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HONDA EZ3500/EZ5000 GENERATOR user manual

1. Owner s Manual GENERATOR EZ3500 EZ5000 Law il r Click here to save this manual to your computer Meet ttt TINN TT ttt tt HH H ade TIS 2002 Honda Motor Co Ltd All Rights Reserved WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING The generator is a potential source of electrical shock if misused Do not expose the generator to moisture rain or snow Do not let the generator get wet and do not operate it with wet hands Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered 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 No part of this publication may be reproduced without written permission Congratulations on your selection of 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 res
2. 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 A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING You KILLED or SERIOUSLY HURT if you don t follow instructions A CAUTION be HURT if you don t follow instruc Safety Headings such as IMPORTANT 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 CONTENTS SAFETY EE EE 5 Safety Label Locations 5 Safety Information 6 7 FN 9 ENE 11 Engine SVIN 11 Pelsen 11 Ground SEN end 15 Special Requirements 15 AC Applications T 16 AG OPA 17 High Altitude Operation 18 N RUM 19 HIDE 19 Fuel 2
3. Inspect the spark arrester for breaks or holes and replace it if necessary 4 Install the spark arrester and the muffler in the reverse order of disassembly 2 5 SPARK ARRESTER SCREEN TRANSPORTING STORAGE When transporting the generator turn the engine switch and the fuel valve OFF Keep the generator level to prevent fuel spillage Fuel vapor or spilled fuel may ignite AW ARNING Contact with a hot engine or exhaust system can cause serious burns or fires Let the engine cool before transporting or storing the generator Take care not to drop or strike the generator when transporting Do not place heavy objects on the generator Before storing the unit for an extended period 1 Be sure the storage area is free of excessive humidity and dust 2 Service according to the table below STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasoline conditioner Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl page 36 Drain the fuel sediment cup page 32 Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl page 36 Drain the fuel sediment cup page 32 Remove the spark plug Put a tablespoon of engine oil into the cylinder Turn the engine slowly with the pull rope to distribute the oil Reinstall t
4. Maximum output Tune up Specifications ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in 0 70 0 80mm Refer page 33 Valve clearance IN 0 15 0 02 mm cold See you authorized EX 0 20 0 02 mm cold Honda dealer Other specifications No other adjustments needed NOTE Specifications may vary according to the types and are subject to change without notice 8 8 4 5 5 0 kVA 41 WARRANTY 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 to 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 number see pages 9 10 e Name of dealer who sold the generator to you e Name and address of dealer who services your generator Date of purchase e Your name address and telephone number e A de
5. securely 3 Refill with the recommended see 19 and check the oil level Oil capacity 1 2 US qt 1 12 1 0 Imp qt UPPER LEVEL OIL DRAIN PLUG OIL FILLER CAP Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain 30 AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the generator in extremely dusty areas Never run the generator without the air filter Rapid engine wear will result 1 Remove the wing nut and the air cleaner cover Remove the elements and separate them Carefully check both elements for holes or tears and replace if damaged 2 Foam element Wash the element solution of household detergent and warm water then rinse thoroughly or wash nonflammable or high flash point solvent Allow the element to dry thoroughly Soak the element clean engine oil and squeeze out the excess oll The engine will smoke during initial start up if too much oil is left in the foam 3 Paper element Tap the element lightly several times on hard surface to remove excess dirt or b
6. tank YES Is there enough oil NO Add the recom in the engine mended oil YES Still NO spark Is there a spark NO Replace the Take the generator from the spark spark plug to an authorized plug Honda generator dealer To check 1 Remove the spark plug cap and clean Be sure there is no any dirt from around spilled fuel around the the spark plug spark plug Spilled fuel 2 Remove the spark may ignite plug and install the spark plug in the 9000 YES plug cap 3 Set the plug side electrode on the cylinder head 4 Crank the engine sparks should jump across the gap NO Clean the fuel sediment cup Is the fuel reaching the carburetor To check 1 off the fuel valve and loosen the drain screw 2 Turn the fuel valve to ON Fuel should flow from the drain when the fuel valve is turned ON If the engine still does not start take the generator to an authorized Honda generator dealer No electricity at the AC receptacles Is the AC circuit breaker NO Turn the AC circuit breaker ON ON YES NO DEFECTS Check the electrical ap Take the generator to an pliance or equipment for authorized Honda generator any defects dealer Replace the electrical ap pliance or equipment eTake the electrical ap pliance or equipment to an electrical shop for repair DEFECTS 38 WIRING DIAGRAM
7. must be followed in order to keep the emissions from your Honda engine 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 part of the 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 25 Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer e Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring e Black exhaust smoke or high fuel consumption 26 Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts 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 manufacturer of an aftermarket part assumes the responsibility that the part
8. the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored Do not overfill the fuel tank there should be no fuel in the filler neck After refueling make sure the tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of vapor KEEP OUT OF REACH OF CHILDREN Fuel tank capacity 23500 1 59 US gal 6 0 1 32 Imp gal EZ5000 1 85 US 7 0 2 1 54 Imp FUEL TANK CAP FUEL STRAINER Occasionally you may hear light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda generator dealer Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 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 st
9. where gasoline is stored Refuel in well ventilated area with the engine stopped Fuel vapors are extremely flammable and may ignite after the engine has started Make sure that any spilled fuel has been wiped up before starting the generator COMPONENT IDENTIFICATION AG RECEPTACLES OIL FILLER CAP OIL DRAIN PLUG ENGINE SWITCH ENGINE SERIAL NUMBER RECOIL STARTER GRIP CHOKE LEVER VALVE LEVER SEDIMENT CUP FUEL DRAIN SCREW CARBURETOR FUEL TANK MUFFLER AC CIRCUIT BREAKER AIR CLEANER SPARK PLUG CAP FRAME SERIAL NUMBER Record the engine and frame serial numbers for your future reference Refer to these serial numbers when ordering parts and when making technical or warranty inquiries see page 42 Frame serial number Engine serial number 10 CONTROLS ENGINE SWITCH To start and stop the engine Switch position OFF To Stop the engine ON Torunthe engine RECOIL STARTER ENGINE SWITCH To start the engine pull the starter grip lightly until resistance is felt then pull briskly Do no allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter STARTER GRIP 11 FUEL VALVE LEVER The fuel valve is located on carburetor When the valve lever is in the ON position fuel is allowed to flow from the fuel tank to the carburetor Be sure to return the fuel valve lever to the OFF position after st
10. 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 page 29 Remember that this schedule 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 unusually wet or dusty conditions will require more frequent service 27 AIR INDEX An Air Index Information hang tag label is applied to engines certified to an emission dur ability time period in accordance withthe requirements of the California Air Resources Board The bar graph ts 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 forthe engine s emission control system See your Emission Control Warranty for additional information Applicable to Emissions Durability Period Moderate 50 hours 0 65 cc 125 hours greater than 65 cc Intermediate 125 hours 0 65 250 hours greater than 65 Exrended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index information hang tag must
11. 0 The Importance of Maintenance 22 1 23 Maintenance Safety iu sees anus unas TRY aya Ya nag 24 Emission Control System Information 1 1 1 1 3 25 MN 28 Maintenance Schedule 29 Engine TANGEN 30 Air Cleaner 31 Fuel Sediment Cup Cleaning 32 Spark 6 1 64 33 Spark Arrester 34 TRANSPORTING STORAGE 66 nnns 35 Storage procedure s nrsunurannnannunnnnvannnennnnnnnnnnvannvennunnunevannuansuvnuansnene 36 m u 39 SPECIFICA HONS 40 WARRANTY SERVICE INFORMATION 42 NE Ne 43 SAFETY SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury Read them carefully label comes off or becomes hard to read contact your Honda Generator dealer for replacement WARNING USING THE GENERATOR IN RAIN SNOW OR NEAR WATER CAN LEAD TO DEATH FROM ELECTRIC SHOCK KEEP GENERATOR DRY WARN
12. EZ3500 EZ5000 ET EXCITER WINDING FIELD WINDING GENERATOR BLOCK 2 39 SPECIFICATIONS Dimensions GX240K1 4 stroke overhead valve single cylinder Engine type Displacement 14 8 242 cm Bore x stroke 2 9 x 2 3 in 73 x 58 Compression 182 1 000050502 Oil capacity Spark plug BPR5ES W16EPR U DENSO Generator Model EZ3500 120 240 V Rated frequency 60Hz 1 1 1 1 AC output 12 5 3 0 3 5 Tune up Specifications ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in 0 70 080mm Refer to page 33 Valve clearance IN 0 15 0 02 mm cold See your authorized EX 0 20 0 02 mm cold Honda dealer Other specifications No other adjustments needed NOTE Specifications may vary according to the types and are subject to change without notice 40 Dimensions _ 25000 2 Power product description code Length Width 20 11 510 gt Height 20 5in 520mm Cs Dry weight 136 7 Ibs 62 0 kg Engine mod Bore x Stroke 3 2 x 2 5 in 82 x 64 mm Compression ratio 80 1 1 1 3 600 rpm Forced air Fuel tank capacit 1 85 US gal 7 0 2 1 54 Imp gal Spark plug BPR5ES W16EPR U DENSO Generator 25000 Rated voltage 20 240 V Rated frequenc output Rated amperage Rated output
13. ING LECTROCUTION OR PROPERTY DAMAGE CAN OCCUR 00 NOT CONNECT THIS GENERATOR TO ANY BUILDING S ELECTRICAL ISOLAT HAS BEEN INSTALLED BY A LICENSED ELECTRICIAN READ OWNERS MANUAL CAREFULLY DO NOT USE INDOORS EXHAUST GAS CONTAINS POISONOUS WARNING carson MONOXIDE NE PAS UTILISER DANS UN ENDROIT FERME A CAUSE DU ATTENTION RISQUE D EMPOISONNEMENT DU GAZ NO LO USE EN LUGARES CERRADOS PORQUE EL MONOXIDE ATENCION DE CARBONO ES VENENOSO SAFETY INFORMATION Honda generators are designed to give safe and dependable service if _ operated according to instructions Read and understand this 5 manual before operating your generator You can help prevent accidents by being familiar with your generator s controls and by observing safe operating procedures Operator Responsibility Know how to stop the generator quickly in case of emergency 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 Carbon Monoxide Hazards Exhaust contains poisonous carbon monoxide colorless and odorless gas Breathing exhaust can cause loss of consciousness and may lead to death If you run the generator in an area that is confined or even partially enclosed the air you breathe could contain dangerous amount of exhaust gas
14. TS 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 n some areas generators are required to be registered with local utility companies Ifthe generator is used at a construction site there be additional regulations which must be observed 15 AG APPLICATIONS Before connecting an appliance or power cord to the generator sure that it is in good working order Faulty appliances or power cords can create potential for electrical shock appliance begings 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 power rating of the generator Power levels between rated and maximum may be used for no more than 30 minuted 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 OFF but will shorten the service life of the generator Limit operation requiring m
15. To keep exhaust gas from accumulating provide adequate ventilation Electric Shock Hazards e The generator produces enough electric power to cause serious shock or electrocution if misused e Using 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 e f generator is stored outdoors unprotected from the weather check all electrical components on the control panel before each use Moisture or ice can cause malfunction or short circuit in electrical components which could result in electrocution e Do not connect to building electrical system unless an isolation switch has been installed by 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 enclose the generator any structure Keep flammable materials away from the generator e The muffler becomes very hot during operation and remains hot for 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 e Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks where the generator is refueled or
16. andards 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 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 your fuel system If you notice any undesirable 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 not covered under warranty _ 21 STARTING THE ENGINE STOPPING THE ENGINE Starting the eng
17. aximum power to 30 minutes Maximum power is EZ3500 3 5 kVA EZ5000 5 0 kVA For continuous operation do not exceed the rated power Rated power is EZ3500 3 0 kVA EZ5000 4 5 kVA In either case 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 16 OPERATION 1 Start the engine see page 22 2 Switch ON the AC circuit breaker 3 Plug in the appliance Be sure that all appliances are in good working order before connect ing them to the generator If an appliance begins to operate abnor mally becomes sluggish or stops suddenly turn off the engine switch immediately Then disconnect the appliance and examine it for signs of malfunction Most motorized appliances require more than their rated wattage for startup ON y lt XG AC CIRCUIT BREAKER a 2 a t p Do not exceed the current limit specified for any one receptacle If an overloaded circuit causes the AC circuit breaker to switch OFF reduce the electrical load on the circuit wait a few minutes and then reset the circuit breaker 17 HIGH ALTITUDE OPERATION At high altitude the standard carburetor air fuel mixture will betoo rich Performance will decrease and fuel consumption will increase very rich mixture will also foul the s
18. cations ua Dove 5 SPECIFICATIONS ee 40 STARTING THE ENGINE STOPPING THE ENGINE 22 TRANSPORTING STORAGE see 35 36 TROUBLESHOOTING 37 WARRANTY SERVICE INFORMATION 42 WIRING DIAGRAM eee 39 44 HONDA The Power of Dreams 31254603 EM3 Y 1000 2002 01 Printed Japan 00 31 254 6030
19. gine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required 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 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 or replacement 24 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 utilizes 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
20. h the generator on a level SAE surface and the engine stopped Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SJ Always check the API SERVICE TEMP 20 label on the oil container to be 0 x 0 Nd d sure it includes the letters SJ AMBIENT TEMPERATURE SAE 10W 30 is recommended for general all temperature use Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range 1 Remove the oil filler cap and wipe the dipstick clean 2 Check the oil level by inserting the dipstick into the filler neck without screwing it in 3 the level is low fill to the top of the oil filler neck with the recommended oil OIL FILLER HOLE VE 254 DIPSTICK FILLER CAP FUEL RECOMMENDATION 1 Remove the filler cap and check the fuel level 2 Refill the tank if the fuel level is low Do not fill above the shoulder of the fuel strainer Use unleaded gasoline with pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank AW ARNING Gasoline is extremely flammable and is explosive under certain conditions e Refuel in a well ventilated area with
21. he spark plug Change the engine 30 After removal from storage drain the sotred gasoline into a suitable container and fill with fresh gasoline before starting Use gasoline conditioners that are formulated to extend storage life Contact your authorized Honda generator dealer for conditioner recommendations 2 months to 1 year 1 year or more 35 Storage Procedure 1 Drain the carburetor by loosening the drain screw Drain the gasoline into a suitable container AW ARNING Gasoline is extremely flammable and is explosive under certain conditions Perform this task in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area during this procedure DRAIN SCREW 2 Change the engine oil Page 30 3 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to distribute the oil then reinstall the spark plug 4 Slowly pull the starter grip until resistance Is felt At this point the piston is ADU 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 Align the notch on the starter pulley with the hole at the top of recoil starter 36 TROUBLESHOOTING When the engine will not start Is there fuel in the NO Refill the fuel tank
22. ine 1 Make sure that the AC circuit breaker is in the OFF position The generator may be hard to start if a load is connected 2 Turn the fuel valve lever to the ON position 3 Turn the choke lever to the CLOSED position 4 Turn the engine switch to the ON position 5 Pull the starter grip lightly until resistance is felt then pull briskly Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter or housing 6 As the engine warms up slowly turn the choke lever to the OPEN position Stopping the engine In an emergency 1 To stop the engine in an emergency turn the engine switch to the OF position normal use 1 Turn the AC circuit breaker to the OFF position 2 Turn the engine switch to the OFF position 3 Turn the fuel valve lever to the OFF position 22 MAINTENANGE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free operation It will also help reduce air pollution AWARNING improper maintenance or failure to correct a problem before opera tion 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 To help you properly care for your generator the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic ha
23. low compressed air through the filter from the inside out Never try to brush the dirt off bushing will force dirt into the fibers Replace the paper element if it is excessively dirty WING NUT AIR CLEANER COVER PAPER ELEMENT FOAM ELEMENT 31 FUEL SEDIMENT CUP CLEANING The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor If the enging has not been run for long time the sediment cup should be cleaned 1 Turn the fuel valve lever to the OFF position Remove the sediment cup O ring and filter 2 Clean the sediment cup O ring and filter in nonflammable or high flash point solvent 3 Reinstall the filter O ring and sediment cup 4 Turn the fuel valve lever ON and check for leaks FUEL VALVE LEVER FUEL FILTER Ceo O RING SEDIMENT CUP 32 SPARK PLUG SERVICE In order to service the spark plug you will need spark plug wrench commercially available Recommended spark plugs 5 W16EPR U DENSO To ensure proper engine operation the spark plug must be properly gapped and free of deposits If the engine has been running the muffler will be very hot Be careful not to touch the muffler 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use spark plug wrench to remove the spark plug SPARK PLUG WRENCH 4 Visually inspect the spark plug Discard it if the insulator is c
24. nd 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 severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use 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 23 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 e Make sure 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 en
25. opping the engine FUEL VALVE LEVER CHOKE LEVER The choke is used to provide proper starting mixture when the engine is cold It can be opened and closed by operating the choke lever manually Move the lever to the CLOSED position to enrich the mixture for cold starting LEVER 12 AC CIRCUIT BREAKER The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle If the AC circuit breaker is switched OFF automatically checkthatthe appliance is working properly and does not exceed the rated load capacity of the AC circuit before switching the circuit breaker ON again The circuit breaker may be used to switch the generator AC power on or off AC CIRCUIT BREAKER GROUND TERMINAL The generator groundterminal is connected to the frame ofthe generator the metal non current carrying parts of the generator and the ground terminals of each receptacle Before usingthe groundterminal consulta 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 13 OIL SYSTEM The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below safe limit the Oil Alert system will automatically s
26. park 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 modificationsto the carburetor If you always operate your generator at altitudes above 5 000 feet 1 500 meters have your 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 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 overheat and result in serious engine dam age For use at low altitudes have your servicing dealer return the carburetor to original factory specifications 18 PRE OPERATION CHECK ENGINE OIL Engine oil is major factor affecting engine performance and service life Non detergent and 2 stroke engine oils will damage the engine and are not recommended Check the oil level BEFORE EACH SAE Vigcosity Gradas USE wit
27. racked or chipped Clean the spark plug with a wire brush if it is to be reused 5 Measure the plug gap with feeler gauge Correct as necessary by carefully bending the side electrode The gap should be 0 028 0 031 0 70 0 80 mm 0 028 0 031 in 0 70 0 80 mm 33 6 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 7 After the spark plug is seated tighten with spark plug wrench to compress the washer If installing new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer NOTICE The spark plug must be securely tightened An improperly tightened spark plug can become very hot and could damage the engine Never use spark plugs which have an improper heat range Use only the recommended spark plugs or equivalent SPARK ARRESTER MAINTENANCE If the generator has been running the muffler will be very hot Allow it to cool before proceeding The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the eight 5 mm screws 1 from the muffler protector OF and remove the muffler protector 2 Remove the 4 mm screw 9 from the spark arrester 0 and remove the spark arrester from the muffler 3 Use a brush to remove carbon deposits from the spark arrester screen
28. remain on the generator until it 1 sold Remove the hang tag before operating the generator 28 MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 Every ear ITEM Performed at every indicated month operationg hour 300 Hrs Engine oil Check level Change Air filter FR Sediment Spark pulg Check adjust RENE HEN fe MOE b Coo SEE VS Replace NK EET Spark arrester Clean Idle speed Check adjust Valve clearance Check adjust PP OG Combustion Clean After every 500 Hrs 2 chamber Fuel tank filter Clean FE GE Lo O Fuel tube Check Every 2 years Replace if necessary 2 NOTE Emission related items Replace the paper element only 1 Service more frequently when used in dusty areas 2 These items should be serviced by an authorized Honda generator dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 3 For commercial use log hours of operation to determine proper maintenance intervals 29 ENGINE OIL CHANGE Drain the oil while the engine 1 warm to assure rapid and complete draining 1 Remove the drain plug and sealing washer remove the oil filler cap and drain the oil 2 Reinstall the drain plug and sealing washer Tighten the plug
29. tailed description of the problem 42 COMPONENT IDENTIFICATION Lada eksamen 9 CONTROLS Que 11 AC Circult Breaker vasre 13 Choke Lever l I 12 Engine Switch RE TN E EE E A 11 Fuel Valve LOVER een 12 Ground Terminal 13 NAT SSN TETTE US 14 Hecoll Starte ass 11 GENERATOR USE Lu 15 AC ADDIICSUOLS 16 AC ua 17 Connections a Building Electrical System 15 Ground SEN sanse 15 Hig Altitude Operation vaare 18 Special Requirements a 15 MAINTENANCE Ape 23 Air Cleaner EE E 31 NR 28 Emission Control System Information 25 Engine OM CHANG P TEE DEO 30 Fuel Sediment Cup Cleaning ias nias ikea noxa E E ak ep IE 32 Mairitenarice save 24 Maintenance Schedule 29 Spark Arrester Maintenance rrnnnnnnnnnuvnnannrrnnnnnnnnnnanenanunnnnnunerannver 34 Spark Plug Serie vest lao a a ea eue 33 The Importance of Maintenance 1 44 1 23 PRE OPERATION CHC RK sa 19 ENOM 87i Fuel Recommendation 2 2 20 SAFE A 5 Safety InTormiatlorn 2 7 Safety Label Lo
30. top the engine the engine switch will remain in the ON position If the engine stops and will not restart check the engine oil level page 19 before troubleshooting in other areas OIL FILLER HOLE AN Ww fex UPPER P W M K LEVEL OIL FILLER CAP 14 GENERATOR USE CONNECTIONS BUILDING ELECTRICAL SYSTEM Connections for standby power to building electrical system must be made by a qualified electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes Atransfer switch which isolates generator power from utility power is available through authorized Honda generator dealers WARNING Improper connections to a building electrical system can allow elec trical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who con tact the lines during power outage and the generator may explode burn or cause fires when utility power is restored Consult the utility company or qualified electrician GROUND SYSTEM Honda portable generators have system ground that connects generator frame components to the ground terminals in the AC output receptacles The system ground is not connected the AC neutral wire Ifthe generator is tested by a receptacle tester it will not show the same ground circuit condition as for a home receptacle SPECIAL REQUIREMEN
31. ults from your new generator and to operate it safely This manual contains the information on how to do that please read it carefully As you read this manual you will find information preceded by symbol That information is intended to help you avoid damage to your generator other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy 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 Your authorized Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd 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

HONDA EZ3500/EZ5000 GENERATOR user manual

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