Honda EP2500CX User's Manual
Contents
1. 25 Starter 1 13 STARTING THEEN GINE rorat anra er a 20 STOPPING THE ENGINE kicasscesaccanceudaseastansliceceaeetanarnand s 22 STORAGE a A 43 47 STORAGE PREPARA 43 Systemi Ground 25 INDEX T TAKING OF UNEXPECTED PROBLEMS 49 TECHNICAL amp CONSUMER INFORMATION 52 TECHNICAL INFORMATION 4 111 0 2 0 0 1 41 1 06 52 THE IM PORTANCE OF MAINTENANCE 27 TRANPORT ING 48 58 67 QUICK REFERENCE INFORMATION Fuel Type Regular unleaded gasoline with a pump octane rating of 86 or higher Spark Plug Type NGK BPR6ES DENSO W20EPR U Electrode Gap 0 028 0 031 in 0 7 0 8 mm Maintenance Before each use Check engine oil level Check air filter First 20 hours Change engine oil Subsequent See Maintenance Schedule page 29 HONDA The Power of Dreams 31Z15601 72. 26 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE 27 MAINTENANCE SAFETY scstcescisectaccstexatecssiuedterasvese asne Eaa REAA 28 Safety Precautions 28 MAINTENANCE SCHEDULE 29 REFUELING 30 32 ENGINE E Eaa 33 ENGINE OIL 6 2 4 1 0 34 AIR CLEANER SERVICE 35 FORM AIR FILTER CUEAINIING aiana siias 37 SEDIMENT CUP 38 SPARK PLUG araa iana 39 SPARK ARRESTER SERVICE 41 STORAGE PREPARA TION 43 Cleaning 43 betel 43 Engine Omes 46 STORAGE PRECAUTIONS 47 REMOV
3. 2 12 CHOKE LVS icc 12 13 Starter ON 13 AC 1 1 1 1 0 4 13 E 14 14 Ground 000000 aE aaa 14 15 ARE YOU READY STARTED 16 16 IS YOUR GENERATOR READY 16 Check the Engi 17 5 23 24 STANDBY POWER 25 Connections to Building s Electrical System 25 System 25 Special
4. 66 61 IS YOUR GENERATOR READY 16 POW CUS 16 MAINTENANCE SAFETY 004402 28 MAINTENANCE SCHEDULE _ 29 POWER AT THE RECEPTACLES 51 Oil Alerte SCI 14 18 Operator Responsibility QUICK REFERENCE INFORMATION nccc Inside back cover R 5 ite sce ree 30 With 8 REMOVAL FROM STORAGE 47 5 SAFE OPERATING PRECAUTIONS 18 SAFETY LABEL LOCATIONS ciiisean aani 9 28 SEDIMENT CUP CEA NIN ea 38 Serial Number 52 SERVICING YOUR GENERATOR 27 SPARK ARRESTER SERVICE 41 SPARK PLUG SERVICE nsin sinai 39 RegqU iremMmentS 26 5 57 STANDBY POWER
5. 10 Customer Service INfOrMAat ON aidaa aana 60 Dealer Locator Information 59 El ctric Shock Mazar dS isese aara E E E 7 Emission Control System Information 54 ENGINE LACKS POWER 225 50 N 46 61 33 ENGINE OIL LEVEL CHECK 31 ENGINE OIL RECOM MENDATIONS 34 Engine Switeh 5 AEE aE Eai 13 ENGINE WILL NOT START 49 INDEX F G H K M e gen E PE E PE A E eo 14 Fire and 000000 7 FOAM AIR FILTER CLEANING 4 37 43 61 We 15 FUEL 5 31 Fuel Valve Lever 12 GENERATOR SAFETY 6 Ground Terminal 14 Honda Publications 59 IMPORTANT SAFETY INFORMATION 6 INITIAL USE INSTRUCTIONS
6. 2000 2007 12 Printed Japan
7. Before beginning your preoperation checks be sure the generator is level surface the engine switch is in the OFF position NOTICE Operating this generator less than 3 feet 1 meter from a building or other obstruction can cause overheating and damage the generator For proper cooling allow at least 3 feet 1 meter of empty space above and around the generator Check the Engine Check the oil level See page 32 A low oil level will cause the Oil Alert system to shut down the engine Check the air filter see page 35 dirty air filter will restrict air flow to the carburetor reducing engine and generator performance Check the fuel level see page 30 Starting with a full tank will help to eliminate or reduce operating interruptions for refueling 17 OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time please review the GENERATOR SAFETY section and the chapter titled BEFORE OPERATION For your Safety do not operate the generator in an enclosed area such as a garage Your generator s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death AWARNING Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas Breathing carbon monoxide can cause unconsciousness or death Never run the generator in a closed or even partly closed are
8. 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 dump it on the ground or pour it down the drain 3 With the generator in a level position fill with the recommended oil to the outer edge of the oil filler hole see page 34 4 Screw in the oil filler cap dipstick securely Wash your hands with soap and water after handling used oil SEALING WASHER OIL DRAIN PLUG OIL FILLER CAP DIPSTICK SERVICING YOUR GENERATOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting engine performance and service life Use 4 stroke motor oil that meets or exceeds the requirements for API service category 5 or later or equivalent Always check the API SERVICE label on the oil container to be sure it includes the letters 5 or later or equivalent 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 indicated range 0 20 40 60 80 100 F 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1 Push the latch tabs and open the air cleaner cover 2 Free the hooks from the setting pins the air cleaner case and remove the air cleaner cover to the right side of the frame pipe taking care not to damage the air cleaner cover
9. 8 mm Refer to page 39 Valve clearance cold IN 0 15 0 02 mm EX 0 20 0 02 See your authorized Honda dealer Other specifications No other adjustments needed Specifications may vary according to the types and are subject to change without notice 57 TECHNICAL amp CONSUMER INFORMATION iring 19 1 57 _ 9 ana O 18 18 LINN 18217 IOHLNOO a HOLIMS 13441 18 lt y9018 ANIDNA _ 40018 HOLIMS 3 HAV ng ng ONIGNIM OIA NIV H 18 1 ONIGNIM NIV OV TITY 2 _ 9 0 E IH 191170 OW 1 TECHNICAL amp CONSUMER INFORMATION CONSUMER INFORMATION Dealer Locator Information To find
10. an authorized Honda Servicing Dealer anywhere in the United States Call 800 426 7701 or visit our web site www hondapowerequipment com dea htm Honda Publications Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by skilled technician Available through your Honda dealer or through Helm Inc at 1 888 292 5395 or visit www hondapowerequipment com own htm Parts Catalog This manual provides complete illustrated parts lists Available through your Honda dealer Accessories Catalog Your authorized Honda power equipment dealer offers a wide selection of accessories optional equipment to make your generator even more useful Visit www hondapowerequipment com acc htm and click on Generators and Welders to see the entire catalog of accessories 59 TECHNICAL amp CONSUMER INFORMATION 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 Relations Office You can write American Honda Motor Co Inc Power Equipment
11. by law to be registered with local utility companies Check local regulations for proper registration and use procedures System Ground Honda portable generators have 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 If the generator is tested with a receptacle tester it will not show the same ground circuit condition as for a home receptacle 25 OPERATION 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 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 26 SERVICING YOUR GENERATOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free operation It will also help reduce air pollution To help you properly care for your generator the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by profes
12. cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Operate outside away from open windows or doors Bums 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 careful when working around gasoline Use only a non flammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 28 SERVICING YOUR GENERATOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 First Every Every Every Perform at every indicated month or Each month 3 6 year operating hour interval whichever comes use months months first 20 Hrs or 1300 Hrs 50 Hrs 100 Hrs Check level Air cleaner Check 1 Canister Check Every 2 years 2 California type Purge tube Check Every 2 years 2 Calif
13. 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 carburetor modification is made 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 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications TECHNICAL amp CONSUMER INFORMATION Emission Control System Information 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 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 The U S and Califomia Clean Air Acts EPA a
14. not covered under warranty If your equipment will be used on an infrequent or intermittent basis please refer to the fuel section of the STORAGE chapter for additional information regarding fuel deterioration 31 SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the engine oil level with the generator on a level surface and the engine stopped 1 Remove the oil filler cap dipstick and wipe it clean 2 Insert and remove the dipstick without screwing it into the oil filler hole Check the oil level shown on the dipstick 3 If the oil level is low fill to the outer edge of the oil filler hole with the recommended oil See page 34 4 Screw in the oil filler cap dipstick securely OIL FILLER CAP DIPSTICK OIL FILLER HOLE 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 32 SERVICING YOUR GENERATOR ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining 1 Place a suitable container below the engine to catch the used oil and then remove the oil filler cap dipstick drain plug and sealing washer 2 Allow the used oil to drain completely and then reinstall the drain plug and sealing washer Tighten the plug securely NOTICE Improper disposal of engine oil can be harmful to the environment
15. refuel with the engine OFF and cool FUEL TANK CAP FUEL GAUGE FUEL GAUGE BEFORE OPERATION ARE YOU READY TO GET STARTED Y our Safety is your responsibility A little time spent in preparation will significantly reduce your risk of injury Knowledge Read 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 24 IS YOUR GENERATOR READY TO GO For your Safety 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 AWARNING Improperly maintaining this generator or failing to correcta problem before operation could cause a malfunction in which you could be seriously injured Always perform a pre operation inspection before each operation and correct any problem 16 BEFORE OPERATION To prevent possible fire keep the generator at least feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine
16. running allow it to cool Refuel carefully to avoid spilling 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 SERVICING YOUR GENERATOR FUEL TANK CAP FUEL GAUGE UPPER LIMIT MARK 7 5 umn FULL FUEL GAUGE After refueling reinstall the fuel tank cap securely FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in 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 performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are
17. 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and turn the fuel valve lever to the OFF position 5 Draining the Fuel Tank and Carburetor AWARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Handle fuel only outdoors Wipe up spills immediately 1 Non california type Place a suitable gasoline container below the carburetor and use a funnel to avoid spilling fuel California type Place a suitable gasoline container below the carburetor drain hose 2 Non california type Remove the drain bolt and sealing washer and drain the gasoline from the carburetor California type Loosen the carburetor drain screw and drain the gasoline from the carburetor NON CALIFORNIA TYPE CALIFORNIA TYPE DRAIN SCREW 5 3 Non california type After all the gasoline has drained into the container tighten the drain bolt securely California type After all the gasoline has drained into the container tighten the drain screw securely 4 Place a suitable gasoline container below the sediment cup and use a funnel to avoid spilling gasoline 5 Remove the sediment cup See page 38 and then turn the fuel valve lever to the ON position 6 Allow the gasoline to drain completely and then
18. 3 Remove the foam air filter from the air cleaner case 4 Check the foam air filter to be sure itis clean and in good condition If the foam air filter is dirty clean it as described on page 37 Replace the foam air filter if it is damaged HOOK AIR CLEANER CASE FORM AIR FILTER AIR CLEANER COVER LATCH TAB 35 SERVICING YOUR GENERATOR 5 Reinstall the foam air filter in the air cleaner case 6 Set the hooks of the air cleaner cover to the setting pins securely then push the air cleaner cover to lock the latch tabs Be sure that the cover is set securely There must be no clearance between the air cleaner cover and case NOTICE 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 5 not covered by the Distributor s Limited Warranty GOOD NO GOOD AIR CLEANER CASE SETTING PIN AIR CLEANER COVER FORM AIR FILTER LATCH TAB 36 SERVICING YOUR GENERATOR FOAM AIR FILTER CLEANING 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 Maintenance Schedule 1 Clean the foam air filter in warm soapy water rinse and allow to dry thoroughly or clean in non flammable solven
19. AL FROM 5 2 47 TRANSPORTING 5 Carburetor Modification for High Altitude 53 Emission Control System Information 54 PM 2 caste 56 57 Winnog gD 58 CONSUMER INFORMATION 59 Dealer Locator Information 59 Pu 59 Customer Service 60 GENERATOR SAFETY IMPORTANT SAFETY INFORMATION Honda generators are designed for use with electrical equipment that has suitable power requirements Other uses can result in injury to the operator or damage to the generator and other property Most accidents can be prevented if you follow all instructions in this manual and on the generator The most common hazards are discussed below along with the best way to protect yourself and others Operator Responsibility Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output receptacles and connections e Be sure that anyone who operates the generator receives proper instruction Do not let children operate the generator witho
20. Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 8 30 am to 8 00 When you write or call please give us this information Model and serial numbers 5 page 52 Name of the dealer who sold the generator to you Name and address of the dealer who services your generator Date of purchase Your name address and telephone number detailed description of the problem INITIAL USE INSTRUCTIONS ENGINE OIL The generator is shipped WITHOUT OIL in the engine Place the generator on a level surface Remove the oil filler cap dipstick Add enough of the recommended oil to bring the oil level to the outer edge of the oil filler hole Use 4 stroke motor oil that meets or exceeds the requirements for API service category 5 or later or equivalent 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 indicated range 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 Screw in the oil filler cap dipstick securely FUEL Refer to pages 30 31 4 43 OIL FILLER CAP DIPSTICK 0 20 40 60 80 100 F 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE UPPER LIMIT 61 INITIAL USE INSTRUCTIONS BEFOR
21. E OPERATION Before using your generator you should become familiar with information contained in the following chapters and sections GENERATOR SAFETY 6 CONTROLS 6 FEATURES OPERATION 18 e STARTING THE ENGINE page 20 e STOPPING THE ENGINE page 22 62 INDEX A AC 8 24 AC lt lt 13 AC 23 AIR CLEANER SERVICE 35 56 ARE YOU READY GET STARVED 16 BEFORE OPERATION 16 62 Carbon Monoxide hazardS 6 Carburetor Modification for High Altitude Operation 53 Check the 17 iesirea a aaa a ainan 12 Clean aa a E N 43 COMPONENT amp CONTROL LOCATIONS eseese 10 Connections to a Building s Electrical System 25 nesa earar anaiai 59 CONTROLS rr re 12 CONTROLS amp FEATURES
22. Emission Durability Period Moderate 50 hours 0 80 inclusive 125 hours greater than 80 cc Intermediate 125 hours 0 80 cc inclusive 250 hours greater than 80 cc Extended 300 hours 0 80 inclusive 500 hours greater than 80 cc 1 000 hours 225 cc and greater TECHNICAL amp CONSUMER INFORMATION Specifications Dimensions Model EP2500CX1 Type Non California type California type AH type ACH type Description code EAHC Length 23 5 in 597 mm Width 17 1 in 435 mm Height 17 2 in 437 mm Dry mass weight 99 2 Ibs 45 0 kg 101 4 Ibs 46 0 kg Engine Model GX160H1 Engine type 4 stroke overhead valve single cylinder Displacement Bore Stroke 9 9 cu in 163 cm 2 68 1 77 in 68 0 45 0 mm Compression ratio 8 5 1 Engine speed 3 600 rom Cooling system Forced air Ignition system Transistorized magneto ignition Oil capacity 0 61 US qt 0 58 2 Fuel tank capacity 3 83 US gal 14 5 2 Spark plug BPR6ES W20EPR U DENSO Generator Type Non California type California type AC output Tuneup Specifications AH type ACH type Rated voltage 20V Rated frequency 60 Hz Rated current 19 2 A Rated output 2 300 VA Maximum output 2 500 VA ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 0 7 0
23. FF Switch circuit breaker ON position after starting Faulty power tool or Replace or repair power tool or appliance appliance Stop and restart the engine Faulty generator Take the generator to an authorized Honda servicing dealer or refer to the shop manual 51 TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER FRAME SERIAL NUMBER Record the engine and frame serial numbers 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 52 TECHNICAL amp CONSUMER INFORMATION Carburetor Modification for 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 Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 5 000 feet 1 500 meters have your authorized Honda servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications
24. N AC OPERATION 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 in the appliance or the rated load capacity of the generator has been exceeded NOTICE Substantial overloading may damage the generator Marginal overloading may shorten the service life of the generator 1 Start the engine see page 20 2 Switch ON the AC circuit breaker 3 Plug in the appliance Most motorized appliances require more than their rated wattage for startup AC CIRCUIT BREAKER PLUG OPERATION AC Applications Before connecting an appliance or power cord to the generator e Make sure that it is in good working order Faulty appliances or power cords can create a potential for electrical shock If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately Disconnect the appliance and determine whether the problem is the appliance or the rated load capacity of the generator has been exceeded e 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 NOTICE Substantial overloading will open the circuit breaker Exceeding the time limit for maximum power operation or sli
25. Owner s Manual GENERATOR EP2500CX 2008 Honda Motor Co Ltd See page 61 for initial use All Rights Reserved instructions WARNING engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm AWARNING Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas Breathing carbon monoxide can cause unconsciousness or death Never run the generator in a closed or even partly closed area where people may be present 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 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 whatever INTRODUCTION Congratulations on your selection of a Honda generator We are certain you will be pleased with your purchase of one of the finest generators on the market We want to help you get the best results from your new generator and to operate it safely This manual contains all the information on how to do that please read it carefully As you read this manual you
26. a where people may be present To prevent possible fire keep the generator at least feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine NOTICE Operating this generator less than 3 feet 1 meter from a building or other obstruction can cause overheating and damage the generator For proper cooling allow at least 3 feet 1 meter of empty space above and around the generator OPERATION Before connecting an AC appliance or power cord to the generator e Use grounded 3 prong extension cords tools and appliances or double insulated tools and appliances Inspect cords and plugs 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 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 Operate the generator at least feet 1 meter away from buildings and other equipment Do not operate the generator an enclosed structure 19 OPERATION STARTING THE ENGINE Refer to SAFE OPERATING PRECAUTIONS on and perform the IS YOUR GENERATOR READY GOchecks 16 Refer to AC OPERA TION see 23 for connecting l
27. ator 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 BEFORE OPERATION chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinder was coated with oil during storage preparation the engine may smoke briefly at startup This is normal 47 TRANSPORTING If the generator has been running allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle A hot engine and exhaust system can burn you and can ignite some materials Keep the generator level when transporting to reduce the possibility of fuel leakage Move the fuel valve lever 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 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Fuel valve lever OFF Turn lever ON Choke OPEN Move to CLOSED unle
28. ble materials away from the generator The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing the generator indoors GENERATOR SAFETY Refuel With Care Gasoline is extremely flammable and gasoline vapor can explode Allow the engine to cool if the generator has been in operation Refuel only outdoors in a well ventilated area with the engine OFF 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 GENERATOR 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 servicing dealer for a replacement keep heat sparks and flame away the fuel tank above the upper limit line CAUTION A hot exhaust system can cause serious burns Avoid contact if the engine has been running CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS Use the two illustrations on these pages to locate and identify the most frequently used controls AC RECEPTACLES GROUND TERMINAL AC CIRCUIT BREAKER CONTROL PANEL ENGINE SWITCH 10 CONTROL am
29. 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 functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air 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 The Distributor s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation 5 You extend fuel storage life by adding gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add gasoline stabilizer following the manufacturer s instructions 2 After adding a gasoline stabilizer the engine outdoors for
30. ghtly 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 2 500 VA For continuous operation longer than 30 minutes do not exceed the rated power Rated power 15 2 300 VA 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 OPERATION STANDBY POWER Connections to a Building s Electrical System Your generator can supply power to a building s electrical system If the generator will be used as an alternative to utility company power an isolation switch must be installed to disconnect the utility lines from the building when the generator is connected Installation must be performed by a qualified electrician and must comply with all applicable laws and electrical codes AWARNING 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 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 ora qualified electrician prior to making any power connections In some areas generators are required
31. he spark plug 1 Disconnect the spark plug cap and remove any dirt from around the Spark plug area 2 Remove the spark plugs with a spark plug wrench SPARK PLUG WRENCH SPARK PLUG CAP 3 Inspect the spark plug Replace SIDE ELECTRODE it if the electrodes are worn or if the insulator is cracked 0 028 0 031in chipped or fouled 0 7 0 8 mm 4 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode SEALING WASHER The gap should be 0 028 0 031 0 7 0 8 mm SERVICING YOUR GENERATOR 5 Make sure that the spark plug sealing washer is in good condition and thread the spark plug in by hand to prevent cross threading 6 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 anew spark plug tighten 1 2 turn after the spark plug seats NOTICE 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 SERVICING YOUR GENERATOR SPARK ARRESTER SERVICE The spark arrester must be 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 spar
32. install the sediment cup see page 38 1 Change the engine 5 page 33 2 Remove spark plug page 39 3 Pour a tablespoon 5 10 of clean engine oil into cylinder 4 Pull the starter grip several times to distribute the oil in the cylinder 5 Reinstall the spark plug 6 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 Return the starter grip gently 46 5 STORAGE PRECAUTIONS If your generator will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve in the OFF position to reduce the possibility of leakage Place the generator on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the gener
33. k arrester 1 Remove the 4mm screw then pull out the spark arrester SPARK ARRESTER 2 Use brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the screen The spark arrester must be free of breaks and tears Replace the spark arrester if it is damaged 41 3 Reinsert the spark arrester tighten the 4 mm screw to reinstall it SERVICING YOUR GENERATOR SPARK ARRESTER 5 STORAGE PREPARATION Proper storage preparation is essential for keeping your generator trouble free and looking good The following steps will help to keep rust and corrosion from impairing your generator s function and appearance and will make the engine easier to start when you use the generator again Cleaning Wipe the generator with a moist cloth After the generator has dried touch up any damaged paint and coat other areas that may rust with a light film of oil Fuel NOTICE Depending on the region where you operate your equipment fuel formulations may deteriorate and oxidize rapidly Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and or fuel system Please check with your servicing dealer for local storage recommendations 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
34. load at the receptacles The circuit breaker may be used to switch the generator power ON or OFF CONTROL amp FEATURES 122 ENGINE SWITCH LY SES AC CIRCUIT BREAKER OFF CONTROL amp FEATURES FEATURES Oil Alert System The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the Oil Alert system will automatically stop the engine the engine switch will remain in the ON position If the engine stops and will not restart check the engine oil level see 32 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 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 CONTROL amp FEATURES Fuel Gauge The fuel gauge is a mechanical device that measures the fuel 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 level surface Always
35. nd California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are e Removal or alteration of any part of intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters TECHNICAL amp CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your authorized Honda servicing dealer Hard starting or stalling after starting Rough idle e Misfiring or backfiring under load e Afterburning backfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your new Honda engine were designed built and certified to conform with applicable emission regulations We recommend the use of Honda Genuine parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of
36. oads to the generator AC CIRCUIT BREAKER 1 Make sure that the AC circuit breaker is in the OFF position The generator may be hard to start if a load is connected 2 Turn the fuel valve lever to the ON position 3 Move the choke lever to the CLOSED position to start a cold engine Leave the choke lever in the OPEN position to restart warm engine 20 OPERATION 4 Turn the engine switch to the ON position aa N ENGINE SWITCH 5 Pull the starter grip lightly until you feel resistance then pull briskly in the direction of the arrow as shown NOTICE Do not allow the starter grip to snap back against the engine 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 STARTER GRIP prematurely 6 If the choke lever was moved to CHOKE LEVER the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up 21 OPERATION STOPPING THE ENGINE To stop the engine in an emergency simply turn the engine switch to the OFF position 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 22 AC CIRCUIT BREAKER ENGINE SWITCH FUEL VALVE LEVER OPERATIO
37. ornia type Charge tube Check Every 2 years 2 California type Sediment cup Clean Spark plug Check adjust Spark arrester Clean equipped type only Valve clearance Check adjust 0 2 Combustion Clean After every 500 Hrs 2 chamber Fuel tank and filter Clean 0 2 Fuel tube Check Every 2 years Replace if necessary 2 1 Service more frequently when used in dusty areas 2 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 3 For commercial use log hours of operation to determine proper maintenance intervals Failure to follow this maintenance schedule could result in non warrantable failures SERVICING YOUR GENERATOR REFUELING With the engine stopped check the fuel gauge Refill the fuel tank if the fuel level is low AWARNING 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 NOTICE Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty Refuel in a well ventilated area before starting the engine If the engine has been
38. p FEATURES FUEL VALVE LEVER CHOKE LEVER OIL FILLER CAP AIR CLEANER DIPSTICK SEDIMENT CUP OIL DRAIN PLUG STARTER GRIP FUEL GAUGE FUEL TANK CAP SPARK PLUG MUFFLER SPARK ARRESTER 11 CONTROL amp FEATURES CONTROLS Fuel Valve Lever The fuel valve lever is located between the fuel tank and carburetor The fuel valve lever must be the ON position for the engine to run After stopping the engine 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 12 FUEL VALVE LEVER CHOKE LEVER Engine Switch The engine switch controls the ignition system OFF Stops the engine ON Running position and for starting Starter Grip Pulling the starter grip operates the recoil starter to crank the engine for starting NOTICE Do not allow the starter grip to snap back against the engine 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 AC Circuit Breaker The circuit breaker will automatically switch OFF if there is ashort circuit or a significant over
39. 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 performance The manufacturer or rebuilder of the part must certify that use of the part will not result a failure of the engine to comply with emission regulations Maintenance Follow the MAINTENANCE SCHEDULE on 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 dusty conditions will require more frequent service TECHNICAL amp CONSUMER INFORMATION Air Index Models certified for sale in Califomia An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board 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 less pollution The durability description is intended to 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 Descriptive Term Applicable to
40. sages preceded by a Safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if DANGER you don t follow instructions A WARNING You be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow CAUTION instructions e Safety Headings such as MPORTANT SAFETY INFORMATION Safety Section such as GENERATOR SAFETY Instructions how to use this generator correctly and safely This entire book is filled with important safety information please read it carefully 2 5 5 IMPORTANT SAFETY INFORMATION 6 OP Er ator RESPONSI MY 6 Carbon Monoxide 5 6 Electric Shock 7 5 7 Refuel With Care 8 SAFETY LABEL LOCATIONS 9 CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS 10 gt aaa Esdra ananake aaa 12
41. sionals and are normally 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 AWARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new Honda Genuine parts or their equivalents for repair and replacement Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to EPA standards 27 SERVICING YOUR GENERATOR MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task AWARNING Failure to properly follow maintenance instructions and precautions can
42. ss engine is warm Engine switch OFF Turn engine switch to ON Out of fuel Refuel 30 Bad fuel generator stored without treating or draining gasoline or refueled with bad gasoline Low oil level caused Oil Alert to stop engine Drain fuel tank and carburetor Refuel with fresh gasoline 30 Add oil 32 32 Turn engine switch to OFF and restart the engine Spark plug faulty fouled or improperly gapped Gap or replace spark plug Spark plug wet with fuel flooded engine Dry and reinstall spark plug Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Take the generator to an authorized Honda servicing dealer or refer to the shop manual TAKING CARE OF UNEXPECTED PROBLEMS ENGINE LACKS POWER gasoline or refueled with bad gasoline Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Possible cause Correction Air filter restricted Clean or replace air filter p 35 thru 37 Bad fuel generator stored Drain fuel tank and carburetor without treating or draining Refuel with fresh gasoline Take the generator to authorized Honda servicing dealer or refer to the shop manual TAKING CARE OF UNEXPECTED PROBLEMS NO POWER AT THE RECEPTACLES Possible Cause Correction Circuit breaker left in the O
43. t and allow to dry 2 Dip the foam air filter in clean engine oil and then squeeze out all excess oil The engine will smoke when started if too much oil is left in the filter 1 Soak 2 Squeeze 3 Oil 4 Squeeze Do not twist Do not twist 00 E gt 5 3 Wipe dirt from the air cleaner housing and cover using a moist Be careful to prevent dirt from entering the air duct that leads to the carburetor 37 SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING 1 Turn the fuel valve lever to the OFF position then remove the sediment cup O ring and filter Discard the O ring AWARNING 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 e Wipe up spills immediately 2 Clean the sediment cup and filter in nonflammable solvent 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 FUEL VALVE LEVER O RING Replace 38 SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs BPR6ES NGK W20EPR U DENSO NOTICE An incorrect spark plug can cause engine damage If the engine is hot allow it to cool before servicing t
44. ut parental supervision Carbon Monoxide Hazards Exhaust contains poisonous carbon monoxide a colorless odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the generator an area that is confined or even partly enclosed area the air you breathe could contain dangerous amount of exhaust gas Never run your generator inside a garage house or near open windows or doors GENERATOR SAFETY Electric Shock Hazards The generator produces enough electric power to cause a serious shock or electrocution if misused e Using a generator or electrical appliance in wet conditions such as rain or snow or near a pool or sprinkler system or when your hands are wet could result in electrocution Keep the generator dry If the generator is stored outdoors unprotected from the weather check all of the electrical components on the control panel before each use Moisture or ice can cause a malfunction or short circuit in electrical components that could result electrocution Do not connect to a building s electrical system unless an isolation switch has been installed by a qualified electrician Fire and Bum Hazards The exhaust system gets hot enough to ignite some materials Keep the generator at least 3 feet 1 meter away from buildings and other equipment during operation Do not enclose the generator in any structure Keep flamma
45. will find information preceded by a NOTICE Symbol That information is intended to help you avoid damage to your generator other property or the environment We suggest you read the Distributor s Limited Warrantyto fully understand its coverage and your responsibilities of ownership The Distributor s Limited Warranty is a separate document that should have been given to you by your dealer 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 Motor Co Ltd FEW WORDS ABOUT SAFETY Your Safety and the safety of others are very important And using this generator safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards 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 Safety Labels on the generator Safety Mes
Download Pdf Manuals
Related Search