Owner’sManual · CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS 120V/240V AC RECEPTACLE 120V RECEPTACLES: Except EG4000CL AC CIRCUIT BREAKER ENGINE SWITCH VOLTAGE SELECTOR SWITCH

00X31-Z30-600031Z30600 AHM.35.2011.02

PRINTED IN U.S.A.Printed on

Recycled Paper © 2011 Honda Motor Co., Ltd.—All Rights Reserved

Owner’s ManualGENERATOR

EG4000CL • EG5000CL • EG6500CL

See page 67 forInitial Use Instructions

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EG4000-6500CL Cover.ai 2/8/2011 10:23:01 AMEG4000-6500CL Cover.ai 2/8/2011 10:23:01 AM

Exhaust contains poisonous carbonmonoxide gas that can build up todangerous levels in closed areas.Breathing carbon monoxide cancause unconsciousness or death.

Never run the generator in a closed,or even partly closed area wherepeople may be present.

The information and specifications included in this publication were ineffect at the time of approval for printing. Honda Motor Co., Ltd.reserves the right, however, to discontinue or change specifications ordesign at any time without notice and without incurring any obligationwhatever.

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 generatorand should remain with the generator if resold.

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birthdefects or other reproductive harm.

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1

INTRODUCTION

Congratulations on your selection of a Honda generator. We arecertain you will be pleased with your purchase of one of the finestgenerators on the market.

We want to help you get the best results from your new generator andto operate it safely. This manual contains all the information on how todo that; please read it carefully.

As you read this manual, you will find information preceded by asymbol. 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 Warranty to fullyunderstand its coverage and your responsibilities of ownership. TheDistributor’s Limited Warranty is a separate document that shouldhave been given to you by your dealer.

When your generator needs scheduled maintenance, keep in mindthat your Honda servicing dealer is specially trained in servicingHonda generators and is supported by the parts and service divisionsof American Honda. Your Honda servicing dealer is dedicated to yoursatisfaction and will be pleased to answer your questions andconcerns.

Best Wishes,Honda Motor Co., Ltd.

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2

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

Your safety and the safety of others are very important. And using thisgenerator safely is an important responsibility.

To help you make informed decisions about safety, we have providedoperating procedures and other information on labels and in thismanual. This information alerts you to potential hazards that couldhurt you or others.

Of course, it is not practical or possible to warn you about all thehazards associated with operating or maintaining a generator. Youmust use your own good judgement.

You will find important safety information in a variety of forms,including:

on the generator.

preceded by a safety alert symbol and oneof three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

be or ifyou don’t follow instructions.

be or ifyou don’t follow instructions.

be if you don’t followinstructions.

such as IMPORTANT SAFETY INFORMATION.

such as

how to use this generator correctly and safely.

This entire book is filled with important safety information pleaseread it carefully.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERATOR SAFETY .

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3

CONTENTS

................................................................................GENERATOR SAFETY .6

........................................................................CONTROLS & FEATURES .11

...............................................................................BEFORE OPERATION .19

..................................................IMPORTANT SAFETY INFORMATION .6......................................................................Operator Responsibility .6

.................................................................Carbon Monoxide Hazards .6.......................................................................Electric Shock Hazards .7........................................................................Fire and Burn Hazards .7

.................................................................................Refuel With Care .8.................................................................SAFETY LABEL LOCATIONS .9

...........................................COMPONENT & CONTROL LOCATIONS .11............................................................................................CONTROLS .13

....................................................................................Engine Switch .13........................................................................................Starter Grip .13

................................................................................Fuel Valve Lever .14.......................................................................................Choke Lever .14

...................................................................Voltage Selector Switch .15.............................................................................AC Circuit Breaker .15

.........................................................................AC Circuit Protectors .16.............................................................................................FEATURES .17

..............................................................................Oil Alert System .17.....................................................Automatic Engine Stop Function .17

..............................................................................Oil Alert Function .17........................................................Overspeed Detection Function .17

............................................Abnormal Voltage Detection Function .17.........................................................................................Fuel Gauge .18

...............................................................................Ground Terminal .18

................................................ARE YOU READY TO GET STARTED? .19.........................................................................................Knowledge .19

..............................................IS YOUR GENERATOR READY TO GO? .19...............................................................................Check the Engine .20

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4

CONTENTS

..............................................................................................OPERATION .21

.............................................................SERVICING YOUR GENERATOR .33

..................................................................................................STORAGE .48

.....................................................SAFE OPERATING PRECAUTIONS .21......................................................................STARTING THE ENGINE .22......................................................................STOPPING THE ENGINE .25

.....................................................................................AC OPERATION .26.................................................................................AC Applications .27

...................................................................AC Receptacle Selection .28.................................................................Power Producing Circuits .28

...................................................................Voltage Selector Switch .29................................................................................STANDBY POWER .31

...............................Connections to a Building’s Electrical System .31.................................................................................System Ground .31

.......................................................................Special Requirements .32

.............................................THE IMPORTANCE OF MAINTENANCE .33......................................................................MAINTENANCE SAFETY .34

............................................................................Safety Precautions .34................................................................MAINTENANCE SCHEDULE .35

...................................................................................................Tools .35...........................................................................................REFUELING .36

...............................................................FUEL RECOMMENDATIONS .37..................................................................ENGINE OIL LEVEL CHECK .38

...........................................................................ENGINE OIL CHANGE .39....................................................ENGINE OIL RECOMMENDATIONS .40

........................................................................AIR CLEANER SERVICE .41..................................................AIR CLEANER ELEMENT CLEANING .43

.........................................................................SPARK PLUG SERVICE .44................................................................SPARK ARRESTER SERVICE .46.................................................................SEDIMENT CUP CLEANING .47

....................................................................STORAGE PREPARATION .48.............................................................................................Cleaning .48

.....................................................................................................Fuel .48..........................................................................................Engine Oil .51

...................................................................STORAGE PRECAUTIONS .52................................................................REMOVAL FROM STORAGE .52

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5

CONTENTS

......................................................................................TRANSPORTING .53

.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54

..........................................TECHNICAL & CONSUMER INFORMATION .57

..................................................................INITIAL USE INSTRUCTIONS .67

....................................................................................OPTIONAL PARTS .70

........................................................................................................INDEX .72

.............................QUICK REFERENCE INFORMATION .Inside back cover

...................................................................ENGINE WILL NOT START .54.......................................................................ENGINE LACKS POWER .55

..............................................NO POWER AT THE AC RECEPTACLES .56

................................................................TECHNICAL INFORMATION .57...................................................................Serial Number Location .57

....................Carburetor Modification for High Altitude Operation .58............................................Emission Control System Information .59

.............................................................................................Air Index .61....................................................................................Specifications .62

.................................................................................Wiring Diagram .63...............................................................CONSUMER INFORMATION .65..............................................................Dealer Locator Information .65

...........................................................................Honda Publications .65.........................................................Customer Service Information .66

...........................................................................................ENGINE OIL .67.......................................................................................................FUEL .68

...........................................................................BEFORE OPERATION .69.....................................................................................REGISTRATION .69

.....................................................................HANDLE INSTALLATION .70.................................................................WHEEL KIT INSTALLATION .71

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6

GENERATOR SAFETY

Operator Responsibility

Carbon Monoxide Hazards

IMPORTANT SAFETY INFORMATION

Honda generators are designed for use with electrical equipment thathas suitable power requirements. Other uses can result in injury to theoperator or damage to the generator and other property.Most injuries or property damage can be prevented if you follow allinstructions in this manual and on the generator. The most commonhazards are discussed below, along with the best way to protectyourself and others.

Be sure that anyone who operates the generator receives properinstruction. Do not let children operate the generator withoutparental supervision.

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles,and connections.

Exhaust contains poisonous carbon monoxide, a colorless, odorlessgas. Breathing carbon monoxide can cause loss of consciousnessand may lead to death.

If you run the generator in an area that is confined, or even partlyenclosed area, the air you breathe could contain a dangerousamount of exhaust gas.

Never run your generator inside a garage, house, or near openwindows or doors.

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GENERATOR SAFETY

Electric Shock Hazards

Fire and Burn Hazards

The generator produces enough electric power to cause a seriousshock or electrocution if misused.

Using a generator or electrical appliance in wet conditions, such asrain or snow, or near a pool or sprinkler system, or when your handsare 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 beforeeach use. Moisture or ice can cause a malfunction or short circuit inelectrical components that could result in electrocution.

Do not connect to a building’s electrical system unless an isolationswitch has been installed by a qualified electrician.

The exhaust system gets hot enough to ignite some materials.Keep the generator at least 3 feet (1 meter) away from buildingsand other equipment during operation.Do not enclose the generator in any structure.Keep flammable materials away from the generator.

The muffler becomes very hot during operation and remains hot fora while after stopping the engine. Be careful not to touch the mufflerwhile it is hot. Let the engine cool before storing the generatorindoors.

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8

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. Refuelonly outdoors in a well-ventilated area with the engine off. Do notoverfill the fuel tank. Never smoke near gasoline, and keep otherflames and sparks away. Always store gasoline in an approvedcontainer. Make sure that any spilled fuel has been wiped up beforestarting the engine.

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9

GENERATOR SAFETY

SAFETY LABEL LOCATIONS

If a label comes off or becomes hard to read, contact your Hondagenerator dealer for a replacement.

These labels warn you of potential hazards that can cause seriousinjury. Read them carefully.

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10

GENERATOR SAFETY

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11

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

120V/240V ACRECEPTACLE

112200VV RREECCEEPPTTAACCLLEESS

: Except EG4000CL

AC CIRCUIT BREAKER

ENGINE SWITCH

VOLTAGE SELECTOR SWITCH

AC CIRCUIT PROTECTORS

GROUND TERMINAL

Use the illustrations on these pages to locate and identify the mostfrequently used controls.

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12

CONTROLS & FEATURES

OIL DRAIN PLUG

AIR CLEANER

FUEL TANK CAP

STARTER GRIP

SEDIMENT CUP

FUEL VALVE LEVER

CHOKE LEVER

FUEL GAUGE

SPARK PLUG

MUFFLER

OIL FILLER CAP/DIPSTICK

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CONTROLS & FEATURES

CONTROLS

Engine Switch

Starter Grip

ENGINE SWITCH

OOFFFF

DDiirreeccttiioonn ttoo ppuullll

OONN

STARTER GRIP

The engine switch controls theignition system.

OFF Stops the engine.

ON Running position, and forstarting.

Pulling the starter grip operatesthe recoil starter to crank theengine.

Do not allow the starter grip tosnap back against the generator.Return it gently to preventdamage to the starter.Do not let the starter rope rubagainst the generator body, orthe rope will wear outprematurely.

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14

CONTROLS & FEATURES

Fuel Valve Lever

Choke Lever

OONN

OOFFFF

FUEL VALVE LEVER

CCLLOOSSEEDD

OPEN

CHOKE LEVER

The fuel valve lever is locatedbetween the fuel tank andcarburetor.

After stopping the engine, turnthe fuel valve lever to the OFFposition.

The fuel valve lever must be in theON position for the engine to run.

The choke is used to provideproper starting mixture when theengine is cold. It can be openedand closed by operating the chokelever manually. Move the chokelever to the CLOSED position toenrich the mixture for coldstarting.

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CONTROLS & FEATURES

Voltage Selector Switch

Switch Position

AC Circuit Breaker

120V/240V:

120V ONLY:

ON

OFF


120V/240V

120V ONLY

AC CIRCUIT BREAKER

The voltage selector switch switches generator output to produce‘‘120V ONLY’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the4-prong receptacle, the switch must be in the ‘‘120V/240V’’ position. Ifonly a 120V appliance is being connected to any of the 120V 3-prongreceptacles, select the ‘‘120V ONLY’’ position.Select the voltage before starting the engine.

The AC circuit breaker may be used to switch the generator power ONor OFF.

The AC circuit breaker will automatically switch OFF if there is a shortcircuit or a significant overload at the receptacles.

The 120V and 120V/240V receptacles can be usedsimultaneously.

ONLY the 120V receptacles can be used. Do not use the120V/240V receptacle in this position. The most power will beavailable at the 30A 120V locking plug receptacle.

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CONTROLS & FEATURES

AC Circuit Protectors

AC CIRCUIT PROTECTOR

PUSH

AC CIRCUIT PROTECTORfor Receptacle

120V 20A

120V 20A

120V 30A

: Except EG4000CL

ON

OFF




120V/240V 20A (EG4000CL)120V/240V 30A (EG5000CL, EG6500CL)

The AC circuit protectors will automatically switch OFF if there is ashort circuit or a significant overload of the generator at eachreceptacle. If an AC circuit protector switches OFF automatically, checkthat the appliance is working properly and does not exceed the ratedload capacity of the circuit before resetting the AC circuit protector ON.

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CONTROLS & FEATURES

Abnormal Voltage Detection Function

Overspeed Detection Function

Oil Alert Function

Automatic Engine Stop Function

FEATURES

Oil Alert System

The engine will automatically stop during generation when it detectsabnormal voltage.

To protect the engine from exceeding the engine load, the engine willautomatically stop if the engine speed becomes abnormal.

During operation, the engine will automatically stop if there is notenough oil in the tank. Moreover, if the generator is on a slope, the oilalert function may operate and stop the engine.

If the engine stops and will not restart, check the engine oil level (seepage ) before troubleshooting in other areas.

The Oil Alert system is designed to prevent engine damage caused byan insufficient amount of oil in the crankcase. Before the oil level in thecrankcase can fall below a safe limit, the Oil Alert system willautomatically stop the engine (the engine switch will remain in the ONposition).

If the engine stops, make sure the oil level is correct. Wait a fewminutes, and then try to restart the engine. If the engine still won’tstart, take the generator to your authorized servicing Honda powerequipment dealer.

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18

CONTROLS & FEATURES

Ground Terminal

Fuel Gauge

GROUND TERMINAL

FUEL GAUGEFUEL TANK CAP

FULL EMPTY

The generator ground terminal is connected to the frame of thegenerator, the metal non-current-carrying parts of the generator, andthe ground terminals of each receptacle.

Before using the ground terminal, consult a qualified electrician,electrical inspector, or local agency having jurisdiction for local codesor ordinances that apply to the intended use of the generator.

The fuel gauge is a mechanical device that measures the fuel level inthe tank. The red indicator in the window will reference the level inrelation to full or empty. To provide increased operating time, startwith a full tank before beginning operation. Check the fuel level withthe generator on a level surface. Always refuel with the engine OFFand cool.

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19

BEFORE OPERATION

ARE YOU READY TO GET STARTED?

Knowledge

IS YOUR GENERATOR READY TO GO?

Your safety is your responsibility. A little time spent in preparation willsignificantly reduce your risk of injury.

Read and understand this manual. Know what the controls do andhow to operate them.

Familiarize yourself with the generator and its operation before youbegin using it. Know how to quickly shut off the generator in case ofan emergency.

For your safety, and to maximize the service life of your equipment, itis very important to take a few moments before you operate thegenerator to check its condition. Be sure to take care of any problemyou find, or have your servicing dealer correct it, before you operatethe generator.

Improperly maintaining thisgenerator, or failing to correct aproblem before operation, couldcause a malfunction in which youcould be seriously injured.

Always perform a pre-operationinspection before each operation,and correct any problem.

If the generator is being used to power appliances, be sure that theydo not exceed the generator’s load rating (see page ).27

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BEFORE OPERATION

Check the Engine

To prevent a possible fire, keep the generator at least 3 feet (1 meter)away from building walls and other equipment during operation. Donot place flammable objects close to the engine.

Before beginning your pre-operation checks, be sure the generator ison a level surface and the engine switch is in the OFF position.

Check the air cleaner (see page ). A dirty air cleaner element willrestrict air flow to the carburetor, reducing engine and generatorperformance.

Check the fuel level (see page ). Starting with a full tank will help toeliminate or reduce operating interruptions for refueling.

Check the oil level (see page ). A low oil level will cause the Oil Alertsystem to shut down the engine or prevent it from starting.

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21

SAFE OPERATING PRECAUTIONS

OPERATION

For your safety, do not operate the generator in an enclosed area suchas a garage. Your generator’s exhaust contains poisonous carbonmonoxide gas that can collect rapidly in an enclosed area and causeillness or death.

Exhaust contains poisonous carbonmonoxide gas that can build up todangerous levels in closed areas.Breathing carbon monoxide cancause unconsciousness or death.

Never run the generator in a closed,or even partly closed area wherepeople may be present.

Use grounded 3-prong extension cords, tools, and appliances, ordouble-insulated tools and appliances.

Before connecting an AC appliance or power cord to the generator:

Inspect cords and plugs, and replace if damaged.Make sure that the appliance is in good working order. Faultyappliances or power cords can create a potential for electric shock.Make sure the electrical rating of the tool or appliance does notexceed that of the generator. Never exceed the maximum powerrating of the generator. Power levels between rated and maximummay be used for no more than 30 minutes.Operate the generator at least 3 feet (1 meter) away from buildingsand other equipment.Do not operate the generator in an enclosed structure.

Before operating the generator for the first time, review chaptersGENERATOR SAFETY (see page ) and BEFORE OPERATION (seepage ).

619

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OPERATION

STARTING THE ENGINE

FUEL VALVE LEVER

OFF

OONN

AC CIRCUIT BREAKER

To prevent a possible fire, keep the generator at least 3 feet (1 meter)away from building walls and other equipment during operation. Donot place flammable objects close to the engine.

Operating this generator less than 3 feet (1 meter) from a building orother obstruction can cause overheating and damage the generator.For proper cooling, allow at least 3 feet (1 meter) of empty spaceabove and around the generator.

Refer to SAFE OPERATING PRECAUTIONS on page and perform theIS YOUR GENERATOR READY TO GO checks (see page ). Refer toAC OPERATION (see page ) for connecting loads to the generator.

Make sure that the AC circuitbreaker is in the OFF position.The generator may be hard tostart if a load is connected.

Turn the fuel valve lever to theON position.

1.

2.

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23

OPERATION

CHOKE LEVER

OOPPEENN

OONN

ENGINE SWITCH

STARTER GRIP

DDiirreeccttiioonn ttoo ppuullll

CCLLOOSSEEDD

Turn the engine switch to theON position.

Pull the starter grip lightly untilyou feel resistance; then pullbriskly in the direction of thearrow as shown.

Do not allow the starter gripto snap back against theengine. Return it gently toprevent damage to the starter.Do not let the starter rope rubagainst the generator body,or the rope will wear outprematurely.

To start a cold engine, move thechoke lever to the CLOSEDposition.To restart a warm engine, leavethe choke lever in the OPENposition.

5.

4.

3.

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OPERATION

CHOKE LEVER

OOPPEENN

If the choke lever was moved tothe CLOSED position to startthe engine, gradually move it tothe OPEN position as theengine warms up.

6.

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25

OPERATION

STOPPING THE ENGINE

OOFFFF

OOFFFF

ENGINE SWITCH

OOFFFF

FUEL VALVELEVER

AC CIRCUIT BREAKER

To stop the engine in an emergency, simply turn the engine switch tothe OFF position. Under normal conditions, use the followingprocedure.

Turn off or disconnect all appliances that are connected to thegenerator.

Move the AC circuit breaker tothe OFF position.

Turn the engine switch to theOFF position.

Turn the fuel valve lever to theOFF position.

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4.

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OPERATION

AC OPERATION

PLUG


120V/240V

120V ONLY

AC CIRCUIT BREAKER

ON

: Except EG4000CL

AC CIRCUIT PROTECTORS

If an appliance begins to operate abnormally, becomes sluggish, orstops suddenly, turn it off immediately. Disconnect the appliance, anddetermine whether the problem is in the appliance or the rated loadcapacity of the generator has been exceeded.

Substantial overloading may damage the generator. Marginaloverloading may shorten the service life of the generator.

With the voltage selector switchin the ‘‘120V/240V’’ position,you can use the 120V and 120V/240V receptaclessimultaneously. If you are NOTusing the 120V/240V receptacle,then select the ‘‘120V ONLY’’position.

Turn the voltage selector switchto either position.

Most motorized appliancesrequire more than their ratedwattage for startup.

Start the engine (see page ).

Switch ON the AC circuit breaker.

Plug in the appliance.

Turn on the appliance.

Do not exceed the current limit specified for any one receptacle. If anoverloaded circuit causes the AC circuit breaker or AC circuit protectorto switch OFF, reduce the electrical load on the circuit, wait a fewminutes and then reset the AC circuit breaker or AC circuit protector.

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2.

3.

4.

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5.

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27

OPERATION

AC Applications

Before connecting an appliance or power cord to the generator:

If an appliance begins to operate abnormally, becomes sluggish, orstops suddenly, turn it off immediately. Disconnect the appliance,and determine whether the problem is the appliance or the ratedload capacity of the generator has been exceeded.

Limit operation requiring maximum power to 30 minutes.Maximum power is:

Make sure that it is in good working order. A faulty appliance orpower cord can create a potential for electrical shock.

Substantial overloading will open the AC circuit breaker. Exceedingthe time limit for maximum power operation or slightly overloadingthe generator may not switch the AC circuit breaker OFF, but willshorten the service life of the generator.

4.0 kVA5.0 kVA6.5 kVA

Make sure that the combined electrical rating of the tools orappliances do not exceed that of the generator. Never exceed themaximum power rating of the generator. Power levels betweenrated and maximum may be used for no more than 30 minutes.

The total power requirements (VA) of all appliances connected mustbe considered. Appliance and power tool manufacturers usually listrating information near the model number or serial number.

5.5 kVA4.5 kVA3.6 kVA

For continuous operation (longer than 30 minutes), do not exceed therated power.Rated power is:

EG4000CL:EG5000CL:EG6500CL:

EG4000CL:EG5000CL:EG6500CL:

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28

OPERATION

AC Receptacle Selection

Power Producing Circuits

4A

4B

4A 4B

120V/240V 120V ONLY

POWER CIRCUIT 1

POWER CIRCUIT 2

POWERCIRCUIT 1

POWERCIRCUIT 2

120V 30A120V 20A (in total)120V 20A (in total)& 120V/240V 20A (EG4000CL)

120V/240V 30A (EG5000CL, EG6500CL)

: Except EG4000CL

The control panel, shown below, has a voltage selector switch andfour receptacles. Receptacle 4, the 240-volt receptacle, has twopowered terminals, 4A and 4B.

When the voltage selector switch is in the 120V ONLY position, thepower producing circuits operate in parallel, sharing the total loadconnected to terminal 4A and receptacles 1, 2, and 3.

This generator is equipped with two power generating circuits.When the voltage selector switch is in the 120V/240V position, eachof the two power producing circuits supplies power to specificreceptacles.

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29

OPERATION

Voltage Selector Switch

120V ONLY Position

Available PowerEG4000CL EG5000CL EG6500CL

SwitchPosition

Receptacle

The power available to each receptacle depends on the position of thevoltage selector switch.

120V ONLY

120V/240V

1

2

3

4A

4B

1

2

3

4A-4B

45.8 A37.5 A30.0 ATotal Current Available:

When the voltage selector switch is in the 120V ONLY position, you donot need to spread the load over the receptacles. You must, however,make sure the load on any receptacle does not exceed its availablepower shown below and the total load does not exceed the totalcurrent available.

30A at 120V

20A at 120V

20A at 120V

20A at 120V

None

15.0A at 120V

15.0A at 120V

15.0A at 120V

15.0A at 240V

30A at 120V

20A at 120V

20A at 120V

30A at 120V

None

18.8A at 120V

18.8A at 120V

18.8A at 120V

18.8A at 240V

30A at 120V

20A at 120V

20A at 120V

30A at 120V

None

22.9A at 120V

20A at 120V

20A at 120V

22.9A at 240V

(EG4000CL)(EG5000CL)(EG6500CL)

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30

OPERATION

120V/240V Position

Total Current AvailableEG6500CLEG5000CLEG4000CL

Set ofReceptacles

Power ProducingCircuit

When the voltage selector switch is in the 120V/240V position, youmust balance the load. Divide the load between the two sets ofreceptacles shown below. Balancing is necessary because each set ofreceptacles is powered by only one power producing circuit that canproduce a maximum of amps( ).

15.0 A18.8 A22.9 A

15.0A

15.0A

18.8A

18.8A

22.9A

22.9A

:(EG4000CL)(EG5000CL)(EG6500CL)

1 3 4B

2 4A

1

2

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31

OPERATION

STANDBY POWER

Connections to a Building’s Electrical System

System Ground

Connections for standby power to a building’s electrical system mustbe made by a qualified electrician. The connection must isolate thegenerator power from utility power, and must comply with allapplicable laws and electrical codes.

Improper connections to a building’selectrical system can allow currentfrom the generator to backfeed intothe utility lines.

Such backfeed may electrocuteutility company workers or otherswho contact the lines during apower outage, and the generatormay explode, burn, or cause fireswhen utility power is restored.

Consult the utility company or aqualified electrician prior to makingany power connections.

In some areas, generators are required by law to be registered withlocal utility companies. Check local regulations for proper registrationand use procedures.

Honda portable generators have a system ground that connects thegenerator frame components to the ground terminals in the AC outputreceptacles. The system ground is not connected to the AC neutralwire. If the generator is tested with a receptacle tester, it will not showthe same ground circuit condition as for a home receptacle.

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OPERATION

Special Requirements

There may be Federal or State Occupational Safety and HealthAdministration (OSHA) regulations, local codes, or ordinances thatapply to the intended use of the generator. Please consult a qualifiedelectrician, electrical inspector, or the local agency having jurisdiction.

In some areas, generators are required to be registered with localutility companies.

If the generator is used at a construction site, there may beadditional regulations that must be observed.

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33

SERVICING YOUR GENERATOR

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement, or repair of the emission control devicesand systems may be performed by any engine repair establishment orindividual, using parts that are ‘‘certified’’ to EPA standards.

Good maintenance is essential for safe, economical, and trouble freeoperation. It will also help reduce air pollution.

To help you properly care for your generator, the following pagesinclude a maintenance schedule, routine inspection procedures, andsimple maintenance procedures using basic hand tools. Other servicetasks that are more difficult or require special tools are best handledby professionals and are normally performed by a Honda technician orother qualified mechanic.

The maintenance schedule applies to normal operating conditions. Ifyou operate your generator under unusual conditions, such assustained high-load or high-temperature operation, or use it in dustyconditions, consult your servicing dealer for recommendationsapplicable to your individual needs and use.

Improper maintenance, or failure tocorrect a problem before operation,can cause a malfunction in whichyou can be seriously hurt or killed.

Always follow the inspection andmaintenance recommendations andschedules in this owner’s manual.

Remember that your servicing dealer knows your generator best andis fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, HondaGenuine parts or their equivalents for repair and replacement.

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－

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34


MAINTENANCE SAFETY

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

Some of the most important safety precautions follow. However, wecannot warn you of every conceivable hazard that can arise inperforming maintenance. Only you can decide whether or not youshould perform a given task.

Failure to properly followmaintenance instructions andprecautions can cause you to beseriously hurt or killed.

Always follow the procedures andprecautions in the owner’s manual.

Make sure the engine is off before you begin any maintenance orrepairs. This will eliminate several potential hazards:

Operate outside away from open windows or doors.

Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have thetools and skills required.

To reduce the possibility of fire or explosion, be careful whenworking around gasoline. Use only a non-flammable solvent, notgasoline, to clean parts. Keep cigarettes, sparks, and flames awayfrom all fuel-related parts.

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35


MAINTENANCE SCHEDULE

Tools

Engine oil

Air cleaner

Sediment cupSpark plug

Spark arresterIdle speedValve clearanceCombustionchamberFuel tank and filterFuel tubeCanisterPurge tubeCharge tube

Check levelChangeCheckCleanCleanCheck-adjustReplaceCleanCheck-adjustCheck-adjustClean

CleanCheckCheckCheckCheck

ITEM

Perform at every indicated monthor operating hour interval,whichever comes first.

REGULAR SERVICE PERIOD (3)Eachuse

(1)

(2)

(2)(2)

page

3839414347444446

Every 2 years (Replace if necessary) (2)Every 2 years (2)Every 2 years (2)Every 2 years (2)

Service more frequently when used in dusty areas.These items should be serviced by your Honda servicing dealer, unless you have the propertools and are mechanically proficient. Refer to the Honda shop manual for service procedures.For commercial use, log hours of operation to determine proper maintenance intervals.

Failure to follow this maintenance schedule could result in non-warrantable failures.

After every 1,000 Hrs. (2)

(1)(2)

(3)

Firstmonth

or20 Hrs.

Every3

monthsor

50 Hrs.

Every6

monthsor

100 Hrs.

Everyyearor

300 Hrs.

A box wrench and wrench handle are supplied with the generator.Use the supplied tools to perform maintenance tasks. Using anincorrect tool may damage the generator.

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36


REFUELING

Gasoline is highly flammable andexplosive.

You can be burned or seriouslyinjured when handling fuel.

Stop the engine and keep heat,sparks, and flame away.Handle fuel only outdoors.Wipe up spills immediately.

Fuel can damage paint and plastic. Be careful not to spill fuel whenfilling your fuel tank. Damage caused by spilled fuel is not coveredunder warranty.

Refuel in a well-ventilated area before starting the engine. If the enginehas been running, allow it to cool. Refuel carefully to avoid spilling fuel.

Never refuel the engine inside a building where gasoline fumes mayreach 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.

Do not fill above the upper level mark.

With the engine stopped, check the fuel gauge. Refill the fuel tank ifthe fuel level is low.

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37


FUEL RECOMMENDATIONS

FUEL GAUGE

UPPER LEVEL MARK (RED)

FUEL TANK CAP

UPPER LEVELMARK (RED)

FUEL STRAINER

FULL EMPTY

If your equipment will be used on an infrequent or intermittent basis,please refer to the fuel section of the STORAGE chapter (page ) foradditional information regarding fuel deterioration.

Engine damage or performance problems that result from using a fuelwith percentages of ethanol or methanol greater than shown aboveare not covered under warranty.

Use of fuels with content of ethanol or methanol greater than shownabove may cause starting and/or performance problems. It may alsodamage metal, rubber, and plastic parts of the fuel system.

You may use regular unleaded gasoline containing no more than 10%ethanol (E10) or 5% methanol by volume. In addition, methanol mustcontain cosolvents and corrosion inhibitors.

Never use stale or contaminated gasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fuel tank.

This engine is certified to operate on regular unleaded gasoline with apump octane rating of 86 or higher.

After refueling, reinstall the fuel tank cap securely.

48

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38


ENGINE OIL LEVEL CHECK

UPPER LIMIT

OIL FILLER HOLE


Check the oil level BEFORE EACH USE with the generator on a levelsurface and the engine stopped.

Remove the oil filler cap/dipstick and wipe it clean.

Insert and remove the dipstick without screwing it into the oil fillerhole. Check the oil level shown on the dipstick.

If the oil level is low, fill to the outer edge of the oil filler hole withthe recommended oil (see page ).

Screw in the oil filler cap/dipstick securely.

The Oil Alert system will automatically stop the engine before the oillevel falls below safe limits. However, to avoid the inconvenience of anunexpected shutdown, check the oil level regularly.

1.

2.

3.

4.

40

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×

×

×

39


ENGINE OIL CHANGE

UPPER LIMIT

SEALINGWASHER


12 15 mmOIL DRAIN PLUG

Drain the oil while the engine is warm to assure rapid and completedraining.

With the generator in a level position, fill with the recommended oilto the outer edge of the oil filler hole (see page ).


Wash your hands with soap and water after handling used oil.

Improper disposal of engine oil can be harmful to the environment. Ifyou change your own oil, please dispose of it properly. Put it in asealed container, and take it to a recycling center. Do not discard it in atrash bin, dump it on the ground, or pour it down a drain.

Place a suitable container below the engine to catch the used oil,and then remove the oil filler cap/dipstick, 12 15 mm drain plug,and sealing washer.

Allow the used oil to drain completely, and then reinstall the 12 15mm drain plug and a new sealing washer. Tighten the plug securely.

1.

2.

3.

4.

38

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40


ENGINE OIL RECOMMENDATIONS

AMBIENT TEMPERATURE

Oil is a major factor affecting performance and service life. Use4-stroke automotive detergent oil.

SAE 10W 30 is recommended for general use. Other viscositiesshown in the chart may be used when the average temperature inyour area is within the recommended range.

The SAE oil viscosity and service category are in the API label on theoil container. Honda recommends that you use API service categorySJ or later (or equivalent) oil.

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41


AIR CLEANER SERVICE

HOOK

SETTING PIN

CLIP

AIR CLEANER CASE

AIR CLEANER ELEMENT

FRAME PIPE

AIR CLEANER COVER

Unsnap the air cleaner cover clips and open the air cleaner cover.

Free the hooks from the setting pins on the air cleaner case andremove the air cleaner cover to the right side of the frame pipe,taking care not to damage the air cleaner cover.

Remove the air cleaner element from the air cleaner case.

Check the air cleaner element to be sure it is clean and in goodcondition.If the air cleaner element is dirty, clean it as described on page .Replace the air cleaner element if it is damaged.

3.

2.

1.

4.

43

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42


HOOK

SETTING PIN

CLIP

AIR CLEANER CASE

AIR CLEANER ELEMENT

AIR CLEANER COVER

GOOD NO GOOD

Reinstall the air cleaner element in the air cleaner case.

Set the hooks of the air cleaner cover to the setting pins securely,and then push the air cleaner cover to lock the clips.Be sure that the cover is set securely. There must be no clearancebetween the air cleaner cover and air cleaner case.

Operating the engine without an air filter or with a damaged air filterwill allow dirt to enter the engine, causing rapid engine wear. This typeof damage is not covered by the Distributor’s Limited Warranty.

6.

5.

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43


AIR CLEANER ELEMENT CLEANING

Wipe dirt from the air cleaner housing and cover using a moist rag.Be careful to prevent dirt from entering the air duct that leads to thecarburetor.

A dirty air cleaner element will restrict air flow to the carburetor,reducing engine performance. If you operate the generator in verydusty areas, clean the air cleaner element more frequently thanspecified in the Maintenance Schedule.

Soak the air cleaner element in clean engine oil and squeeze out theexcess oil. The engine will smoke during initial startup if too muchoil is left in the air cleaner element.

Wash the air cleaner element in a solution of household detergentand warm water and rinse thoroughly, or wash in nonflammable orhigh flashpoint solvent. Allow the air cleaner element to drythoroughly.

3.

4. Squeeze1. Soak 3. Oil2. Squeeze to Dry

1.

2.

Do not twist.Do not twist.

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44


SPARK PLUG SERVICE

Recommended spark plugs:

SPARK PLUG WRENCH

SPARK PLUG CAP

BPR5ES (NGK)

To ensure proper engine operation, the spark plug must be properlygapped and free of deposits.

An incorrect spark plug can cause engine damage.

If the engine is hot, allow it to cool before servicing the spark plug.

Disconnect the spark plug cap, and remove any dirt from around thespark plug area.

Remove the spark plug with a spark plug wrench.

1.

2.

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45


0.028 0.031 in (0.7 0.8 mm)

SIDE ELECTRODE

SEALING WASHER

Measure the spark plug electrode gap with a wire-type feeler gauge.Correct the gap, if necessary, by carefully bending the side electrode.

Visually inspect the spark plug. Replace it if the electrodes are wornor if the insulator is cracked, chipped, or fouled.

A loose spark plug can overheat and damage the engine.Overtightening the spark plug can damage the threads in the cylinderhead.

If installing a new spark plug, tighten 1/2 turn after the spark plugseats to compress the washer. If reinstalling a used spark plug,tighten 1/8 1/4 turn after the spark plug seats to compress thewasher.

After the spark plug is seated, tighten with a spark plug wrench tocompress the washer.

Check that the spark plug sealing washer is in good condition, andthread the spark plug in by hand to prevent cross-threading.

Attach the spark plug cap.

0.028 0.031 in (0.7 0.8 mm)The gap should be:

3.

4.

5.

6.

7.

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46


SPARK ARRESTER SERVICE

SPARK ARRESTER SCREEN

SPARK ARRESTER5 mm SCREWS

The spark arrester must be serviced every 100 hours to keep itfunctioning as designed.

If the engine has been running, the muffler will be very hot. Allow themuffler to cool before servicing the spark arrester.

Clean the spark arrester as follows:

Remove the two 5 mm screws, and remove the spark arrester.

Use a brush to remove carbon deposits from the spark arresterscreen.Be careful to avoid damaging the screen.The spark arrester must be free of breaks and tears. Replace thespark arrester if it is damaged.

Install the spark arrester in the reverse order of removal.

1.

2.

3.

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47


SEDIMENT CUP CLEANING

FUEL VALVE LEVER

O-RING(Replace.)

SEDIMENT CUP

OFF

The sediment cup prevents dirt or water that may be in the fuel tankfrom entering the carburetor. If the engine has not been run for a longtime, the sediment cup should be cleaned.

Turn the engine switch to the OFF position.




Reinstall the new O-ring andsediment cup, and tighten thesediment cup securely.

Turn the fuel valve lever to theON position and check for leaks.

Turn the fuel valve lever to theOFF position; then remove thesediment cup and the O-ring.Discard the O-ring.

Clean the sediment cup innonflammable solvent, and dryit thoroughly.

1.

2.

5.

4.

3.

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48

STORAGE PREPARATION

Cleaning

Fuel

STORAGE

Proper storage preparation is essential for keeping your generatortrouble-free and looking good. The following steps will help to keeprust and corrosion from impairing your generator’s function andappearance, and will make the engine easier to start when you use thegenerator again.

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 alight film of oil.

You can extend fuel storage life by adding a gasoline stabilizer that isformulated for that purpose, or you can avoid fuel deteriorationproblems by draining the carburetor, sediment cup, and/or fuel tank.

The does not cover fuel system damage orengine performance problems resulting from neglected storagepreparation.

The length of time that gasoline can be left in your fuel tank andcarburetor without causing functional problems will vary with suchfactors as gasoline blend, your storage temperatures, and whether thefuel tank is partially or completely filled. The air in a partially filled fueltank promotes fuel deterioration. Very warm storage temperaturesaccelerate fuel deterioration. Fuel deterioration problems may occurwithin a few months, or even less if the gasoline was not fresh whenyou filled the fuel tank.

Gasoline will oxidize and deteriorate in storage. Old gasoline willcause hard starting, and it leaves gum deposits that clog the fuelsystem. If the gasoline in your generator deteriorates during storage,you may need to have the carburetor and other fuel systemcomponents serviced or replaced.

Depending on the region where you operate your equipment, fuelformulations may deteriorate and oxidize rapidly. Fuel deteriorationand oxidation can occur in as little as 30 days and may cause damageto the carburetor and/or fuel system. Please check with your servicingdealer for local storage recommendations.

Distributor’s Limited Warranty

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49

STORAGE

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TOPREVENT HARD STARTING

Service according to the table below:

Less than 1 month1 to 2 months

2 months to 1 year

1 year or more

Use gasoline stabilizers that are formulated to extend storage life.Follow the manufacturer’s instructions for use.Contact your authorized Honda generator dealer for stabilizerrecommendations.

No preparation requiredFill with fresh gasoline and add gasolinestabilizer *.Fill with fresh gasoline and add gasolinestabilizer *.Drain the carburetor float bowl (page 50 ).Drain the fuel sediment cup (page 47 ).Fill with fresh gasoline and add gasolinestabilizer *.Drain the carburetor float bowl (page 50 ).Drain the fuel sediment cup (page 47 ).Remove the spark plug. Put a teaspoon ofengine oil into the cylinder. Turn the engineslowly with the pull rope to distribute the oil.Reinstall the spark plug.Change the engine oil (page 39 ).After removal from storage, drain the storedgasoline into a suitable container, and fill withfresh gasoline before starting.

*

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50

STORAGE

Draining the Fuel Tank and Carburetor

SEALING WASHER

DRAIN BOLT




Remove the drain bolt and sealing washer and drain the gasolinefrom the carburetor.

Place a suitable gasoline container below the carburetor, and use afunnel to avoid spilling fuel.

1.

2.

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51

STORAGE

Engine Oil

FUEL VALVE LEVER

OONN

Align the notch on the starter pulleywith the hole at the top of recoil starter.

After all the gasoline has drained into the container, tighten thedrain bolt securely.

Place a suitable gasoline container below the sediment cup, and usea funnel to avoid spilling gasoline.

Remove the sediment cup (see page ), and then turn the fuelvalve lever to the ON position.

Allow the gasoline to drain completely, and then install the sedimentcup (see page ).

Slowly pull the starter grip until resistance is felt. At this point, thepiston is coming up on its compression stroke, and both the intakeand exhaust valves are closed. Storing the engine in this positionwill help to protect it from internal corrosion.

Change the engine oil (see page 39).

Remove the spark plug, and pour between one and two teaspoons(5 cc) of clean engine oil into the cylinder. Crank the engine severalrevolutions to distribute the oil, then reinstall the spark plug.

2.

1.

3.

3.

4.

5.

6.

47

47

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52

STORAGE

STORAGE PRECAUTIONS

REMOVAL FROM STORAGE

If your generator will be stored with gasoline in the fuel tank andcarburetor, it is important to reduce the hazard of gasoline vaporignition.

If possible, avoid storage areas with high humidity, because thatpromotes rust and corrosion.

Also avoid any area with a spark-producing electric motor, or wherepower tools are operated.

Select a well ventilated storage area away from any appliance thatoperates with a flame, such as a furnace, water heater, or clothes dryer.

With the engine and exhaust system cool, cover the generator to keepout dust. A hot engine and exhaust system can ignite or melt somematerials.

Do not use sheet plastic as a dust cover. A nonporous cover will trapmoisture around the generator, promoting rust and corrosion.

Check your generator as described in the BEFORE OPERATION chapterof this manual (see page ).

If the cylinder was coated with oil during storage preparation, theengine may smoke briefly at startup. This is normal.

Place the generator on a level surface. Tilting or laying it on its sidecan cause fuel or oil leakage.

Unless all fuel has been drained from the fuel tank, leave the engineswitch in the OFF position, and the fuel valve lever in the OFF position(see page ) to reduce the possibility of leakage.

If the generator was stored for 1 year or longer, drain the fuel tank (seepage ) and refuel with fresh gasoline. If you keep a container ofgasoline for refueling, be sure that it contains only fresh gasoline.Gasoline oxidizes and deteriorates over time, causing hard starting.

19

25

51

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53

TRANSPORTING

Do not lay the generator on its side when moving, storing, oroperating it. Oil or fuel may leak and damage the engine or yourproperty.

If the generator has been running, allow the engine to cool for at least15 minutes before loading the generator on the transport vehicle. Ahot engine and exhaust system can burn you and can ignite somematerials.

Keep the generator level when transporting to reduce the possibility offuel leakage. Move the fuel valve lever to the OFF position.

When using ropes or tie-down straps to secure the generator fortransportation, be sure to only use the frame bars as attachmentpoints. Do not fasten ropes or straps to any portions of the generatorbody.

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54

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause CorrectionFuel valve lever OFF.Choke OPEN.

Engine switch OFF.

Out of fuel.Bad fuel; generator storedwithout treating or draininggasoline, or refueled with badgasoline.Low oil level caused Oil Alertto stop engine.

Spark plug faulty, fouled, orimproperly gapped.Spark plug wet with fuel(flooded engine).Fuel filter restricted,carburetor malfunction,ignition malfunction, valvesstuck, etc.

Turn lever ON (p. 22).Move to CLOSED unless engineis warm (p. 23).Turn engine switch to ON(p. 23).Refuel (p. 36).Drain fuel tank and carburetor(p. 50).Refuel with fresh gasoline(p. 36).Add oil (p. 38).Turn engine switch to OFF andthen restart the engine.Gap or replace spark plug(p. 44).Dry and reinstall spark plug.

Take the generator to anauthorized Honda servicingdealer, or refer to the shopmanual.

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55


ENGINE LACKS POWER

Possible cause CorrectionAir filter restricted.

Bad fuel; generator storedwithout treating or draininggasoline, or refueled with badgasoline.Fuel filter restricted,carburetor malfunction,ignition malfunction, valvesstuck, etc.

Clean or replace air filter(p. 41 43).Drain fuel tank and carburetor(p. 50).Refuel with fresh gasoline(p. 36).Take the generator to anauthorized Honda servicingdealer, or refer to the shopmanual.

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56


Possible Cause Correction

NO POWER AT THE AC RECEPTACLES

AC circuit breaker left in theOFF position after starting.AC circuit protector tripped.

Faulty power tool orappliance.

Faulty generator.

Switch AC circuit breaker ON(p. 26).Check AC load and reset ACcircuit protector (p. 16).Replace or repair power tool orappliance.Stop and restart the engine.Take the generator to anauthorized Honda servicingdealer, or refer to the shopmanual.

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57

TECHNICAL INFORMATION

Serial Number Location

TECHNICAL & CONSUMER INFORMATION

FRAME SERIAL NUMBERENGINE SERIAL NUMBER

Record the engine and frame serial numbers and date purchased inthe spaces below. You will need this information when ordering partsand when making technical or warranty inquiries.

Date purchased:

Frame serial number:

Engine serial number:

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58


Carburetor Modification for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be toorich. Performance will decrease, and fuel consumption will increase. Avery rich mixture will also foul the spark plug and cause hard starting.Operation at an altitude that differs from that at which this engine wascertified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modificationsto the carburetor. If you always operate your generator at altitudesabove 5,000 feet (1,500 meters), have your authorized Honda servicingdealer perform this carburetor modification. This engine, whenoperated at high altitude with the carburetor modifications for highaltitude use, will meet each emission standard throughout its usefullife.

Even with carburetor modification, engine horsepower will decreaseabout 3.5% for each 1,000-foot (300-meter) increase in altitude. Theeffect of altitude on horsepower will be greater than this if nocarburetor modification is made.

When the carburetor has been modified for high altitude operation,the air/fuel mixture will be too lean for low altitude use. Operation ataltitudes below 5,000 feet (1,500 meters) with a modified carburetormay cause the engine to overheat and result in serious engine damage.For use at low altitudes, have your servicing dealer return thecarburetor to original factory specifications.

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59


Emission Control System Information

Source of Emissions

The U.S. and California Clean Air Acts

Tampering and Altering

The combustion process produces carbon monoxide, oxides ofnitrogen, and hydrocarbons. Control of hydrocarbons and oxides ofnitrogen is very important because, under certain conditions, theyreact to form photochemical smog when subjected to sunlight. Carbonmonoxide does not react in the same way, but it is toxic.

Honda utilizes appropriate air/fuel ratios and other emissions controlsystems to reduce the emissions of carbon monoxide, oxides ofnitrogen, and hydrocarbons.

EPA and California regulations require all manufacturers to furnishwritten instructions describing the operation and maintenance ofemission control systems.

The following instructions and procedures must be followed in orderto keep the Honda engine emissions within the emission standards.

Additionally, Honda fuel systems utilize components and controltechnologies to reduce evaporative emissions.

Tampering with or altering the emission control system may increaseemissions beyond the legal limit. Among those acts that constitutetampering are:

Removal or alteration of any part of intake, fuel, or exhaust systems.

Altering or defeating the governor linkage or speed-adjustingmechanism to cause the engine to operate outside its designparameters.

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60


Problems That May Affect Emissions

Replacement Parts

Maintenance

If you are aware of any of the following symptoms, have your engineinspected and repaired by your authorized Honda servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Follow the MAINTENANCE SCHEDULE on page . Remember thatthis schedule is based on the assumption that your machine will beused for its designed purpose. Sustained high-load or high-temperature operation, or use in dusty conditions, will require morefrequent service.

The emission control systems on your new Honda engine weredesigned, built, and certified to conform with applicable emissionregulations. We recommend the use of Honda Genuine partswhenever you have maintenance done. These original-designreplacement parts are manufactured to the same standards as theoriginal parts, so you can be confident of their performance. The useof replacement parts that are not of the original design and qualitymay impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility thatthe part will not adversely affect emission performance. Themanufacturer or rebuilder of the part must certify that use of the partwill not result in a failure of the engine to comply with emissionregulations.

35

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61


Air Index

An Air Index Information label is applied to engines certified to anemission durability time period in accordance with the requirementsof the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability tocompare the emissions performance of available engines. The lowerthe Air Index, the less pollution.

The durability description is intended to provide you with informationrelating to the engine’s emission durability period. The descriptiveterm indicates the useful life period for the engine’s emission controlsystem. See your Emission Control System Warranty for additionalinformation.

Descriptive TermModerate

Intermediate

Extended

Applicable to Emission Durability Period50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)125 hours (0 80 cc, inclusive)250 hours (greater than 80 cc)300 hours (0 80 cc, inclusive)500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

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－－±±

〔 ×× 〕

〔 × 〕〔 ×× 〕

62


Specifications

Generator

Dimensions

MAINTENANCESPECIFICATION

Engine

Tuneup

ITEM

Specifications may vary according to the types, and are subject tochange without notice.

60 Hz

BPR5ES (NGK)

3,600 rpmForced air

CDI magneto1.2 US qt (1.1 L)

6.34 US gal (24.0 L)

ModelType

ACoutput

ModelTypeDescription codeLengthWidthHeightDry mass [weight]

120 V/240 VAT type

Refer to page 44

See your authorizedHonda dealer.

0.028 0.031 i n(0.7 0.8 mm)

4-stroke, overhead valve, single cylinder

AT type

26.8 in (681 mm)20.9 in (530 mm)22.5 in (571 mm)

IN: 0.15 0.02 mmEX: 0.20 0.02 mm

No other adjustments needed.

EG6500CL

178.6 lbs(81.0 kg)

EG4000CL

147.7 lbs(67.0 kg)

173.1 lbs(78.5 kg)

GX390T2

23.7 cu-in (389 cm )3.46 2.52 in

(88.0 64.0 mm)

GX270T2

8.5:1

45.8 A/22.9 A5.5 kVA6.5 kVA

37.5 A/18.8 A4.5 kVA5.0 kVA

30.0 A/15.0 A3.6 kVA4.0 kVA

EBEC

EG5000CL

EBBCEBGC

ModelEngine typeDisplacementBore Stroke

Compression ratioEngine speedCooling systemIgnition systemOil capacityFuel tank capacitySpark plug

8.2:1

Spark plug gap

Valve clearance (cold)

Other specifications

Rated voltage

Rated currentRated output

EG6500CLEG4000CL EG5000CL

16.5 cu-in (270 cm )

3.03 2.28 in

(77.0 58.0 mm)

Rated frequency

Maximum output

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63


Wiring Diagram

Abbreviations Wire color code

Engine switch

SymbolAC OAC CBCBBD-AVR

D-CDIESwEgBEX WFrBFuFWGeBGNDGTIgCJ/BMWOLSwPoCSPVSSw

BlYBuGRWBrLgGrLbOP

BLACKYELLOWBLUEGREENREDWHITEBROWNLIGHT GREENGRAYLIGHT BLUEORANGEPINK

Part nameAC OutletAC Circuit BreakerControl Box BlockDigital-AutomaticVoltage RegulatorDigital-CDIEngine SwitchEngine BlockExciter WindingFrame BlockFuseField WindingGenerator BlockGroundGround TerminalIgnition CoilJunction BoxMain WindingOil Level SwitchPower CoilSpark PlugVoltage SelectorSwitch

OFFON

DC12VIG

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12

EG4000CL: 1 · EG5000CL, EG6500CL: 2

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65


CONSUMER INFORMATION

Dealer Locator Information

Honda Publications

Shop Manual

Parts Catalog

Accessories Catalog

To find an authorized Honda Servicing Dealer anywhere in the UnitedStates, visit our website: www.hondapowerequipment.com/dealerlocator/

This manual covers complete maintenance and overhaul procedures.It is intended to be used by a skilled technician.Available through your Honda dealer or through Helm Inc. at1 (888) 292-5395 or visit www.hondapowerequipment.com/products/manuals/

This manual provides complete, illustrated parts lists. Availablethrough your Honda dealer.

Your authorized Honda power equipment dealer offers a wideselection of accessories (optional equipment) to make your generatoreven more useful.Visit www.hondapowerequipment.com/products/accessories/and click on Generators and Welders to see the entire catalog ofaccessories.

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Customer Service Information

Honda Power Equipment dealership personnel are trainedprofessionals. They should be able to answer any question you mayhave. If you encounter a problem that your dealer does not solve toyour satisfaction, please discuss it with the dealership’s management.The Service Manager or General Manager can help. Almost allproblems are solved in this way.

If you are dissatisfied with the decision made by the dealership’smanagement, contact the Honda Power Equipment CustomerRelations Office. You can write:

American Honda Motor Co., Inc.Power Equipment DivisionCustomer Relations Office4900 Marconi DriveAlpharetta, Georgia 30005-8847

When you write or call, please give us this information:

Model and serial numbers (see page )Name of the dealer who sold the generator to youName and address of the dealer who services your generatorDate of purchaseYour name, address, and telephone numberA detailed description of the problem

Or telephone: (770) 497-6400 8:30 am to 7:00 pm ET

57

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67

INITIAL USE INSTRUCTIONS

WITHOUT OIL

ENGINE OIL

Do not overfill the engine with oil.

UPPER LIMIT

OIL FILLER HOLE


Place the generator on a level surface.

The generator is shipped in the engine.

Remove the oil filler cap/dipstick.

Add enough SAE 10W-30 API service category SJ or later (orequivalent) oil to bring the oil level to the upper limit of the oil fillerhole. SAE 10W-30 oil is recommended for general use; for additionalrecommendations, see page .

If the engine is overfilled, theexcess oil may be transferred to the air cleaner housing and air filter.


1.

2.

3.

4.

40

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FUEL

FUEL STRAINER

FUEL TANK CAP

UPPER LEVEL MARK

UPPER LEVEL MARK (RED)


Add fuel to the generator in a well-ventilated area. Never refuel theengine inside a building where gasoline fumes may reach flames orsparks. Keep gasoline away from appliance pilot lights, barbecues,electric appliances, power tools, etc. Spilled fuel is not only a firehazard, it causes environmental damage. Wipe up spills immediately.

This engine is certified to operate on unleaded gasoline with a pumpoctane rating of 86 or higher. Refer to page for additional fuelrecommendations.



Remove the fuel tank cap.

After refueling, reinstall the fuel tank cap securely.

Fuel carefully to avoid spilling fuel. Do not fill the fuel tank above theupper level mark (red) on the fuel strainer.

1.

2.

3.

37

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BEFORE OPERATION

GENERATOR SAFETY

CONTROLS & FEATURES

BEFORE OPERATION

OPERATION

STARTING THE ENGINE

STOPPING THE ENGINE

MAINTENANCE SCHEDULE

REGISTRATION

Please Register Your Generator

Fuel can damage paint and plastic. Be careful not to spill fuel whenfilling your fuel tank. Damage caused by spilled fuel is not coveredunder warranty.

Move the generator at least 10 feet (3 meters) away from the fuelingsource and site before starting the engine.

(pages )

(pages )

(pages )

(page )

(pages )

(page )

(page )

Before using the generator, all generator operators must read thefollowing chapters and sections:

If your dealer did not collect registration information from you, pleasetake a few minutes and register your purchase with Honda. This allowsus to contact you with any important updates regarding yourgenerator. Please note registration is not required to obtain warrantyservice. You can register your generator by visiting the Honda PowerEquipment website, www.hondapowerequipment.com and selectingProduct Registration. Your information will remain confidential. It willnot be released to any other company or organization.

6 10

11 18

19 20

21

22 24

25

35

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70

OPTIONAL PARTS

HANDLE INSTALLATION

TORQUE:

RIGHT HANDLEBRACKET

LEFT UPPER HANDLE ASSY RIGHT UPPER HANDLE ASSY

8 16 mm FLANGE BOLT (4)

LEFT HANDLE BRACKET

Install the right and left handles on the generator upper frame usingthe handle brackets and four flange bolts.

17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)

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OPTIONAL PARTS

WHEEL KIT INSTALLATION

TORQUE:

WHEEL (2)

8 mm FLANGE NUT (4)

STAND (2)

GENERATORSIDE

LONGER

UNDER FLAME

4 28 mmSPLIT PIN (2)

8 16 mm FLANGE BOLT (8)

AXLE SHAFT

20 mmPLAIN WASHER (2)

Install the two wheels on the axle shaft using the plain washers andsplit pins.

Install the axle assembly on the generator using four 8 16 mmflange bolts and 8 mm flange nuts.

Install the two stands on the under frame using four 8 16 mmflange bolts.

17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m)

1.

2.

3.

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INDEX

A

B

C

D................................................................Dealer Locator Information . 65

..................................................................Carbon Monoxide Hazards . 6......................Carburetor Modification for High Altitude Operation . 58

................................................................................Check the Engine . 20.........................................................................................Choke Lever . 14

...............................................................................................Cleaning . 48..........................................COMPONENT & CONTROL LOCATIONS . 11

.................................Connections to a Building’s Electrical System . 31..............................................................CONSUMER INFORMATION . 65

............................................................................................CONTENTS . 3

..........................................................................................CONTROLS . 13..................................................................CONTROLS & FEATURES . 11

..........................................................Customer Service Information . 66

....................................................................BEFORE OPERATION . 19, 69

..............................................Abnormal Voltage Detection Function . 17...................................................................................AC Applications . 27

...............................................................................AC Circuit Breaker . 15..........................................................................AC Circuit Protectors . 16

...................................................................................AC OPERATION . 26....................................................................AC Receptacle Selection . 28

................................................AIR CLEANER ELEMENT CLEANING . 43......................................................................AIR CLEANER SERVICE . 41

...............................................................................................Air Index . 61...............................................ARE YOU READY TO GET STARTED? . 19

......................................................Automatic Engine Stop Function . 17

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INDEX

F

G

H

I

K

E.........................................................................Electric Shock Hazards . 7

..............................................Emission Control System Information . 59.....................................................................ENGINE LACKS POWER . 55

......................................................................................Engine Oil . 51, 67.........................................................................ENGINE OIL CHANGE . 39

................................................................ENGINE OIL LEVEL CHECK . 38..................................................ENGINE OIL RECOMMENDATIONS . 40

.....................................................................................Engine Switch . 13.................................................................ENGINE WILL NOT START . 54

...........................................................................................FEATURES . 17..........................................................................Fire and Burn Hazards . 7

.................................................................................................Fuel . 48, 68..........................................................................................Fuel Gauge . 18

.............................................................FUEL RECOMMENDATIONS . 37..................................................................................Fuel Valve Lever . 14

..........................................................................GENERATOR SAFETY . 6.................................................................................Ground Terminal . 18

...................................................................HANDLE INSTALLATION . 70.............................................................................Honda Publications . 65

................................................IMPORTANT SAFETY INFORMATION . 6............................................................INITIAL USE INSTRUCTIONS . 67

............................................IS YOUR GENERATOR READY TO GO? . 19

...........................................................................................Knowledge . 19

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INDEX

M

O

Q

R

N

P

....................................................................MAINTENANCE SAFETY . 34..............................................................MAINTENANCE SCHEDULE . 35

............................................NO POWER AT THE AC RECEPTACLES . 56

...................................................................Power Producing Circuits . 28

........................QUICK REFERENCE INFORMATION . Inside back cover

................................................................................Oil Alert Function . 17

................................................................................Oil Alert System . 17.........................................................................................OPERATION . 21

.......................................................................Operator Responsibility . 6..............................................................................OPTIONAL PARTS . 70

..........................................................Overspeed Detection Function . 17

..........................................................................................REFUELING . 36...................................................................................Refuel With Care . 8

.....................................................................................REGISTRATION .69..............................................................REMOVAL FROM STORAGE . 52

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INDEX

S

T

W

V

.................................TAKING CARE OF UNEXPECTED PROBLEMS . 54....................................TECHNICAL & CONSUMER INFORMATION . 57

...............................................................TECHNICAL INFORMATION . 57............................................THE IMPORTANCE OF MAINTENANCE . 33

....................................................................................................Tools . 35.................................................................................TRANSPORTING . 53

...................................................SAFE OPERATING PRECAUTIONS . 21................................................................SAFETY LABEL LOCATIONS . 9

...............................................................SEDIMENT CUP CLEANING . 47..............................................................................Safety Precautions . 34

.....................................................................Serial Number Location . 57.......................................................SERVICING YOUR GENERATOR . 33

..............................................................SPARK ARRESTER SERVICE . 46.......................................................................SPARK PLUG SERVICE . 44........................................................................Special Requirements . 32

......................................................................................Specifications . 62..............................................................................STANDBY POWER . 31

..........................................................................................Starter Grip . 13....................................................................STARTING THE ENGINE . 22....................................................................STOPPING THE ENGINE . 25

............................................................................................STORAGE . 48.................................................................STORAGE PRECAUTIONS . 52..................................................................STORAGE PREPARATION . 48

...................................................................................System Ground . 31

...............................................................WHEEL KIT INSTALLATION . 71...................................................................................Wiring Diagram . 63

...............................................................Voltage Selector Switch . 15, 29

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QUICK REFERENCE INFORMATION

BPR5ES (NGK)0.028 0.031 in (0.7 0.8 mm)

Fuel

Engine Oil

Spark Plug

Maintenance

Type

Type

TypeElectrode GapBefore eachuseFirst 20 hoursSubsequent

Regular unleaded gasoline witha pump octane rating of 86 orhigherSAE 10W-30, API SJ or later (orequivalent), for general use(page 40)

Check engine oil level.Check air cleaner element.Change engine oil.See Maintenance Schedule(page 35)

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00X31-Z30-600031Z30600 AHM.35.2011.02

PRINTED IN U.S.A.Printed on

Recycled Paper © 2011 Honda Motor Co., Ltd.—All Rights Reserved

Owner’s ManualGENERATOR

EG4000CL • EG5000CL • EG6500CL

See page 67 forInitial Use Instructions

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EG4000-6500CL Cover.ai 2/8/2011 10:23:01 AMEG4000-6500CL Cover.ai 2/8/2011 10:23:01 AM

Documents

Owner’sManual · CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS 120V/240V AC RECEPTACLE 120V RECEPTACLES: Except EG4000CL AC CIRCUIT BREAKER ENGINE SWITCH VOLTAGE SELECTOR SWITCH