Honda EMS4500 Owner'S Manual Download | Manualshive

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Summary of Contents for EMS4500

Page 1: ...Owner s Manual EMS4000 l EMS4500 H Q HONDA MOTOR CO LTD 1983 I I I J 11 _ _ _ I I 31ZA1611 Printed on 00X31 ZAl 6110 Recycled Paper I I I I i 1 I I PRIrR AH D I I 1 I I ...

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Page 3: ... remain with the generator if it is sold Pay special attention to statements preceded by the following words w Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any que...

Page 4: ...ON 4 3 PRE OPERATION CHECK 6 4 STARTING THE ENGINE g 5 GENERATOR USE 16 6 STOPPING THE ENGINE 19 7 MAlNTENANCE 21 8 TRANSPORTING STORAGE 30 9 TROUBLESHOOTING 32 10 SPECIFICATIONS 35 11 WIRING DIAGRAM 36 12 INSTALLATION OF OPTIONAL PARTS 38 13 WARRANTY SERVICE 43 2 ...

Page 5: ...osed area Be sure to provide adequate ventilation l Know how to stop the generator quickly and understand operation of all the controls Never permit anyone to operate the generator without proper instructions l Keep children and pets away from the generator when it is in operation l Keep away from rotating parts while the generator is running l The generator is a potential source of electrical sho...

Page 6: ...NTIFICATION VOLT METER VOLTAGE SELECTOR AUTO THROTTLE SWITCH SWITCH ENGINE SWITCU w OIL ALERT SWITCH FIIFI VAIVF I RECOIL STARTER GRIP DC Cl RCUIT PROTECTOR AC RECEPTACLE DC TERMINALS ENGINE OIL DRAIN PLUG EMS45001 4 ...

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Page 8: ...ertified to meet or exceed U S automobile manufacturer s requirements for Service Classification SE or SF Motor oils classified SE or SF will show this designation on the container SAE low 40 is recommended for general all temperature use Remove the oil filler cap and wipe the dipstick with a clean rag Check the oil level by inserting the dipstick in the filler hole without screwing it in If the o...

Page 9: ...it However to avoid the inconv enience of an unexpected shutdown it is still advisable to visually Inspect the oil level regularly If the Oil Alert Switch is tripped add oil to the top of the oil filler neck re set the Oil Alert Switch and restart the engine according to instructions P 9 OIL ALERT SWITCH 7 ...

Page 10: ...y flammable and explosive under certain conditions Refuel in a well ventilated area with the engine stopped l Do not smoke or allow flames or sparks in the area where the generator is refueled or where gasoline is stored e Do not overfill the tank and make sure the filler cap is securely closed after refueling l Be careful not to spill fuel when refueling Fuel vapor or spilled fuel may ignite If a...

Page 11: ...ARTING THE ENGINE NOTE Make sure that the AC circuit breaker is OFF and that nothing connected to the DC terminals The generator may be hard to start if a load is connected AC CIRCUIT BREAKER DC TERMINALS 9 ...

Page 12: ... MANUAL STARTING 1 Turn the fuel valve on 2 Pull the choke rod out to CLOSE FUEL VALVE CHOKE ROD 3 Make sure the Oil Alert switch is on OIL ALERT ITCH 10 ...

Page 13: ... time will be required fc warm up AUTO THROTTLE SWITCH 5 Turn the engine switch on ENGINE SWITCH 6 Pull the starter grip until compression is felt then pull briskly NOTE Do not allow the starter grip to snap back Return it slowly by hand STARTER GRIP 11 ...

Page 14: ...7 Push the choke rod to OPEN as the engine warms up CHOKE ROD 8 If auto throttle will be used turn the switch to AUTO after the engine has warmed up AUTO THROTTLE SWITCH 12 ...

Page 15: ...ELECTRIC STARTING 1 Turn the fuel valve on FUEL VALVE 2 Make sure the oil alert switch is on 3 Make sure the auto throttle switch is off or more time will be required for warm up AUTO THROTTLE SWITCH 13 ...

Page 16: ...tached for remote control operation make sure the switch on the relay box is turned off or the engine will not start 0 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 14 ...

Page 17: ...Turn the auto throttle switch to AUTo after the engine has warmed up I AUTO THROTTLE SWITCH NOTE The choke is operated automatically whenever a battery is connect ed to the generator s starting circuit 15 ...

Page 18: ...lified electrician and must comply with all applicable laws and electri cal codes Improper installation may result in personal injury or damage to equipment or property Auto throttle system With the switch in the AUTO position engine speed is automatically reduced to an idle when all loads are turned off or disconnected When appliances are turned on or reconnected the engine resumes the rated spee...

Page 19: ...exceed the maximum load Substantial over loading will switch off the circuit breaker Marginal overloading may not switch off the circuit breaker but it will shorten the service life of the gen erator Be sure that all appliances are in good working order before connecting them to the generator If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn off the circuit break...

Page 20: ...to start an automobile engine while the generator is still con nected to the battery The generator may be damaged l Connect the positive battery terminal to the positive generator terminal Do not reverse the charging cables or serious damage to the generator and or battery may occur NOTE l The DC terminals may be used while the AC power is in use l An overloaded DC circuit will trip the DC circuit...

Page 21: ...o stop the engine in an emergency turn the engine switch OFF In normal use 1 Turn the AC circuit breaker off and or disconnect the charging leads at the DC terminals AC CIRCUIT BREAKER 2 Turn the engine switch OFF ENGINE SWITCH 19 ...

Page 22: ...3 Turn the fuel valve OFF FUEL VALVE 20 ...

Page 23: ...d in the table on the next page m Shut off the engine before performing any maintenance If the engine must be run make sure the area is well ventilated The ezhaust contains poisonous carbon monoxide gas CAUTION Use only genuine HONDA parts or their equivalent The use of replacement parts which are not of equivalent quality may damage the generator 21 ...

Page 24: ...valve cleaning Fuel line inspection Replace if necessary Spark arrester Clean every 100 operating hours Daily 0 l First month or 20 Hrs 0 Every 3 months 60 Lrs 1 Every 6 months or 100 Hrs 0 0 l Every year 3000trlrs l 21 2 0 NOTE 1 Service more frequently when used in dusty areas 2 These items should be serviced by an authorized Honda dealer unless the owner has the proper tools and is mechanically...

Page 25: ... Always keep the kit with the generator Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the drain plug and filler cap and drain the oil Retighten the plug securely 2 Refill with the recommended oil see page 6 and check the level OIL FILLER CAP DRAIN PLUG 23 ...

Page 26: ... when operating the generator in extremely dusty areas w Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION Never run the generator without the air cleaner Rapid engine wear will result 1 Unsnap the clips remove the air cleaner cover and remove the element AIR CLEANER CLIP COVER AIR CLEANER ELEMENT CLIP 24 ...

Page 27: ...he element in a non flammable or high flash point solvent and dry it thoroughly 3 Soak the element in clean engine oil and squeeze out the excess oil 4 Reinstall the air cleaner element and the cover ELEMENT 25 ...

Page 28: ...If the engine has not been run for a long time the cup should be cleaned 1 Turn the fuel valve OFF Remove the sediment cup 2 Clean the cup thoroughly 3 Reassemble Do not damage the rubber gasket m After installing the sediment cup check for fuel leaks and make sure the area is dry before starting the engine FUEL VALVE 26 ...

Page 29: ... BPR4HS 10 NGK W14FPR ULlO ND To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cover 2 Clean any dirt from around the spark plug base 3 Remove the spark plug cap PLUG CAP 27 ...

Page 30: ...e side electrode 7 Attach the plug washer Thread the plug in by hand to prevent cross threading 8 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 B 1 4 turn after the plug seats CAUTION l The spark plug must be securely tightened An improperly tightened plug can become very hot and possibly damage the engine l Never use a spa...

Page 31: ... remove the exhaust pipe 3 Check the muffler exhaust port for carbon deposits clean if necessary 4 Remove the spark arrester from the muffler Clean the screen with a stainless steel wire brush and inspect the mesh for damage Replace the spark arrester if there are any holes or breaks in the screen 5 Install the spark arrester in the muffler 6 Install the muffler and gasket and tighten the bolts an...

Page 32: ...el may ignite Before storing the unit for an extended period 1 Be sure the storage area is free of excessive humidity and dust 2 Drain the fuel i C With the fuel valve OFF remove and empty the sediment cup Turn the fuel valve ON and drain the gasoline in the fuel tank suitable container Replace the sediment cup and tighten securely FUEL VALVE SEDIMENT CUP into a ...

Page 33: ...ontainer DRAIN SCREW e Slowly pull the starter grip until resistance is felt At this point the piston is coming up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in this position will help to protect it from internal corrosion STARTER GRIP 31 ...

Page 34: ...uel valve on m If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Fuel vapor or spilled fuel may ignite DRAIN SCRE 4 Is there enough oil in the crankcase Is the oil alert switch on 5 Is the AC circuit breaker off and nothing connected to the DC terminals 6 Is the engine switch on 7 Is there a spark at the spark plug page 27 32 ...

Page 35: ...h is on e Grounding the side electrode to the stay pull the recoil starter to see if sparks jump across the gap OIL ALERT ENGINE SWITCH GROUNDING I I SV T CH STAY STARTER 1 C f If there are no sparks replace the plug and check again If OK try to start the engine according to the instructions 8 If there is still no spark or if the engine still does not start take the gen erator to an authorized Hon...

Page 36: ...witch will turn off after starting C No electricity at the AC receptacles 1 Are the AC circuit breakers on 2 Check the electrical appliance or equipment for any defects D No electricity at the DC terminals 1 Is the DC circuit protector on 2 Check the condition of the battery cables and the battery itself 34 ...

Page 37: ...EL AC output DC output Rated voltage Rated frequency Rated ampere Rated output Maximum output Honda G E400 4Stroke side valve 1 cylinder 406 cc 24 8 cu in B6 x 70 mm 3 4 x 2 8 in 6 8 1 3 600 rpm Forced air cooling CDI Capacitor Discharge Ignition 1 2 Q 5 1 us qt 16 5 L 4 4 US gal BPR4HS10 NGK W14FPRULlO ND EMS4000 EMS4500 12OW 24OV 60Hz 32 OA I 6 OA 33 5A l6 5A 3 8kW 3 8kVA 4 0kW 4 0kVA 4 0kW 4 0k...

Page 38: ...11 WIRING DIAGRAM EMS4000 r J G ________________ I I I I I I I gl I L __ ___ 7 36 ...

Page 39: ...LL ____ __ _ 1 L BLOCll B G R W Lg P L Y Gr BLACK GREEN RED WHITE LIGHT GREEN PINK BLUE YELLOW GRAY ...

Page 40: ...the outer terminal of the starter magnetic relay 4 Attach the ground cable to the frame at the upper left of the generator as shown Tighten securely 5 Install the battery in the battery tray and connect the battery cables to the battery NOTE Use a battery rated at 12V 32AH or more CAUTION Do not reverse polarity Serious damage to the generator and or battery may occur Battery NOTE Check the electr...

Page 41: ...STARTER GROUND CABLE BATTERY TRAY 39 ...

Page 42: ...abs of the pipe frame on the right generator side and attach it with the two 6 mm screws 2 Disconnect the 8 pin coupler from the back of the control box and connect the relay box coupler in its place 3 Connect the remote control cable to the remote control box and the relay box RELAY BOX I REMOTE CONTROL BOX REMOTE CONTROL CABLE 40 ...

Page 43: ...lve on 2 Turn the oil alert switch on 3 Turn the auto throttle switch off 4 Turn the ignition switch key off or remove it from the generator 5 Turn the relay switch on RELAY SWITCH 6 Flip the remote control engine switch knob up to ON Pull ON 1 START 41 ...

Page 44: ...pilot lamp comes on when the engine starts NOTE Do not hold the starter button on for more than 15 seconds at a time If the engine has not started by then check through the starting procedure above to be sure that all switches valves etc are in the correct position 42 ...

Page 45: ...to your satisfaction contact the Customer Relations Department at the zone service office of Ameri can Honda Motor Co Inc in your area Zone service office locations are shown on the following page We will need the following information in order to assist you Your name address and telephone number Engine model and serial number Date of purchase Dealer name and address Nature of the problem After re...

Page 46: ...his 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 Mod...

Page 47: ...Alaska end Hawaii American Honda Motor Co Inc Customer Relations Depanment P O Box 420 Gardena CA 90247 0642 213 604 2400 L Jy y EASTERN ZONE SERVICE OFFICE includesPuetto Rim American Honda Motor Co Inc Customer Relations Depxtmern 1500 Morrison Parkway Alpharetta GA 30201 404 442 zoo0 ...

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