general all temperature use Other viscosities in the chart may be used when the temperature in your area is within the indicated range Do not overfill engine oil If the engine is overfilled the excess oil may get transferred to the air cleaner housing and air filter Fuel Refer to page 56 UPPER LIMIT 2 ASSEMBLY SAE Viscosity Grades 20 0 20 40 60 80 100 20 10 0 10 20 30 40 AMBIENT TEMPERATURE OIL FILLER HOLE FILLER CAP DIPSTICK 83 ASSEMBLY BEFORE OPERATION Before using your generator you should become familiar with information contained in the following chapters and sections GENERATOR SAFETY CONTROLS amp FEATURES 10 OPERATION 27 STARTING THE ENGINE page 28 STOPPING THE ENGINE 31 84 INDEX A APC ANIONS sessir 36
57. shown in the chart may be used when the average temperature in your area is within the recommended range SAE Viscosity Grades 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SJ oil 48 SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1 Loosen the cover screws and remove the air cleaner cover FOAM AIR FILTER AIR CLEANER COVER SCREW 2 Remove the foam air filter from the air cleaner cover 3 Check the foam air filter to be sure it is clean and in good condition If the foam air filter is dirty clean it as described 50 Replace the foam air filter if it is damaged 4 Reinstall the foam air filter in the air cleaner cover 5 Reinstall the air cleaner cover NOTICE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty 49 SERVICING YOUR GENERATOR FOAM AIR FILTER CLEANING A dirty foam air filter will restrict air flow to the carburetor reducing engine performance If you operate the generator in very dusty areas clean the foam air filter more frequently than specified in the Maintenance Schedule 1 Clean the foam air filter warm FOAM AIR FILTER
58. sibility of a fire or explosion be careful when working around gasoline or batteries Use only a nonflammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from all fuel related parts 77 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 14mm wrench 2 pliers not included Loose Parts 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 Description Oty 1 Wheel 2 2 Axle 1 3 Handle assy 1 4 Rear pipe 1 5 Stand 2 6 20 mm Washer 2 7 4 0 X28 mm Cotter pin 2 8 12 mm Washer 2 9 Spring Washer 2 10 Handle holder bolt 2 11 8x 45 mm Flange 2 12 8X 16 mm Flange 8 13 8X 16 mm Flange bolt black 4 14 Hanger 1 15 Hanger bracket 2 78 ASSEMBLY Wheel Kit Installation Do not operate the generator without the wheel kit installed The wheel kit provides an air space between the ground and the generator air intake NOTICE If the wheel kit is not installed it may be possible for dirt and debris to be drawn into the generator air intake causing possible generator damage Always operate the generator with the wheel kit installed 1 Install the two wheels on the axle shaft using the washers
59. top the engine before the oil level falls below safe limits However to avoid the inconvenience of an unexpected shutdown check the oil level regularly 46 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 then remove the oil filler cap dipstick drain plug and sealing washer 2 Allow the used oil to drain completely then reinstall the drain plug and sealing washer Tighten the plug securely NOTICE disposal of engine oil can be harmful to the environment If you change your own oil please dispose of the used oil properly Put it in a sealed container and take it to a recycling center Do not discard it in a trash bin dump it on the ground or pour it down the drain 3 With the generator in a level position the outer edge of the filter hole with the recommended oil see page 48 4 Screw in the oil filler cap dipstick securely Wash your hands with soap and water after handling used oil aN UPPER LIMIT Ny SEALING WASHER OIL FILLER OIL DRAIN PLUG CAP DIPSTICK OIL FILLER CAP DIPSTICK 47 SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10 30 is recommended for general use Other viscosities
60. trical components which could result in electrocution Do not connect EB5000i EB7000i generator a home building s electrical system Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials Keep the generator at least 3 feet 1 meter away from buildings and other equipment during operation Do not enclose the generator in any structure Keep flammable materials away from the generator The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing the generator indoors 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 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 servicing dealer for a replacement A WARNING A WARNING GASOLINE 15 HIGHLY FLAMMABLE AND EXPLOSIVE YOU COULD
61. ur fuel system If you notice any undersirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty 67 TECHNICAL amp CONSUMER 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 Honda uses lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of intake fuel or exhaust syste
62. ur 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 If the generator is being used to power appliances be sure that they do not exceed the generator s load rating page 36 IS YOUR GENERATOR READY TO GO For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the generator to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the generator AWARNING Improperly maintaining this generator or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem 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 preoperation checks be sure the generator is on a level surface and the engine switch is in the OFF position 25 BEFORE OPERATION Check the Engine Check the oil level see page 46 A low oil level will cause the Oil Alert system to shut down the e
63. ure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 42 SERVICING YOUR GENERATOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 First Every Every Every ITEM Each month 3 6 year Perform at every indicated month or use or months months or operating hour interval whichever comes 20 Hrs or 300Hrs first 50 Hrs 100 Hrs Engine oil Check level Change Air filter Check Clean O 1 operation Check Sediment cup Clean Spark plug Check adjust Replace Spark arrester Clean Valve clearance Check adjust O 2 Combustion Clean After every 500 Hrs 2 chamber Fuel tank and filter Clean 0 2 Fuel tube Check Every 2 years Replace if necessary 2

HONDA EB3000 EB4000 GENERATOR user manual

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