Honda Eg5000X Ea7 4135487 Through 4154683 Owners Manual

2014-11-13

: Honda Honda-Eg5000X-Ea7-4135487-Through-4154683-Owners-Manual-108355 honda-eg5000x-ea7-4135487-through-4154683-owners-manual-108355 honda pdf

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Page Count: 51

COVER
INTRODUCTION
A FEW WORDS ABOUT SAFETY
CONTENTS
GENERATOR SAFETY
- SAFETY LABEL LOCATIONS
- IMPORTANT SAFETY INFORMATION
COMPONENT IDENTIFICATION
CONTROLS
GENERATOR USE
PRE-OPERATION CHECK
STARTING THE ENGINE
STOPPING THE ENGINE
THE IMPORTANCE OF MAINTENANCE
MAINTENANCE
TRANSPORTING / STORAGE
TROUBLESHOOTING
TECHNICAL INFORMATION
CONSUMER INFORMATION
WIRING DIAGRAM
INDEX

31ZC2770

00X31-ZC2-7700

00X31-ZC2-7700 EG5000X

o2001-2007 Honda Motor Co., Ltd. -All Rights ReservedK2eY1400.2007.12

"Printed in Japan

Owner’s Manual

GENERATOR

EG5000X

BK DIC

F101

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.

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.

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.

Keep this owner’s manual handy so that 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 engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

08/02/05 13:44:59 31ZC2770_001

INTRODUCTION

Congratulations on your selection of a Honda generator. We are

certain you will be pleased with your purchase of one of the finest

generators on the market.

We want to help you get the best results from your new generator and

to operate it safely. This manual contains the information on how to

do that; please read it carefully.

As you read this manual, you will find information preceded by a

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.

08/02/05 13:45:05 31ZC2770_002

−

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

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:

on the generator.

preceded by a safety alert symbol and one

of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

be or if

you don’t follow instructions.

be or if

you don’t follow instructions.

be if you don’t follow

instructions.

such as

IMPORTANT SAFETY INFORMATION

Your safety and the safety of others are very important. And using

this generator safely is an important responsibility.

such as

how to use this generator correctly and safely.

This entire book is filled with important safety information please

read it carefully.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERAT OR SAFET Y .

08/02/05 13:45:14 31ZC2770_003

CONTENTS

..............................................................................GENERATOR SAFETY . 5

.......................................................................Safety Label Locations . 5

............................................................Important Safety Information . 6

..............................................................COMPONENT IDENTIFICATION . 8

..............................................................................................CONTROLS . 10

....................................................................................Engine Switch . 10

........................................................................................Starter Grip . 10

................................................................................Fuel Valve Lever . 11

.......................................................................................Choke Lever . 11

...................................................................................Circuit Breaker . 12

................................................................................Circuit Protector . 12

...............................................................................Ground Terminal . 13

................................................................................Oil Alert System . 13

............................Voltage Selector Switch (Dual Voltage System) . 14

...................................................................................GENERATOR USE . 15

..................................Connections to a Building Electrical System . 15

.................................................................................Ground System . 15

.......................................................................Special Requirements . 15

.................................................................................AC Applications . 16

.....................................................................................AC Operation . 17

...................................................................AC Receptacle Selection . 18

....................................................................High Altitude Operation . 20

.......................................................................PRE-OPERATION CHECK . 21

..........................................................................................Engine Oil . 21

............................................................................................Refueling . 22

....................................................................Fuel Recommendations . 23

........................................................................STARTING THE ENGINE . 24

........................................................................STOPPING THE ENGINE . 25

08/02/05 13:45:18 31ZC2770_004

......................................................................................MAINTENANCE . 26

......................................................The Importance of Maintenance . 26

..........................................................................Maintenance Safety . 27

.....................................................................Maintenance Schedule . 28

............................................................................Engine Oil Change . 29

...........................................................................Air Cleaner Service . 30

...........................................................Fuel Sediment Cup Cleaning . 31

............................................................................Spark Plug Service . 32

............................................................Spark Arrester Maintenance . 33

..................................................................TRANSPORTING/STORAGE . 34

.............................................................................Storage Procedure .35

.............................................................................TROUBLESHOOTING . 36

..................................................................TECHNICAL INFORMATION . 38

............................................Emission Control System Information . 38

.............................................................................................Air Index . 41

....................................................................................Specifications . 42

............................................................CONSUMER INFORMATION . 43

...............................................................Dealer Locator Information .43

.........................................................Customer Service Information .43

............................................................................Honda Publications .44

.................................................................................Wiring Diagram . 45

......................................................................................................INDEX . 46

08/02/05 13:45:21 31ZC2770_005

GENERATOR SAFETY

SAFETY LABEL LOCATIONS

If a label comes off or becomes hard to read, contact your Honda

generator dealer for a replacement.

These labels warn you of potential hazards that can cause serious

injury. Read them carefully.

08/02/05 13:45:32 31ZC2770_006

Operator Responsibility

Carbon Monoxide Hazards

IMPORTANT SAFETY INFORMATION

Honda generators are designed to give safe and dependable service if

operated according to instructions. Read and understand this owner’s

manual before operating your generator. You can help prevent

accidents by being familiar with your generator’s controls and by

observing safe operating procedures.

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.

Exhaust contains poisonous carbon monoxide, a colorless and

odorless gas. Breathing carbon monoxide can cause loss of

consciousness and may lead to death.

If you run the generator in an area that is confined, or even partly

enclosed area, the air you breathe could contain dangerous amount

of exhaust gas.

Never run your generator inside a garage, house, or near open

windows or doors.

08/02/05 13:45:39 31ZC2770_007

−

Electric Shock Hazards

Fire and Burn 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 that could result in electrocution.

Do not connect to a building’s electrical system unless an isolation

switch has been installed by a qualified electrician.

The exhaust system gets hot enough to ignite some materials.

Keep the generator at least 3 feet (1 meter) away from buildings

and other equipment during operation.

Do not enclose the generator in any structure.

Keep flammable materials away from the generator.

The muffler becomes very hot during operation and remains hot for

a while after stopping the engine. Be careful not to touch the muffler

while it is hot. Let the engine cool before storing the generator

indoors.

Gasoline is extremely flammable and is explosive under certain

conditions. Do not smoke or allow flames or sparks where the

generator is refueled or where gasoline is stored. Refuel in a 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.

08/02/05 13:45:47 31ZC2770_008

COMPONENT IDENTIFICATION

ENGINE SWITCH

ENGINE SERIAL NUMBER

VOLTAGE SELECTOR

SWITCH

CARBURETOR

DRAIN SCREW

SEDIMENT

CUP

AC RECEPTACLES

AC CIRCUIT BREAKER

OIL FILLER CAP

OIL DRAIN PLUG

CHOKE LEVER

FUEL

VALVE

LEVER CIRCUIT

PROTECTORS

STARTER GRIP

08/02/05 13:45:52 31ZC2770_009

MUFFLER

FRAME SERIAL NUMBER

GROUND TERMINAL

AIR CLEANER

SPARK PLUG

CAP

FUEL TANK CAP

Record the engine and frame serial numbers and date of purchase

for your future reference. Refer to these serial numbers when

ordering parts and when making technical or warranty inquiries (see

page ).

Frame serial number:

Engine serial number:

Date of purchase:

08/02/05 13:45:57 31ZC2770_010

CONTROLS

ENGINE SWITCH

STARTER GRIP

Switch position:

OFF:

ON:

OFF

ENGINE SWITCH

STARTER GRIP

DDiirreeccttiioonnttooppuullll

To start and stop the engine.

Do not allow the starter grip to snap back against the engine. Return it

gently to prevent damage to the starter.

To stop the engine.

To start and run the engine.

To start the engine, pull the starter grip lightly until you feel resistance,

then pull briskly in the direction of the arrow as shown below.

08/02/05 13:46:06 31ZC2770_011

CHOKE LEVER

FUEL VALVE LEVER

OPEN

OFF

CLOSED

CHOKE LEVER

FUEL VALVE LEVER

The fuel valve is located on the carburetor. When the fuel valve lever is

in the ON position, fuel is allowed to flow from the fuel tank to the

carburetor. Be sure to return the fuel valve lever to the OFF position

after stopping the engine.

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 choke lever to the CLOSED position to enrich the

mixture for cold starting.

08/02/05 13:46:13 31ZC2770_012

CIRCUIT BREAKER

CIRCUIT PROTECTOR

120V 30A

120V 20A

120V/240V 20A

CIRCUIT PROTECTOR

for Receptacle

CIRCUIT PROTECTOR

for Receptacle

CIRCUIT PROTECTOR

for Receptacle ,

The AC circuit breaker will automatically switch OFF if there is a short

circuit or an overload of the generator at the AC receptacle. If the AC

circuit breaker is switched OFF automatically, check that the appliance

is working properly and does not exceed the rated load capacity of the

AC circuit before switching the AC circuit breaker ON again.

The AC circuit breaker may be used to switch the generator AC power

ON or OFF.

The circuit protectors will automatically switch OFF if there is a short

circuit or a significant overload of the generator at the 120V 20A, 120V

30A locking plug, or 120/240V 20A locking plug receptacle. If a 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 circuit protector to the ON position.

08/02/05 13:46:20 31ZC2770_013

GROUND TERMINAL

OIL ALERT SYSTEM

OIL DRAIN PLUG UPPER

LEVEL

GROUND TERMINAL

The generator 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.

If the engine stops and will not restart, check the engine oil level (see

page ) before troubleshooting in other areas.

The Oil Alert system is designed to prevent engine damage caused by

an insufficient amount of oil in the crankcase. Before the oil level in the

crankcase can fall below a safe limit, the Oil Alert system will

automatically stop the engine (the engine switch will remain in the ON

position).

08/02/05 13:46:29 31ZC2770_014

VOLTAGE SELECTOR SWITCH (DUAL VOLTAGE SYSTEM)

120/240V:

120V ONLY:

VOLTAGE SELECTOR

SWITCH

120/240V

120V

The voltage selector switches the main power carrying windings of the

generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance

is connected to the 4-prong receptacle, the switch must be in the ‘‘120/

240V’’ position. If only a 120V appliance is being connected to any of

the 120V 3-prong receptacles, select the ‘‘120V ONLY’’ position.

ONLY the 120V receptacles can be used. Do not use the

120/240V receptacle in this position. Rated power will

be available at the 30A 120V locking plug receptacle.

The 120V and 120/240V receptacles can be used

simultaneously.

08/02/05 13:46:34 31ZC2770_015

GENERATOR USE

CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM

Improper connections to a building electrical system can allow

electrical 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 or a qualified electrician.

GROUND SYSTEM

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.

Honda portable generators have a system ground that connects

generator frame components 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 by a receptacle tester, it will not show

the same ground circuit condition as for a home receptacle.

If the generator is used at a construction site, there may be

additional regulations that must be observed.

In some areas, generators are required to be registered with local

utility companies.

Connections for standby power to a building electrical system must be

made by a qualified electrician. The connection must isolate the

generator power from utility power, and must comply with all

applicable laws and electrical codes. A transfer switch, which isolates

generator power from utility power, is available through authorized

Honda generator dealers (see page ).43

08/02/05 13:46:41 31ZC2770_016

AC APPLICATIONS

Before connecting an appliance or power cord to the generator:

Make sure that it is in good working order. Faulty appliances or

power cords can create a potential for electrical shock.

If an appliance begins to operate abnormally, becomes sluggish, or

stops suddenly, turn it off immediately. Disconnect the appliance,

and determine whether the problem is the appliance or the rated

load capacity of the generator has been exceeded.

Make sure that the electrical rating of the tool or appliance does not

exceed that of the generator. Never exceed the maximum power

rating of the generator. Power levels between rated and maximum

may be used for no more than 30 minutes.

Limit operation requiring maximum power to 30 minutes.

Maximum power is:

For continuous operation, do not exceed the rated power.

Rated power is:

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.

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.

5.0 kVA

4.5 kVA

08/02/05 13:46:49 31ZC2770_017

AC OPERATION

VOLTAGE SELECTOR

SWITCH AC CIRCUIT

BREAKER

Start the engine (see page ).

Turn the voltage selector switch to either position.

With the voltage selector switch in the ‘‘120/240V’’ position, you can

use the 120V and 120/240V receptacles simultaneously. If you are NOT

using the 120/240V receptacle but require more power from the 120V

locking plug receptacle, then select the ‘‘120V ONLY’’ position.

Plug in the appliance.

Switch ON the AC circuit breaker.

Most motorized appliances require more than their rated wattage for

startup.

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

AC circuit breaker.

08/02/05 13:46:57 31ZC2770_018

＃＃

＃

＃＃

AC RECEPTACLE SELECTION

Power Producing Circuits

120V/240V 120V ONLY

POWER

CIRCUIT 1

POWER

CIRCUIT 2

POWER CIRCUIT 1

POWER CIRCUIT 2

RECEPTACLE 3 RECEPTACLE 4

RECEPTACLE 5

RECEPTACLE 2RECEPTACLE 1

The control panel, shown below, has a voltage selector switch and

five receptacles. Receptacle 4 and 5 comprise one 240-volt

receptacle with two powered terminals.

When the voltage selector switch is in the 120V ONLY position, the

power producing circuits operate in parallel, sharing the total load

connected to receptacles 1, 2, 3, and 4.

This generator is equipped with two power generating circuits. When

the voltage selector switch is in the 120V/240V position, each of the

two power producing circuits supplies power to specific receptacles.

08/02/05 13:47:04 31ZC2770_019

＋＋

＋

Voltage Selector Switch

120V ONLY Position

120V/240V Position

Switch Position Receptacle

Total Current

Available

Power Producing

Circuit

Set of

Receptacles

Available Power

The power available to each receptacle depends on the position of the

voltage selector switch.

When the voltage selector switch is in the 120V ONLY position, you

do not need to spread the load over the receptacles. You must,

however, make sure the load on any receptacle does not exceed its

available power shown in the preceding table and the total load does

not exceed 37.5 amps.

When the voltage selector switch is in the 120V/240V position, you

must balance the load. Divide the load between the two sets of

receptacles shown below. Balancing is necessary because each set of

receptacles is powered by only one power producing circuit that can

produce a maximum of 18.8 amps.

120V ONLY

120V/240V

4-5

18.8A

135

30A at 120V

20A at 120V

None

18.8A at 120V

18.8A at 240V

08/02/05 13:47:12 31ZC2770_020

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 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 ef-

fect 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 damage.

For use at low altitudes, have your servicing dealer return the

carburetor to original factory specifications.

08/02/05 13:47:16 31ZC2770_021

PRE-OPERATION CHECK

ENGINE OIL

OIL FILLER HOLE UPPER

LEVEL

AMBIENT TEMPERRATURE

OIL FILLER CAP/DIPSTICK

Before beginning your pre-operation checks, be sure the generator is

on a level surface and the engine switch is in the OFF position.

Engine oil is a major factor affecting engine performance and service

life. Non-detergent and 2-stroke engine oils will damage the engine

and are not recommended.

Check the oil level EACH USE

with the generator on a level

surface and the engine stopped.

Use 4-stroke motor oil that

meets or exceeds the

requirements for API service

classification SJ or later (or

equivalent). Always check the

API SERVICE label on the oil

container to be sure it includes

the letter SJ or later (or

equivalent).

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.

Remove the oil filler cap and wipe the dipstick clean.

Check the oil level by inserting the dipstick into the filler neck

without screwing it in.

If the level is low, fill to the upper limit of the oil filler neck with the

recommended oil.

08/02/05 13:47:28 31ZC2770_022

REFUELING

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.

FUEL TANK CAP

TETHER

(CALIFORNIA TYPE)

UPPER LIMIT MARK

With the engine stopped, remove the fuel tank cap and check the fuel

level. Refill the fuel tank if the fuel level is low.

Fuel can damage paint and plastic. Be careful not to spill fuel when

filling your fuel tank. Damage caused by spilled fuel is not covered

under warranty.

Spilled fuel is not only a fire hazard, it causes environmental damage.

Wipe up spills immediately.

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.

After refueling, reinstall the fuel tank cap securely.

Refuel in a well-ventilated area with the engine stopped. If the engine

has been running, allow it to cool first. Refuel carefully to avoid

spilling fuel. Do not fill above the upper limit mark.

08/02/05 13:47:36 31ZC2770_023

FUEL RECOMMENDATIONS

This engine is certified to operate on regular unleaded gasoline with a

pump octane rating of 86 or higher.

Never use stale or contaminated gasoline or an oil/gasoline mixture.

Avoid getting dirt or water in the fuel tank.

You may use regular unleaded gasoline containing no more than 10%

ethanol (E10) or 5% methanol 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.

08/02/05 13:47:41 31ZC2770_024

STARTING THE ENGINE

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.

For your safety, do not operate 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.

To prevent a possible fire, keep the generator at least 3 feet (1 meter)

away from building walls and other equipment during operation. Do

not place flammable objects close to the engine.

Operating this generator less than 3 feet (1 meter) from a building or

other obstruction can cause overheating and damage the generator.

For proper cooling, allow at least 3 feet (1 meter) of empty space

above and around the generator.

Refer to

AC APPLICATIONS

(see page ) for connecting loads to the

generator.

Perform the

PRE-OPERATION CHECK

(see page ).

Make sure that the AC circuit breaker is in the OFF position. The

generator may be hard to start if a load is connected.

Turn the fuel valve lever to the ON position.

Turn the choke lever to the CLOSED position.

Turn the engine switch to the ON position.

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.

As the engine warms up, slowly turn the choke lever to the OPEN

position.

08/02/05 13:47:52 31ZC2770_025

STOPPING THE ENGINE

In an emergency:

In normal use:

To stop the engine in an emergency, turn the engine switch to the

OFF position.

Turn the AC circuit breaker to the OFF position.

Turn the engine switch to the OFF position.

Turn the fuel valve lever to the OFF position.

08/02/05 13:47:59 31ZC2770_026

MAINTENANCE

THE IMPORTANCE OF MAINTENANCE

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.

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.

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 severe conditions, such as

sustained high-load or high-temperature operation, or use it in

unusually wet or dusty conditions, consult your servicing dealer for

recommendations applicable to your individual needs and use.

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, Honda

Genuine parts or their equivalents for repair or replacement.

08/02/05 13:48:06 31ZC2770_027

−

MAINTENANCE SAFETY

Safety Precautions

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.

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

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.

Make sure the engine is off before you begin any maintenance or

repairs. This will eliminate several potential hazards:

Operate outside away from open windows or doors.

Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have the

tools and skills required.

To reduce the possibility of fire or explosion, be careful when

working around gasoline. Use only a non-flammable solvent, not

gasoline, to clean parts. Keep cigarettes, sparks, and flames away

from all fuel-related parts.

08/02/05 13:48:13 31ZC2770_028

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

ITEM

First

month

20 Hrs.

Every

3 months

50 Hrs.

(1)

Each

usePerform at every indicated

month or operating hour inter-

val, whichever comes first.

Engine oil

Air cleaner

Sediment Cup

Spark pulg

Spark arrester

Valve clearance

Combustion

chamber

Fuel tank and filter

Fuel tube

Every

year

300 Hrs.

(2)

Every

6 months

100 Hrs.

(2)

After every 500 Hrs.(2)

Every 2 years (Replace if necessary) (2)

Service more frequently when used in dusty areas.

These items should be serviced by your Honda servicing dealer, unless you have the

proper tools and are mechanically proficient. Refer to the Honda shop manual for service

procedures.

For commercial use, log hours of operation to determine proper maintenance intervals.

Failure to follow this maintenance schedule could result in non-warrantable failures.

Check level

Change

Check

Clean

Check-adjust

Replace

Clean

Check-adjust

Clean

Check

(1)

(2)

(3)

08/02/05 13:48:24 31ZC2770_029

ENGINE OIL CHANGE

UPPER LEVELOIL DRAIN PLUG

Drain the oil while the engine is warm to assure rapid and complete

draining.

Remove the drain plug and sealing washer, remove the oil filler cap,

and drain the oil.

Reinstall the drain plug and sealing washer. Tighten the plug

securely.

Refill with the recommended oil (see page ) and check the oil level.

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 pour it down a drain.

3. 21

08/02/05 13:48:32 31ZC2770_030

AIR CLEANER SERVICE

Using gasoline or flammable solvent to clean the air filter can cause a

fire or explosion. Use only soapy water or non-flammable solvent.

AIR CLEANER COVERWING NUT

PAPER ELEMENT

FORM ELEMENT

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.

Paper element: Tap the element lightly several times on a hard

surface to remove excess dirt, or blow compressed air through the

filter from the inside out. Never try to brush the dirt off; brushing will

force dirt into the fibers.

Replace the paper element if it is excessively dirty.

Soak the element in clean engine oil and squeeze out the excess oil.

The engine will smoke during initial start-up if too much oil is left in

the foam.

Foam element: Wash the element in a solution of household

detergent and warm water, then rinse thoroughly, or wash in non-

flammable or high flash point solvent. Allow the element to dry

thoroughly.

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.

Operating the engine without an air filter or with a damaged air filter

will allow dirt to enter the engine, causing rapid engine wear. This type

of damage is not covered by the

Distributor’s Limited Warranty.

08/02/05 13:48:43 31ZC2770_031

FUEL SEDIMENT CUP CLEANING

SEDIMENT CUP

O-RING

SEDIMENT CUP

FUEL FILTER

O-RING

FUEL VALVE

LEVER

The sediment cup prevents dirt or water that may be in the fuel tank

from entering the carburetor. If the engine has not been run for a long

time, the sediment cup should be cleaned.

Clean the sediment cup, O-ring, and filter in non-flammable or high

flash point solvent.

Turn the fuel valve lever to the OFF position. Remove the sediment

cup, O-ring, and filter.

Reinstall the filter, O-ring, and sediment cup.

Turn the fuel valve lever ON and check for leaks.

08/02/05 13:48:51 31ZC2770_032

−−

SPARK PLUG SERVICE

Recommended spark plugs:

The gap should be:

PLUG WRENCH

0.028 0.031 in (0.7 0.8 mm)

SEALING WASHER

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.

Visually inspect the spark plug. Discard it if the insulator is cracked

or chipped. Clean the spark plug with a wire brush if it is to be

reused.

Use a spark plug wrench to remove the spark plug.

Remove the spark plug cap.

Clean any dirt from around the spark plug base.

Measure the plug gap with a wire-type feeler gauge.

Correct as necessary by carefully bending the side electrode.

W16EPR-U (DENSO)

BPR5ES (NGK)

0.028 0.031 in (0.7 0.8 mm)

08/02/05 13:49:01 31ZC2770_033

−

SPARK ARRESTER MAINTENANCE

SPARK

ARRESTER

SCREEN

Check that the spark plug washer is in good condition, and thread

the spark plug in by hand to prevent cross-threading.

Afterthesparkplugisseated,tightenwithasparkplugwrenchto

compress the washer.

Install the spark arrester and the muffler in the reverse order of

disassembly.

Use a brush to remove carbon deposits from the spark arrester

screen.

Inspect the spark arrester for breaks or holes, and replace it if

necessary.

If the generator has been running, the muffler will be very hot. Allow it

to cool before proceeding.

Never use spark plugs which have an improper heat range. Use only

the recommended spark plugs or equivalent.

The spark plug must be securely tightened. An improperly tightened

spark plug can become very hot and could damage the engine.

If installing a new spark plug, tighten 1/2 turn after the spark plug

seats to compress the washer. If reinstalling a used spark plug,

tighten 1/8 1/4 turn after the spark plug seats to compress the

washer.

Remove the eight 5 mm screws from the muffler protector ,

and remove the muffler protector.

Remove the 4 mm screw from the spark arrester , and remove

the spark arrester from the muffler .

The spark arrester must be serviced every 100 hours to maintain its

efficiency.

08/02/05 13:49:14 31ZC2770_034

TRANSPORTING/STORAGE

Contact with a hot engine or exhaust system can cause serious burns

or fires. Let the engine cool before transporting or storing the

generator.

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

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.

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:

Less than 1 month

1 to 2 months

2 months to 1 year

1 year or more

Use gasoline stabilizers that are formulated to extend storage

life.

Contact your authorized Honda generator dealer for stabilizer

recommendations.

No preparation required

Fill with fresh gasoline and add gasoline

stabilizer *.

Fill with fresh gasoline and add gasoline

stabilizer *.

Drain the carburetor float bowl. (page 35 ).

Drain the fuel sediment cup. (page 31 ).

Fill with fresh gasoline and add gasoline

stabilizer *.

Drain the carburetor float bowl. (page 35 ).

Drain the fuel sediment cup. (page 31 ).

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 the spark plug.

Change the engine oil. (page 29 ).

After removal from storage, drain the stored

gasoline into a suitable container, and fill

with fresh gasoline before starting.

08/02/05 13:49:21 31ZC2770_035

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.

Storage Procedure

DRAIN SCREW

Align the notch on the starter pulley

with the hole at the top of recoil starter.

Drain the carburetor by loosening the drain screw. Drain the

gasoline into a suitable container.

Slowly pull the starter grip until resistance is felt. At this point, the

piston is coming up on its compression stroke and both the intake

and exhaust valves are closed. Storing the engine in this position

will help to protect it from internal corrosion.

Change the engine oil (see page 29 ).

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.

08/02/05 13:49:29 31ZC2770_036

TROUBLESHOOTING

DRAIN SCREW

FUEL VALVE LEVER

When the engine will not start:

Clean the fuel

sediment cup.

Refill the fuel tank

(see page 22).

Add the recom-

mended oil (see

page 21).

Adjust the gap and

dry the spark plug.

Replace it if

necessary (see

page 32).

Is fuel reaching the

carburetor?

To check:

1. Turn the fuel

valve lever OFF

and loosen the

drain screw.

2. Turn the fuel

valve lever ON.

Fuel should flow

from the around

the drain screw.

If the engine still

does not start, take

the generator to an

authorized Honda

generator dealer.

Is there fuel in the

tank?

Is there enough oil

in the engine?

Is the spark plug in

good condition?

YES

08/02/05 13:49:36 31ZC2770_037

No electricity at the AC receptacles:

Turn the AC circuit breaker

ON (see page 17).

Take the generator to an

authorized Honda generator

dealer.

Replace the electrical ap-

pliance or equipment.

Take the electrical ap-

pliance or equipment to an

electrical shop for repair.

Is the AC circuit breaker

ON?

Check the electrical ap-

pliance or equipment for

any defects.

YES

DEFECTS

NO DEFECTS

08/02/05 13:49:40 31ZC2770_038

TECHNICAL INFORMATION

EMISSION CONTROL SYSTEM INFORMATION

Source of Emissions

Tampering and Altering

The U.S. and California Clean Air Acts

The combustion process produces carbon monoxide, oxides of

nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of

nitrogen are 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 appropriate air/fuel ratios and other emissions control

systems to reduce the emissions of carbon monoxide, oxides of

nitrogen, and hydrocarbons.

Removal or alteration of any part of the intake, fuel, or exhaust

systems.

Altering or defeating the governor linkage or speed-adjusting

mechanism to cause the engine to operate outside its design

parameters.

Tampering with or altering the emission control system may increase

emissions beyond the legal limit. Among those acts that constitute

tampering are:

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 emissions from your Honda engine within the emission

standards.

Additionally, Honda fuel systems utilize components and control

technologies to reduce evaporative emissions.

08/02/05 13:49:48 31ZC2770_039

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engine

inspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

08/02/05 13:49:51 31ZC2770_040

Replacement Parts

Maintenance

The emission control systems on your new Honda engine were

designed, built, and certified to conform with applicable emission

regulations. We recommend the use of Honda Genuine 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.

Follow the

Maintenance Schedule

on page . 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.

08/02/05 13:49:56 31ZC2770_041

−

AIR INDEX

Extended

Intermediate

Moderate

Descriptive Term

300 hours (0 80 cc, inclusive)

500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

125 hours (0 80 cc, inclusive)

250 hours (greater than 80 cc)

50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)

Applicable to Emission Durability Period

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.

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.

An Air Index Information label is applied to engines certified to an

emission durability time period in accordance with the requirements

of the California Air Resources Board.

(Models certified for sale in California)

08/02/05 13:50:04 31ZC2770_042

〔〕 ××

−−

Tune-up Specifications

SPECIFICATIONS

ITEM MAINTENANCESPECIFICATION

Dimensions

Engine

Generator

Specifications may vary according to the types, and are subject to

change without notice.

Spark plug gap

Valve clearance

Other specifications No other adjustments needed.

IN: 0.15 0.02 mm (cold)

EX: 0.20 0.02 mm (cold)

Refer to page: 32

See your authorized

Honda dealer

Model

Type

Power product description code

Length

Width

Height

Dry weight

Model

Engine type

Displacement

Borexstroke

Compression ratio

Engine speed

Cooling system

Ignition system

Oil capacity

Fuel tank capacity

Spark plug

Model

Rated voltage

Rated frequency

AC output Rated ampere

Rated output

Maximum output 5.0 kVA

4.5 kVA

37.5/18.8 A

60 Hz

120/240 V

146.6 lbs (66.5 kg)

18.9 in (480 mm)

25.7 in (653 mm)

EA7

Non-California type

(AN type) California type

(AC type)

W16EPR-U (DENSO)

BPR5ES (NGK)

1.61 US gal (6.1 )

1.2 US qt (1.1 )

Transistor magneto

Forced air

3,600 rpm

8.0 : 1

[3.2 2.5 in (82.0 64.0 mm)]

20.6 cu-in (337 cm )

19.1 in (485 mm) 19.6 in (497 mm)

GX340K1

EG5000X

0.028 0.031 in (0.7 0.8 mm)

4-stroke, overhead valve, single cylinder

08/02/05 13:50:19 31ZC2770_043

Dealer Locator Information

CONSUMER INFORMATION

Customer Service Information

To find an authorized Honda Servicing Dealer anywhere in the United

States:

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:

Servicing dealership personnel are trained professionals. They should

be able to answer most questions 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.

Visit our website:

www.hondapowerequipment.com

American Honda Motor Co., Inc.

Power Equipment Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, Georgia 30005-8847

Model and serial number (see page )

Name of dealer who sold the generator to you

Name and address of dealer who services your generator

Date of purchase

Your name, address, and telephone number

A detailed description of the problem

When you write or call, please give us this information:

Or telephone: (770) 497-6400 8:30 am to7:00 pm ET

08/02/05 13:50:28 31ZC2770_044

Shop Manual

Parts Catalog

Accessories Catalog

Honda Publications

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

This manual provides complete, illustrated parts lists. Available

through your Honda dealer.

Your authorized Honda power equipment dealer offers a wide

selection of accessories (optional equipment) to make your generator

even more useful.

Visit www.hondapowerequipment.com

and click on Generators and Welders to see the entire catalog of

accessories.

08/02/05 13:50:35 31ZC2770_045

WIRING DIAGRAM

08/02/05 13:50:43 31ZC2770_046

INDEX