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41

SERVICING YOUR GENERATOR

AIR FILTER CLEANING

A dirty air filter will restrict air flow to the carburetor, reducing engine

performance. If you operate the generator in very dusty areas, clean

the air filter more frequently than specified in the Maintenance

Schedule (see page 31).

1.Clean the air filter in warm soapy water, rinse, and allow to dry

thoroughly, or clean in nonflammable solvent and allow to dry.

2.Dip the air filter in clean engine oil, then squeeze out all excess oil.

The engine will smoke when started if too much oil is left in the air

filter.

3.Wipe dirt from the air cleaner case and cover using a moist rag. Be

careful to prevent dirt from entering the air duct that leads to the

carburetor.

Squeeze and dry

Squeeze

Do not twist.

Do not twist.

Clean

Dip in oil

4MZ416010_Eng.book 41 ページ２０１４年９月１０日　水曜日　午後２時３１分

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Summary of Contents for ER2500CX

Page 1: ...Honda ER2500CX OWNER S MANUAL MANUAL DE EXPLICACIONES 4MZ416010_Eng book 1 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 2: ...th the generator if resold The information and specifications included in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever 4MZ416010_Eng book 0 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 3: ...eded by a symbol That information is intended to help you avoid damage to your generator other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership When your generator needs scheduled maintenance keep in mind that your authorized Honda servicing dealer is specially trained in servicing Honda generators Your auth...

Page 4: ...judgement You will find important safety information in a variety of forms including Safety Labels on the generator Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Safety Headings such as IMPORTANT SAFETY INFORMATION Safety Section such as GENERATOR SAFETY Instructions how to use this generator correctly and safely T...

Page 5: ...N 9 CONTROLS FEATURES 12 COMPONENT CONTROL LOCATIONS 12 CONTROLS 14 Fuel Valve Lever 14 Choke Lever 14 Engine Switch 15 Starter Grip 15 AC Circuit Breaker 15 Power Plug 16 FEATURES 17 Oil Alert System 17 Ground Terminal 17 Fuel Gauge 18 BEFORE OPERATION 19 ARE YOU READY TO GET STARTED 19 Knowledge 19 IS YOUR GENERATOR READY TO GO 19 Check the Engine 20 4MZ416010_Eng book 3 ページ２０１４年９月１０日水曜日午後２時３...

Page 6: ... IMPORTANCE OF MAINTENANCE 29 MAINTENANCE SAFETY 30 Safety Precautions 30 MAINTENANCE SCHEDULE 31 REFUELING 32 FUEL RECOMMENDATIONS 34 ENGINE OIL LEVEL CHECK 35 ENGINE OIL CHANGE 36 ENGINE OIL RECOMMENDATIONS 38 AIR CLEANER SERVICE 39 AIR FILTER CLEANING 41 SEDIMENT CUP CLEANING 42 SPARK PLUG SERVICE 43 STORAGE 45 STORAGE PREPARATION 45 Cleaning 45 Fuel 45 STORAGE PROCEDURE 46 STORAGE PRECAUTIONS ...

Page 7: ...Truck 50 TAKING CARE OF UNEXPECTED PROBLEMS 51 ENGINE WILL NOT START 51 ENGINE LACKS POWER 51 NO POWER AT THE AC RECEPTACLE 52 TECHNICAL INFORMATION 53 SERIAL NUMBER LOCATIONS 53 CARBURETOR MODIFICATION FOR HIGH ALTITUDE OPERATION 54 SPECIFICATIONS 55 WIRING DIAGRAM 56 4MZ416010_Eng book 5 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 8: ...children operate the generator without parental supervision Carbon Monoxide Hazards A generator s exhaust contains toxic carbon monoxide which you cannot see or smell Breathing carbon monoxide can KILL YOU IN MINUTES To avoid carbon monoxide poisoning follow these instructions when operating a generator Only run a generator OUTSIDE far away from windows doors and vents Never operate a generator in...

Page 9: ...lectrical 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 Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials Keep the generator at least 1 meter away from buildings and other equipment during operation Do not enclose the generator in any structure K...

Page 10: ...it has been in operation Refuel only outdoors in a well ventilated area and on a level sueface Never smoke near gasoline and keep other flames and sparks away Do not overfill the fuel tank Make sure that any spilled fuel has been wiped up before starting the engine Always store gasoline in an approved container 4MZ416010_Eng book 8 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 11: ...TION 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 servicing dealer for a replacement 4MZ416010_Eng book 9 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 12: ...bon monoxide a colorless odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the generator in an area that is confined or even partially enclosed area the air you breathe could contain a dangerous amount of exhaust gas Never run your generator inside a garage house or near open windows or doors Gasoline is highly flammable and explosive Turn the ...

Page 13: ...and electrical codes Improper connections can allow electrical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and when utility power is restored the generator may explode burn or cause fires in the building s electrical system A hot exhaust system can cause serious burns Avoid...

Page 14: ... pages to locate and identify the most frequently used controls CHOKE LEVER OIL FILLER CAP STARTER GRIP OIL DRAIN PLUG SEDIMENT CUP AIR CLEANER ENGINE SWITCH FUEL VALVE LEVER CONTROL PANEL FUEL TANK CAP MUFFLER SPARK PLUG FUEL GAUGE 4MZ416010_Eng book 12 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 15: ...IT BREAKER GROUND TERMINAL AC RECEPTACLE CONTROL PANEL AC CIRCUIT BREAKER GROUND TERMINAL AC RECEPTACLES K R RE S types L type AC CIRCUIT BREAKER GROUND TERMINAL AC RECEPTACLE M type 4MZ416010_Eng book 13 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 16: ...ne turn the fuel valve lever to the OFF position Choke Lever The choke lever opens and closes the choke valve in the carburetor The CLOSED position enriches the fuel mixture for starting a cold engine The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm engine FUEL VALVE LEVER OFF ON CHOKE LEVER CLOSED OPEN 4MZ416010_Eng book 14 ページ２０１４年９月１０日 ...

Page 17: ...tes the recoil starter to crank the engine for starting AC Circuit Breaker The circuit breaker will automatically switch OFF if there is a short circuit or a significant overload at the receptacle The circuit breaker may be used to switch the generator power ON or OFF OFF ON ON ENGINE SWITCH OFF STARTER GRIP AC CIRCUIT BREAKER ON OFF 4MZ416010_Eng book 15 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 18: ... electrical technicians unless you have the proper tools and are electrically proficient Electrical work should be performed by qualified electrical technicians in accordance with all applicable laws and electrical codes GROUND PIN Terminal with protrusion RUBBER COVER RAISED SECTION PLUG BODY GROOVE CABLE LIVE PIN Example K R RE S types 4MZ416010_Eng book 16 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 19: ...gine stops and will not restart check the engine oil level see page 35 before troubleshooting in other areas Ground Terminal The ground terminal is connected to the frame of the generator the metal non current carrying parts of the generator and the ground terminal of receptacle Before using the ground terminal consult a qualified electrician electrical inspector or local agency having jurisdictio...

Page 20: ...e 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 RED INDICATOR EMPTY FULL FUEL GAUGE 4MZ416010_Eng book 18 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 21: ...nsure compliance with environmental regulations and to maximize the service life of your equipment it is very important to take a few moments before you operate the generator to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the generator To prevent a possible fire keep the generator at least 1 meter away from building w...

Page 22: ...d around the generator Check the Engine Before each use look around and underneath the engine for signs of oil or gasoline leaks Check the oil level see page 35 A low oil level will cause the Oil Alert system to shut down the engine Check the air filter see page 39 A dirty air filter will restrict air flow to the carburetor reducing engine and generator performance Check the fuel level see page 32...

Page 23: ... and replace if damaged Make sure that the appliance is in good working order Faulty appliances or power cords can create a potential for electric shock Make sure the electrical rating of the tool or appliance does not exceed the rated power of the generator or the receptacle being used Operate the generator at least 1 meter away from buildings and other equipment Do not operate the generator in a...

Page 24: ...proper cooling allow at least 1 meter of empty space above and around the generator Refer to SAFE OPERATING PRECAUTIONS on page 21 and perform the IS YOUR GENERATOR READY TO GO checks see page 19 Refer to AC OPERATION see page 25 for connecting loads to the generator 1 Make sure that all appliances are disconnected from the AC receptacle 2 Make sure that the AC circuit breaker is in the OFF positi...

Page 25: ...as shown Do not allow the starter grip to snap back against the generator Return it gently to prevent damage to the starter Do not let the starter rope rub against the generator body or the rope will wear out prematurely 7 If the choke lever was moved to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE LEVER CLOSED OPEN OFF ON ENGINE SWITC...

Page 26: ...ion Under normal conditions use the following procedure 1 Move the AC circuit breaker to the OFF position 2 Turn the engine switch to the OFF position 3 Turn the fuel valve lever to the OFF position AC CIRCUIT BREAKER OFF OFF ON ENGINE SWITCH OFF FUEL VALVE LEVER OFF 4MZ416010_Eng book 24 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 27: ...the generator has been exceeded Substantial overloading may damage the generator Marginal overloading may shorten the service life of the generator 1 Start the engine see page 22 2 Switch ON the AC circuit breaker 3 Plug in the appliance Most motorized appliances require more than their rated wattage for startup PLUG ON K M R RE S types L type ON PLUG AC CIRCUIT BREAKER AC CIRCUIT BREAKER 4MZ41601...

Page 28: ...artup Make sure the electrical rating of the tool or appliance does not exceed the maximum power rating of the generator Maximum power is K M R RE types 2 2 kVA L S types 2 5 kVA For continuous operation do not exceed the rated power Rated power is K M R RE types 2 0 kVA L S types 2 3 kVA In either case the total power requirements VA of all appliances connected must be considered Appliance and po...

Page 29: ...s System Ground This generator has a system ground that connects the generator frame components to the ground terminals in the AC output receptacles The system ground is not connected to the AC neutral wire Improper connections 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 wh...

Page 30: ... or ordinances that apply 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 4MZ416010_Eng book 28 ページ２０１４年９月１０日水曜日午後２時３１...

Page 31: ...tions 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 authorized Honda servicing dealer for recommendations applicable to your individual needs and use Remember that your authorized Honda servicing dealer knows your generator best and is fully equipped to maintain and repair it To ensure the...

Page 32: ...doors Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep ...

Page 33: ... with the generator Use the supplied tools to perform maintenance tasks Using an incorrect tool may damage the generator Each use First month or 20 hrs Every 3 months or 50 hrs Every 6 months or 100 hrs Every year or 300 hrs Page Engine oil Check level o 35 Change o o 36 Air cleaner Check o 39 Clean o 1 41 Sediment cup Clean o 42 Spark plug Check adjust o 43 Replace o 43 Valve clearance Check adju...

Page 34: ...lling fuel Do not fill the fuel tank above the upper limit mark on the fuel strainer 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 Gasoline is highly flammable and ex...

Page 35: ...33 SERVICING YOUR GENERATOR After refueling reinstall the fuel tank cap securely FUEL TANK CAP UPPER LIMIT MARK UPPER LIMIT 4MZ416010_Eng book 33 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 36: ...osolvents and corrosion inhibitors Use of fuels with content of ethanol or methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty If your equ...

Page 37: ...low the upper limit fill with the recommended oil see page 38 to the upper limit 3 Reinstall the oil filler cap securely The Oil Alert system will automatically stop the engine before the oil level falls below safe limits However to avoid the inconvenience of an unexpected shutdown check the oil level regularly OIL FILLER CAP UPPER LIMIT 4MZ416010_Eng book 35 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 38: ... the oil filler cap drain plug and sealing washer 3 Allow the used oil to drain completely and then reinstall the drain plug and a new sealing washer Tighten the plug securely 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...

Page 39: ...he recommended oil see page 38 to the outer edge of the oil filler hole 5 Reinstall the oil filler cap securely Wash your hands with soap and water after handling used oil OIL FILLER CAP UPPER LIMIT SEALING WASHER Replace DRAIN PLUG 4MZ416010_Eng book 37 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 40: ...ded 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 SE or later or equivalent oil AMBIENT TEMPERATURE 4MZ416010_Eng book 38 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 41: ... side of the frame pipe taking care not to damage the air cleaner cover 3 Remove the air filter from the air cleaner case 4 Check the air filter to be sure it is clean and in good condition If the air filter is dirty clean it as described on page 41 Replace the air filter if it is damaged LATCH TAB AIR FILTER AIR CLEANER COVER HOOK SETTING PIN AIR CLEANER CASE 4MZ416010_Eng book 39 ページ２０１４年９月１０日 ...

Page 42: ...hat the cover is set securely There must be no clearance between the air cleaner cover and case Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the warranty LATCH TAB AIR FILTER AIR CLEANER COVER HOOK SETTING PIN AIR CLEANER CASE GOOD NO GOOD 4MZ416010_Eng book 40 ページ２０１４年９月...

Page 43: ...soapy water rinse and allow to dry thoroughly or clean in nonflammable solvent and allow to dry 2 Dip the air filter in clean engine oil then squeeze out all excess oil The engine will smoke when started if too much oil is left in the air filter 3 Wipe dirt from the air cleaner case and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor Squee...

Page 44: ...sediment cup and filter in nonflammable or high flash point solvent and dry them thoroughly 3 Reinstall the filter new O ring and sediment cup and tighten the sediment cup securely 4 Turn the fuel valve lever to the ON position and check for leaks Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away...

Page 45: ...round the spark plug area 2 Remove the spark plug with a spark plug wrench 3 Inspect the spark plug Replace it if the electrodes are worn or if the insulator is cracked chipped or fouled 4 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode The gap should be 0 7 0 8 mm SPARK PLUG WRENCH SPARK PLUG CAP SIDE ELECTROD...

Page 46: ...he 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 plug can damage the threads in the cylinder head 7 Attach the spark plug cap 4MZ416010_Eng book 44 ページ２０１４年９月１０日水曜日午後...

Page 47: ...ions Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your generator deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functiona...

Page 48: ... by turning 1 to 2 turns counterclockwise and drain the fuel from the carburetor c Place a suitable gasoline container below the sediment cup and use a funnel to avoid spilling fuel Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately DRAIN BOLT 4...

Page 49: ...page 36 3 Remove the spark plug see page 43 4 Pour a teaspoon 5 cm3 of clean engine oil into the cylinder 5 Pull the starter grip several times to distribute the oil in the cylinder 6 Reinstall the spark plug 7 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...

Page 50: ...ator on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the generator to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the generator promoting rust and corrosion REMOVAL FROM STORAGE Check your generator as described in the BEFOR...

Page 51: ...ting the generator turn the engine switch and the fuel valve lever OFF and Keep the generator level to reduce the possibility of fuel leakage Avoid a place exposed to direct sunlight when putting the generator on a vehicle If the generator is left in an enclosed vehicle for many hours high temperature inside the vehicle could cause fuel to vaporize resulting in a possible explosion Do not drive on...

Page 52: ...r tie down straps When using ropes or tie down straps to secure the generator for transportation only use the frame bars as attachment points by protecting them with protective cloths or equivalent Do not fasten ropes or straps to any other portions of the generator body Protective cloths or equivalent FRAME BARS 4MZ416010_Eng book 50 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 53: ...ngine Spark plug faulty fouled or improperly gapped Gap or replace spark plug see page 43 Spark plug wet with fuel flooded engine Dry and reinstall spark plug Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Take generator to your servicing dealer or refer to shop manual Possible cause Correction Air filter restricted Clean or replace air filter see page 39 throu...

Page 54: ...r left in the OFF position after starting Switch circuit breaker ON see page 25 Faulty power tool or appliance Replace or repair power tool or appliance Stop and restart the engine Faulty generator Take generator to your servicing dealer or refer to shop manual 4MZ416010_Eng book 52 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 55: ...bers and date purchased in the spaces below You will need this information when ordering parts and when making technical or warranty inquiries Engine serial number Frame serial number Date purchased FRAME SERIAL NUMBER ENGINE SERIAL NUMBER 4MZ416010_Eng book 53 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 56: ...es above 1 500 meters have your authorized Honda servicing dealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made When the carburetor has been modified for high altitude operation the air fuel m...

Page 57: ...single cylinder Displacement 163 cm3 Bore Stroke 68 0 45 0 mm Cooling System Forced air Ignition System Transistor magneto ignition Oil Capacity 0 58 L Fuel Tank Capacity 14 5 L Spark Plug BPR6ES NGK W20EPR U DENSO Model ER2500CX Type K M R RE L S AC output Rated voltage 230 V 220 V 120 V 220 V Rated frequency 50 Hz 60 Hz Rated ampere 8 7 A 9 1 A 19 2 A 10 5 A Rated output 2 0 kVA 2 3 kVA Maximum ...

Page 58: ...e Automatic Voltage Regulator Control Box Block Engine Block Engine Switch Engine Winding Field Winding Generator Block Generator Ground Ground Terminal Ignition Coil Main Winding Oil Alert Unit Oil Level Switch Spark Plug Transistor Magneto Unit Bl Br G Bu O R W Y Black Brown Green Blue Orange Red White Yellow 4MZ416010_Eng book 56 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 59: ... types M ACR K R RE S CBxB ACR GT MW GG ExW FW GB EgB OAU AVR Tr MU OLSw SP IgC EgSw ACCB GT R R Br Y Y Br Y Y Y Y Bl Bl Bl Bu Bu R R R R Y G Y G Y G Y G Y G Y a b c a b c Bu Bu Bu Bu Y Bu 4MZ416010_Eng book 57 ページ２０１４年９月１０日水曜日午後２時３１分 ...

Page 60: ...RMATION L type CBxB ACR GT MW2 MW1 GG ExW FW GB EgB OAU AVR Tr MU OLSw SP IgC EgSw ACCB W R W W Br Y Y Br Y Y Y Y Y Bl Bl Bl Y W W R Br R R R R R Y G Y G Y G Bu Bu Bu Bu 4MZ416010_Eng book 58 ページ２０１４年９月１０日水曜日午後２時３１分 ...

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