Honda EM5000is Owner'S Manual Download Page 59

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SERVICING YOUR GENERATOR

Battery Removal

WARNING:

Wash hands after handling.

POSITIVE (

) CABLE

MAINTENANCE COVER

COVER SCREW

BATTERY STRAP

BATTERY BOOT

NEGATIVE (

) CABLE

Battery posts, terminals, and related accessories contain

lead and lead compounds.

Lift the handle upward. The lock levers will lock and secure the
handle into place.

Loosen the cover screw and remove the battery maintenance cover.

Remove the negative (

) cable from the battery first, and then

remove the positive (

) cable from the battery.

Unhook the battery strap from the bottom hook of the generator.

Remove the battery from the battery tray.

11/03/27 08:00:52 31Z11710_058

Summary of Contents for EM5000is

Page 1: ......

Page 2: ...specifications or design at any time without notice and without incurring any obligation whatever Keep this owner s manual handy so that you can refer to it at any time This owner s manual is considered a permanent part of the generator and should remain with the generator if resold Never run the generator in a closed or even partly closed area where people may be present The engine exhaust from t...

Page 3: ...r generator other property or the environment When your generator needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda generators and is supported by the parts and service divisions of American Honda Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda M...

Page 4: ...ds associated with operating or maintaining a generator You must use your own good judgement You will find important safety information in a variety of forms including on the generator preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean be or if you don t follow instructions be or if you don t follow instructions be if you don t follow ...

Page 5: ...ENT CONTROL LOCATIONS 10 CONTROLS 12 Fuel Valve Lever 12 Engine Switch 12 Starter Grip 13 Eco Throttle Switch 13 Voltage Selector Switch 14 AC Circuit Protectors 14 Folding Handle 15 FEATURES 16 Ground Terminal 16 Output Indicator 17 Overload Indicator 17 Oil Alert Indicator 18 i Monitor 19 Fuel Gauge 22 ARE YOU READY TO GET STARTED 23 Knowledge 23 IS YOUR GENERATOR READY TO GO 24 Check the Engine...

Page 6: ...Y POWER 39 Connections to a Building s Electrical System 39 System Ground 39 Special Requirements 40 THE IMPORTANCE OF MAINTENANCE 41 MAINTENANCE SAFETY 42 Safety Precautions 42 MAINTENANCE SCHEDULE 43 REFUELING 44 FUEL RECOMMENDATIONS 45 ENGINE OIL LEVEL CHECK 46 ENGINE OIL CHANGE 47 ENGINE OIL RECOMMENDATIONS 48 AIR CLEANER SERVICE 49 FOAM AIR FILTER CLEANING 50 SEDIMENT CUP CLEANING 51 SPARK PL...

Page 7: ...peration 70 Emission Control System Information 71 Air Index 74 Specifications 75 Wiring Diagram 77 CONSUMER INFORMATION 78 Honda Publications 78 Dealer Locator Information 79 Customer Service Information 79 SAFETY 80 The Importance of Proper Assembly 80 Important Safety Precautions 81 ASSEMBLY 82 Unpacking 82 Loose Parts 82 Wheel Kit Installation 83 Handle Installation 84 Rear Bar Installation 85...

Page 8: ...rself and others Be sure that anyone who operates the generator receives proper instruction Do not let children operate the generator without parental supervision Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output receptacles and connections Exhaust contains poisonous carbon monoxide a colorless odorless gas Breathing carbon monoxide can...

Page 9: ...can cause a malfunction or short circuit in electrical components that could result in electrocution Do not connect to a building s electrical system unless an isolation switch has been installed by a qualified electrician The 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 befor...

Page 10: ...peration Refuel only outdoors in a well ventilated area with the engine off Do not refuel during operation Do not overfill the fuel tank Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container Make sure that any spilled fuel has been wiped up before starting the engine 11 03 27 07 53 36 31Z11710_009 ...

Page 11: ... LOCATIONS These labels warn you of potential hazards that can cause serious injury Read them carefully If a label comes off or becomes hard to read contact your Honda servicing dealer for a replacement 11 03 27 07 53 49 31Z11710_010 ...

Page 12: ...OR FUEL VALVE VOLTAGE SELECTOR SWITCH OVERLOAD INDICATOR RECEPTACLES i MONITOR BUTTON i MONITOR ECO THROTTLE SWITCH CIRCUIT PROTECTORS OIL ALERT INDICATOR Use the illustrations on these pages to locate and identify the most frequently used controls 11 03 27 07 53 55 31Z11710_011 ...

Page 13: ...L DRAIN PLUG WHEEL MUFFLER TIP SPARK PLUG INSPECTION COVER FUEL GAUGE FUSE Inside maintenance cover OIL FILLER CAP DIPSTICK AIR CLEANER STARTER GRIP GROUND TERMINAL BATTERY TRAY Inside maintenance cover MAINTENANCE COVER 11 03 27 07 54 01 31Z11710_012 ...

Page 14: ...er must be in the ON position for the engine to run After stopping the engine turn the fuel valve lever to the OFF position REMOTE For using the remote control kit optional parts START Operates the electric starter ON Running position and for starting with the recoil starter OFF Stops the engine The engine switch key can be removed inserted The engine switch controls the ignition system and it ope...

Page 15: ...electrical load If high electrical loads are connected simultaneously turn the Eco Throttle switch to the OFF position to reduce voltage changes ON Recommended to minimize fuel consumption and further reduce noise levels when a reduced load or no load is applied to the generator OFF The Eco Throttle system does not operate Generator operates at full output Do not allow the starter grip to snap bac...

Page 16: ...s being connected to any of the 120 V 3 prong receptacles select the 120 V ONLY position Always disconnect or turn OFF all appliances or tools connected to the generator before changing the voltage selector switch position The 120 V and 120 V 240 V receptacles can be used simultaneously ONLY the 120 V receptacles can be used Do not use the 120 V 240 V receptacle in this position The most power wil...

Page 17: ...nary position HANDLE The foldable handle is intended for ease of transportation and should be folded when the generator is stationary Do not rest objects on the extended handle Lift handle upward Lock levers will lock and secure the handle into place Lower the handle Press handle lock levers downward 2 1 11 03 27 07 54 45 31Z11710_016 ...

Page 18: ...he 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 11 03 27 07 54 51 31Z11710_017 ...

Page 19: ... electrical power at the receptacles If the generator is overloaded or if there is a short circuit in a connected appliance or if the inverter is overheated the red overload indicator will go ON When the generator is operating overloaded the red overload indicator will stay ON and after about five seconds current to the connected appliance s will shut off and the green output indicator will go OFF...

Page 20: ...N position If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to START or pull the starter grip check the engine oil level see page before troubleshooting in other areas Even when oil is added to the engine the generator will not restart until the Oil Alert indicator is reset To reset the Oil Alert indicator turn the engine switch OFF add the proper amount of o...

Page 21: ...id of an observer Once the generator is running the Output indicator green and the i Monitor display will remain lit If the key is left in the ON position for over 30 seconds without starting the engine the display will start to flash The i Monitor display is divided into two screens The single digit screen displays the i Monitor mode which is represented by a number 1 through 4 The four digit scr...

Page 22: ...en The output is expressed in VA volt amperes The output value is not an exact measurement and should be regarded as a reference only Power output will not display until a load is connected to the generator When the i Monitor is in this mode the engine s speed expressed in revolutions per minute RPM is displayed This mode displays the battery condition expressed in Volts DC 11 03 27 07 55 24 31Z11...

Page 23: ...will stay running and the electrical output may stay constant Normal remote control operation will be restored after the E 01 error message clears automatically If the E 01 error message does not clear automatically or if any other error message displays contact an authorized Honda generator dealer If the engine switch is turned to the START position and batt is shown on the i Monitor display the ...

Page 24: ...uel level in the tank The red indicator in the window will reference the level in relation to full or empty To provide increased operating time start with a full tank before beginning operation Check the fuel level with the generator on a level surface Always refuel with the engine OFF and cool 11 03 27 07 55 36 31Z11710_023 ...

Page 25: ...and understand this manual Know what the controls do and how to operate them Familiarize yourself with the generator and its operation before you begin using it Know how to quickly shut off the generator in case of an emergency If the generator is being used to power appliances be sure that they do not exceed the generator s load rating see page 35 11 03 27 07 55 42 31Z11710_024 ...

Page 26: ...ously injured Always perform a pre operation inspection before each operation and correct any problem To prevent a possible fire keep the generator at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine Before beginning your pre operation checks be sure the generator is on a level surface and the engine switch is in ...

Page 27: ...see page A dirty air filter will restrict air flow to the carburetor reducing engine and generator performance Check the fuel level see page Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Never operate the generator without the maintenance cover in place as poor engine and generator performance will result 46 49 44 11 03 27 07 55 56 31Z11710_026 ...

Page 28: ... no more than 30 minutes Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for electric shock Inspect cords and plugs and replace if damaged Use grounded 3 prong extension cords tools and appliances or double insulated tools and appliances Before connecting an AC appliance or power cord to the generator Exhaust contains poisonous carbon m...

Page 29: ... page for additional information regarding battery and fuel deterioration Refer to SAFE OPERATING PRECAUTIONS on page and perform the IS YOUR GENERATOR READY TO GO checks see page Refer to AC Operation see page for connecting loads to the generator Make sure that all appliances connected to the generator are turned off The generator may be hard to start if a load is connected Set the Voltage Selec...

Page 30: ... to the START position and hold it there until the engine starts When the engine starts release the key allowing the switch to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the starter again Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it Do not lea...

Page 31: ...esistance then pull briskly in the direction of the arrow as shown If you wish to use the Eco Throttle system turn the Eco Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes Do not let the starter rope rub against the generator body or the rope will wear out prematurely Do not allow the starter grip to snap back against the engine Return it gently to prevent damag...

Page 32: ...e switch to the REMOTE far left position Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it If the engine fails to start within 5 seconds release the button and wait at least 10 seconds before operating the starter again Press and hold the START button on the remote control until the PILOT lamp illuminates The START button will automatica...

Page 33: ...he engine in an emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure Unplug all appliances from all generator AC receptacles Turn the fuel valve lever to the OFF position Turn the engine switch to the OFF position 1 2 3 11 03 27 07 56 56 31Z11710_032 ...

Page 34: ...te control optional part ON O OF FF F ENGINE SWITCH REMOTE O OF FF F FUEL VALVE LEVER OFF BUTTON Turn the engine switch to the OFF position Turn the fuel valve lever to the OFF position Press the OFF button 1 2 3 11 03 27 07 57 05 31Z11710_033 ...

Page 35: ...loading that continuously lights the red overload indicator may damage the generator Marginal overloading that temporarily lights the red overload indicator may shorten the service life of the generator Turn the voltage selector switch to either position With the voltage selector switch in the 120 V 240 V position you can use the 120 V and 120 V 240 V receptacles simultaneously If you are NOT usin...

Page 36: ...he appliance power cord If the generator is overloaded or if there is a short circuit in a connected appliance or if the inverter is overheated the red overload indicator will come ON The red overload indicator will stay ON and after about five seconds current to the connected appliance s will shut off and the green output indicator will go OFF Stop the engine and investigate the problem When an e...

Page 37: ...ed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes Limit operation requiring maximum power to 30 minutes Maximum power is Substantial overloading will open the circuit protector Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit protector OFF but will shorten ...

Page 38: ...d four receptacles Receptacle 4 the 240 volt receptacle has two powered terminals 4A and 4B This generator is equipped with two power generating circuits When the voltage selector switch is in the 120 V 240 V position each of the two power producing circuits supplies power to specific receptacles When the voltage selector switch is in the 120 V ONLY position the power producing circuits operate in...

Page 39: ...20 V ONLY position you do not need to spread the load over the receptacles You must however make sure the load on any receptacle does not exceed its available power shown in the preceding table and the total load does not exceed 37 5 amps 120 V ONLY 120 V 240 V 1 2 3 4A 4B 1 2 3 4A 4B 30 A at 120 V 20 A at 120 V 20 A at 120 V 30 A at 120 V None 18 8 A at 120 V 18 8 A at 120 V 18 8 A at 120 V 18 8 ...

Page 40: ...trical loads are connected simultaneously turn the Eco Throttle switch to the OFF position to reduce voltage changes The Eco Throttle system is not effective for use with appliances or tools that require only momentary power If the tool or appliance will be turned ON and OFF quickly the Eco Throttle switch should be in the OFF position With the switch in the ON position engine speed is automatical...

Page 41: ... to a building s electrical system can allow current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause fires when utility power is restored Consult the utility company or a qualified electrician prior to making any power connections Your genera...

Page 42: ...ply to the intended use of the generator Please consult a qualified electrician electrical inspector or the local agency having jurisdiction In some areas generators are required to be registered with local utility companies If the generator is used at a construction site there may be additional regulations that must be observed 11 03 27 07 58 09 31Z11710_041 ...

Page 43: ...lly performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your generator under unusual conditions such as sustained high load or high temperature operation or use it in dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Improper maintenance or failure to ...

Page 44: ... killed Always follow the procedures and precautions in the owner s manual Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Operate outside away from open windows or doors Let the engine and exhaust system cool before touching Do not run the engine unless instructed to do so Read the instructions before you begin and make sure yo...

Page 45: ...51 52 52 54 Every 2 years Replace if necessary 2 Service more frequently when used in dusty areas These items should be serviced by your Honda servicing dealer unless you have the proper tools and are mechanically proficient Refer to the Honda shop manual for service procedures For commercial use log hours of operation to determine proper maintenance intervals Failure to follow this maintenance sc...

Page 46: ...If the engine has been running allow it to cool Refuel carefully to avoid spilling fuel Never refuel the engine inside a building where gasoline fumes may reach flames or sparks Keep gasoline away from appliance pilot lights barbecues electric appliances power tools etc Spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately Fuel can damage paint and plasti...

Page 47: ...the fuel tank You may use regular unleaded gasoline containing no more than 10 ethanol E10 or 5 methanol by volume In addition methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of ethanol or methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performa...

Page 48: ... However to avoid the inconvenience of an unexpected shutdown check the oil level regularly Remove the oil filler cap dipstick and wipe it clean Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick Screw in the oil filler cap dipstick securely If the oil level is low fill with the recommended oil to the top of the oil filler neck outer e...

Page 49: ...oil Screw in the oil filler cap dipstick securely With the generator in a level position fill with the recommended oil to the outer edge of the oil filler hole see page Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of the used oil properly Put it in a sealed container and take it to a recycling center Do not discard it in a trash bin du...

Page 50: ...ent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range The SAE oil viscosity and service category are in the API label on the oil container Honda recommends that you use API service category SJ or later or equivalent oil 11 03 27 07 59 24 31Z11710_049 ...

Page 51: ...amaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty Reinstall the air cleaner cover Reinstall the foam air filter in the air cleaner housing Check the foam air filter to be sure it is clean and in good condition If the foam air filter is dirty clean it as described on page Replace the foam air filt...

Page 52: ...f too much oil is left in the filter Wipe dirt from the air cleaner housing and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor A dirty foam air filter will restrict air flow to the carburetor reducing engine performance If you operate the generator in very dusty areas clean the foam air filter more frequently than specified in the Mainten...

Page 53: ...e away Handle fuel only outdoors Wipe up spills immediately Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Remove the sediment cup by turning it counterclockwise Turn the fuel valve lever to the OFF position and remove the key Reinstall the new O ring and sediment cup Turn the fuel valve to the ON position and check for leaks 2 3 4 1 5 11 03 27...

Page 54: ...orrect spark plugs can cause engine damage If the engine is hot allow it to cool before servicing the spark plug Remove the spark plug with a 13 16 inch spark plug wrench commercially available Disconnect the spark plug cap and remove any dirt from around the spark plug area Loosen the cover screw and remove the spark plug inspection cover 1 2 3 11 03 27 08 00 02 31Z11710_053 ...

Page 55: ...tion and thread the spark plug in by hand to prevent cross threading After the spark plug seats tighten with a 13 16 inch spark plug wrench to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats A loose spark plug can overheat and damage the engine Overtightening the spark p...

Page 56: ...e serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester Remove the two 8 mm flange bolts and remove the rear bar Remove the six 6 mm flange nuts and remove the muffler protector 1 2 11 03 27 08 00 21 31Z11710_055 ...

Page 57: ...e screen Use a brush to remove carbon deposits from the spark arrester screen The spark arrester must be free of breaks and tears Replace the spark arrester if it is damaged Install the spark arrester and the exhaust tail pipe in the reverse order of removal 6 3 lbf ft 8 5 N m 0 87 kgf m Install the muffler protector and the rear pipe in the reverse order of removal 8 lbf ft 11 N m 1 1 kgf m 3 4 5...

Page 58: ...isonous Getting electrolyte in your eyes or on your skin can cause serious burns Wear protective clothing and eye protection when working near the battery KEEP CHILDREN AWAY FROM THE BATTERY Flush with water from a cup or other container for at least fifteen minutes Water under pressure can damage the eye Immediately call 911 USA only or a physician Remove contaminated clothing Flush the skin with...

Page 59: ...ain lead and lead compounds Lift the handle upward The lock levers will lock and secure the handle into place Loosen the cover screw and remove the battery maintenance cover Remove the negative cable from the battery first and then remove the positive cable from the battery Unhook the battery strap from the bottom hook of the generator Remove the battery from the battery tray 1 2 3 4 5 11 03 27 08...

Page 60: ...itive terminal first and tighten the bolt securely Install the battery into the generator Clean the outside of the battery and the battery compartment with a solution of baking soda and water Connect the battery charger following the manufacturer s instructions The battery is rated at 11 2 Ah ampere hours Charging current should equal 10 of the battery s ampere hour rating A battery charger should...

Page 61: ...sition and remove the key before checking or replacing the fuse Loosen the cover screw and remove the battery maintenance cover 1 A 15 A Never use a fuse with a different rating from that specified Serious damage to the electrical system or fire may result Replace the fuse with a fuse of the same type and rating Remove the fuse holder cover and pull the fuse out Install the fuse holder cover and t...

Page 62: ... and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard s...

Page 63: ...fuel sediment cup page 51 Remove the spark plug Put a teaspoon of engine oil into the cylinder Turn the engine slowly with the pull rope to distribute the oil Reinstall the spark plug Change the engine oil page 47 After removal from storage drain the stored gasoline into a suitable container and fill with fresh gasoline before starting Use gasoline stabilizers that are formulated to extend storage...

Page 64: ...below the carburetor drain hose Loosen the carburetor drain screw and drain the gasoline from the carburetor After all the fuel has drained into the container tighten the drain screw securely Place an approved gasoline container below the sediment cup and use a funnel to avoid spilling fuel Remove the sediment cup and then move the fuel valve lever to the ON position see page Allow the fuel to dra...

Page 65: ...he intake and exhaust valves are closed Storing the engine in this position will help to protect it from internal corrosion Return the starter grip gently Pull the starter grip several times to distribute the oil in the cylinder Charge the battery before storing the generator see page Pour a teaspoon 5 cc of clean engine oil into the cylinder Reinstall the spark plug 1 2 3 6 5 4 47 52 58 11 03 27 ...

Page 66: ...e Tilting can cause fuel or oil leakage Unless all fuel has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of leakage If possible avoid storage areas with high humidity because that promotes rust and corrosion Also avoid any area with a spark producing electric motor or where power tools are operated Select a well ventilated storage area away fro...

Page 67: ...nite some materials Keep the generator level when transporting to reduce the possibility of fuel leakage Move the fuel valve to the OFF position When using ropes or tie down straps to secure the generator for transportation be sure to only use the frame bars as attachment points Do not fasten ropes or straps to any portions of the generator body or the folding transport handle 11 03 27 08 02 10 31...

Page 68: ...line or refueled with bad gasoline Low oil level caused Oil Alert to stop engine Spark plug faulty fouled or improperly gapped Spark plug wet with fuel flooded engine Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Turn lever ON Turn engine switch to ON Refuel p 44 Drain fuel tank and carburetor p 62 Refuel with fresh gasoline p 44 Add oil p 46 Turn engine switc...

Page 69: ...al Air filter restricted Bad fuel generator stored without treating or draining gasoline or refueled with bad gasoline Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Clean or replace air filter p 49 Drain fuel tank and carburetor p 62 Refuel with fresh gasoline p 44 Replace or repair faulty components as necessary 1 2 3 11 03 27 08 02 25 31Z11710_068 ...

Page 70: ...ir power tool or appliance Stop and restart the engine Replace or repair faulty components as necessary Check output and overload indicator Check circuit protectors Check the power tool or appliance at a known good AC power source Take generator to an authorized Honda servicing dealer or refer to shop manual Output indicator is OFF and overload indicator is ON Circuit protector s tripped Faulty po...

Page 71: ... INFORMATION FRAME SERIAL NUMBER Frame serial number Date purchased Record the frame serial number and date purchased in the spaces below You will need this information when ordering parts and when making technical or warranty inquiries 11 03 27 08 02 39 31Z11710_070 ...

Page 72: ...er perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carbu...

Page 73: ... same way but it is toxic Honda utilizes appropriate air fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons Additionally Honda fuel systems utilize components and control technologies to reduce evaporative emissions EPA and California regulations require all manufacturers to furnish written instructions describing the oper...

Page 74: ...ission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 11 03 27 08 02 57 31Z11710_073 ...

Page 75: ...riginal design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performan...

Page 76: ... provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine s emission control system See your Emission Control System Warranty for additional information The bar graph is intended to provide you our customer the ability to compare the emissions performance of available engines The lower the Air Index the le...

Page 77: ...pacity Spark plug Rated voltage Rated frequency AC output Rated current Rated output Maximum output 225 1 lbs 102 1 kg 27 9 in 709 mm 27 2 in 692 mm 26 2 in 666 mm 45 5 in 1 155 mm 31 9 in 810 mm EAJJ EM5000is 5 0 kVA 4 5 kVA 37 5 18 8 A 60 Hz 120 240 V W16EPR U DENSO BPR5ES NGK 4 23 US gal 16 0 L 1 2 US qt 1 1 L Full transistor Forced air 2 400 3 600 rpm 8 2 1 3 46 2 52 in 88 0 64 0 mm 23 7 cu in...

Page 78: ...2 mm IN 0 15 0 02 mm No other adjustments needed Spark plug gap Valve clearance cold Other specifications Refer to page 52 See your authorized Honda dealer Specifications may vary according to the types and are subject to change without notice 0 028 0 031 in 0 7 0 8 mm 11 03 27 08 03 38 31Z11710_077 ...

Page 79: ...77 TECHNICAL CONSUMER INFORMATION Wiring Diagram 11 03 27 08 04 03 31Z11710_078 ...

Page 80: ...gh Helm Inc at 1 888 292 5395 or visit www hondapowerequipment com products manuals Visit www hondapowerequipment com products accessories and click on Generators and Welders to see the entire catalog of accessories Your authorized Honda power equipment dealer offers a wide selection of accessories optional equipment to make your generator even more useful This manual provides complete illustrated...

Page 81: ...gia 30005 8847 If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write 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 d...

Page 82: ...on assembling and servicing a unit can easily result in faulty operation damage to the machine or injury to the operator Some of the most important safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing this assembly Only you can decide whether or not you should perform a given task Failure to properly follow instructions and precauti...

Page 83: ... the engine is off before you begin any assembly maintenance or repairs This will help eliminate several potential hazards To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries Use only a non flammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from all fuel related parts Do not run the engine unless the instructio...

Page 84: ...loose parts shown below are not included with your generator 12 mm wrench 10 mm wrench or Phillips head screwdriver for battery connections pliers not included 1 2 Ref No 8 9 10 11 12 Qty 2 2 2 2 8 Ref No 1 2 3 4 5 6 7 Qty 2 1 1 1 2 2 2 Description Wheel Axle Handle assembly Rear pipe Stand 20 mm Washer 4 0 28 mm Cotter pin Description 12 mm Washer Spring Washer Handle holder bolt 8 45 mm Flange b...

Page 85: ...ator using four 8 16 mm flange bolts If the wheel kit is not installed it may be possible for dirt and debris to be drawn into the generator air intake possibly causing generator damage Always operate the generator with the wheel kit installed Do not operate the generator without the wheel kit installed The wheel kit provides an air space between the ground and the generator air intake Install the...

Page 86: ...LOCK LEVER 17 22 lbf ft 24 29 N m 2 4 3 0 kgf m Operation must be checked after attaching the handle Raise the handle to the horizontal position The handle will click into place when locked Install the handle assembly on the generator upper frame using the 12 mm washers spring washers and handle holder bolts 11 03 27 08 05 10 31Z11710_085 ...

Page 87: ...MBLY Rear Bar Installation TORQUE REAR BAR 8 45mm FLANGE BOLT 2 17 22 lbf ft 24 29 N m 2 4 3 0 kgf m Install the rear bar on the generator frame using the two 8 45 mm flange bolts 11 03 27 08 05 16 31Z11710_086 ...

Page 88: ...ected and the battery cables and blue coupler harness are clamped twist clipped into the battery tray for shipment Only remove the battery cables from the twist clip Make sure that the 4 pin blue coupler harness is secured with the twist clip Return the battery to its tray Remove the protective cover from the battery positive terminal and connect the positive cable to the battery positive terminal...

Page 89: ...l the maintenance cover in the reverse order of removal see page Never operate the generator without the maintenance cover in place as poor engine and generator performance will result 7 57 11 03 27 08 05 32 31Z11710_088 ...

Page 90: ...ler neck Do not overfill the engine with oil If the engine is overfilled the excess oil may get transferred to the air cleaner housing and air filter SAE 10W 30 is recommended for general all temperature use Other viscosities in the chart may be used when the temperature in your area is within the indicated range Use a 4 stroke motor oil that meets the requirements for API service category SJ or l...

Page 91: ...STOPPING THE ENGINE STARTING THE ENGINE OPERATION BEFORE OPERATION Before using your generator you should become familiar with information contained in the following chapters and sections page page page page page page 6 10 23 26 27 31 11 03 27 08 05 52 31Z11710_090 ...

Page 92: ...side PLUG 6 PIN CONNECTOR Remove the maintenance cover see page Remove the plug from the 6 pin connector View the back of the maintenance cover and locate the knockout near the top center of the cover Carefully remove the knockout 1 2 3 57 11 03 27 08 05 59 31Z11710_091 ...

Page 93: ...trol cable into the 6 pin connector Install the maintenance cover and tighten the cover screw To avoid accidentally unplugging the remote control cable secure the cable to the generator frame with a cable tie as shown When the remote control is not being used replace it with the plug on the connector Never operate the generator without the maintenance cover in place as poor engine and generator pe...

Page 94: ...OPERATION STARTING THE ENGINE STOPPING THE ENGINE Before using your generator by remote control you should become familiar with the information contained in the following chapters and sections page page page page page page 10 8 6 23 26 31 27 11 03 27 08 06 17 31Z11710_093 ...

Page 95: ...EL TANK RIB 8 16 mm FLANGE BOLT 4 Position the hanger at the generator s balance point as shown below Fit the end tabs of the hanger through the bracket slots and bolt the brackets to the hanger and tighten securely 17 22 lbf ft 24 29 N m 2 4 3 0 kgf m 1 2 11 03 27 08 06 25 31Z11710_094 ...

Page 96: ...Locator Information 79 Eco Throttle Switch 13 ECO THROTTLE SYSTEM 38 Electric Shock Hazards 7 Emission Control System Information 71 Engine Oil 63 ENGINE OIL CHANGE 47 ENGINE OIL LEVEL CHECK 46 ENGINE OIL RECOMMENDATIONS 48 ENGINE PROBLEMS 66 Engine Switch 12 Battery 86 BATTERY SERVICE 56 BEFORE OPERATION 23 AC Applications 35 AC Circuit Protectors 14 AC OPERATION 33 AC Receptacle Selection 36 AIR...

Page 97: ...NDATIONS 45 Fuel Valve Lever 12 FUSE 59 GENERATOR PROBLEMS 68 GENERATOR SAFETY 6 Ground Terminal 16 Handle Installation 84 Hanger Kit 93 Honda Publications 78 i Monitor 19 IMPORTANCE OF MAINTENANCE 41 IMPORTANT SAFETY INFORMATION 6 Important Safety Precautions 81 INDEX 94 IS YOUR GENERATOR READY TO GO 24 Loose Parts 82 11 03 27 08 06 40 31Z11710_096 ...

Page 98: ...ndicator 17 Overload Indicator 17 Rear Bar Installation 85 REFUELING 44 Refuel With Care 8 Remote Control Kit 90 REMOVAL FROM STORAGE 64 QUICK REFERENCE INFORMATION Inside back cover Power Producing Circuits 36 Maintenance Cover 25 MAINTENANCE SAFETY 42 MAINTENANCE SCHEDULE 43 11 03 27 08 06 46 31Z11710_097 ...

Page 99: ...ements 40 Specifications 75 STANDBY POWER 39 Starter Grip 13 STARTING THE ENGINE 27 STOPPING THE ENGINE 31 STORAGE 60 STORAGE PRECAUTIONS 64 STORAGE PREPARATION 60 System Ground 39 TAKING CARE OF UNEXPECTED PROBLEMS 66 TECHNICAL CONSUMER INFORMATION 69 TECHNICAL INFORMATION 69 The Importance of Proper Assembly 80 TRANSPORTING 65 Unpacking 82 Voltage Selector Switch 14 37 Wheel Kit Installation 83 ...

Page 100: ...98 MEMO 11 03 27 08 06 56 31Z11710_099 ...

Page 101: ...99 MEMO 11 03 27 08 06 58 31Z11710_100 ...

Page 102: ...100 MEMO 11 03 27 08 07 01 31Z11710_101 ...

Page 103: ...intenance Type Type Type Subsequent W16EPR U BPR5ES SAE 10W 30 API SJ or later or equivalent for general use page 48 0 028 0 031 in 0 7 0 8 mm Check engine oil level Check air cleaner Change engine oil See Maintenance Schedule page 43 NGK DENSO Electrode Gap Before each use First 20 hours 11 03 27 08 07 08 31Z11710_102 ...

Page 104: ...00X31Z117200 ...

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Honda EM5000is, Owner'S Manual

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