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HONDA EU65OOis GENERATOR user manual(1)

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2. OPERATION 5 Turn the engine switch to the START position and hold it there until the engine starts When the engine starts release the key allowing the switch to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the starter again NOTICE Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it 28 OPERATION Usethe recoil starter when the battery voltage is too low to turn the starter motor a Turn the engine switch to the ON position b Open the right maintenance cover by turning its latch counterclockwise Pull the starter grip lightly ENGINE until you feel resistance then pull briskly in the direction of the allow as shown STARTER GRIP NOTICE Do not exceed 20 degrees from horizontal when pulling the starter grip Do notallow the starter grip to snap back against the engine Return it gently to prevent damage to the starter e Do not let the starter rope rub against the generator body or the rope will wear out prematurely d Close the right ECOTHROTTLE SWITCH maintenance cover by turning its latch clockwise 6 If you wish to usethe EcoThrottle system turn the EcoThrottle switch to the ON ECC Or ON position after the engine has warmed
3. HANDLE ASSEMBLY 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 HANDLE LOCK LEVER 82 ASSEMBLY Rear Bar Installation Install the rear bar on the generator frame using the two 6 30mm bolts and two cap nuts TORQUE 17 22 Ibf ft 24 29 N m 2 4 3 0 kgf m CAP NUT 2 REAR BAR 6X30 mm BOLT 2 83 ASSEMBLY Battery WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling The battery is disconnected and strapped into the battery tray for shipment 1 Remove the battery maintenance cover see page 56 2 Remove the battery strap from the bottom hook and then remove the battery 3 Remove the red cable and the black cable from the twist clip and reinstall the battery 4 Remove the protective cover from the battery positive terminal connect the red cable to the battery positive terminal 5 Connect the black cable to the battery negative terminal 6 Secure the battery by hooking the strap onto the bottom hook of the generator TWIST CLIP BLACK CABLE NEGATIVE CABLE RED CABLE BATTERY STRAP POSITIVE CABLE 7 Install the battery maintenance cover in the reverse order of removal page 56 N
4. 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 in warm FOAM AIR FILTER 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 3 Wipe dirt from the air cleaner housing and cover using 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 and remove the key 2 Open the left maintenance cover by turning its latch counterclockwise FUEL VALVE LEVER 3 Unscrew the sediment cup and remove it 4 Remove the O ring 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 5 Wash the sediment cup and O r
5. Avoid any enclosed areas or activities that expose you to carbon monoxide Before connecting an AC appliance or power cord to the generator Use grounded 3 prong extension cords tools and appliances or double insulated tools and appliances Inspect cords and plugs and replace if damaged e Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for electric shock 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 26 OPERATION STARTING THE ENGINE Refer to Safe Operating Precautions on page 25 1 Make sure that all appliances are disconnected from the AC receptacles The generator may be hard to start if a load is connected 2 Set the Voltage Selector Switch VOLTAGE SELECTOR SWITCH to match the voltage requirements for the application TL _ 120v 4 240V se 120V 4 ONLY 3 Turn the fuel valve lever to the FUEL VALVE LEVER ON position epy CO DEF 4 Make sure the EcoThrottle switch is in the OFF position or ECOTHROTTLE SWITCH more time will be required for a f y M E OFF ON warm up 27
6. T 7 I A 22 RIGHT MAINTENANCE LEFT MAINTENANCE COVER COVER Ed Close the cover and push 16 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 17 CONTROL amp FEATURES Output Indicator The output indicator green is illuminated when the generator is operating normally It indicates that the generator is producing electrical power at the receptacles OUTPUT INDICATOR TN Br D 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 5 20a i 18 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 crank
7. 65 U UNDaACKING 80 V Voltage Selector Switch T 14 Wheel 81 75 93 94 MEMO QUICK REFERENCE INFORMATION Fuel Type Regular 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 Battery Part Number Honda P N 31500 M CR D02 Yuasa Model YTZ14S Maintenance Before each use Check engine oil level Check air filter First 20 hours Change engine oil Subsequent See Maintenance Schedule page 43 HONDA The Power of Dreams 31225600 gt gt 0 1000 2006 09 00 31 225 6000 Printed in J
8. M nm 60 COMPONENT amp CONTROL LOCA TIONS 10 Connections to a Building s Electrical System 39 CONSUMER INFORMATION 76 CONTROLS drastan ae 12 CONTROLS amp FEATURES bises o ext quus 10 Customer Service InFOFodlklell ueeuicues socie opui S Ere Rte a Perte 77 EcoThrottle Switch 13 ECO TRO Die SYSTEM r E 38 Electri Shock Hazards RR T oo m 7 Emission Control System Information 71 ENGINE LACKS POWER 67 PNIS 63 ENGINE DIL CHANGE 47 ENGINE DIE LEVEL CHECK 46 ENGINE OIL RECOM MENDATIONS ccrto pnus cen put atten ut ntu ee uite tapas 48 Engine Switch 12 ENGINE WIL NET 66 90 F FEATURES inrita HIEMIS 17 Fire and Burn Hazards essere enean 7 Folding Handle recur 15 FOAM AIR FILTER CLEANING eene 50 dui m V 60
9. Sexe beu 45 ENGINE DIL LEVEL CHECK totiens 46 ENGINE DIL C HABIGE tna ta oett tenetis 47 ENGINE DIL RECOMMENDATIONS reete inen 48 AIR CLEANER SERVICE 49 FOAM AIR FILTER CLEANING irata tano Shear 50 SEDIMENT CUP CLEANIN Bre acest daccatenees 51 SPARK 52 SPARK 54 BATTERY S 55 gi eC TX E 59 STORAGE PREPARATION i didi nigra Fd petu Mena ended ial 60 CNS IMIG m 60 gi M C H 9 60 perle PEE TC dX 63 STORAGE PRECAUTIONS e ttaterdintiaicndsatidiansiasdecnasttadeals 64 REMOVAL FROM STORAGE ph ner enn Rep phas 64 CONTENTS TRANSPORTING TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START 66 ENGINE LACKS POWER ea 67 NO POWER AT THE RECEPTAGCLBS 68 TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORIMLA TION 69 Serial Number LOCation nae sauna 69 Carburetor Modification for High Altitude Operation 70 Emission Control System Information iere 71 TON idl e oy eot UN CR TEN 73 SCC AUN ONS T 74 Winnog ES 75
10. aU ee MET TRY 23 FUEL RECOMMENDATIONS eene 45 Fuel Valve Lever eese nennen eee ena 12 FUSE ntes Le Le e EE 59 G GENERATOR SAFETY 6 Ground Terminal eese nennen enne nennen 17 H Handle Installation eeeeeeeeeeennnnnne 83 gi d cat secu 89 Honda Publications eeeeeeeeee nennen nnne 76 9 20 IMPORTANT SAFETY INFORMATION een 6 Important Safety Precautions 79 90 IS YOUR GENERATOR READY 24 K PN v cs o PPP PI c 24 L Loose cnn beau Ee E Fra EE RR OE ERU 80 91 INDEX M Maintenance COVER EP REDDE CREER 16 MAINTENANCE SAFETY rite ye 42 MAINTENANCE SCHEDULE eene eene 43 N NO POWER AT THE RECEPTACLES eee 68 Oil Alert Indicator esee nennen 19 OPERATION Deae dee so Oe Eae 26 Operator Responsibility 6 OPTIONAL PARTS 87 Output dift 18 Overload Indicator 18 Q QUICK REFERENCE INFORMATION Inside back cover R Rear Bar Installation eeeeeee eene 83 RIGOII SEATEOE ciiin 13 niri tret hcm ree Eee ect Ee ei ees 44 Refuel With 8 Remote e x ret xe e er
11. gapped Gap or replace spark plug Spark plug wet with fuel flooded engine Dry and reinstall spark plug Fuel filter restricted carburetor malfunction ignition malfunction valves Stuck etc Take the generator to an authorized Honda servicing dealer or refer to the shop manual 66 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE LACKS POWER Possible cause Correction Air filter restricted Clean or replace air filter p 49 Bad fuel generator stored Drain fuel tank and carburetor without treating or draining gasoline or refueled with bad Refuel with fresh gasoline gasoline D Fuel filter restricted Take the generator to an carburetor malfunction authorized Honda servicing ignition malfunction valves dealer or refer to the shop stuck etc manual 67 TAKING CARE OF UNEXPECTED PROBLEMS NO POWER AT THE RECEPTACLES Possible Cause Correction 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 Circuit protector s tripped Check AC load and reset circuit protector s p 14 Faulty power tool or appliance Replace or repair power tool or appliance Stop and restart the engine Faulty generator 68 Take the generator to an authorized Honda servicing dealer or refer to the shop manual TECHNICAL amp
12. 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 24 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 engine 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 a full tank will help to eliminate or reduce operating interruptions for refueling Battery Maintenance Cover Never operate the generator without the battery maintenance cover in place as poor engine and generator performance will result BATTERY MAINTENANCE COVER 25 OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time please review the GENERATOR SAFETY section and the chapter titled BEFORE OPERA TION 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 that can collect rapidly in an enclosed area and cause illness or death A WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you
13. 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 and it operates the electric starter OFF Stops the engine The engine switch key can be removed inserted ON Running position and for starting with the recoil starter START Operates the electric starter REMOTE For using the remote le control kit optional parts WO REMOTE ENGINE SWITCH 12 CONTROL amp FEATURES Recoil Starter Used when the battery voltage is STARTER GRIP too low to turn the starter motor Pulling the starter grip operates the recoil starter to crank the engine for starting NOTICE Do not exceed 20 degrees from horizontal when pulling the starter grip Do notallow 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 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
14. the EcoThrottle switch to the OFF position to reduce voltage changes ON Recommended to minimize fuel consumption and further ECOTHROTTLE SWITCH reduce noise levels when a reduced load or no load is applied to the generator OFF ON OFF The EcoThrottle system does not operate Generator E operates at full speed 4 ES CONTROL amp FEATURES Voltage Selector Switch The voltage selector switch changes generator output to produce 120V ONLY 120 240 If a 240V appliance is connected to 4 prong receptacle the switch must be in the 120 240V position If only the 120V 3 prong receptacles are being used 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 30A 120V locking plug receptacle VOLTAGE SELECTOR SWITCH lt SS 120V ONLY EN 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 PROTE
15. website www hondapowerequipment com Honda Publications Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Available through your Honda dealer or through Helm Inc at 1 888 292 5395 or visit www hondapowerequipment com Parts Catalog This manual provides complete illustrated parts lists Available through your Honda dealer 76 TECHNICAL amp CONSUMER INFORMATION Customer Service Information Honda Power Equipment dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager or General Manager can help Almost all problems are solved in this way 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 8 30 am to 7 00 pm ET When you write or call please give us this information Model and serial numbers see page 69 Name of the dealer who sold the generator to you Name and address of the dealer who services your generator Date of purchase Your name address and tele
16. 1 3 4 22 9A rated Main Circuit Il 2 and 5 24 5222 9A rated 36 OPERATION 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 1 The equation tells us that the total power draw on circuit 1 is 25A This is a substantial overload of this circuit To eliminate the excess power draw on circuit I 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 84 D 120V 30A 2 120V 20A 8 120V 20A 120 240V 30A 37 OPERATION ECOTHROTTLE SYSTEM With the switch in the ON position engine speed is automatically lowered when loads are reduced turned OFF or disconnected When appliances 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 rpm 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 O
17. 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 9 Attach the spark plug cap 10 Reinstall the spark plug inspection cover and tighten the cover screw 11 Close the left maintenance cover 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 very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the two 5 X 14 mm pan head screws and remove the spark arrester SPARK ARRESTER 5 14 mm PAN HEAD SCREW 2 2 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 itis damaged 3 Install the spark arrester in the reverse order of removal 54 SERVICING YOUR GENERATOR BATTERY SERVICE Your generator s engine charging system charges the battery while the engine is running However if the generator is only used periodically the battery must be charged monthly to maintain the battery service life A WARNING The battery contains sulfuric acid electrolyte which is highly corros
18. AS Length Handle in up position 33 5 in 850 mm 47 0 in 1 195 mm Width 26 5 in 672 mm Height 27 5 in 699 mm Handle in up position 28 2 in 716 mm Dry weight 254 Ibs 115 kg Without battery Engine Model GX390K1 Engine Type 4 stroke overhead valve single cylinder Displacement 23 7 cu in 389 cm Bore x Stroke 3 5 X 2 5 in 88 X 64 mm Compression Ratio 8 0 1 Engine S peed 2 400 3 600 rpm EcoThrottle ON gt Cooling System Forced air Ignition System Full transistor Tuneup Specifications Oil Capacity 1 18 US qt 1 12 2 Fuel Tank Capacity 4 36 US gal 16 5 0 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 9 A Rated Output 5 5 kVA Maximum Output 6 5 KVA ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in 0 70 0 80 mm Valve clearance cold IN 0 15 0 02 mm EX 0 20 0 02 mm See your authorized Honda dealer Other specifications No other adjustments needed Specifications may vary according to the types and are subject to change without notice 74 TECHNICAL amp CONSUMER INFORMATION iagram D iring
19. CAP DIPSTICK OIL FILLER CAP WASHER OIL DRAIN PLUG DIPSTICK SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range 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 or later oil 48 SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1 Open the left maintenance cover by turning its latch counterclockwise 2 Loosen the cover screws and remove the air cleaner cover 3 Remove the foam air filter from the air cleaner cover 4 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 on page 50 Replace the foam air filter if itis damaged 5 Reinstall the foam air filter in the air cleaner cover 6 Reinstall the air cleaner cover 7 Close the left maintenance 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 theDistributor s Limited Warranty 49
20. CONSUMER INFORMATION 76 Honda 76 Customer Service Infor TiellOli 77 The Importance of Proper Assembly 78 Important Safety Precautions 79 80 eR 80 oferi i gne 80 Wheel KiEInstall GEDET as aeiccr tiui 81 ael sigues nre TENE m 82 Rear Bar se oq 83 lj aie mM M 85 e st 85 anu dic T 86 OPERA TION 86 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 protect yourself and others Operator Responsibility e 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 Ca
21. CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location Record the frame serial number in the space below You will need this serial number when ordering parts and when making technical or warranty inquiries Frame serial number Date purchased 69 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 3 596 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 modif
22. CTOR CIRCUIT PROTECTOR CIRCUIT PROTECTOR for Receptacle 2 for Receptacle 3 for Receptacle 2 AC CIRCUIT PROTECTOR C CIRCU C TM N S CIRCUIT PROTECTOR p is ON for Receptacle CA OFF ma PUSH D120V 30A 120V 20A 120V 20A 120 240V 30A 14 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 the extended the handle To Extend The Handle Lift handle upward Lock levers will lock and secure the handle into place To Fold The Handle 1 Press both handle lock levers downward 2 Lower the handle HANDLE HANDLE LOCK LEVER Handle transport position Generator stationary position 15 CONTROL amp FEATURES Maintenance Cover Open and close the maintenance cover for maintenance of the EU6500is Open the maintenance cover too to use the recoil starter when the battery is discharged Be sure to close the maintenance cover while the generator is running Work made with the right maintenance cover open Engine oil inspection replacement Work made with the left maintenance cover open e Spark plug inspection replacement Air cleaner inspection cleaning Sediment cup cleaning To open Turn the ratch 90 to unlock and open the maintenance cover To close Turn the ratch 90 to lock while pushing the cover RATCH ey
23. F position 3 Turn the fuel valve lever to the OFF position OFF A j ENGINE SWITCH FUEL VALVE LEVER 32 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 EM SELECTOR SWITCH NL 120V 240V SF 120V ONLY 2 Start the engine and make sure the output indicator green comes on GREEN OVERLOAD DS INDICATOR RED 33 OPERATION 3 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 in a connected appliance or if the inverter is overheated the overload indicator r
24. FF 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 x r EC OFF ON 38 OPERATION STAND BY POWER Connections to a Building s Electrical System Your generator can supply power to a building s electrical system If the generator will be used as an alternative to utility company power an isolation switch must be installed to disconnect the utility lines from the building when the generator is connected Installation must be performed by a qualified electrician and must comply with all applicable laws and electrical codes AWARNING Improper connections to a building s electrical system can allow current from the generator to backfeed into the utility lines Such backfeed may electrocute 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 Consult the utility company ora qualified electrician prior to making any power connections In some areas generators are required by law to be registered with local utility companies Check local regulations for proper registration and use procedures System Ground Honda portable generators have a system ground that connects the generator frame c
25. L SOURCE OF ELECTRICAL SHOCK IF NOT KEPT DRY 00 NOT EXPOSE THE GENERATOR TO MOISTURE RAIN OR SNOW 00 NOT OPERATE THE GENERATOR WITH WET HANDS EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT CAN BUILD UP TO DANGEROUS LEVELS iN CLOSED AREAS BREATHING CARBON MONOXIDE CAN CAUSE UNCONSCIOUSNESS OR DEATH NEVER RUN THE GENERATOR IN A CLOSED OR EVEN PARTLY CLOSED AREA WHERE PEOPLE MAY BE PRESENT READ OWNER S MANUAL CAREFULLY BEFORE OPERATION CAUTION A HOT EXHAUST SYSTEM CAN CAUSE SERIOUS BURNS WAVOID CONTACT IF THE ENGINE HAS BEEN RUNNING 10 CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS Use the two illustrations on these pages to locate and identify the most frequently used controls OVERLOAD OIL ALERT i MONITOR ECOTHROTTLE SWITCH INDICATOR INDICATOR BUTTON P CIRCUIT PROTECTORS 5 OUTPUT S INDICATOR Is le i MONITOR S GS ENGINE SWITCH RECEPTACLES VOLTAGE SELECTOR SWITCH CONTROL amp FEATURES FUEL GAUGE FUEL TANK CAP FUSE STARTER GRIP inside battery maintenance cover BATTERY inside battery maintenance cover OIL FILLER CAP DIPSTICK HANDLE OIL DRAIN PLUG RIGHT MAINTENANCE GROUND TERMINAL COVER SPARK PLUG INSPECTION COVER MUFFLER TIP AIR CLEANER LEFT MAINTENANCE COVER 11 CONTROL amp FEATURES CONTROLS Fuel Valve Lever The fuel valve
26. Oi 1 dd HOLIMS 3NION3 jd A DS E Ty E AR E 4 3814 ana 2018 LT lt 1 9 t 2 SRIONS DE i 43 5 5 ovis ES or at DIS SHE ex wo A nee viS FS ng ren dois ora 3 H reni uF omus wa vol a M HEDH WA ou ESH ume HH ama T 8 m an LE u x FSH yo E3H 5 5 ONG i SE s MOIVH3N3O ub 20 ES spa St a 1 H shra TES YES 2 0 ees 311108H1 023 p T woo EHI WALAANI in ANON AONI ano poten u 5 Ed nm pis m ng bs 9 9 t s b a Nw a S M 6 zino ov nao rei na ng 6 Lino av i vA W nivN E me Ern M NW SH ne ae a B 19 A NIV n L wt m d AES a iw iino av usi A v n3 2018 TANWd 1051409 30078 75 TECHNICAL amp CONSUMER INFORMATION CONSUMER INFORMATION Dealer Locator Information To find an authorized Honda Servicing Dealer anywhere in the United States Visit our
27. Owner s Manual GENERATOR EU6500is 2006 Honda Motor Co Ltd See page 78 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 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 and your responsi
28. ad IndICatOF rre aara 18 Oil Alert ndiCalOr error ner ene iE ren recente 19 CR er D RR E Em 20 a Lccr cte 23 BEFORE OPERATION ARE YOU READY TO GET STARTED eee ener 24 mee EM 24 IS YOUR GENERATOR READY TO GO sesm meme 24 Check the ao cte ar anre 25 Battery Maintenance Str erae E Ere 25 CONTENTS STARTING THE ENGINE isset tnnt pt enano rtv ten uates 27 Starting the engine with remote control optional part 30 STOPPING THE ENGINE Stopping the engine with remote control optional part 32 AC OPERATION Rea A A 33 AC ieee ee 35 Receptacle 36 ECOTBROTTEE SYSTEM 38 STAND BY POWER EE 39 Connections to a Building s Electrical System 39 39 special Requiremierits aout E up e eiu undi 40 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE 41 MAINTENANCE SAFE Y etes repertis raa etus tato ei UE Supp stu crat 42 Safety Precautions Pr T 42 MAINTENANCE SCHEDULE oratio rette anto ta dea SERE 43 REFUELING n 44 EDELRECOMMENBATIDNIS
29. bilities of ownership The Distributor s Limited Warrantyis 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 itis 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 and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if DANGER you don t follow instructions A WARNING You be KILLED or SERIOUSLY HURT if you don t follow i
30. case 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 stops engine the engine switch will remains the ON position The i Monitor display will shows OIL on the screen and the Oil Alert indicator illuminats If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to START or pull the starter grip check the engine oil level see page 46 before troubleshooting in other areas Even when oil is added to the engine the generator will not restart until the Oil Alert indicator is reset To reset the Oil Alert indicator turn the engine switch OFF add the proper amount of oil and then turn the engine switch back ON OIL ALERT RED OUTPUT OVERLOAD OIL INDICATOR ALARM ALERT DL It blinks 19 CONTROL amp FEATURES i Monitor The i Monitor is a user interface that allows the operator to view when the generator is running total operating time in hours generator output engine RPM battery voltage and error messages The different display modes are selected by pressing the i Monitor button i Monitor at Startup 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 Once the generator is running the Output indicator green and the i Monitor display will remain lit Display Ba
31. cklight Flashes If the key is leftin the ON position for over 30 seconds without starting the engine the display will start to flash 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 4 The four digit screen displays the four mode values 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 0 When the operating time is one hour or greater the display will be 1 or 2 and so on Base the generator s maintenance schedule on the accumulated time displayed i MONITOR BUTTON SINGLE DIGIT ih 3irpm HIB SCREEN DISPLAY B gt uui 99 mmt SCREEN DISPLAY 20 CONTROL amp FEATURES i Monitor Display Mode 2 Power Output 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 i Monitor Display Mode 3 Engine RPM When the i Monitor is in this mode the engine s speed expressed in revolutions per minute RPM is displa
32. continues to fail discontinue generator use and consult an authorized Honda generator dealer 1 the engine switch OFF and remove the key before checking or replacing the fuse 2 Loosen the cover screw and remove the battery maintenance cover BATTERY MAINTENANCE COVER COVER SCREW 3 Remove the fuse holder cover and pull the fuse out FUSE 1A FUSE 15A 4 Replace the fuse with a fuse of the same type and rating Specified fuse 1A 15A NOTICE Never use a fuse with a different rating from that specified Serious damage to the electrical system or fire FUSE HOLDER COVER may result 5 Install the fuse holder cover and the battery maintenance cover in the reverse order of removal see page 56 Never operate the generator without the maintenance cover in place as poor engine and generator performance will result 59 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 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 ga
33. d 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 A WARNING 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 A WARNING 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 sure the engine is off before you begin any maintenance or repairs This will
34. dule is based on the 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 72 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 itis sold Remove the hang tag before operating the generator 73 TECHNICAL amp CONSUMER INFORMATION Specifications Dimensions Model Type EU 6500is Power product description code E
35. e 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 63 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 Fully charge the battery Recharge the battery once a month see page 58 REMOVAL FROM STORAGE 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
36. ed 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 itis 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 34 OPERATION AC Applications Before connecting an appliance or power cord to the generator Make sure that it is in good working order Faulty appliances or power cords can create a potential for electrical shock f an appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded Make sure that the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum powe
37. 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 e 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 operating hour interval whichever comes 20 Hrs or 1300 Hrs first 50 Hrs 100 Hrs Engine oil Check level Air filter Check Clean O 1 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 1 Service more frequently when used in dusty areas 2 These items should be serviced by your se
38. ever operate the generator without the maintenance cover in place as poor engine and generator performance will result 84 Engine Oil The generator is shipped WITHOUT OIL in the engine Place the generator on a level surface Open the right maintenance cover by turning its latch counterclockwise Add enough of the recommended oil to bring the oil level to the top of the oil filler neck Use 4 stroke motor oil that meets the requirements for API service classification SJ or later 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 Close the right maintenance cover by turning its latch clockwise Fuel Refer to page 60 UPPER LIMIT ASSEMBLY SAE Viscosity Grades 20 0 20 40 60 80 100 20 0 0 10 20 30 40 OIL FILLER HOLE OIL FILLER CAP DIPSTICK Se 85 ASSEMBLY Battery Voltage Check the battery voltage with the i Monitor The battery voltage should be 12 3 V or more If the battery voltage is low charge the battery until the battery voltage will be 12 3 V or more BEFORE OPERATION Before using your generator you should become familiar with i
39. evo exe roue ae 87 REMOVAL FROM STORAGE eene enne enne 64 92 S SAFE OPERATING PRECAUTIONS 26 e C 78 SAFETY LABEL EOCATIONGSI up ES erence rte a ande 9 Safety 42 SEDIMENT CUP CLEANING 51 Serial Number CG 69 SERVICING YOUR GENERATOR antera 41 SPARK ARRESTER SERVICE 54 SPARK PLUG SERVICE 52 Special RegullemiertEs aa M 40 SUSI OIG TL 74 STAND BY POWER 39 STARTING THE ENGINE 2 27 STOPPING THE ENGINE sicht 31 uertice Aai 60 STORAGE PRECAUTIONS 64 STORAGE PREPARA paea nter 60 SSA CNN MEET RR m 39 T TAKING CARE OF UNEXPECTED PROBLEM S itta bacs 66 TECHNICAL amp CONSUMER INFORMATION rne 69 TECHNICAL INFORMAT ION 69 THE IM PORTANCE OF MAINTENANCE ette nca 41 The Importance of Proper Assembly 78 HU uec cer
40. gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery maintenance The battery is rated at 11 2 Ah ampere hours Charging current should equal 1096 of the battery s ampere hour rating A battery charger should be used that can be adjusted to deliver 1 1 amps 1 Connect the battery charger following the manufacturer s instructions 2 Charge the battery 5 10 hours 3 Clean the outside of the battery and the battery compartment with a solution of baking soda and water Battery Installation 1 Install the battery into the generator 2 Connect the battery positive cable to the battery positive terminal first and tighten the bolt securely 3 Slide the battery boot over the positive cable and terminal 4 Connect the battery negative cable to the battery negative terminal and tighten the bolt securely 5 Install the battery strap 6 Install the maintenance cover in the reverse order of removal see page 56 Never operate the generator without the maintenance cover in place as poor engine and generator performance will result 58 SERVICING YOUR GENERATOR FUSE If the fuse is blown the starter motor won t operate In the event of fuse failure locate the cause of failure and repair before you continue operation If the fuse
41. gasoline with a pump octane rating of 86 or higher You may use regular unleaded gasoline containing no more than 1096 Ethanol E10 or 596 M ethanol by volume In addition Methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank 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 Open the right maintenance cover by turning its latch counterclockwise 2 Remove the oil filler cap dipstick and wipe it clean 3 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 4 If the oil level is low fill to the top of the oil filler neck with the recommended oil page 48 5 Screw in the oil filler cap dipstick securely 6 Close the right maintenance cover by turning its latch clockwise UPPER LIMIT Lan OIL FILLER CAP V DIPSTICK The Oil Alert system will automatically stop
42. ied 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 overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications 70 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 e Removal or alteration of any par
43. 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 FUEL TANK CAP 23 BEFORE OPERATION ARE YOU READY TO GET STARTED Your safety is your responsibility A little time spent in preparation will significantly reduce your risk of injury Knowledge Read and understand this manual Know what the controls do and how to operate them Familiarize yourself with the generator and its operation before you begin using it Know how to quickly shut off the generator in case of an emergency If the generator is being used to power appliances be sure that they do not exceed the generator s load rating see page 35 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 A WARNING 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
44. ing in nonflammable solvent and dry them thoroughly 6 Reinstall the O ring and sediment cup 7 Close the left maintenance cover O RING SEDIMENT CUP 51 SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs BPR5ES W16EPR U DENSO NOTICE An incorrect spark plug can cause engine damage 1 Open the left maintenance cover by turning its latch counterclockwise 2 Loosen the cover screw and remove the spark plug inspection cover SPARK PLUG INSPECTION COVER COVER SCREW 3 Disconnect the spark plug cap and remove any dirt from around the spark plug area 4 Remove the spark plug with a 13 16 inch spark plug wrench commercially available SPARK PLUG WRENCH 52 SERVICING YOUR GENERATOR 5 Inspect the spark plug Replace p 0 028 0 031 in it if the electrodes are worn or if T 0 70 0 80 mm the insulator is cracked chipped or fouled SEALING WASHER 6 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode The gap should be 0 028 0 031 in 0 70 0 80 mm 7 Make sure that the spark plug sealing washer is in good condition and thread the spark plug in by hand prevent cross threading 8 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
45. ive and poisonous Getting electrolyte in your eyes or on your Skin can cause serious burns Wear protective clothing and eye protection when working near the battery KEEP CHILDREN AWAY FROM THE BATTERY Emergency Procedures Eyes Flush with water from a cup or other container for at least fifteen minutes Water under pressure can damage the eye Immediately call 911 USA only or a physician Skin Remove contaminated clothing Flush the skin with large quantities of water Call a physician immediately Swallowing Drink water or milk Call your local Poison Control Center USA only or a physician immediately 55 SERVICING YOUR GENERATOR Battery Removal WARNING Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling 1 Lift handle upward Lock levers will lock and secure handle into place HANDLE HANDLE LOCK LEVER COVER SCREW BATTERY MAINTENANCE COVER 56 SERVICING YOUR GENERATOR 3 Remove the negative cable from the battery negative terminal then remove the positive cable from the battery positive terminal 4 Unhookthe battery strap from the bottom hook of the generator BATTERY STRAP POSITIVE CABLE 5 Remove the battery from the battery tray 57 SERVICING YOUR GENERATOR Battery Charging A WARNING The battery gives off explosive hydrogen
46. m Washer 2 14 8mm Washer t 22 3 mm 4 7 40 28 2 15 6 mm nut 2 8 12 mm Washer 2 80 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 and cotter pins 2 Install the axle assembly on the generator using four 8 mm washers and 8 X 16 mm flange bolts 3 Install the two stands on the under frame using four 8 mm washers and 8 X 16 mm flange bolts TORQUE 17 22 Ibf ft 24 29 N m 2 4 3 0 kgf m 8 mm WASHER 4 t 6mm 8 16 mm FLANGE BOLT 4 Wi Lae ae jc 3 LL Ww SHORTER i 2mm SUR 4 STAND t 2 3 mm el gt mm WASHER WHEEL 2 1 d 4 0 28 mm COTTER PIN 2 8X 16 mm FLANGE BOLT 4 81 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 5 24 29 N m 2 4 3 0 kgf m HANDLE HOLDER BOLT 2 SPRING WASHER 2 dd 12 mm WASHER 2 Sm
47. nformation contained in the following chapters and sections e GENERATOR SAFETY page 6 e CONTROLS amp FEATURES page 10 OPERATION 26 e STARTING THE ENGINE page 27 e STOPPING THE ENGINE page 31 86 OPTIONAL PARTS Remote Control Kit 1 Remove the battery maintenance cover see page 56 2 Remove the plug from the 6 pin connector 3 View the back of the maintenance cover and locate the knockout near the top center of the cover Carefully remove the knockout KNOCKOUT BATTERY MAINTENANCE COVER 87 OPTIONAL PARTS 4 Pass the remote control cable through the supplied wire grommet and fitthe grommet into the battery maintenance cover knockout 5 Plug the remote control cable into the 6 pin connector 6 Install the battery maintenance cover and tighten the cover screw REMOTE CONTROL CABLE GROMMET REMOTE CONTROL CABLE BATTERY MAINTENANCE COVER 7 To avoid accidentally unplugging the remote control cable secure the cable to the generator frame with a cable tie as shown CABLE TIE Never operate the generator without the battery maintenance cover in place as poor engine and generator performance will result e When the remote control is not being used replace the plug on the connector 88 OPTIONAL PARTS Hanger Kit Protect the fuel tank and frame pipe with the protector films during installation of the hanger 1 Insert the b
48. nstructions You CAN be HURT if you don t follow CAUTION instructions Safety Headings such as MPORTANT SAFETY INFORMATION Safety Section such as GENERATOR SAFETY Instructions how to use this generator correctly and safely This entire book is filled with important safety information please read it carefully 2 CONTENTS GENERATOR SAFETY IMPORTANT SAFETY INFORMATION eene 6 Operator 6 Carbon Monoxide 6 Electric Shock HazardS 7 Fire and Burn Hazards r rer rr annainn 7 Refuel With Care eeeeeee 8 SAFETY LABEL LOCATIONS eeee enne nennen 9 CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS 10 CONTROLS rtt EE R Aaaa 12 Fuel ValveJlever eee re E T E A 12 12 Recoil 13 EcoThrottle aaa iaae ai 13 Voltage Selector Switch sicicessissscanassccnsesacaseresncaetcnssesactenasscnateuesaasecence 14 AC Circuit 14 Folding Hardlei 15 Maintenance 16 FEATURES 17 Ground Termirialk 17 Output Indicator 18 Overlo
49. of gasoline for refueling be 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 64 TRANSPORTING If the generator has been running allow the engine to cool for atleast 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 the folding transport handle 65 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Fuel valve lever OFF Turn lever ON Engine switch OFF Turn engine switch to ON Out of fuel Refuel p 44 Bad fuel generator stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor Refuel with fresh gasoline Low oil level caused Oil Alert to stop engine Add oil p 46 Turn engine switch to OFF and restart the engine Spark plug faulty fouled or improperly
50. omponents to the ground terminals in the AC output receptacles The system ground is not connected to the AC neutral wire If the generator is tested with a receptacle tester it will not show the same ground circuit condition as for a home receptacle 39 OPERATION Special Requirements There may be Federal or State Occupational Safety and Health Administration OSHA regulations local codes or ordinances that apply to the intended use of the generator Please consult a qualified electrician electrical inspector or the local agency having jurisdiction IN some areas generators are required to be registered with local utility companies the generator is used at a construction site there may be additional regulations that 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 you operate your generator under unusual conditions such as sustaine
51. otto touch the muffler while itis 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 WARNING IMPROPER CONNECTIONS TO A BUILDING CAN ALLOW ELECTRICAL CURRENT TO BACKFEED INTO UTILITY LINES CREATING AN ELECTROCUTION HAZARD CONNECTIONS TO A BUILDING MUST ISOLATE GENERATOR POWAR FROM UTILITY POWER AND COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES WARNING GASOLINE 1S HIGHLY FLAMMABLE AND EXPLOSIVE YOU COULD BE BURNED OR SERIOUSLY INJURED IF THE GASOLINE IS IGNITED BEFORE REFUELING STOP THE ENGINE AND KEEP HEAT SPARKS AND FLAME AWAY W HANDLE FUEL ONLY OUTDOORS W DO NOT FILL THE FUEL TANK ABOVE THE UPPER LIMIT LINE W WIPE UP SPILLS IMMEDIATELY Ch THE GENERATOR 15 A POTENTIA
52. phone number A detailed description of the problem 77 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 A WARNING Improper assembly can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in the assembly instructions carefully 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 A WARNING 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 78 ASSEMBLY Important Safety Precautions e Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment When performing this assembly be especially careful of the following Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Make sure the engine is off before you begin any maintenance or repairs This
53. r 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 6 500 VA For continuous operation longer than 30 minutes do not exceed the rated power Rated power is 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 35 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 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 45 8A Main power circuit Receptacles powered by each main circuit Power distribution Main Circuit 1 3and4
54. racket installation part at one end of the hanger into the clearance between the frame pipe and fuel tank 2 Slide the hanger and insert another bracket installation part of the hanger into the gap between the frame pipe and fuel tank on the other side HANGER 3 Slide the hanger along the frame pipe to align the center of the hanger with the recessed part on the rear side of the fuel tank Install the hanger brackets on both ends of the hanger and tighten the 8 X 16 mm flange bolts securely TORQUE 17 22 Ibf ft 24 29 N m 2 4 3 0 kgf m HANGER 8X 16 mm FLANGE BOLT 4 HANGER BRACKET 2 89 INDEX A C 35 AC Circuit PFOLGCEOUS 14 AC OPERA ION MM e e 33 AC Receptacle Selection 36 AIR CLEANER SERVICE 49 ids e D 73 ARE YOU READY TO GET STARTED 24 ASSEMBLY EE 78 80 86 Battery Maintenance Cover sse 25 BATTERY SERVICE desine n Reston 55 BEFORE OPERA TION 22 24 Earbon Monoxide hazards uut uenit cota un 6 Carburetor Modification for High Altitude Operation 70 Maze EY ENGINE a o ooo T 25 Cleaning RE RR
55. rbon Monoxide Hazards Exhaust contains poisonous carbon monoxide a colorless odorless gas Breathing exhaust can cause loss of consciousness and may lead to death Operate outdoors away from buildings open doors or windows Never run the generator in a closed or partially enclosed area GENERATOR SAFETY Electric Shock Hazards The generator produces enough electric power to cause a serious shock or electrocution if misused Using a generator or electrical appliance in wet conditions such as rain or snow or near a pool or sprinkler system or when your hands are wet could result in electrocution Keep the generator dry If the generator is stored outdoors unprotected from the weather check all of the electrical components on the control panel before each use Moisture or ice can cause a malfunction or short circuit in electrical components which could result in electrocution Do not connect to a building electrical system unless an isolation Switch has been installed by a qualified electrician 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 n
56. rvicing 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 Failure to follow this maintenance schedule could result in non warrantable failures 43 SERVICING YOUR GENERATOR REFUELING With the engine stopped check the fuel level gauge Refill the fuel tank if the fuel level is low A WARNING 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 e Wipe up spills immediately FUEL TANK CAP MAXIMUM FUEL LEVEL FUEL STRAINER SHOULDER A 7 Refuel in a well ventilated area before starting the engine If the engine has been running allow itto 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 FUEL GAUGE EMPTY SERVICING YOUR GENERATOR FUEL RECOMMENDATIONS Use regular unleaded
57. 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 61 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 1 Open the right maintenance cover by turning its latch counterclockwise 2 Place a suitable gasoline container DRAIN SCREW below the carburetor drain hose 3 Movethe fuel valve to the ON position 4 Loosen the carburetor drain screw and drain the gasoline from the carburetor and tank 5 After all the fuel has drained into the container tighten the drain screw securely 6 Remove the sediment cup and empty it 7 Reinstall the sediment cup see page 51 62 STORAGE Engine Oil 1 Changethe engine oil see page 47 2 Remove the spark plug see page 52 3 Pour atablespoon 5 10 cc of clean 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 th
58. soline 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 depending on the gasoline formulation in your area 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 60 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 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
59. t of intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 71 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 Hard starting or stalling after starting e Rough idle e Misfiring or backfiring under load e Afterburning backfiring 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 Remember that this sche
60. 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 Open the right maintenance cover by turning its latch counterclockwise 2 Reach under the generator and remove the black rubber seal located below the oil drain plug 3 Place a suitable container underneath the generator to catch the used oil 4 Remove the oil filler cap dipstick 5 Remove the oil drain plug and sealing washer and allow the oil to drain completely 6 Reinstall the oil drain plug and sealing washer Tighten the plug securely 7 Reach under the generator and reinstall the black rubber seal NOTICE Improper 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 a trash bin dump it on the ground or pour it down the arain 8 With the generator in a level position fill to the outer edge of the oil filler hole with the recommended oil see page 48 9 Screw in the oil filler cap dipstick securely 10 Close the right maintenance cover by turning its latch clockwise Wash your hands with soap and water after handling used oil BLACK RUBBER SEAL OIL FILLER
61. up for 2 or 3 minutes OPERATION Starting the engine with remote control optional part 1 Determine the voltage requirements and adjust the voltage selector switch as needed 2 Turn the fuel valve to the ON position 3 Turn the engine switch to the REMOTE far left position REMOTE ENGINE SWITCH 7 OFF FUEL VALVE LEVER 4 Press and hold the start button until the engine pilot lamp illuminates The start button will automatically be disabled after the engine starts If the engine fails to start within 5 seconds release the button and wait at least 10 seconds before operating the starter again NOTICE Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it HONDA PILOT LAMP START DFF START BUTTON 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 Unplug all appliances from the generator AC receptacles 2 Turn the engine switch to the OFF position ENGINE SWITCH 3 Turn the fuel valve lever to the OFF position FUEL VALVE LEVER 31 OPERATION Stopping the engine with remote control optional part 1 Press the stop button HONDA PILOT START OFF PILOT LAMP STOP BUTTON 2 Turn the engine switch to the OF
62. 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 e To reduce the possibility 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 79 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 14 mm wrench 2 10 mm wrench or Phillips head screwdriver for battery connections 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 Qty Ref No Description Qty al Wheel 2 9 Spring Washer 2 2 Axle 1 10 Handle holder bolt 2 3 Handle assy 1 11 6 30 mm Flange bolt 2 4 Stand 2 12 8 16 mm Flange bolt 8 5 Rear pipe 1 13 8mm Washer t 6 mm 4 6 20 m
63. yed i Monitor Display Mode 4 Battery Voltage This mode displays the battery condition expressed in Volts DC HI 1395 21 CONTROL amp FEATURES i Monitor Low Battery Message If the engine switch is turned to the START position and batt is shown on the i Monitor display the battery voltage is too low to operate the engine s electric starter Use the recoil starter to start the generator Have the battery recharged and checked see page 58 battle i Monitor System Error Messages If the generator has a system malfunction it will show an error message on the i Monitor display During remote control operation an E 01 error message may display if the starter button is pressed for more than 10 seconds With an E 01 error message the engine will stay running and the electrical output may stay constant Normal remote control operation will be restored after the E 01 error message clears If the E 01 error message will not clear or if any other error message displays contact an authorized Honda generator dealer OVERLOAD INDICATOR LIGHT 7 OUTPUT OIL INDICATOR ALARM ALERT jirpm ERROR MESSAGE Example E 01 22 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

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