Related Manuals for Honda EM3800SX
Summary of Contents for Honda EM3800SX
- Page 1 EM3800SX•EM5000SX•EM6500SX See page 54 for instructions on assembling your generator.
- Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The generator is a potential source of electrical shock if misused. Do not expose the generator to moisture, rain or snow. Do not let the generator get wet, and do not operate it with wet hands.
- Page 3 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.
- Page 4 A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
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Page 5: Table Of Contents
SAFETY Safety Label Locations Safety Information COMPONENT IDENTIFICATION CONTROLS Engine Switch Recoil Starter Fuel Valve Lever Choke Rod Voltage Selector Switch (Dual Voltage System) Ground Terminal DC Terminal DC Circuit Protector Oil Alert System Auto Throttle System AC Circuit Breaker AC Circuit Protector GENERATOR USE Connections to a Building’s Electrical System... - Page 6 TRANSPORTING/STORAGE TROUBLESHOOTING WIRING DIAGRAM SPECIFICATIONS ASSEMBLY WARRANTY SERVICE INFORMATION INDEX . 44 . 47 . 49 . 51 . 54 . 66 . 67...
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Page 7: Safety
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 generator dealer for a replacement. -
Page 8: Safety Information
SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating procedures. - Page 9 Electric Shock 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.
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Page 10: Component Identification
COMPONENT IDENTIFICATION CHOKE ROD AIR CLEANER FUEL VALVE LEVER RECOIL STARTER GRIP ENGINE SERIAL NUMBER CONTROL PANEL ＊ 1:Except EM3800SX AC CIRCUIT BREAKER DC CIRCUIT PROTECTOR DC OUTPUT TERMINAL AUTO THROTTLE SWITCH ENGINE SWITCH OIL DRAIN BOLT AC CIRCUIT PROTECTORS ＊... -
Page 12: Controls
CONTROLS Engine Switch To start and stop the engine. Key position: OFF: To stop the engine. Key can be removed/inserted. To run the engine after starting. START: To start the engine by operating the starter motor. Recoil Starter To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly. -
Page 13: Fuel Valve Lever
Fuel Valve Lever The fuel valve is located between the fuel tank and carburetor. When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the OFF position after stopping the engine. -
Page 14: Voltage Selector Switch (Dual Voltage System)
Voltage Selector Switch (Dual Voltage System) The voltage selector switch switches the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’... -
Page 15: Dc Terminal
DC Terminals The DC terminals may ONLY be used for charging 12 volt automotive type batteries. The terminals are colored red to identify the positive ( ) terminal and black to identify the negative ( ) terminal. The battery must be connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal). -
Page 16: Oil Alert System
Oil Alert System The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position). -
Page 17: Ac Circuit Breaker
AC Circuit Breaker The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle. If the AC circuit breaker is switched OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before switching the AC circuit breaker ON again. -
Page 18: Ac Circuit Protector
30A 120V locking plug, or 120/240V locking plug receptacle. If a 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. ＊ 1:Except EM3800SX AC CIRCUIT PROTECTORS ＊... -
Page 19: Generator Use
Connections to a Building Electrical System Connections for standby power to a building electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. A transfer switch, which isolates generator power from utility power, is available through authorized Honda generator dealers. -
Page 20: Ac Applications
OFF, but will shorten the service life of the generator. Limit operation requiring maximum power to 30 minutes. Maximum power is: EM3800SX: 3,800 VA EM5000SX: 5,000 VA EM6500SX:... -
Page 21: Ac Operation
Plug in the appliance. Most motorized appliances require more than their rated power for startup. ＊ 1:Except EM3800SX AC CIRCUIT PROTECTORS AC CIRCUIT BREAKER Do not exceed the current limit specified for any one receptacle. If an overloaded circuit causes the AC circuit breaker or AC circuit protector to switch OFF, reduce the electrical load on the circuit, wait a few minutes and then reset the AC circuit breaker or AC circuit protector. -
Page 22: Ac Receptacle Selection
AC Receptacle Selection EM3800SX: The generator has two separate main power producing circuits. These two circuits supply equal power to different receptacles shown when the voltage selector switch is in the 120/240V position. When two or more receptacles are used; prevent overloading by dividing the load between the two power circuits. - Page 23 EM5000SXK2: The generator has separate main power producing circuits. These two circuits supply equal power to different receptacles shown when the voltage selector switch is in the 120/240V position. When two or more receptacles are used; prevent overloading by dividing the load between the two power circuits. The chart below shows the rated load in amperes that can be connected to each receptacle to balance the generator.
- Page 24 EM6500SX: The generator has separate main power producing circuits. These two circuits supply equal power to different receptacles shown when the voltage selector switch is in the 120/240V position. When two or more receptacles are used; prevent overloading by dividing the load between the two power circuits. The chart below shows the rated load in amperes that can be connected to each receptacle to balance the generator.
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Page 25: Dc Operation
DC Operation The DC terminals may ONLY be used for charging 12 volt automotive type batteries. Connecting the battery cables: Before connecting the battery charging cables to a battery that is installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( ) terminal. - Page 26 An overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit protector (PUSH button extends out). If this happens, wait a few minutes before pushing in the circuit protector to resume operation. If the DC circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer.
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Page 27: Auto Throttle System
Auto Throttle System With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the auto throttle system does not operate. The auto throttle system will not respond to electrical loads of less than 1 ampere or intermittent loads such as a staple gun. -
Page 28: High Altitude Operation
High Altitude Operation At high altitude, the standard carburetor air/fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions. -
Page 29: Pre-Operation Check
Engine Oil Engine oil is a major factor affecting engine performance and service life. Non detergent and 2-stroke engine oils will damage the engine and are not recommended. Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped. -
Page 30: Fuel
Fuel Check the fuel gauge, and refill the tank if the fuel level is low. Refuel carefully to avoid spilling fuel. Do not fill above the shoulder of the fuel strainer. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. - Page 31 Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda generator dealer.
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Page 32: Starting The Engine/Stopping The Engine
STARTING THE ENGINE/STOPPING THE ENGINE Starting the Engine Make sure that the AC circuit breaker is in the OFF position. The generator may be hard to start if a load is connected. Turn the fuel valve lever to the ON position. The automatic choke will be closed if the engine is cold. -
Page 33: Maintenance
MAINTENANCE The Importance of Maintenance Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. -
Page 34: Maintenance Safety
Maintenance Safety Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. -
Page 35: Emission Control System Information
Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen are very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. - Page 36 Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
- Page 37 Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.
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Page 38: Air Index
Air Index An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. -
Page 39: Maintenance Schedule
Maintenance Schedule REGULAR SERVICE PERIOD (3) ITEM Performed at every indicated month or operating hour interval, whichever comes first. Engine oil Check Change Air cleaner Check Clean Sediment cup Clean Spark plug Clean-Adujst Replace Spark arrester Clean Idle speed Check-Adujst Valve clearance Check-Adujst Combustion... -
Page 40: Engine Oil Change
Engine Oil Change Drain the oil while the engine is warm to assure rapid and complete draining. Remove the drain plug and sealing washer, remove the oil filler cap, and drain the oil. Reinstall the drain plug and sealing washer. Tighten the plug securely. -
Page 41: Air Cleaner Service
Air Cleaner Service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. Never run the generator without the air filter. Rapid engine wear will result. -
Page 42: Fuel Sediment Cup Cleaning
Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. Turn the fuel valve lever to the OFF position. Remove the sediment cup, O-ring, and filter. -
Page 43: Spark Plug Service
Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler. -
Page 44: Spark Arrester Maintenance
Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent cross-threading. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. − If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. -
Page 45: Fuse Replacement
Fuse Replacement If the fuse is blown, the starter motor won’t operate. Turn the engine switch to the OFF position. Remove the fuse holder cover and replace the fuse. The specified fuse is 10A. If frequent fuse failure occurs, determine the cause and correct the problem before attempting to operate the generator further. -
Page 46: Transporting/Storage
TRANSPORTING/STORAGE When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Contact with a hot engine or exhaust system can cause serious burns or fires. - Page 47 Before storing the unit for an extended period: 1. Be sure the storage area is free of excessive humidity and dust. 2. Service according to the table below: STORAGE TIME Less than 1 month 1 to 2 months 2 months to 1 year 1 year or more Use gasoline conditioners that are formulated to extend storage life.
- Page 48 Storage Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.
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Page 49: Troubleshooting
When the engine will not start: Is there fuel in the tank? Is there enough oil in the engine? Is the spark plug in good condition? Is the fuel reaching the carburetor? If the engine still does not start, take the generator to an authorized Honda generator dealer. - Page 50 No electricity at the AC receptacles: Is the AC circuit breaker Check the electrical ap- pliance or equipment for any defects. DEFECTS Turn the AC circuit breaker NO DEFECTS Take the generator to an authorized Honda generator dealer. Replace the electrical ap- pliance or equipment.
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Page 51: Wiring Diagram
WIRING DIAGRAM EM3800SX... - Page 52 EM5000SX, EM6500SX...
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Page 53: Specifications
ITEM Spark plug gap Valve clearance Other specifications Specifications may vary according to the types, and are subject to change without notice. EM3800SX EAMC 40.9 in (1,040 mm) 27.2 in (690 mm) 28.3 in (720 mm) 192 lbs (87 kg) - Page 54 Dimensions Model Power product description code Length Width Height Dry weight Engine Model Engine Type Displacement Bore × Stroke Compression Ratio Engine Speed Cooling System Ignition System Oil Capacity Fuel Tank Capacity Spark Plug Generator Model Type Rated voltage Rated frequency AC output Rated current Rated output...
- Page 55 Dimensions Model Power product description code Length Width Height Dry weight Engine Model Engine Type Displacement Bore × Stroke Compression Ratio Engine Speed Cooling System Ignition System Oil Capacity Fuel Tank Capacity Spark Plug Generator Model Type Rated voltage Rated frequency AC output Rated current Rated output...
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Page 56: Assembly
ASSEMBLY The Importance of Proper Assembly Proper assembly is essential to operator safety and the reliability of the machine. Any error or oversight made by the person assembling and servicing a unit can easily result in faulty operation, damage to the machine, or injury to the operator. - Page 57 Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing this assembly, be especially careful of the following: □ Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely.
- Page 58 Unpacking Remove the generator and loose parts box from the carton. Compare the loose parts with the inventory list below. Tools Required: 14 mm wrench (2), pliers Loose Parts (Wheel kit and handle) Check all loose parts against the following list. Contact your dealer if any of the loose parts shown below are not included with your generator.
- Page 59 Handle Installation Install the right and left handles on the generator upper frame using the brackets and 4 flange bolts. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) − 8 16 mm FLANGE BOLT (4) × LEFT UPPER HANDLE ASSY LEFT HANDLE BRACKET −...
- Page 60 Wheel Kit Installation Install the two wheels on the axle shaft using the washers and cotter pins. Install the axle assembly on the generator using four 8 flange bolts and 8 mm flange nuts. Install the two stands on the under frame using four 8 flange bolts.
- Page 61 Hanger Kit Installation (optional) Position the hanger at the generator’s balance point as shown below. Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) −...
- Page 62 Remote Control Kit (optional) Remove the blind 6-P connector from the back of the control panel. Connect the remote control cable to the back of the control panel and remote control box. Install the two cable ties as shown. REMOTE CONTROL CABLE CABLE TIES REMOTE CONTROL...
- Page 63 Remote Control Box PILOT LAMP START SWITCH Starting the engine with remote control Turn the fuel valve to the ON position. Turn the auto-throttle switch to the OFF position. Turn the engine switch to the ON position. Press the start switch untill the pilot lamp comes on. Stopping the engine with remote control Press the stop switch.
- Page 64 Battery Tray Kit (optional) Install the battery guard on the frame. Set the battery tray on the battery guard and tighten the bolts. Route the starter cable under the tank and connect it to the starter solenoid. Connect the ground cable to the generator rear housing. Set the battery on the battery tray and secure with the battery bracket.
- Page 65 STARTER SOLENOID STARTER CABLE BATTERY BRACKET BATTERY Use a battery rated at BATTERY GUARD BATTERY GUARD PLATE STARTER CABLE (positive) GROUND CABLE CABLE ○ ○ ＋ ＋ ○ ○ − − BATTERY GUARD BATTERY TRAY CABLE TIE GROUND CABLE...
- Page 66 Engine Oil SAE Viscosity Grades The generator is shipped WITHOUT OIL in the engine. Place the generator on a level surface. Add enough of the recommended oil to bring the oil level to the top of the oil filler neck. AMBIENT TEMPERATURE Use a 4-stroke motor oil that meets the requirements for...
- Page 67 BEFORE OPERATION Before using your generator, you should become familiar with information contained in the following chapters and sections: SAFETY (page CONTROLS (page GENERATOR USE (page STARTING THE ENGINE STOPPING THE ENGINE (page (page...
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Page 68: Warranty Service Information
WARRANTY SERVICE INFORMATION Servicing dealership personnel are trained professionals. They should be able to answer any questions you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help. -
Page 69: Index
ASSEMBLY COMPONENT IDENTIFICATION CONTENTS CONTROLS AC Circuit Breaker AC Circuit Protector Auto Throttle System Choke Rod DC Circuit Protector DC Terminal Engine Switch Fuel Valve Lever Ground Terminal Oil Alert System Recoil Starter Voltage Selector Switch (Dual Voltage System) GENERATOR USE AC Applications AC Operation AC Receptacle Selection... - Page 70 PRE-OPERATION CHECK Engine Oil Fuel SAFETY Safety Information Safety Label Locations SPECIFICATIONS STARTING THE ENGINE/STOPPING THE ENGINE TRANSPORTING/STORAGE TROUBLESHOOTING WARRANTY SERVICE INFORMATION WIRING DIAGRAM . 27 . 27 . 28 . 51 . 30 . 44 . 47 . 66 .
- Page 71 K2:EM5000SX 31Z21600 00X31-Z21-6000...