Honda Ex5500 Ea1 1000001 Through 1099999 Owners Manual

2014-11-13

: Honda Honda-Ex5500-Ea1-1000001-Through-1099999-Owners-Manual-108486 honda-ex5500-ea1-1000001-through-1099999-owners-manual-108486 honda pdf

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Thank you for purchasing a Honda generator.
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.
This owner’s manual describes the operation and maintenance of the
Honda Generator: EX5500.
All information in this publication is based on the latest product
information available at the time of printing.
Honda Motor Co., Ltd. reserves the right to make changes at any time
without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
This manual should be considered a permanent part of the generator
and should remain with it if it is resold.
Safety

Messages

Your safety and the safety of others is very important. We have
provided important safety messages in this manual and on the
generator. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is receded by a safety alert symbol
and one of three words: DAN c!fEl?, WARNING, or CAUTION.
A
These mean
m
follow
B
follow
w

You WILL
instructions.

be KILLED

or SERIOUSLY

HURT

if you

don’t

You CAN
instructions.

be KILLED

or SERIOUSLY

HURT

if you

don’t

You CAN be HURT if you don’t follow

instructions.

Each message tells you what the hazard is, what can happen,
what you can do to avoid or reduce injury.
Damage

Prevention

and

Messages

You will also see other important
word NOTICE.

messages that are preceded by the

This word means:
1 NOTICE 1Your generator
don’t follow instructions.

or other

property

could

be damaged

The purpose of these messages is to help prevent damage
generator, other property, or the environment.

if you

to your

CONTENTS
SAFETY .......................................................................................................
Safety Label Locations ........................................................................
Safety Information ...............................................................................
...............................................................
COMPONENT IDENTIFICATION

4
4
6
8

CONTROLS ...............................................................................................
Engine Switch .....................................................................................
Circuit Breaker ....................................................................................
Fuel Valve ...........................................................................................
Ground Terminal ................................................................................
Voltage Adjustment Knob .................................................................
Volt Meter ...........................................................................................
Auto-throttle System .........................................................................
Pilot Lamp ...........................................................................................
Oil Pressure Lamp ..............................................................................
GENERATOR USE ....................................................................................
Connections to a Building’s Electrical System ................................
Ground System ..................................................................................
Special Requirements ........................................................................
AC Applications ..................................................................................
AC Operation ......................................................................................
AC Receptacle Selection ....................................................................
Auto-throttle System .........................................................................
High Altitude Operation .....................................................................
PRE-OPERATION CHECK ........................................................................
Engine Oil ...........................................................................................
......................................................................
Fuel Recommendation
Coolant ................................................................................................
STARTING THE ENGINE .........................................................................
STOPPING THE ENGINE .........................................................................
.......................................................................................
MAINTENANCE
Maintenance Schedule ......................................................................
Emission Control System ..................................................................
Engine Oil and Oil Filter Change .......................................................
Air Cleaner Service ............................................................................
Spark Plug Service .............................................................................
Fuel Sediment Cup Cleaning ............................................................
Fuse Replacement ..............................................................................
.............................................................
Spark Arrester Maintenance
Battery .................................................................................................

10
10
10
11
11
12
12
13
13
14
15
15
15
15
16
17
18
19
20
21
21
22
24
26
27
28
28
29
30
32
33
34
35
36
37

...................................................................
TRANSPORTING/STORAGE
..............................................................................
TROUBLESHOOTING
WIRING DIAGRAM ..................................................................................
SPECIFICATIONS .....................................................................................
INSTALLATION OF OPTIONAL PARTS ..................................................
CUSTOMER SERVICE INFORMATION ...................................................
INDEX .......................................................................................................

39
41
ii
45
49
50

SAFETY
SAFETY

LABEL LOCATIONS

These labels warn you of potential
injury.
Read them carefully.

hazards that can cause serious

If a label comes off or becomes hard to read, contact your Honda
Generator dealer for a replacement.
.

/r
CAUTION
BE SURE TO FILL CRANKCASE
RESERVE TANK OF RADIATOR
BEFORE USING.
FOR DETAILED EXPLANATION,
1

WITH RECOMMENDED
WITH RECOMMENDED

OIL AND
COOLANT

SEE THE OWNER’S MANUAL.

WARNING
NOT USE INDOORS DUE TO DANGER
NOXIDE POISONING.

I
OF CARBON
1

IGASOLINE

CAUTION

LABEL
I

EX5500

120 VI240 v
SO Hz
5.0 KVA
5.5 KVA
10

VOLTAGE
FREQUENCY
RATED OUTPUT
MAX OUTPUT
PHASE

GASOLINE (PETROL)

FUEL

EXHAUST

CAUTION

LABEL

EXHAUST
HOT
ECHAPPEMENT
l

CHAUD
I

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.
Operator
l
l

Carbon
l

Monoxide

Hazards

Exhaust contains poisonous carbon monoxide,
a 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 a dangerous amount of
exhaust gas. To keep exhaust gas from building up, provide
adequate ventilation.

Electric
l

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.

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 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’s electrical system unless an isolation
switch has been installed by a qualified electrician.

Fire and Burn Hazards
l

The exhaust system gets hot enough to ignite some materials.
-Keep the generator at least 1 meter (3 feet) 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 wellventilated 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

AIR CLEANER

COOLANT
RESERVE TANK

j
/

FRAME
SERIAL NUMBER

TOP COVER LOCK LEVE

GROUND . . . . . . . . .._______
TERMINAL

COOLANT
DRAIN PLUG
’

ENGINE OIL DRAIN PLUG

\
ENGINE OIL FILLER CAP

FUEL TANK CAP
\

ENGINE OIL FILTER

FUEL GAUGE
\\

MUFFLER

BAlTERY

- RADIATOR

CONTROL
VOLTAGE
ADJUSTMENT

BOX
OIL LAMP

COOLANT LiMP

KNOB
RESET BUTTON

REMOTE
CONTROL SWITCH

FUEL VALVE KNOB

CIRCUIT BREAKER
AUTO-THROTTLE

SWITCH

ENGINE SWITCH

AC RECEPTACLES

*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 49 ).
Frame serial number:
Engine serial number:

COMTROLS
Engine

Switch

To start and stop the engine.
Key position:
OFF:

ON:
START:

To stop the engine. Key can be removed/inserted.
To run the engine after starting.
To start the engine by operating the starter motor.

ENGINE SWITCH

Return the key to the ON position once the engine has started. Do
not use the starter for more than 5 seconds at a time. If the engine
fails to start, release the switch and wait 10 seconds before
operating the starter again.
Circuit

Breaker

The circuit breaker will automatically switch OFF if there is a short
circuit or a significant overload of the generator at the receptacle. If the
circuit breaker is switched OFF automatically, check that the appliance
is working properly and does not exceed the rated load capacity of the
circuit before switching the circuit breaker ON again.
The circuit breaker may be used to switch the generator power on or
Off.
CIRCUIT BREAKER

Fuel Valve

The fuel valve is located between the fuel tank and carburetor. When
the knob is in the ON position, fuel is allowed to flow from the fuel
tank to the carburetor. Be sure to return the knob to the OFF position
after stopping the engine.

OFF

FUEL VALVE KNOB

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.

GROUND TERMINAL

Volt Meter

The volt meter shows output voltage on a dual scale that is calibrated
for both 120V and 240V operation.

VOLT METER

Voltage

Adjustment

Knob

The voltage adjustment knob can be used to make fine adjustments in
output voltage. Set output voltage at 12OV/24OV, as shown on the volt
meter.
VOLTAGE
ADJUSTMENT

Auto-throttle

System

The auto-throttle 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 rated speed.
Recommended
to minimize fuel consumption
and
AUTO:
further reduce noise levels when no load is applied to
the generator.
OFF:
The auto-throttle system does not operate.
Recommended to minimize warm-up time when the
generator is started.

AUTO-THRhLE

SWITCH

Pilot Lamp

The pilot lamp is illuminated when the generator is operating normally.
It indicates that the generator is providing electrical power at the
receptacles. When the pilot light is illuminated, the voltmeter should
read 120/240 volts.
PILOT LAMP
/

Oil Pressure

Lamp

Lights when the engine oil level is low or the engine lubrication
system is not working properly. The engine will stop automatically
when the light comes on.
If this occurs:
l Check
the engine oil level, and add the correct engine oil if
necessary (see page 21 1.
l To
restart the engine, turn the engine switch to the OFF position.
Next, push the reset button and start according to the starting
procedure (see page 26 ).
l If the oil pressure
indicator light continues to light even though the
engine oil level is correct, stop operating the generator and see an
authorized Honda generator dealer.
Coolant

Temperature

Lamp

Lights when the coolant temperature becomes higher than normal.
The engine will stop automatically when the light comes on.
If this occurs:
l Check the coolant
level, and add coolant if the level is low (see page
24 ).
l Check the cooling
air openings and the radiator for obstructions that
would restrict air flow.
l To restart the engine,
first turn the engine switch to the OFF position.
Next, push the reset button, turn the engine switch to the ON
position, and observe the coolant temperature indicator light. If the
light remains on, allow the engine to cool before attempting to start
the engine.
l If the coolant
temperature indicator light continues to come on even
though the coolant level is correct, discontinue operation and see an
authorized Honda generator dealer.
[ NOTICE 1
Check the coolant
level before
indicator
light may not function
radiator.

each use. The coolant
temperature
if there is insufficient
coolant in the

RESET BUlTON
OIL PRESSURE LAMP
COOLANT TEMPERATURE

LAMP

GENERATOR USE
Connections

to a Building’s

Electrical

System

Connections for standby power to a building’s 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.

Improper
connections
to a building’s
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.
Consult
the utility
company or a qualified electrician.
) NOTICE

)

Improper
connections
to a building’s
electrical
system
can allow
electrical
current
from the utility
company
to backfeed
into the
generator.
When utility power is restored, the generator
may explode,
burn, or cause fires in the building’s
electrical system.
Ground

System

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.
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.
l In some
areas, generators are required to be registered with local
utility companies.
l If
the generator is used at a construction site, there may be
additional regulations which must be observed.

AC Applications

Before connecting
l

an appliance or power cord to the generator:

Make sure that it is in good working order. Faulty appliances
power cords can create a potential for electrical shock.

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 if the rated
load capacity of the generator has been exceeded.
Make sure that the electrical rating of the tool or appliance does not
exceed that of the generator. Never exceed the maximum power
rating of the generator. Power levels between rated and maximum
may be used for no more than 30 minutes.

Substantial
overloading
will open the circuit breaker.
Exceeding
time limit for maximum
power operation
or slightly overloading
generator
may not switch the circuit breaker OFF, but will shorten
service life of the generator.

the
the
the

Limit operation requiring maximum power to 30 minutes.
Maximum power is:
5.5 kVA
For continuous operation, do not exceed the rated power.
Rated power is:
5.0 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.

AC Operation

1. Start the engine (see page 26 1.
2. Switch the AC circuit breaker ON.
3. Plug the appliance into the appropriate AC receptacle.
4. Make sure that the voltmeter indicates the specified voltage.
If not, adjust with the voltage adjustment knob.
Do not exceed the current limit specified for any one receptacle. If an
overloaded circuit causes the AC circuit breaker or circuit protector to
switch OFF, reduce the electrical load on the circuit, wait a few minutes
and then reset the circuit breaker.

VOLT

CIRCUIT BREAKERS

OFF

AC Receptacle

Selection

The generator has two separate main power
reducing circuits.
These two circuits supply equal power to di R erent receptacles
shown.

Main
--

Circuit

‘The table shows the specifications
plug receptacle is used for 120V.

when

the 120/24OV locking

Example:
Receptacle 3 has a 10A load connected to it. Receptacle 4 has a
15A load connected to it. Both receptacles are powered by main
power circuit II. The equation tells us that the total power draw on
circuit II is 25A. This is a substantial overload of this circuit. To
eliminate the excess power draw on circuit II, the load from
receptacle 3 should be switched to receptacle 2. Now circuit I is
powering the IOA load (less than 20.8A) and circuit II is powering
a 15A load (less than 20.8A).

Auto-throttle

System

With the switch in the AUTO position, engine speed is automatically
reduced when ALL loads are turned OFF or disconnected. When
appliances are turned ON or reconnected, the engine returns to rated
speed. In the OFF position, the auto-throttle system does not operate.
The auto-throttle system will not respond to electrical loads of less
than 1 ampere. Turn the auto-throttle to the OFF position to operate
loads of less than 1 amp.
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 auto-throttle 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.
To avoid extended warm-up periods, keep the switch OFF until the
engine reaches operating temperature.
The auto-throttle 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 auto-throttle switch should be in the OFF
position.

AUTO-THROTTLE

SWITCH

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.
High altitude performance can be improved by specific modifications
to the carburetor. If you always operate your engine at altitudes above
1,800 meters (6,000 feet), have your dealer perform this carburetor
modification.
Even with carburetor modification, engine horsepower will decrease
about 3.5% for each 300 meter (1,000 foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor
modification is made.
1 NOTICE )
When the carburetor
has been modified
for high altitude
operation,
the air-fuel mixture will be too lean for low altitude
use. Operation
at
altitudes
below 1,800 meters (6,000 feet) with a modified
carburetor
may cause the engine
to overheat
and result
in serious
engine
damage.
For use at low altitudes,
have your dealer
return
the
carburetor
to original factory specifications.

PRE-OPERATION CHECK
Engine

Oil

piEiq
Engine oil is a major factor affecting engine performance
life. Non-detergent
and P-stroke engine oils will damage
and are not recommended.

and service
the engine

Check the oil level BEFORE
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 SF or SG. Always check
the API SERVICE label on the oil
container to be sure it includes
the letters SF or SG.

-30

-20

-10

40°C

AMBIENT TEMPERATURE

SAE low-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 check the oil level.
2.lf the level is low, fill to the top of the oil filler neck with the
recommended oil.

Fuel Recommendation

Check the fuel gauge, and refill the tank if the fuel level is low.
Use unleaded gasoline with a pump octane rating of 86 or higher.
This engine is certified to operate on unleaded gasoline.
Unleaded gasoline produces fewer engine and spark plug deposits
and extends exhaust system life.
Never use stale or contaminated
asoline
Avoid getting dirt or water in the fue ?tank.

or oil/gasoline

mixture.

Refuel carefully to avoid spilling fuel. Do not fill above the fuel strainer
shoulder.
Gasoline
is highly flammable
and explosive,
or seriously injured when refueling.
l
l
l

Stop engine and keep heat, sparks,
Refuel only outdoors.
Wipe up spills immediately.

and you can be burned

and flame

away.

Fuel tank capacity:

16.5 fI (4.36 US gal, 3.63 Imp gal)

Do not fill above fuel

LEVEL

Fuel can damage paint and plastic. Be careful not to spill fuel when
filling your fuel tank. Damage caused by spilling fuel is not covered
under warranty.

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 pin ing occurs at a steady engine speed, under
normal load, change %rands of gasoline. If spark knock or pinging
persists, see an authorized Honda generator dealer.
riiziq
Running the engine
engine damage.

with

persistent

spark knock

or pinging

can cause

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 standards, some areas of the
United Sates 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
?Ee”Pollowing 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
Jz;,meay
use gasoline contarnrng up to 15% MTBE by
(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 dama e or performance problems resulting from the use
of an oxygenate 8 fuel containing more than the percentages of
oxygenates mentioned above are not covered under warranty.
METHANOL

Coolant

Check the coolant level in the reserve tank while on a level surface.
When the en ine is at operating temperature, the coolant level should
be between tii e MIN and MAX marks on the reserve tank. If the level is
near the MIN mark, add coolant to bring the level up to the MAX mark.

(LOWER LEVEL)
RESERVE TANK

The engine protection system will automatically stop the engine if the
coolant
ets too hot, which may occur if the coolant level is too low.
To avoi c7the inconvenience of an unexpected shutdown, inspect the
coolant level in the reserve tank regularly.

If there

is no coolant

in the reserve

tank:

Make sure the engine is cool, then check the coolant system for leaks
and have repairs made if needed. Add coolant to the radiator and
reserve tank before starting the engine.
Hot coolant is under pressure.
If you remove the radiator cap when
the engine is hot, you may be scalded. Wait for the engine to cool.

l.When the engine is cool, relieve any remaining coolant pressure by
turning the radiator cap counterclockwise until it reaches its stop;
DO NOT PRESS DOWN WHILE TURNING
THE CAP. After all
pressure has been relieved, press the cap down, and continue
turning the cap to remove it.
1

RADIATOR CAP

2.Fill the radiator with coolant, and reinstall the radiator cap. Tighten
the cap securely.
3.Fill the reserve tank to the MAX mark with coolant.
Antifreeze/Coolant

Recommendation

lycol coolant that is specifically formulated
Use high quality ethylene
for aluminum engines. Iii ix the coolant with low-mineral drinking
water or distilled water.
A 50/50 mixture of ethylene glycol coolant and water is recommended
for most temperatures, and it provides good corrosion protection. A
higher concentration of coolant decreases cooling efficiency and is
recommended if additional protection against freezing is needed. A
concentration of less than 40% antifreeze will not provide enough
corrosion protection.
[I
The wrong
type
corrosion damage

of coolant,
hard
in the engine.

water,

or salt

water

can

cause

STARTING THE ENGINE
Starting

the engine’

1. Turn the fuel valve ON.
2. Make sure that the circuit breaker is OFF.
The generator may be hard to start if a load is connected.
3.Make sure the auto-throttle
switch is off, or more time will be
required for warm up.
4.Turn the engine switch to START and hold it there until the engine
starts.
Do not use the electric starter for more than 5 seconds at a time. If
the engine fails to start, release the switch and wait 10 seconds
before operating the starter again.

When the speed of the starter motor drops after a period
an indication
that the battery should be recharged.

of time,

5. After the engine starts, let the engine switch return to ON.
6. Warm up the engine for 2-3 minutes. Turn the auto-throttle
AUTO after the engine has warmed up.

it is

switch to

Stopping the engine
In an emergency:

l.To stop the engine in an emergency,
OFF position.
In normal

move the engine switch to the

use:

1. Turn the AC circuit breaker to the OFF position.
2. Move the engine switch to the OFF position.
3. Turn the fuel valve to the OFF position.

MAINTENANCE
Periodic maintenance
and adjustment
is necessary to keep the
generator in good operating condition. Perform the service and
inspection at the intervals shown in the maintenance schedule below.
Exhaust
gas contains
poisonous
carbon
engine before performing
any maintenance.
make sure the area is well-ventilated.

monoxide.
Shut off the
If the engine must be run,

p6iG-j
Use only genuine
HONDA parts or their equivalent
for maintenance
or repair. Replacement
parts which are not of equivalent
quality may
damage the generator.
Maintenance

NOTE:

Schedule

Emission related items.

(*IReplace 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.

Emission
Source

Control

System

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 Motor Co., Ltd, utilizes lean carburetor settings and other
systems to reduce the emissions of carbon monoxide, oxides of
nitrogen, and hydrocarbons.
The California

Clean Air Act

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.
Proper Maintenance is The Owner’s Responsibility
Replacement Parts
The emission control systems on your new Honda were designed,
built, and certified to conform with the California regulations. Honda
recommends only the use of new, genuine Honda parts or their
equivalent. The use of other replacement parts which are not of
equivalent quality may impair the effectiveness of your emission
control system.
Maintenance
Follow the maintenance schedule on page 28 . Remember that this
schedule is based on the assumption that your machine will be
used for its designed purpose. Sustained
high-load
or hightemperature operation or use in unusually wet or dusty conditions
will require more frequent service.
Tampering and Altering
Tampering or altering the emission control system may increase
emissions beyond the legal limit. Among those acts presumed to
constitute tampering are:
l Removal
or alteration of any part of the intake, fuel, or exhaust
systems.
l Altering
or defeating the governor linkage or speed-adjusting
mechanism to cause the engine to operate outside its design
parameters.
Problems That Mav Affect Emissions
If you are aware of any of the following symptoms, have your
en ine inspected and repaired by your authorized Honda dealer:
l I?ard starting
or stalling after starting.
l Rough
idle.
l Misfiring
or backfiring under load.
l After
burning (backfiring).
l Black exhaust
smoke or high fuel consumption.

Engine

Oil and Oil Filter Change

Drain the oil while the engine is warm to assure rapid and complete
draining.
1 .Remove the drain plug and filler cap, and drain the oil. Retighten the
plug securely, and reinstall the filler cap.
2.Remove the oil filter with a filter wrench and let the remaining oil
drain out.
3.Apply a thin coat of engine oil to the filter rubber seal and screw it in
by hand until you feel it seat against the engine, then turn It 3/4 of a
turn more.
4.Fill the crankcase with the recommended
oil (See page 21 ) and
check the level. Recheck the level after running the engine for a few
minutes.
Oil refill capacity

without

filter

1.1 0 (1.2 US qt, 1.0 Imp
Oil refill capacity

with

1.4 !.I(1.5 USqt,

change:

filter cR ange:

1.2 Impqt)

OIL FILTER

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.

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.

Using gasoline
or flammable
solvent
cause a fire or explosion.
Use only
solvent.

to clean the filter element
can
soapy water or nonflammable

piieiq
Never run the
will result.

generator

without

the

air cleaner.

Rapid

engine

wear

1. Pull the lock levers out and open the top cover.
2. Remove the wing nuts and air cleaner cover. Remove the elements
and separate them. Carefully check both elements for holes or tears,
and replace if damaged.
WING NUTS

,
AIR CLEAbiER COVER

AIR CLEANER ELEMENTS
(URETHANE AND PAPER)

3. Foam element: Clean in warm soapy water, rinse, and allow to dry
thoroughly. Or clean in nonflammable solvent and allow to dry. Dip
the element in clean engine oil and squeeze out all excess oil. The
engine will smoke during initial running if too much oil is left in the
foam.
4. Paper element: Tap the element several times on a hard surface to
remove excess dirt, or blow compressed air [not exceeding 207 kPa
(30 psi)] through the filter from the inside. Never try to brush off dirt;
brushing will force dirt into the fibers.
5. Reinstall the air cleaner elements and the cover.
6. Reinstall the top cover.

URETHANE ELEMENT

Spark

Plug Service

Recommended

spark plug:

BPRGHS (NGK)

To ensure proper engine operation,
gapped and free of deposits.

the spark plug must be properly

1. Pull the lock levers out and open the top cover.
2. Remove the spark plug cap.
3. Use a plug wrench to remove the spark plug.
4.Visually inspect the spark plug. Discard it if the insulator is cracked
or chipped.
5. Measure the plug gap with a feeler gauge.
Correct as necessary by carefully bending the side electrode.
The gap should be:
0.60-0.70
mm (0.024-0.028

in)
6. Attach the plug washer. Thread the plug in by hand to prevent crossthreading.
7.Tighten a new spark plug l/2 turn with the wrench to compress the
washer. If you are reusing a plug, it should only take l/8-1/4
turn
after the plug seats.
8. Reinstall the top cover.
1 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.
/
-

PLUG GAP
0.60-0.70
mm
(0.024-0.028
in)

PLUG

WRENCH

Fuel Sediment

Cup Cleaning

The sediment cup prevents dirt or water which may be in the fuel tank
from entering the carburetor. If the engine has not been run for a long
time, the sediment cup should be cleaned.
1. Turn the two lock pins and open the side cover.
2. Turn the fuel valve OFF. Remove the sediment cup.
3. Clean the cup thoroughly.
4. Reassemble. Do not damage the O-ring.
5. Close the carburetor cover and lock with the lock pins.

SEDIMENT

CUP

Fuse Replacement

If the fuse is blown, the engine will not start until it is replaced.
1. Pull the lock levers out and open the top cover.
2. Turn the engine switch OFF.
3. Remove the fuse holder and replace the fuse. Use only a IOA fuse.
4. Close the top cover.
1 NOTICE
l

If frequent
fuse failure occurs, determine
the cause and correct the
problem before attempting
to operate the generator further.
Never use a fuse with a rating other than IOA. Serious damage to
the electrical system or a fire may result.

Spark

Arrester

Maintenance

If the generator has been running, the muffler will be very hot. Allow it
to cool before proceeding.
(1
The spark
efficiency.

arrester

must

be serviced

every

100 hours

to maintain

its

1. Loosen two 5 mm pan screws on the arrester cap.
2. Remove the arrester cap, then pull out spark arrester, taking care not
to damage the wire mesh.
3. Inspect the spark arrester, and clean if necessary. Use a brush to
remove deposits from the spark arrester screen. The spark arrester
must be free of breaks and holes. Replace if necessary.
4.Check the muffler exhaust port for carbon deposits; clean if
necessary.
5. Install the spark arrester and arrester cap on the muffler.
6. Tighten two 5 mm pan screws to the arrester cap.

5 mm PAN SCREWS

Battery

The generator’s engine has a 1 amp charging system to charge the
battery while the engine is running. If the generator is only. used
periodically, the battery must be charged monthly to maintain the
battery service life.
A lead acid battery self discharges at a rate of 0.5- 1.O% per day. This
means that the battery, if the generator is not operated in a month,
can discharge as much as 30% in the same period. This could cause
the engine not to crank or shorten the service life of the battery. To
charge the battery, follow the procedures below.
Removal:

1. Open the battery cover.
2. Remove the battery set plate.
3.Remove the negative (-1 cable from the battery negative (-)
terminal; then remove the positive (+) cable from the battery
positive (+) terminal.
BAlTERY

SE1. PLATE

BATTERY COVER

4.Remove the battery from the
battery tray.
Inspection:

1. Remove the battery cell caps.
2.lnspect the electrolyte level of
each cell. The electrolyte level
must be maintained between
the UPPER and LOWER level
marks.
3.lf the electrolyte level is near
the LOWER mark, add distilled
water as necessary.

UPPER LEVEL
LOWER LEVEL

Charging:

The battery is rated at 14AH (ampere-hour). 10% of the ampere-hour
ratin
should be used as the charging current. A battery charger
shou 9d be used that can be adjusted to deliver 1.4 amps.
The battery
gives off explosive
gasses; keep sparks, flames
and
cigarettes
away from the battery while chargrng.
Provide adequate
ventilation
when charging.
l The
battery contains sulfuric acid (electrolyte).
Contact with skin or
eyes may cause severe burns. Wear protective
clothing
and a face
shield.
-If electrolyte
gets on your skin, flush with water.
-If electrolyte
gets in your eyes, flush with water for at least 15
minutes and call a physician
immediately.
l Electrolyte
is poisonous.
-If swallowed,
drink large quantities
of water or milk and follow
with milk of magnesia or ve etable oil and call a physician.
l KEEP OUT
OF REACH OF CHIL % REN.

1. Remove the battery cell caps.
2.Connect
the battery
charger
following
the manufacturer’s
instructions.
3.Charge the battery 3-4 hours.
4.After the battery is charged, inspect the electrolyte level in each of
the cells. Add distilled water as necessary.
5.lnstall the battery ca s.
6.Clean the outside o P the battery and the battery tray compartment
with a solution of baking soda and water.
Installation:

1. Install the battery in the generator.
2.Install the positive (+) cable to the battery positive (+) terminal;
then install the negative (-)
cable to the battery negative (-1
terminal.
3. Install the battery set plate.
4.Close and latch the battery cover.

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.

Contact with a hot engine
or fires. Let the engine
generator.

or exhaust system can cause serious burns
cool before
transporting
or storing
the

Take care not to drop or strike the generator when transporting.
place heavy objects on the generator.

Do not

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
PREVENT

HARD STARTING

Less than 1 month
1 to 2 months

No preparation required
Fill with fresh gasoline and add gasoline
conditioner *.
Fill with fresh gasoline and add qasoline
2 months to 1 year
conditioner *.
Drain the carburetor float bowl. (page 40).
Drain the fuel sediment cup. (page 34).
Fill with fresh gasoline and add gasoline
conditioner *.
Drain the carburetor float bowl. (page 40).
Drain the fuel sediment cup. (page 34).
Remove the spark plugs. Pour a tablespoon
(5-10
cc) of clean engine oil into each
1 year or more
cylinder. Using the electric starter, crank the
engine a few revolutions to distribute the oil
in the cylinders. Reinstall the spark plugs.
Change the engine oil. (page 30).
After removal from storage, drain the stored
gasoline into a suitable container, and fill
with fresh gasoline before starting.
*Use gasoline cone tioners that are formulated to extend storage
life.
Contact your authorized Honda generator dealer for conditioner
recommendations.

l.Drain the carburetor by loosening
gasoline into a suitable container.

the

drain

screw.

Drain

the

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.

SCREW

2.Change the engine oil.
3.Remove the spark plugs, and pour about a tablespoon of c!ean
engine oil into each cylrnder. Crank the engine several revolutrons
to distribute the oil, then reinstall the spark plugs.
4.Once a month, recharge the battery (see page 38).

TROUBLESHOOTING
When the engine will not start:
Is there fuel in the
tank?

Is there enough
in the engine?
I
YES

oil

b Refill the fuel tank.

~ Add the recommended oil.
Still NO spark

Is there a spark NO
from
the
spark plug?

Replace
the
sparkplug.

Take the generator
to an authorized
Honda
generator
dealer.

To check:
1)Remove
one 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 apark
may ignite.
plug and install the
spark plug in the
I
YES
plug cap.
3)Set the plug side
electrode
on the
cylinder head.
4)Crank
the engine,
sparks should jump
across the gap.
NO
Is the fuel reaching
c Clean the fuel
the carburetor?
sediment cup.

If the engine still
does not start, take
the generator to an
authorized
Honda
generator dealer.

To check:
lITurn
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.

DRAIN S/CREW

No electricity at the AC receptacles:
Is the AC circuit breaker
ON?
YES
Check the electrical
pliance or equipment
any defects.

p Turn
ON.

apfor

Take the
authorized
dealer.

DEFECTS

~
l

breaker

NO DEFECTS

the AC circuit

generator
to an
Honda generator

Replace the electrical appliance or equipment.
Take the electrical appliance or equipment
to an
electrical shop for repair.

WIRING DIAGRAM

%PECIFICATIOM§
Dimensions

Model
Power product description
Length
Width
Height
Dry weight
-

EX5500
code

EAI
965
590
730
175

mm (38.0 in)
mm (23.2 in)
mm (28.7 in)
kg (386 Ibs)

Generator
Model

...i

Type

AC output

Tune-up

Rated voltage
Rated frequency
Rated ampere
Ratedoutput
Maximum output

Specification
ITEM
_ _

-. -Other specification

-.SPECIFICATION
10.60-0.70

Spark. plug-gap
Valve clearance

EX5500
A
-.12OJ240 V
60 Hz
1 41.7/20.8 A
1 5.0 kVA
1 5.5 kVA

mm (0.024-0.028

1 MAINTENANCE
in) !
I

Refer

to page:

IN: 0.10 - 0.14 mm cold
See your authorized
Honda dealer
EX: 6.18 - 0.22 mm
-.-I cold
No other adjustments needed.

NOTE:
Specifications may vary according
change without notice.

to the types, and are subject, to

INSTALLATION
Remote

Control

OF OPTIONAL PARTS

Kit

The generator may be adapted for remote control operation
an optional kit.

by use of

INSTALLATION

1. Remove the six 6 x 10 mm flange bolts that attach the control panel.
Remove the control panel.
6 x 10 mm FLANGE BOLTS

6 x 10 mtk FLANGE BOLTS

2. Position the relay box on the back of the control panel with the studs
inserted through the holes in the relay box flange. Install a 4 mm nut
and lock washer on each stud and tighten securely.
4 x 10 mm SELFTAPPING SCRE
CONTROL PANEL
COUPLER HOLDER

HOLE IN SUB PANEL

4 mm NUT

3. Remove the 6-P coupler
female coupler. Connect
harness female coupler.
4. Insert the relay box 6-P
below the control panel,
and coupler holder.

6-P FEMALE COUPLER

with a jumper wire from the wire harness
the relay box 6-P male coupler to the wire
female coupler in the hole in the subpanel
and install with the two self-tapping screws

5. Reinstall the control panel with the 6 x 10 mm flange bolts.
6. Connect the remote control 6-P male coupler to the 6-P coupler on
the subpanle. Secure the remote control cable to the front hook with
a wire band positioned where shown.

WIRE BAND

FROiT

HOOK

7. Connect the remote control 6-P male coupler to the switch box.

OPERATION

1. Turn
2. Turn
3. Turn
4. Turn

the
the
the
the

fuel valve on.
auto-throttle switch to AUTO.
ignition switch key off or remove it from the generator.
relay switch on.

RELAY SWITCH

5. Flip the remote control engine switch up to ON.

6. Depress the starter button until the pilot lamp is on.
7.To stop the engine, flip the remote control engine switch down to
OFF. When the generator is not in use, turn the fuel valve off.

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 Service
Office. You can write to:
American Honda Motor Co., Inc.
Honda Power Equipment Division
Customer Service Office
4475 River Green Parkway
Duluth, Georgia 30136-2565
Or telephone:

(404) 497-6400

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

Model and serial number (see pages 8 and 9 1

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

A detailed description of the problem

number

Current customer service contact information:
United States, Puerto Rico, and U.S. Virgin Islands:
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, GA 30005-8847
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST
When you write or call, please provide the following information:
•

Model and serial numbers

•

Name of the dealer who sold the Honda power equipment to you

•

Name and address of the dealer who services your equipment

•

Date of purchase

•

Your name, address, and telephone number

•

A detailed description of the problem

UUWEX
...............................................................
COMPONENT IDENTIFICATION
CONTROLS ...............................................................................................
Auto-throttle System .........................................................................
Circuit Breaker ....................................................................................
Engine Switch .....................................................................................
Fuel Valve ...........................................................................................
Ground Terminal ................................................................................
Oil Pressure Lamp ..............................................................................
Pilot Lamp ...........................................................................................
Voltage Adjustment Knob .................................................................
Voltmeter ............................................................................................
...................................................
CUSTOMER SERVICE INFORMATION
GENERATOR USE ....................................................................................
AC Applications ..................................................................................
AC Operation ......................................................................................
AC Receptacle Selection ....................................................................
Auto-throttle

System

.........................................................................

Connections to a Building’s Electrical System ................................
Ground System ..................................................................................
High Altitude Operation .....................................................................
Special Requirements ........................................................................
INDEX .......................................................................................................
INSTALLATION OF OPTIONAL PARTS ..................................................
.......................................................................................
MAINTENANCE
Air Cleaner Service ............................................................................
Battery .................................................................................................
Emission Control System ..................................................................
Engine Oil and Oil Filter Change .......................................................
Fuel Sediment Cup Cleaning ............................................................
Fuse Replacement

..............................................................................

Maintenance Schedule ......................................................................
.............................................................
Spark Arrester Maintenance
Spark Plug Service .............................................................................

8
10
13
10
10
11
11
14
13
12
12
49
15
16
17
18
19

15
15
20
15
50
45
28
30
36
29
30
34
35

28
36
33

PRE-OPERATION CHECK ........................................................................
Engine Oil ...........................................................................................
Coolant ................................................................................................
......................................................................
Fuel Recommendation
SAFETY .......................................................................................................
Safety Information ...............................................................................
Safety Label Locations ........................................................................
SPECIFICATIONS .....................................................................................
STARTING THE ENGINE .........................................................................
STOPPING THE ENGINE .........................................................................
...................................................................
TRANSPORTING/STORAGE
..............................................................................
TROUBLESHOOTING
WIRING DIAGRAM ..................................................................................

21
21
24
22
4
6
4
44
26
27
39
41
43

MEMO

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