Honda EM5000is User manual

Keep this owner’s manual handy, so you can refer to it at any time.

This owner’s manual is considered a permanent part of the generator

and should remain with the generator if resold.

The information and specifications included in this publication were in

effect at the time of approval for printing. Honda Motor Co., Ltd.

reserves the right, however, to discontinue or change specifications or

design at any time without notice and without incurring any obligation

whatever.

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

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1

INTRODUCTION

Congratulations on your selection of a Honda generator. We are

certain you will be pleased with your purchase of one of the finest

generators on the market.

We want to help you get the best results from your new generator and

to operate it safely. This manual contains all the information on how to

do that; please read it carefully.

As you read this manual, you will find information preceded by a

symbol. That information is intended to help you avoid

damage to your generator, other property, or the environment.

We suggest you read the warranty policy to fully understand its

coverage and your responsibilities of ownership. The warranty policy

is a separate document that should have been given to you by your

dealer.

When your generator needs scheduled maintenance, keep in mind

that your Honda servicing dealer is specially trained in servicing

Honda generators and is supported by the parts and service divisions

of American Honda. Your Honda servicing dealer is dedicated to your

satisfaction and will be pleased to answer your questions and

concerns.

Best Wishes,

Honda Motor Co., Ltd.

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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 this

generator safely is an important responsibility.

To help you make informed decisions about safety, we have provided

operating procedures and other information on labels and in this

manual. This information alerts you to potential hazards that could

hurt you or others.

Of course, it is not practical or possible to warn you about all the

hazards associated with operating or maintaining a generator. You

must use your own good judgement.

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

including:

on the generator.

preceded by a safety alert symbol and one

of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

be or if

you don’t follow instructions.

be or if

you don’t follow instructions.

be if you don’t follow

instructions.

such as

IMPORTANT SAFETY INFORMATION

.

such as

how to use this generator correctly and safely.

This entire book is filled with important safety information please

read it carefully.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERAT OR SAFET Y .

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3

CONTENTS

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

........................................................................CONTROLS & FEATURES .10

...............................................................................BEFORE OPERATION .23

..................................................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 .10

............................................................................................CONTROLS .12

................................................................................Fuel Valve Lever .12

....................................................................................Engine Switch .12

.....................................................................................Recoil Starter .13

.........................................................................Eco-throttle Switch .13

...................................................................Voltage Selector Switch .14

.........................................................................AC Circuit Protectors .14

..................................................................................Folding Handle .15

.............................................................................................FEATURES .16

...............................................................................Ground Terminal .16

.......................................................................Output Indicator Light .17

...................................................................Overload Indicator Light .17

...................................................................Oil Alert

Indicator Light .18

.........................................................................................i-Monitor .19

.........................................................................................Fuel Gauge .22

................................................ARE YOU READY TO GET STARTED? .23

.........................................................................................Knowledge .23

..............................................IS YOUR GENERATOR READY TO GO? .23

...............................................................................Check the Engine .24

TM

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4

CONTENTS

..............................................................................................OPERATION .25

.............................................................SERVICING YOUR GENERATOR .38

..................................................................................................STORAGE .58

.....................................................SAFE OPERATING PRECAUTIONS .25

......................................................................STARTING THE ENGINE .26

......................................................................STOPPING THE ENGINE .29

.....................................................................................AC OPERATION .30

.................................................................................AC Applications .32

...................................................................AC Receptacle Selection .33

.................................................................ECO-THROTTLE SYSTEM .35

...............................................................................STAND BY POWER .36

...............................Connections to a Building’s Electrical System .36

.................................................................................System Ground .36

.......................................................................Special Requirements .37

.............................................THE IMPORTANCE OF MAINTENANCE .38

......................................................................MAINTENANCE SAFETY .39

............................................................................Safety Precautions .39

................................................................MAINTENANCE SCHEDULE .40

...........................................................................................REFUELING .41

...............................................................FUEL RECOMMENDATIONS .42

..................................................................ENGINE OIL LEVEL CHECK .43

...........................................................................ENGINE OIL CHANGE .44

....................................................ENGINE OIL RECOMMENDATIONS .45

........................................................................AIR CLEANER SERVICE .46

.............................................................FOAM AIR FILTER CLEANING .48

.................................................................SEDIMENT CUP CLEANING .49

.........................................................................SPARK PLUG SERVICE .50

................................................................SPARK ARRESTER SERVICE .52

...............................................................................BATTERY SERVICE .54

......................................................................................................FUSE .57

....................................................................STORAGE PREPARATION .58

.............................................................................................Cleaning .58

.....................................................................................................Fuel .58

..........................................................................................Engine Oil .61

...................................................................STORAGE PRECAUTIONS .62

................................................................REMOVAL FROM STORAGE .62

TM

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5

CONTENTS

......................................................................................TRANSPORTING .63

.......................................TAKING CARE OF UNEXPECTED PROBLEMS .64

..........................................TECHNICAL & CONSUMER INFORMATION .67

................................................................INSTALLATION OF KIT PARTS .78

........................................................................................................INDEX .90

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

.............................................................................ENGINE PROBLEMS .64

....................................................................GENERATOR PROBLEMS .66

................................................................TECHNICAL INFORMATION .67

...................................................................Serial Number Location .67

....................Carburetor Modification for High Altitude Operation .68

.............................................................................Oxygenated Fuels .69

............................................Emission Control System Information .70

.............................................................................................Air Index .72

....................................................................................Specifications .73

.................................................................................Wiring Diagram .75

...............................................................CONSUMER INFORMATION .76

...........................................................................Honda Publications .76

.........................................................Customer Service Information .77

..................................................................................................SAFETY .78

..............................................The Importance of Proper Assembly .78

..........................................................Important Safety Precautions .79

........................................................................STANDARD KIT PARTS .80

..........................................................................................Unpacking .80

........................................................................................Loose Parts .80

........................................................................Wheel Kit Installation .81

............................................................................Handle Installation .82

..........................................................................Rear Bar Installation .83

................................................................................................Battery .84

..........................................................................OPTIONAL KIT PARTS .85

............................................................................Remote Control Kit .85

......................................................................Hanger Kit Installation .89

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6

GENERATOR SAFETY

Operator Responsibility

Carbon Monoxide Hazards

IMPORTANT SAFETY INFORMATION

Honda generators are designed for use with electrical equipment that

has suitable power requirements. Other uses can result in injury to the

operator or damage to the generator and other property.

Most accidents can be prevented if you follow all instructions in this

manual and on the generator. The most common hazards are

discussed below, along with the best way to protect yourself and

others.

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

Understand the use of all generator controls, output receptacles,

and connections.

Be sure that anyone who operates the generator receives proper

instruction. Do not let children operate the generator without

parental supervision.

If you run the generator in a confined or even partially enclosed area,

the air you breathe could contain dangerous amounts of exhaust

gas. To keep exhaust gas from building up, provide adequate

ventilation.

Exhaust contains poisonous carbon monoxide, a colorless, odorless

gas. Breathing exhaust can cause loss of consciousness and may

lead to death.

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7

GENERATOR SAFETY

Electric Shock Hazards

Fire and Burn Hazards

The generator produces enough electric power to cause a serious

shock or electrocution if misused.

Using a generator or electrical appliance in wet conditions, such as

rain or snow, or near a pool or sprinkler system, or when your hands

are wet, could result in electrocution. Keep the generator dry.

If the generator is stored outdoors, unprotected from the weather,

check all of the electrical components on the control panel, before

each use. Moisture or ice can cause a malfunction or short circuit in

electrical components which could result in electrocution.

Do not connect to a building electrical system unless an isolation

switch has been installed by a qualified electrician.

The muffler becomes very hot during operation and remains hot for

a while after stopping the engine. Be careful not to touch the muffler

while it is hot. Let the engine cool before storing the generator

indoors.

Keep the generator at least 3 feet (1 meter) away from buildings

and other equipment during operation.

Do not enclose the generator in any structure.

Keep flammable materials away from the generator.

The exhaust system gets hot enough to ignite some materials.

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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. Refuel

only outdoors in a well-ventilated area with the engine OFF. Do not

overfill the fuel tank. Never smoke near gasoline, and keep other

flames and sparks away. Always store gasoline in an approved

container. Make sure that any spilled fuel has been wiped up before

starting the engine.

04/03/17 09:17:58 31Z11600_009

9

GENERATOR SAFETY

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause serious

injury. Read them carefully. If a label comes off or becomes hard to

read, contact your Honda servicing dealer for a replacement.

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10

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

ENGINE SWITCH

OUTPUT

INDICATOR

i-MONITOR

BUTTON

i-MONITOR

ECO-THROTTLE SWITCH

FUEL VALVE

VOLTAGE SELECTOR SWITCH

CIRCUIT PROTECTORS

OVERLOAD

INDICATOR

RECEPTACLES

OIL ALERT

INDICATOR

TM

Use the two illustrations on these pages to locate and identify the

most frequently used controls.

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11

CONTROL & FEATURES

SPARK PLUG

INSPECTION COVER

HANDLE

AIR CLEANER

FUEL TANK CAP

STARTER GRIP

GROUND TERMINAL

STAND

OIL DRAIN PLUG

OIL FILLER

CAP/DIPSTICK

WHEEL

MUFFLER TIP

FUSE(Inside the maintenance cover)

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12

CONTROL & FEATURES

CONTROLS

Fuel Valve Lever

Engine Switch

FUEL VALVE LEVER

OOFFFF

OONN

OOFFFF

OONN

OOFFFF

SSTTAARRTT

ENGINE SWITCH

RREEMMOOTTEE

The fuel valve must be in the ON

position for the engine to run.

After stopping the engine, turn

the fuel valve to the OFF position.

The fuel valve lever is located on

the control panel.

The engine switch controls the

ignition system, and it operates

the electric starter.

OFF Stops the engine. Key

can be removed/inserted.

ON Running position, and for

starting with the recoil starter.

START Operates the electric

starter.

REMOTE For using the remote

control kit (optional parts).

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13

CONTROL & FEATURES

Recoil Starter

Eco-throttle Switch

STARTER GRIP

ECO-THROTTLE SWITCH

ONOFF

Pulling the starter grip operates

the recoil starter to crank the

engine for starting.

The eco-throttle system automatically reduces engine speed when

all loads are turned off or disconnected. When appliances are turned

on or reconnected, the engine returns to the proper speed to power

the electrical load.

If high electrical loads are connected simultaneously, turn the eco-

throttle switch to the OFF position to reduce voltage changes.

ON Recommended to minimize

fuel consumption and further

reduce noise levels when a

reduced load or no load is applied

to the generator.

OFF The eco-throttle system

does not operate. Generator

operates at full output.

Do not allow the starter grip to

snap back against the engine.

Return it gently to prevent

damage to the starter.

Do not let the starter rope rub

against the generator body or

the rope will wear out

prematurely.

TM

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14

CONTROL & FEATURES

AC Circuit Protectors

Voltage Selector Switch

AC CIRCUIT PROTECTOR

OFF PUSH

ON

120V/240V

120V ONLY

VOLTAGE SELECTOR SWITCH

CIRCUIT PROTECTOR

for Receptacle

CIRCUIT PROTECTOR

for Receptacle

CIRCUIT PROTECTOR

for Receptacle

CIRCUIT PROTECTOR

for Receptacle

120V 30A

120V 20A

120/240V 30A

The AC circuit protectors will automatically switch OFF if there is a

short circuit or a significant overload of the generator at the each

receptacles. If an AC circuit protector switches OFF automatically,

check that the appliance is working properly and does not exceed the

rated load capacity of the circuit before resetting the AC circuit

protector ON.

The voltage selector switch is used to select generator AC voltage;

either 120 V or 120/240 V.

Select the voltage before starting the engine.

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15

CONTROL & FEATURES

Folding Handle

To Extend Handle

To Fold Handle

HANDLE

HANDLE LEVER

The foldable handle is intended for ease of transportation and should

be folded when the generator is stationary. Do not rest objects on

extended handle.

Lift handle upward. Lock levers will lock and secure handle into place.

Press both handle lock levers downward.

Lower handle.

1.

2.

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16

CONTROL & FEATURES

FEATURES

Ground Terminal

GROUND TERMINAL

The ground terminal is connected to the frame of the generator, the

metal non-current-carrying parts of the generator, and the ground

terminals of each receptacle.

Before using the ground terminal, consult a qualified electrician,

electrical inspector or local agency having jurisdiction for local codes

or ordinances that apply to the intended use of the generator.

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17

CONTROL & FEATURES

Output Indicator Light

Overload Indicator Light

OUTPUT

INDICATOR

LIGHT (GREEN)

OVERLOAD

INDICATOR

LIGHT (RED)

The output indicator light (green) is illuminated when the generator is

operating normally. It indicates that the generator is producing

electrical power at the receptacles.

If the generator is overloaded, or if there is a short circuit in a

connected appliance, or if the inverter is overheated, the overload

indicator light (red) will go ON. When the generator is operating

overloaded, the overload indicator light (red) will stay ON, and after

about five seconds, current to the connected appliance(s) will shut off,

and the output indicator light (green) will go OFF.

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18

CONTROL & FEATURES

Oil Alert Indicator Light

It blinks.

OIL ALERT

(RED)

The Oil Alert system is designed to prevent engine damage caused

by an insufficient amount of oil in the crankcase. Before the oil level in

the crankcase can fall below a safe limit, the Oil Alert

indicator light

comes on and the Oil Alert

system automatically will stop the engine

(the engine switch will remain in the ON position).

If the engine stops or the Oil Alert

indicator light comes on when you

turn the engine switch to START or pull the starter grip, check the

engine oil level (see page ) before troubleshooting in other areas.

Even when oil is added to the engine, the generator will not restart

until the Oil Alert

indicator light is reset. To reset the Oil Alert

indicator light, turn the engine switch OFF, add the proper amount of

oil (see page ), and then turn engine switch back ON.

The i-Monitor display will show ‘‘OIL’’ on the screen and the Oil

Alert

indicator lamp will illuminate.

43

44

TM

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