Honda Ex5500 Ea1 1000001 Through 1099999 Owners Manual

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

A c!f

receded by a safety alert symbol

and one of three words: DAN El?, WARNING, or CAUTION.

These mean

m You WILL be KILLED or SERIOUSLY HURT if you don’t

follow instructions.

B You CAN be KILLED or SERIOUSLY HURT if you don’t

follow instructions.

w You CAN be HURT if you don’t follow instructions.

Each message tells you what the hazard is, what can happen, and

what you can do to avoid or reduce injury.

Damage Prevention Messages

You will also see other important messages that are preceded by the

word NOTICE.

This word means:

1 NOTICE 1

Your generator or other property could be damaged if you

don’t follow instructions.

The purpose of these messages is to help prevent damage to your

generator, other property, or the environment.

1

CONTENTS

SAFETY ....................................................................................................... 4

Safety Label Locations ........................................................................ 4

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

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

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

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

Circuit Breaker .................................................................................... 10

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

Ground Terminal ................................................................................ 11

Voltage Adjustment Knob ................................................................. 12

Volt Meter ........................................................................................... 12

Auto-throttle System ......................................................................... 13

Pilot Lamp ........................................................................................... 13

Oil Pressure Lamp .............................................................................. 14

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

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

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

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

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

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

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

Auto-throttle System ......................................................................... 19

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

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

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

Fuel Recommendation ...................................................................... 22

Coolant ................................................................................................ 24

STARTING THE ENGINE ......................................................................... 26

STOPPING THE ENGINE ......................................................................... 27

MAINTENANCE ....................................................................................... 28

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

Emission Control System .................................................................. 29

Engine Oil and Oil Filter Change ....................................................... 30

Air Cleaner Service ............................................................................ 32

Spark Plug Service ............................................................................. 33

Fuel Sediment Cup Cleaning ............................................................ 34

Fuse Replacement .............................................................................. 35

Spark Arrester Maintenance ............................................................. 36

Battery ................................................................................................. 37

2

TRANSPORTING/STORAGE ................................................................... 39

TROUBLESHOOTING .............................................................................. 41

WIRING DIAGRAM ..................................................................................

SPECIFICATIONS ..................................................................................... ii

INSTALLATION OF OPTIONAL PARTS .................................................. 45

CUSTOMER SERVICE INFORMATION ................................................... 49

INDEX ....................................................................................................... 50

3

SAFETY

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause serious

injury.

Read them carefully.

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

Generator dealer for a replacement.

/r .

CAUTION

BE SURE TO FILL CRANKCASE WITH RECOMMENDED OIL AND

RESERVE TANK OF RADIATOR WITH RECOMMENDED COOLANT

BEFORE USING.

FOR DETAILED EXPLANATION, SEE THE OWNER’S MANUAL.

1 WARNING I

NOT USE INDOORS DUE TO DANGER OF CARBON

NOXIDE POISONING. 1

I-

GASOLINE CAUTION LABEL I

AC EX5500

VOLTAGE

FREQUENCY

RATED OUTPUT

MAX OUTPUT

PHASE

FUEL

120 VI240 v

SO Hz

5.0 KVA

5.5 KVA

10

GASOLINE (PETROL)

EXHAUST CAUTION LABEL

HOT l EXHAUST 3

ECHAPPEMENT l CHAUD

I

5

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 Responsibility

l Know how to stop the generator quickly in case of emergency.

l Understand the use of all generator controls, output receptacles,

and connections.

l Be sure that anyone who operates the generator receives proper

instruction. Do not let children operate the generator without

parental supervision.

Carbon Monoxide Hazards

l Exhaust contains poisonous carbon monoxide, a colorless and

odorless gas. Breathing exhaust can cause loss of consciousness

and may lead to death.

l 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 Shock Hazards

l The generator produces enough electric power to cause a serious

shock or electrocution if misused.

l 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.

l 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.

l 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.

l 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.

l 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.

l 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.

7

COMPONENT IDENTIFICATION

AIR CLEANER j COOLANT

/

RESERVE TANK

/ 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

8

CONTROL BOX

VOLTAGE

ADJUSTMENT KNOB OIL LAMP COOLANT LiMP

RESET BUTTON

REMOTE

CONTROL SWITCH

CIRCUIT BREAKER FUEL VALVE KNOB

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: To stop the engine. Key can be removed/inserted.

ON: To run the engine after starting.

START: 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.

II CIRCUIT BREAKER

/

10

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

11

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

12

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.

AUTO: Recommended to minimize fuel consumption and

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

/

13

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

indicator light may

radiator.

level before each use. The coolant temperature

not function if there is insufficient coolant in the

RESET BUlTON

OIL PRESSURE LAMP

COOLANT TEMPERATURE LAMP

14

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.

15

AC Applications

Before connecting an appliance or power cord to the generator:

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

power cords can create a potential for electrical shock.

l 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.

l 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 the

time limit for maximum power operation or slightly overloading the

generator may not switch the circuit breaker OFF, but will shorten the

service life of the generator.

Limit operation requiring 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.

16

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

These two circuits supply equal power to di

R reducing circuits.

shown. erent receptacles

Main Circuit II

--

‘The table shows the specifications when the 120/24OV locking

plug receptacle is used for 120V.

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).

18

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

19

l 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 ef-

fect 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.

20

PRE-OPERATION CHECK

Engine Oil

piEiq

Engine oil is a major factor affecting engine performance and service

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

and are not recommended.

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 require-

ments for API service classifi-

cation SF or SG. Always check

the API SERVICE label on the oil -30 -20 -10 0 10 20 30 40°C

container to be sure it includes

the letters SF or SG.

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.

21

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 or oil/gasoline mixture.

Avoid getting dirt or water in the fue ?

tank.

Refuel carefully to avoid spilling fuel. Do not fill above the fuel strainer

shoulder.

Gasoline is highly flammable and explosive, and you can be burned

or seriously injured when refueling.

l Stop engine and keep heat, sparks, and flame away.

l Refuel only outdoors.

l Wipe up spills immediately.

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.

22

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

normal load, change %

ing occurs at a steady engine speed, under

rands of gasoline. If spark knock or pinging

persists, see an authorized Honda generator dealer.

riiziq

Running the engine with persistent spark knock or pinging can cause

engine damage.

Running the engine with persistent spark knock or pinging is misuse,

and the Distributor’s Limited Warranty does not cover parts damaged

by misuse.

Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or an

ether compound. These gasolines are collectively referred to as

oxygenated fuels. To meet clean air 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”

P

ollowing 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

METHANOL - (methyl or wood alcohol) 5% by volume

You may use gasoline containing up to 5% methanol

by volume as long as it also contains cosolvents and

corrosion inhibitors to protect the fuel system.

Gasoline containing more than 5% methanol by

volume may cause starting and/or performance

problems. It may also damage metal, rubber, and

plastic parts of your fuel system.

If you notice any undesirable operating symptoms, try another service

station or switch to another brand of gasoline.

Fuel system 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.

23

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 t

ii 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 c7 the inconvenience of an unexpected shutdown, inspect the

coolant level in the reserve tank regularly.

24

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

Use high quality ethylene lycol coolant that is specifically formulated

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 of coolant, hard water, or salt water can cause

corrosion damage in the engine.

25

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 of time, it is

an indication that the battery should be recharged.

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 switch to

AUTO after the engine has warmed up.

26

Stopping the engine

In an emergency:

l.To stop the engine in an emergency, move the engine switch to the

OFF position.

In normal 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.

27

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 monoxide. Shut off the

engine before performing any maintenance. If the engine must be run,

make sure the area is well-ventilated.

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 Schedule

NOTE: l 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.

28

Emission Control System

Source of Emissions

The combustion process produces carbon monoxide, oxides of

nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of

nitrogen is very important because, under certain conditions, they

react to form photochemical smog when subjected to sunlight.

Carbon monoxide does not react in the same way, but it is toxic.

Honda 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 in-

structions 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 high-

temperature 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.

29

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 change:

1.1 0 (1.2 US qt, 1.0 Imp t)

Oil refill capacity with filter c

R ange:

1.4 !.I (1.5 USqt, 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.

30

I 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 to clean the filter element can

cause a fire or explosion. Use only soapy water or nonflammable

solvent.

piieiq

Never run the generator without the air cleaner. Rapid engine wear

will result.

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)

31

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

32

Spark Plug Service

Recommended spark plug: BPRGHS (NGK)

To ensure proper engine operation, the spark plug must be properly

gapped and free of deposits.

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 cross-

threading.

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 1

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

33

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

34

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 1

l If frequent fuse failure occurs, determine the cause and correct the

problem before attempting to operate the generator further.

l Never use a fuse with a rating other than IOA. Serious damage to

/ the electrical system or a fire may result.

35

Spark Arrester Maintenance

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

to cool before proceeding.

(1

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

efficiency.

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

36

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.

. PLATE

BAlTERY SE1

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. UPPER LEVEL

3.lf the electrolyte level is near

the LOWER mark, add distilled

water as necessary.

LOWER LEVEL

37

Charging:

The battery is rated at 14AH (ampere-hour). 10% of the ampere-hour

ratin 9

shou d should be used as the charging current. A battery charger

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.

38

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 exhaust system can cause serious burns

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

generator.

Take care not to drop or strike the generator when transporting. Do not

place heavy objects on the generator.

Before storing the unit for an extended period:

1. Be sure the storage area is free of excessive humidity and dust.

2. Service according to the table below:

STORAGE TIME

Less than 1 month

1 to 2 months

2 months to 1 year

1 year or more

*Use gasoline cone

life.

PREVENT HARD STARTING

No preparation required

Fill with fresh gasoline and add gasoline

conditioner *.

Fill with fresh gasoline and add qasoline

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

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.

tioners that are formulated to extend storage

Contact your authorized Honda generator dealer for conditioner

recommendations.

39

l.Drain the carburetor by loosening the drain screw. Drain the

gasoline into a suitable container.

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).

40

TROUBLESHOOTING

When the engine will not start:

Is there fuel in the NO b Refill the fuel tank.

tank?

Is there enough oil NO

in the engine?

I

~ Add the recom-

mended oil.

YES Still NO spark

Is there a spark NO Replace the Take the generator

from the spark - sparkplug. - to an authorized

plug? 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.

I plug and install the

spark plug in the

YES plug cap.

3)Set the plug side

electrode on the

cylinder head.

4)Crank the engine,

sparks should jump

across the gap.

NO c Clean the fuel

sediment cup.

Is the fuel reaching

the carburetor?

If the engine still

does not start, take

the generator to an

authorized Honda

generator dealer.

To check:

lITurn off ‘the fuel DRAIN S/CREW

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.

No electricity at the AC receptacles:

Is the AC circuit breaker No p Turn the AC circuit breaker

ON? ON.

YES NO DEFECTS

Check the electrical ap- Take the generator to an

pliance or equipment for * authorized Honda generator

any defects. dealer.

1 DEFECTS ~

l Replace the electrical appli-

ance or equipment.

l Take the electrical appli-

ance or equipment to an

electrical shop for repair.

42

WIRING DIAGRAM

%PECIFICATIOM§

Dimensions

Model

Power product description code

Length

Width

Height

Dry weight -

EX5500

EAI

965 mm (38.0 in)

590 mm (23.2 in)

730 mm (28.7 in)

175 kg (386 Ibs)

Generator

Model i EX5500

~- . . .

Type A

--

-.-

Rated voltage 12OJ240 V

Rated frequency 60 Hz

AC output Rated ampere 1 41.7/20.8 A

Ratedoutput 1 5.0 kVA

Maximum output 1 5.5 kVA

Tune-up Specification

ITEM _ _ -.SPECIFICATION 1 MAINTENANCE

Spark. plug-gap 10.60-0.70 mm (0.024-0.028 in) ! Refer to page: 33

Valve clearance I

IN: 0.10 - 0.14 mm cold See your authorized

-.-I

.

EX: 6.18 - 0.22 mm cold Honda dealer

-. --

Other specification No other adjustments needed.

NOTE:

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

change without notice.

INSTALLATION OF OPTIONAL PARTS

Remote Control Kit

The generator may be adapted for remote control operation by use of

an optional kit.

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 SELF-

TAPPING SCRE

CONTROL PANEL

COUPLER HOLDER

HOLE IN SUB PANEL

4 mm NUT

45

3. Remove the 6-P coupler with a jumper wire from the wire harness

female coupler. Connect the relay box 6-P male coupler to the wire

harness female coupler.

4. Insert the relay box 6-P female coupler in the hole in the subpanel

below the control panel, and install with the two self-tapping screws

and coupler holder.

6-P FEMALE COUPLER

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.

47

OPERATION

1. Turn the fuel valve on.

2. Turn the auto-throttle switch to AUTO.

3. Turn the ignition switch key off or remove it from the generator.

4. Turn the 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

l Name of dealer who sold the generator to you

l Name and address of dealer who services your generator

l Date of purchase

l Your name, address, and telephone number

l A detailed description of the problem

49

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