Honda EM500 User's Manual
Contents
1. HONDA Power Equipment Owner s Manual Generator EM500 EM600 Click here to save this manual to your computer 6 1 A Jd LLLLLLLLLIS 1997 American Honda Motor Inc All Rights Reserved Thank you for purchasing a Honda generator This manual covers operation and maintenance of the EM500 and EM600 generators All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the riqht to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the generator and remain with the generator when sold Pay special attention to statements preceded by the following words EXT 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 questions about the generator consult an authorized Honda dealer OMITE The Honda generator is designed to give safe and dependable service if operated according to instructions Read and2. Refuel in a well ventilated area with the engine stopped e 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 e Be careful not to spill fuel when refueling Fuel vapor or spilled fuel may ignite If any fuel is spilled make sure the area is dry before starting the engine FUEL FILLER HOLE 4 STARTING THE ENGINE 1 Disconnect the load from the AC or DC receptacle 2 Move the engine switch to ENGINE CAUTION Do not allow the starter grip to snap back against the generator Return it gently to prevent damage to the housing NOTE Make sure the pilot lamp comes If not the filament may be burnt out 5 GENERATOR USE EXITS prevent electrical shock from faulty appliances the generator should be grounded Connect a length of heavy wire between the ground terminal and the ground source GROUND TERMINAL CAUTION e Limit operation requiring maximum power EM500 500VA EM600 600VA to 30 minutes For continuous operation do not exceed the rated power of 400VA EM500 and 450VA EM600 e Do not exceed the current limit specified for any one receptacle e Do not connect the generator to a household circuit This could cause damage to the generator or to electrical appliances in the house NOTE e The EM500 EM600 generate both AC
3. and DC power but they cannot be used at the same time The interlock selector switch prevents simultaneous use e Most appliance motors require more than their rated wattage for start up If the required starting wattage exceeds 100W the AC circuit will be over loaded AC operation 1 2 3 Start the engine and make sure the pilot lamp comes on If not the fila ment may be burnt out Move the selector switch to the AC position Plug in the appliance CAUTION Be sure that appliances do not exceed the rated load for more than 30 minutes and never exceed the maximum load Substantial over loading will switch off the circuit breaker Lesser overloading will not switch off the circuit breaker and will shorten the service life of the gen erator Check the frequency meter to verify that the generator is operating at 60Hz If it is not turn the throttle knob to increase or decrease engine speed until the correct frequency is obtained meter bar next to 60 will vibrate NOTE e An overloaded AC circuit will trip the AC circuit breaker If this occurs wait a few minutes before pushing the circuit breaker to resume operation pO DE FREQUENCY METER THROTTLE KNOB DC operation Start the engine and move the selector switch to the DC position The DC receptacle may be used for charging 12 volt automotive type batteries only W WARNING Batteries produce explosive gases Keep spar
4. the generator in rain or snow and do not let it get wet When charging a battery e Battery electrolyte contains sulphuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and call a doctor if your eyes were exposed e Batteries generate hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near a battery especially while charging it 2 COMPONENT IDENTIFICATION CIRCUIT BREAKERS OIL ALERT LAMP EM600 ONLY f f mins PILOT LAMP AC DC SELECTOR 3 SWITCH SPARK PLUG CAP ENGINE SWITCH DC RECEPTACLE FREQUENCY METER AC RECEPTACLE EXHAUST OUTLET RECOIL STARTER CARRYING HANDLE THROTTLE KNOB FUEL TANK CAP mm 9 IR CLEANER 9 AIR CL COVER SSS gt gt SS gt cu eu lt lt gt alii ROUND TERMINAL GRO OIL FILLER CAP 3 PRE OPERATION CHECK CAUTION Be sure to check the generator on a level surface with the engine stopped 1 Check the engine oil level CAUTION Engine oil is a major factor affecting engine performance and service life Non detergent or vegetable oils are not recommended Use Honda 4 stroke oil or an equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufacturer s requirements for Service Classification SE or SF Motor oils classified SE or SF will show
5. this designation on the container SAE 10W 40 is recommended for general all temperature use Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range Remove the oil filler cap and check the oil level If the level is low fill to the top of the oil filler neck with the recom mended oil CAUTION Running the engine with insufficient oil can cause serious engine damage OIL FILLER CAP FILLER HOLE 20W 40 20W 50 20 O 20 40 60 80 100F o A 30 20 10 0 10 20 30 40 NOTE e The oil alert lamp EM600 only will light during operation before the engine oil level becomes too low If this occurs stop the engine and fill to the top of the filler neck with the recommended oil page 4 e The oil alert lamp should always light when starting but should go out after the engine is running if there is sufficient oil If the lamp does light at all replace the bulb Ni IK SS E E fac OIL ALERT An 6 2 Check the fuel level Use low lead or unleaded automotive gasoline with a pump octane rating of 86 or higher Never use an oil gasoline mixture or dirty gasoline Avoid getting dirt dust or water in the fuel tank CAUTION Gasoline substitutes are not recommended they may be harmful to the fuel system components e Gasoline is extremely flammable and explosive under certain conditions
6. thoroughly wash your hands with soap and water as soon as possible after handling used oil NOTE Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground 14 Air cleaner service A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly page 13 Service more frequently when operating the generator in extremely dusty areas OMITA 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 may result 1 Loosen the cover bolt remove the air cleaner cover and remove the ele ment 2 Wash the 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 AIR CLEANER COVER 15 Spark plug service Recommended spark plug BPMR4A 10 NGK W14MPR U10 ND To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cap 2 Use the wrench supplied in the tool kit to remove the spark plug 3 Visually inspect the spark plug Discard it i
7. ap b Loosen the drain screw and drain the fuel into a suitable container Retighten the screw c Move the engine switch to OFF DRAIN SCREW 3 Pull the starter grip until resistance is felt the piston is coming up on its compression stroke At this position the exhaust and intake valves are closed and this will help protect the engine from corrosion 21 9 TROUBLESHOOTING A When the engine will not start 1 Is the engine switch ON 2 15 there enough fuel 3 15 nothing connected at the AC and DC receptacles 4 15 gasoline reaching the carburetor To check remove the side cover and loosen the drain screw with the fuel valve ON DITE 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 5 Is there a spark at the spark plug a Remove the spark plug cap Clean any dirt form around the spark plug base then remove the spark plug b Install the spark plug in the plug cap c Turn the engine switch on 22 d Grounding the side electrode to the cover pull the recoil starter to see if sparks jump across the gap SPARK PLUG e If there are no sparks replace the plug If OK try to start the engine according to the instructions 6 If the engine still does not start take the generator to the dealer B No electricity at the AC receptacles 1 Is the AC circuit breaker on 2 Check the electrical a
8. avoid damaging the spark arrester screen 18 MUFFLER 6 CE O ask y NS N A UA 7 522 ES 257 HEAT SHIELD AUTOMATIC CHOKE SETTING BOLT EXHAUST PIPE 5 Use a brush to remove carbon deposits from the spark arrester screen SCREEN 6 Check the exhaust pipe gaskets replace if damaged Reassemble the exhaust system See next page The automatic choke system needs adjustment when reinstalling 19 Automatic choke adjustment 1 Loosen the automatic choke setting bolt 2 Push the choke valve arm at the carburetor so the choke valve is closed 3 Adjust distance A to 3 mm 0 12 in by relocating the bimetal strip Retighten the bolt securely NOTE e Recheck distance A after tightening the bimetal strip e Hard starting or lack of power will result if not adjusted properly CHOKE VALVE ARM F Q le E IS MAA CARBURETOR e IN i PO 2 CN TEN 41 8 A 41 _ 3 mm A i 0 12 in AUTOMATIC CHOKE BIMETAL STRIP 20 8 TRANSPORTING STORAGE EZAMI When transporting the generator turn the engine switch OFF and keep the generator level to prevent fuel spillage Fuel vapor or spilled fuel 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 a With the engine switch ON remove the fuel filler c
9. dures listed on page 13 The 10 mm socket end of the spark plug wrench can also be used to turn the ground terminal nut Always keep the tool kit with the generator ES COMBINATION SCREWDRIVER PLUG WRENCH 10 mm WRENCH SCREWDRIVER HANDLE 12 Maintenance Schedule REGULAR SERVICE PERIOD Perform at every indi cated month or oper ating hour interval whichever occurs first Every year Every 6 months Every 3 months or or 100 Hrs 300 Hrs Air cleaner element Spark plug maintenance Valve clearance adjustment Combustion chamber and valve cleaning Fuel line inspection Replace if necessary Clean every 100 operating hours 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 proficient See the Honda Shop Manual 13 Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the oil filler cap and drain the oil 2 Refill with the recommended oil see page 4 and check the level OIL CAPACITY 0 352 0 37 US qt OIL FILLER CAP CAUTION Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to
10. f the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 4 Measure the plug gap with a feeler gauge The gap should be 0 9 1 0 mm 0 035 0 039 in Correct as necessary by bending the side electrode 0 9 mm 1 0 mm 0 035 0 039 in 16 5 Attach the plug washer Thread the plug in by hand to prevent cross threading 6 Tighten a new spark plug 1 2 turn with the wrench to compress the washer If you are reusing a plug it should only take 1 8 1 4 turn after the plug seats CAUTION e The spark plug must be securely tightened An improperly tightened plug can become very hot and possibly damage the generator e Never use a spark plug with an improper heat range 17 Spark arrester maintenance DT the generator has been running the muffler will be very hot Allow it to cool before proceeding CAUTION The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the four left side cover screws and remove the cover SCREW 2 Remove the mounting bolt for the muffler the mounting bolt for the choke bimetal strip and the two nuts that attach the exhaust pipe to the engine Remove the muffler and exhaust pipe 3 Remove the two screws that attach the heat shield to the muffler Remove the heat shield 4 Remove the two bolts that attach the exhaust pipe to the muffler Remove the exhuast pipe from the muffler carefully to
11. hat action can be taken Please bear in mind that your problem will likely be resolved at the dealership using the dealer s facilities equipment and personnel so it is very important that your initial contact be with the dealer Your purchase of a Honda product is greatly appreciated by both your dealer and American Honda Motor Co Inc We want to assist you in every way possible to assure your complete satisfaction with your purchase 29 30 MEMO vi I ns AM a ll a a 4 R a Titi TIN 8 lt o JI III P Eee 755 m Z a 11111111 _ ESE a BENENNEREERE s LLLLLLLLLL las l 1 j 5 Q 2 III TT II EE 11111841 LLLLLLELLELLLLLLLLLL EL N 11 4 gt lt O S ES
12. ks flames and cigarettes away To prevent the possibility of creating a spark near the battery connect the charging cord first to the battery then to the generator and disconnect the cord first at the generator Disconnect the vehicle s grounded battery cable first and after charging reconnect the grounded cable last This procedure will prevent the possibility of a short circuit and sparks if your tools accidentally make con tact between a battery terminal and the vehicle s frame or body CAUTION e Do not attempt to start an automobile engine with the generator still connected to the battery The generator may be damaged e Connect the positive battery terminal to the positive charging cord Do not reverse the charging cables or serious damage to the generator and or battery may occur NOTE e An overloaded DC circuit will trip the DC circuit breaker push button comes out If this happens wait a few minutes before pushing the circuit breaker to resume operation I III BLACK NEGATIVE li WES 10 6 STOPPING THE ENGINE To stop the engine in an emergency move the engine switch to OFF In normal use 1 Turn off the electrical appliance or disconnect the charging cord from the generator 2 Move the engine switch to OFF e High altitude operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will dec
13. nding Lamp Winding Main Winding AC Output Receptacle DC Output Receptacle Pulser Coil Pilot Lamp Spark Plug Black Blue Brown Green Gray Light green Red White Yellow 28 MEMO Warranty Service Owner Satisfaction Your satisfaction and goodwill are important to your dealer and to us All Honda warranty details are explained in the Distributor s Limited Warranty Normally any problems concerning the product will be handled by your dealer s service department If you have a warranty problem that has not been handled to your satisfaction we suggest you take the following action e Discuss your problem with a member of dealership management Often complaints can be quickly resolved at that level If the problem has already been reviewed with the Service Manager contact the owner of the dealership or the General Manager if your problem still has not been resolved to your satisfaction contact the Power Equipment Customer Relations Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipment Customer Relations Department P O Box 50 Gardena California 90247 0805 Telephone 213 604 2400 We will need the following information in order to assist you Your name address and telephone number Product model and serial number Date of purchase Dealer name and address Nature of the problem After reviewing all the facts involved you will be advised of w
14. ppliance or equipment for any defects C No electricity at the DC receptacles 1 15 the DC circuit breaker on 2 Check the electrical appliance or equipment for any defects 23 10 SPECIFICATIONS ____ Dimensions EM500 355 x 250 x 325 mm 14 0 x 9 84 x 12 8 in EM600 365 x 250 x 325 mm 14 4 x 9 84 x 12 8 in 500 18 0 kg 39 7 Ib W Engine Length x Width x Height Engine Type 4 stroke side valve 1 cylinder 59 8 cc 3 65 cu in 46 x 36 mm 1 81 x 1 42 in Displacement Bore x Stroke Compression Ratio 1 Engine Speed 3 600 r p m Cooling System Forced air cooling Ignition System C D I 0 35 0 37 US qt 2 0 0 5 US gal 10 W14MPR U10 ND Oil Capacity Fuel Tank Capacity Spark Plug Generator a Rated Voltage 120 V Rated Frequency 60 Hz EM500 3 3 A AC output 500 400 VA 400 W EM600 450 VA 450 W TAA 500 500 VA 500 W P EM600 600 VA 600 W Only for charging 12 V automotive DC output batteries 24 Maximum charging output 8 3 A WIRING DIAGRAM 11 EM500 25 EM600 MS LINN 26 Automatic Voltage Regulator DC Diode Rotor Exciter Winding Stator Exciter Winding Engine Switch Exciter Winding Frequency Meter Circuit Breaker Field Winding Ground Terminal Ignition Coil Ignition Wi
15. rease and feul consumption will increase High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the generator at altitudes higher than 6 000 feet above sea level have your authorized Honda Generator dealer perform these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 96 for each 1 000 foot increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification in made CAUTION Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance overheating and serious engine damage caused by an excessively lean air fuel mixture 11 7 MAINTENANCE The purpose of the maintenance schedule and adjustment is to keep the generator in the best operating condition Inspect or service as scheduled in the table on the next page Shut off the engine before performing any maintenance If the engine must be run make sure the area is well ventilated The exhaust 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 Tool kit The screwdriver and spark plug wrench stored under the generator will enable you to perform the owner maintenance proce
16. understand the Owner s Manual before operating the generator Failure to do so could result in personal injury or equipment damage Fan CONTENTS CONTENTS GENERATOR SAFETY ae 1 OMPONEN DEN ATION arcadas pesa Ed p 2 FHE O PEHATION CHECK 4 E 7 15 GENERATOR USE des sce 00 ran 8 H Q 11 7ZMAINTENANCE 12 18 TRANSPORTING STORAGE 21 IS TROUBLESHOOTING HERR SC rwn 22 1 GENERATOR SAFETY NY WARNING To ensure safe operation e Place the generator at least 1 m 3 ft away from buildings or other equip ment when operating the generator e Operate the generator on a level surface If the generator is tilted fuel spillage may resuit e Exhaust gas contains poisonous carbon monoxide Never run the generator in an enclosed area Be sure to provide adequate ventilation e Know how to stop the generator quickly and understand operation of all the controls Never permit anyone to operate the generator without proper instructions e Keep children and pets away from the generator when it is in operation e Keep away from rotating parts while the generator is running e The generator is a potential source of electrical shocks when misused do not operate with wet hands e Do not operate
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