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INTRODUCTION
How to use this manual
This supplement covers the construction, function, and
servicing procedures of the Honda EM10000K1 (SH,
SKH, LDH type) generators.
For service information that is not covered in this
supplement, please refer to the EM10000K1/
ET120000K1 base shop manual (part number
62Z2650).
All information contained in this manual is based on the
latest product information available at the time of
printing. We reserve the right to make changes at
anytime without notice.
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any
means, electronic, mechanical, photocopying,
recording, or otherwise, without prior written permission
of the publisher. This includes text, figures, and tables.
As you read this manual, you will find information that is
preceded by a
symbol. The purpose of this
message is to help prevent damage to this Honda
product, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important.
To help you make informed decisions, we have
provided safety messages and other safety information
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated
with servicing these products. You must use your own
good judgement.
You will find important safety information in a variety of
forms, including:
· Safety Labels – on the product.
· Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER,
WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be HURT if you don't follow
instructions.
· Instructions – how to service these products correctly
and safely.
© Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
Date of Issue: May 2012
How to use this manual
OUTLINE OF CHANGES
SPECIFICATIONS
SERVICE INFORMATION
MAINTENANCE
TROUBLESHOOTING
COVER
FUEL SYSTEM
GOVERNOR SYSTEM
GENERATOR/CHARGING SYSTEM
IGNITION SYSTEM
STARTING SYSTEM
OTHER ELECTRICAL
MUFFLER
ENGINE REMOVAL/INSTALLATION
LUBRICATION SYSTEM
CYLINDER
CRANKCASE
TECHNICAL FEATURES
WIRING DIAGRAMS
INDEX
The marked sections contain no changes.
They are not covered in this supplement.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
0-1

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Summary of Contents for Honda EM10000K1

  • Page 1 As you read this manual, you will find information that is preceded by a symbol. The purpose of this OTHER ELECTRICAL message is to help prevent damage to this Honda product, other property, or the environment. MUFFLER SAFETY MESSAGES ENGINE REMOVAL/INSTALLATION LUBRICATION SYSTEM Your safety and the safety of others are very important.
  • Page 2 How to use this manual SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommend engine oil, unless otherwise specified.
  • Page 3: Governor Spring

    OUTLINE OF CHANGES How to use this manual Item SH, SKH, LDH type RRH, MH, KH, RGH, UH type Governor spring installation position GOVERNOR SPRING GOVERNOR SPRING Stator SH, SKH type: RRH, MH type: • Main winding resistance: 0.1 - 0.3 Ω •...
  • Page 4 OUTLINE OF CHANGES How to use this manual Item SH, SKH, LDH type RRH, MH, KH, RGH, UH type Control panel SH type: RRH type: • Circuit breaker: 45 A • Circuit breaker: 40 A • Receptacle: • Receptacle: 60 A - 250 V, 30 A - 250 V, 20 A - 250 V 60 A - 250 V, 30 A - 250 V, 20 A - 250 V KH, RGH type: •...
  • Page 5: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVES··························· 1-4 SPECIFICATIONS ·········································1-2...
  • Page 6: Serial Number Location

    The engine serial number (1) is stamped on the crankcase, and the frame serial number (2) is stamped on the engine bed. Refer to it when ordering parts or making technical inquiries. SPECIFICATIONS DIMENSIONS AND WEIGHTS Model EM10000K1 Type Description code EBTC Overall length 973 mm (38.3 in)
  • Page 7 SPECIFICATIONS GENERATOR Model EM10000K1 Type Description code EBTC Generator type Double electrode field rotation type Excitation Self–excitation and power coil excitation Voltage regulation system Digital AVR (Automatic Voltage Regulator) Phase Single phase Rotating direction Counterclockwise (Viewed from the generator) Rated 9.0 kVA...
  • Page 8: Performance Curves

    dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES – The curve shows performance of the generator under average conditions. – Performance may vary to some degree depending on ambient temperature and humidity. – The output voltage will be higher than usual when the generator is still cold, immediately after the engine starts. AC EXTERNAL CHARACTERISTIC CURVES SH, SKH type RATED CURRENT 40.9A...
  • Page 9: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 HARNESS ROUTING···································· 2-4 HOW TO READ CONNECTOR DRAWINGS ···························2-3...
  • Page 10: Maintenance Standards

    dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE ALL type Unit: mm (in) Part Item Standard Service limit Engine Engine speed (at no load) 3,750 ± 150 min (rpm) – Carburetor Pilot screw No.1 cylinder 2 - 1/2 turns out –...
  • Page 11 dummyhead dummyhead SERVICE INFORMATION HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins and the shape of terminal (male or female). Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are shown for the dedicated connectors.
  • Page 12: Harness Routing

    dummyhead dummyhead SERVICE INFORMATION HARNESS ROUTING GENERATOR SH, SKH type HARNESS BAND GROUND TERMINAL Cut the band end so its length is 5 – 10 mm (0.2 – 0.4 in). FIELD WINDING FIELD WINDING TERMINAL TERMINAL CABLE TIE Cut the band end so its length is 5 –...
  • Page 13 dummyhead dummyhead SERVICE INFORMATION LDH type HARNESS BAND Cut the band end so its length GROUND TERMINAL FIELD WINDING is 5 – 10 mm (0.2 – 0.4 in). TERMINAL FIELD WINDING TERMINAL CABLE TIE Cut the band end so its length is 5 –...
  • Page 14 dummyhead dummyhead SERVICE INFORMATION CONTROL BOX D-AVR SIDE (INSIDE OF THE CONTROL BOX) SH, SKH type D-AVR 9P D-AVR 4P CONNECTOR D-AVR 4P CONNECTOR CONNECTOR D-AVR 5P CONNECTOR CABLE TIE ·Clamp on the harness tube. ·Cut the band end so its length is 5 –...
  • Page 15 dummyhead dummyhead SERVICE INFORMATION LDH type D-AVR 9P D-AVR 4P CONNECTOR D-AVR 4P CONNECTOR CONNECTOR D-AVR 5P CONNECTOR CABLE TIE ·Clamp on the harness tube. ·Cut the band end so its length is 5 – 10 mm (0.2 – 0.4 in). CABLE TIE D-AVR 2P Cut the band end so its length is...
  • Page 16 dummyhead dummyhead SERVICE INFORMATION CONTROL PANEL SIDE (INSIDE OF THE CONTROL BOX) SH type CABLE TIE CIRCUIT BREAKER Cut the band end so TERMINAL its length is 5 – 10 CIRCUIT BREAKER mm (0.2 – 0.4 in). TERMINAL COMBINATION ([5] MARK) Do not contact the SWITCH 3P CABLE TIE...
  • Page 17: Spring Washer

    dummyhead dummyhead SERVICE INFORMATION Cable/terminal specified angle/direction RECEPTACLE TERMINAL ([6] MARK) Do not contact the receptacle of side. WASHER (6 mm) GROUND CABLE TERMINAL RETAINER SPRING WASHER (6 mm) (2) 40 ± 5° NUT (6 mm) (2) 30 ± 10° BOLT (6 x 28 mm) Terminal Wire color...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION SKH type CIRCUIT BREAKER CABLE TIE TERMINAL Cut the band end so ([5] MARK) its length is 5 – 10 mm (0.2 – 0.4 in). RECEPTACLE TERMINAL COMBINATION Do not contact the CIRCUIT BREAKER CABLE TIE C SWITCH 3P wire harness and TERMINAL...
  • Page 19 dummyhead dummyhead SERVICE INFORMATION Cable/terminal specified angle/direction RECEPTACLE TERMINAL ([6] MARK) Do not contact the receptacle of side. WASHER (6 mm) GROUND CABLE TERMINAL RETAINER SPRING WASHER (6 mm) (2) 40 ± 5° NUT (6 mm) (2) 30 ± 10° BOLT (6 x 28 mm) Terminal Wire color...
  • Page 20 dummyhead dummyhead SERVICE INFORMATION LDH type CIRCUIT BREAKER CIRCUIT BREAKER CABLE TIE TERMINAL TERMINAL ([6] MARK) CABLE TIE C Cut the band end so Do not contact the its length is 5 – 10 Cut the band end so CIRCUIT BREAKER wire harness and mm (0.2 –...
  • Page 21 dummyhead dummyhead SERVICE INFORMATION Cable/terminal specified angle/direction WASHER (6 mm) GROUND CABLE TERMINAL RETAINER SPRING WASHER (6 mm) (2) NUT (6 mm) (2) 15 ± 10° BOLT (6 x 28 mm) Terminal Wire color Terminal Wire color number number Bl/Y Control panel W/Bl harness side...
  • Page 22 dummyhead dummyhead MEMO...
  • Page 23: Governor System

    dummytext 7. GOVERNOR SYSTEM GOVERNOR ARM/CONTROL REMOVAL/INSTALLATION··························7-2...
  • Page 24 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR ARM/CONTROL REMOVAL/INSTALLATION GOVERNOR SYSTEM GOVERNOR SPRING INSTALLATION Hook the governor spring (1) to the throttle lever (2) of the control and the governor arm (3) as shown.
  • Page 25 dummytext 8. GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM DIAGRAM ··············8-2 MAIN WINDING INSPECTION···················· 8-11 GENERATOR SYSTEM EXCITER WINDING INSPECTION ············· 8-14 TROUBLESHOOTING···································8-5 FIELD WINDING INSPECTION ·················· 8-15 REAR HOUSING/STATOR REMOVAL/INSTALLATION··························8-9...
  • Page 26 dummyhead dummyhead GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM DIAGRAM GENERATOR/CHARGING SYSTEM SH type...
  • Page 27 dummyhead dummyhead GENERATOR/CHARGING SYSTEM SKH type...
  • Page 28 dummyhead dummyhead GENERATOR/CHARGING SYSTEM LDH type...
  • Page 29 dummyhead dummyhead GENERATOR/CHARGING SYSTEM GENERATOR SYSTEM TROUBLESHOOTING ABNORMAL OUTPUT (NONE, LOW OR HIGH) AT RECEPTACLE Abnormal Check the maximum engine speed with the Adjust the engine speed (page 7-4). circuit breaker in the ON position. Check the engine speed. Engine speed (at no load): 3,750 ±...
  • Page 30 dummyhead dummyhead GENERATOR/CHARGING SYSTEM From page 8-7 Abnormal SH, SKH type: Replace the stator (page 8-16). Disconnect the main winding terminals ( ) and exciter 3P connector LDH type: Disconnect the main winding terminals ( ) and exciter 3P connector Measure the resistance between the terminals of the stator winding.
  • Page 31 dummyhead dummyhead GENERATOR/CHARGING SYSTEM From page 8-8 Abnormal SH, SKH type: Replace the stator (page 8-16). Disconnect the main winding terminals ( ), field winding connectors ( ) and exciter 3P connector LDH type: Disconnect the main winding terminals ( ), field winding connectors ) and exciter 3P connector Connect a known good 12 V battery to the brush...
  • Page 32 dummyhead dummyhead GENERATOR/CHARGING SYSTEM From page 8-9 Abnormal Disconnect the power coil 2P connector Replace the charge/power coil (page 8-15). Measure the resistance between the power coil 2P connector terminals of the power coil side. Resistance: 1.92 – 2.88 Ω Normal Abnormal Remove the D-AVR unit (page 11-6).
  • Page 33 dummyhead dummyhead GENERATOR/CHARGING SYSTEM REAR HOUSING/STATOR REMOVAL/INSTALLATION • Take care not to damage the stator coil and rotor coil when removing/installing them. • Do not strike any part of the rotor when removing it. The rotor may be damaged. • Place the stator core side down. Do not set the stator on the coil end.
  • Page 34 dummyhead dummyhead GENERATOR/CHARGING SYSTEM Attach a chain hoist (1) to the engine hangers and pull the chain tight to support the engine. Or place wooden blocks under the front housing to support the generator/ engine assembly. Remove the tapping screw. Remove the washer-bolts and brush holder.
  • Page 35 dummyhead dummyhead GENERATOR/CHARGING SYSTEM REAR HOUSING/STATOR INSTALLATION Assemble the rear housing, stator and stator cover with the bolt (page 8-10). Install the stator and rear housing assembly (1) to the front housing. MAIN WINDING INSPECTION VOLTAGE INSPECTION Remove the generator end cover (Base shop manual: page 5-2).
  • Page 36 dummyhead dummyhead GENERATOR/CHARGING SYSTEM SH, SKH type: SH, SKH type: Disconnect the main winding terminals ( ), field winding connectors ( ) and exciter 3P connector LDH type: Disconnect the main winding terminals ( ), field winding connectors ( and exciter 3P connector Connect a known good 12 V battery to the brush terminals.
  • Page 37 dummyhead dummyhead GENERATOR/CHARGING SYSTEM CONTINUITY INSPECTION Remove the generator end cover (Base shop manual: page 5-2). SH, SKH type: SH, SKH type: Disconnect main winding terminals ( and exciter 3P connector LDH type: Disconnect the main winding terminals ( ) and exciter 3P connector Measure the resistance between the stator side terminals according to the table below.
  • Page 38: Resistance Inspection

    dummyhead dummyhead GENERATOR/CHARGING SYSTEM EXCITER WINDING INSPECTION VOLTAGE INSPECTION Disconnect the main winding terminals ( SH, SKH type shown: ), field winding connectors ( ) and exciter 3P connector Connect a known good 12 V battery to the brush terminals. •...
  • Page 39 dummyhead dummyhead GENERATOR/CHARGING SYSTEM FIELD WINDING INSPECTION VOLTAGE INSPECTION Remove the generator end cover (Base shop manual: SH, SKH type shown: page 5-2). Start the engine and measure the DC voltage at the brush terminals. ALL type Voltage Field winding terminal (VDC) (Red/White) –...
  • Page 40 dummyhead dummyhead MEMO...
  • Page 41: Ignition System

    dummytext 9. IGNITION SYSTEM IGNITION COIL INSPECTION·······················9-2...
  • Page 42: Ignition Coil Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL INSPECTION IGNITION SYSTEM Remove the fan cover (Base shop manual: page 5-3). 1 (IGN) 2 (EXT) Remove the spark plug cap (1). Disconnect the ignition coil 4P connector (2). Measure the resistance between the terminals and be sure that measurements...
  • Page 43: Other Electrical

    dummytext 11. OTHER ELECTRICAL CONTROL BOX CONTROL PANEL REMOVAL/INSTALLATION························11-2 DISASSEMBLY/ASSEMBLY ······················ 11-6 CONTROL BOX CIRCUIT BREAKER INSPECTION ············ 11-9 DISASSEMBLY/ASSEMBLY ······················11-5 11-1...
  • Page 44 dummyhead dummyhead OTHER ELECTRICAL CONTROL BOX REMOVAL/INSTALLATION OTHER ELECTRICAL Remove the following: SH, SKH type: – Maintenance cover/center beam (Base shop manual: page 5-2) – Fuel tank (Base shop manual: page 6-4) – Air cleaner (Base shop manual: page 6-6) –...
  • Page 45 dummyhead dummyhead OTHER ELECTRICAL Remove the fuse holder (1) from the control box. Remove the harness clips (1) from the frame. Open the harness clip (2) and release the wire harness (3). Remove the fuel valve tube (1) from the tube clip (2) on the control box.
  • Page 46: Control Box

    dummyhead dummyhead OTHER ELECTRICAL Remove the bolts and R/L. side covers. Remove the mounting bolts and remove the control box as an assembly with the control panel. Installation is reverse order of removal. • Route the harnesses properly (page 2-4, Base shop manual: page 2-12). TORQUE: CHOKE CABLE HOLDER 2.5 N·m...
  • Page 47: Control Panel

    dummyhead dummyhead OTHER ELECTRICAL CONTROL BOX DISASSEMBLY/ASSEMBLY Remove the control box (page 11-2). Installation is reverse order of removal. • Route the harnesses properly (page 2-4, Base shop manual: page 2-12). SH type shown: HARNESS CLIP (2) CHOKE CABLE GROMMET CONTROL PANEL D-AVR BOLT (6 x 16 mm) (2)
  • Page 48 dummyhead dummyhead OTHER ELECTRICAL CONTROL PANEL DISASSEMBLY/ASSEMBLY Remove the control panel (page 11-5). Installation is reverse order of removal. • Route the harnesses properly (page 2-4, Base shop manual: page 2-12). SH type CONTROL PANEL BOLT (6 x 28 mm) CHOKE CABLE NUT WIRE HARNESS 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
  • Page 49 dummyhead dummyhead OTHER ELECTRICAL SKH type CONTROL PANEL BOLT (6 x 28 mm) CHOKE CABLE NUT WIRE HARNESS 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) CABLE TIE (2) COMBINATION SWITCH WASHER-SCREW (6 x 16 mm) (2) i-MONITOR CABLE TIE C (3) CIRCUIT BREAKER (45 A) CHOKE CABLE SWITCH NUT...
  • Page 50 dummyhead dummyhead OTHER ELECTRICAL LDH type CABLE TIE (2) CONTROL PANEL CHOKE CABLE NUT WIRE HARNESS 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) WASHER-SCREW (6 x 16 mm) (2) COMBINATION SWITCH CABLE TIE C (3) i-MONITOR BOLT (6 x 28 mm) CIRCUIT BREAKER (41 A) CHOKE CABLE SWITCH NUT...
  • Page 51: Circuit Breaker Inspection

    dummyhead dummyhead OTHER ELECTRICAL CIRCUIT BREAKER INSPECTION SH, SKH TYPE Remove the circuit breaker (page 11-6). Check for continuity between the terminals according to the table below. Position Terminal Continuity Continuity LDH TYPE Remove the circuit breaker (page 11-6). Check for continuity between the terminals according to the table below.
  • Page 52 dummyhead dummyhead MEMO...
  • Page 53: Wiring Diagrams

    dummytext 18. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM WIRING DIAGRAMS ··································· 18-3 & RELATED INFORMATION ······················18-2 18-1...
  • Page 54 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a...
  • Page 55 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAMS SH type 18-3...
  • Page 56 dummyhead dummyhead WIRING DIAGRAMS SKH type 18-4...
  • Page 57 dummyhead dummyhead WIRING DIAGRAMS LDH type 18-5...
  • Page 58 dummyhead dummyhead MEMO...
  • Page 59 INDEX dummytext INDEX CIRCUIT BREAKER INSPECTION ······························11-9 MAIN WINDING INSPECTION····································· 8-11 CONTROL BOX DISASSEMBLY/ASSEMBLY ·············11-5 MAINTENANCE STANDARDS ······································ 2-2 CONTROL BOX REMOVAL/INSTALLATION···············11-2 PERFORMANCE CURVES············································ 1-4 CONTROL PANEL DISASSEMBLY/ASSEMBLY ·········11-6 REAR HOUSING/STATOR EXCITER WINDING INSPECTION·······························8-14 REMOVAL/INSTALLATION············································ 8-9 FIELD WINDING INSPECTION ····································8-15 SERIAL NUMBER LOCATION ·······································...

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