Honda EM3500SX Owner's Manual
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Honda EM3500SX Owner's Manual

Honda EM3500SX Owner's Manual

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  • Page 2 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.
  • 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.

  • Page 5: Table Of Contents

    CONTENTS SAFETY ...................... SAFETY LABEL LOCATIONS .............. SAFETY INFORMATION ..............COMPONENT IDENTIFICATION .............. CONTROLS ....................11 Engine Switch ..................11 Recoil Starter ..................11 Fuel Valve Lever ................. 12 Choke Rod ................... 12 Circuit Breaker ...................
  • Page 6 MAINTENANCE ..................31 The Importance of Maintenance ............31 Maintenance Safety ................32 Emission Control System Information ..........33 Air Index ....................36 Maintenance Schedule ..............37 Engine Oil Change ................38 Air Cleaner Service ................

  • 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 9: 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 10 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.

  • Page 11: Component Identification

    COMPONENT IDENTIFICATION VOLT METER PILOT LAMP VOLTAGE SELECTOR SWITCH ENGINE SWITCH AC CIRCUIT BREAKER CHOKE ROD FUEL VALVE AC CIRCUIT LEVER PROTECTOR CLEANER RECEPTACLES RECOIL STARTER GROUND TERMINAL GRIP OIL FILLER CAP DC CIRCUIT PROTECTOR AUTO-THROTTLE SWITCH DC OUTPUT TERMINAL OIL DRAIN PLUG ENGINE SERIAL NUMBER...
  • Page 12 FUEL TANK CAP FUEL METER SPARK PLUG FRAME SERIAL NUMBER MUFFLER Record the engine and frame serial numbers for your future reference. Refer to these serial numbers when ordering parts, and when making technical or warranty inquiries (see page Frame serial number: Engine serial number:...

  • Page 13: 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. START ENGINE SWITCH Return the key to the ON position once the engine has started. Do not use the starter for more than 5 seconds at a time.

  • Page 14: 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 15: Circuit Breaker

    CIRCUIT BREAKER The AC circuit breaker will automatically switch OFF if there is a short circuit or an overload of the generator at the AC 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 AC circuit before switching the AC circuit breaker ON again.

  • 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: Pilot Lamp

    Pilot Lamp The pilot lamp is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the 120 or 120/240 volt receptacles. If the pilot light is illuminated, the volt meter should be displaying 120 or 240 volts depending on the position of the voltage selector switch.

  • Page 18: Dc Terminals

    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 19: Generator Use

    GROUND SYSTEM Honda portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire.

  • Page 20: Ac Applications

    AC APPLICATIONS Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock. If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.

  • Page 21: Ac Operation

    AC OPERATION Start the engine (see page Turn the voltage selector switch to either position. With the voltage selector switch in the ‘‘120/240V’’ position, you can use the 120V and 120/240V receptacles simultaneously. If you are NOT using the 120/240V receptacle, but require more power from the 120V locking plug receptacle, then select the ‘‘120V ONLY’’...

  • Page 22: Ac Receptacle Selection

    AC RECEPTACLE SELECTION 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: 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 cable to a battery that is installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( ) terminal.

  • Page 24: Disconnecting The Battery Cables

    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 circuit protector continues to go OFF, discontinue charging and see your authorized Honda generator dealer. Disconnecting the battery cables: Stop the engine.

  • Page 25: 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.

  • Page 26: 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 27: Pre-Operation Check

    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. SAE Viscosity Grades Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped.

  • Page 28: Fuel Recommendation

    FUEL RECOMMENDATION Check the fuel level gauge. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.
  • Page 29 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. Running the engine with persistent spark knock or pinging can cause engine damage.
  • Page 30 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.

  • Page 31: Starting 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. If you want to operate the choke manually, pull the choke rod out to the CLOSED position.

  • Page 32: Stopping The Engine

    STOPPING THE ENGINE In an emergency: To stop the engine in an emergency, move the engine switch to the OFF position. In normal use: Turn the AC circuit breaker to the OFF position. Disconnect DC battery charging cables. Turn the engine switch to the OFF position. Turn the fuel valve lever to the OFF position.

  • Page 33: Maintenance

    Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions. If...

  • Page 34: Maintenance Safety

    Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, genuine Honda parts or their equivalents for repair or replacement.

  • Page 35: Emission Control System Information

    The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit.
  • 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.

  • Page 38: Air Index

    AIR INDEX An Air Index Information hang tag/label was applied to this engine 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. The lower the Air Index, the less pollution.

  • Page 39: Maintenance Schedule

    Emission related items. Service more frequently when used in dusty areas. These items should be serviced by an authorized Honda generator dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop Manual. For commercial use, log hours of operation to determine proper maintenance intervals.

  • 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: BPR5ES (NGK) W16EPR-U (DENSO) 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.

  • 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: Transporting/Storage

    Change the engine oil. (page 38 ). After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting. Use gasoline conditioners that are formulated to extend storage life. Contact your authorized Honda generator dealer for conditioner recommendations.
  • Page 46 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.

  • Page 47: Troubleshooting

    R e p l a c e t h e Take the generator f rom the spark spark plug. to an authorized plug? Honda generator dealer. To check: Remove the spark plug cap and clean Be sure there is no...
  • Page 48 Is the AC circuit breaker Turn the AC circuit breaker NO DEFECTS Check the electrical ap- Take the generator to an pliance or equipment for authorized Honda generator any defects. dealer. Replace the electrical ap- pliance or equipment. DEFECTS Take the electrical ap- pliance or equipment to an electrical shop for repair.

  • Page 49: Wiring Diagram

    WIRING DIAGRAM...

  • Page 50: Specifications

    SPECIFICATIONS Dimensions Model EM3500SX Power product description code Length 23.8 in (605 mm) Width 19.5 in (495 mm) Height 19.1 in (485 mm) Dry weight 143.3 lbs (65.0 kg) Engine Model GX240K1 Engine type 4-stroke, overhead valve, single cylinder Displacement 14.8 cu-in (242 cm )

  • Page 51: Installation Of Optional Parts

    INSTALLATION OF OPTIONAL PARTS Remote Control Kit Install the relay box on the right side of the generator. Remove the blind 8 P connector from the back of the control box and connect the relay box connector instead. Connect the remote control cable to the remote control and relay box.
  • Page 52 Remote Control Box PILOT LAMP ENGINE STARTER SWITCH BUTTON Starting the engine with remote control Turn the fuel valve to the ON position. Turn the auto-throttle switch to the OFF position. Turn off the engine switch at the generator and remove the key. Turn the relay box switch to the ON position.
  • Page 53 Turn the engine switch at the remote control box to the ON position. Press the starter button untill the pilot lamp comes on. Stopping the engine Turn the engine switch at the remote control box to the OFF position. Turn the relay box switch to the OFF position. Turn the fuel valve to the OFF position.
  • Page 54 4 Wheel Kit Installation Install the four wheels on the axle shaft. Install the axle assembly on the generator using two bolts and nuts. Install the shaft with wheel stopper facing engine side. Inside Longer Shorter WHEEL STOPPER...
  • Page 55 BATTERY TRAY KIT 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 56 STARTER STARTER CABLE SOLENOID (positive) STARTER CABLE BATTERY GUARD GROUND CABLE BATTERY Use a battery rated at 12V-18-35AH or more BATTERY BRACKET BATTERY GUARD BATTERY TRAY BATTERY GUARD PLATE...

  • Page 57: Warranty Service Information

    General Manager can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Power Equipment Customer Relations Office. You can write to: American Honda Motor Co., Inc.

  • Page 58: Index

    INDEX COMPONENT IDENTIFICATION .............. CONTROLS ....................11 Auto-throttle System ................ . 14 Choke Rod ................... 12 Circuit Breaker ..................13 Circuit Protector ................. 13 DC Circuit Protector ................16 DC Terminals ..................16 Engine Switch ..................
  • Page 59 SAFETY ...................... SAFETY INFORMATION ..............SAFETY LABEL LOCATIONS .............. SPECIFICATIONS ..................48 STARTING THE ENGINE ................ . 29 STOPPING THE ENGINE ................ . 30 TRANSPORTING/STORAGE ..............43 TROUBLESHOOTING ................45 WARRANTY SERVICE INFORMATION ..........55 WIRING DIAGRAM .................
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