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Owner’s Manual GENERATOR EG4000CL/EG5000CL/EG6500CL Click to Save As See page 71 for instructions on assembling your generator. 2015 Honda Motor Co., Ltd. -All Rights Reserved...
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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 whatsoever.
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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.
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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.
CONTENTS GENERATOR SAFETY ................6 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 CONTROLS & FEATURES...............11 COMPONENT & CONTROL LOCATIONS...........11 CONTROLS...................13 Engine Switch ..................13 Starter Grip..................13 Fuel Valve Lever................14 Choke Lever..................14...
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CONTENTS OPERATION .....................22 SAFE OPERATING PRECAUTIONS.............22 STARTING THE ENGINE ..............23 STOPPING THE ENGINE ..............26 GFCI OPERATION CHECK ..............27 AC OPERATION..................29 AC Applications................31 AC Receptacle Selection..............32 Power Producing Circuits..............32 Voltage Selector Switch ..............33 STANDBY POWER ................35 Connections to a Building’s Electrical System ......35 System Ground ................35 Special Requirements..............36 SERVICING YOUR GENERATOR............37...
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Carburetor Modification for High Altitude Operation....62 Emission Control System Information...........63 Air Index ...................65 Specifications ...................66 Wiring Diagram................67 CONSUMER INFORMATION...............69 Dealer Locator Information .............69 Honda Publications................69 Customer Service Information............70 INITIAL USE INSTRUCTIONS ..............71 ENGINE OIL ..................71 FUEL......................72 BEFORE OPERATION................73 REGISTRATION..................73 OPTIONAL PARTS ...................74 HANDLE INSTALLATION ..............74...
GENERATOR SAFETY 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 injuries or property damage can be prevented if you follow all instructions in this manual and on the generator.
GENERATOR SAFETY 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.
GENERATOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Do not refuel during operation. Allow the engine to cool if it has been in operation. Refuel only outdoors in a well-ventilated area and on a level surface. Never smoke near gasoline, and keep other flames and sparks away.
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 generator dealer for a replacement.
CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS Use the illustrations on these pages to locate and identify the most frequently used controls. AC CIRCUIT BREAKER VOLTAGE SELECTOR SWITCH AC CIRCUIT PROTECTORS GFCI RECEPTACLES ENGINE SWITCH RECEPTACLES GROUND TERMINAL *: Except EG4000CL...
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CONTROLS & FEATURES FUEL GAUGE CHOKE LEVER FUEL VALVE LEVER OIL FILLER CAP STARTER GRIP OIL DRAIN PLUG AIR CLEANER SEDIMENT CUP FUEL TANK CAP SPARK PLUG MUFFLER...
CONTROLS & FEATURES CONTROLS Engine Switch The engine switch controls the ignition system. OFF – Stops the engine. ON – Running position, and for starting. ENGINE SWITCH Starter Grip Pulling the starter grip operates the recoil starter to crank the engine.
CONTROLS & FEATURES Fuel Valve Lever The fuel valve lever is located between the fuel tank and carburetor. The fuel valve lever must be in the ON position for the engine to run. After stopping the engine, turn the fuel valve lever to the OFF position.
CONTROLS & FEATURES Voltage Selector Switch The voltage selector switch switches generator output to produce ‘‘120V ONLY’’ or ‘‘120V/240V.’’ If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120V/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’...
AC CIRCUIT PROTECTOR for Receptacle 120V 30A GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE) 120/240 V 20 A (EG4000CL) 120/240 V 30 A (EG5000CL, EG6500CL) GFCI RECEPTACLE (120 V 20 A DUPLEX RECEPTACLE) *: Except EG4000CL AC CIRCUIT PROTECTOR...
CONTROLS & FEATURES Ground Fault Circuit Interrupter (GFCI) Receptacle Each 120 V 20 A duplex receptacle is protected by a Ground Fault Circuit Interrupter (GFCI) for protection against the shock hazard of ground-fault currents. An example of ground-fault current is the current that would flow through a person who is using an appliance with faulty insulation and, at the same time, is in contact with an electrical ground such as a plumbing fixture, wet floor, or earth.
If the engine stops, make sure the oil level is correct. Wait a few minutes, and then try to restart the engine. If the engine still won’t start, take the generator to your authorized servicing Honda power equipment dealer.
CONTROLS & FEATURES Fuel Gauge The fuel gauge is a mechanical device that measures the fuel level in the tank. The red indicator in the window will reference the level in relation to full or empty. To provide increased operating time, start with a full tank before beginning operation.
BEFORE OPERATION ARE YOU READY TO GET STARTED? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Knowledge Read and understand this manual. Know what the controls do and how to operate them. Familiarize yourself with the generator and its operation before you begin using it.
BEFORE OPERATION To prevent a possible fire, keep the generator at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects close to the engine. Before beginning your pre-operation checks, be sure the generator is on a level surface and the engine switch is in the OFF position.
OPERATION SAFE OPERATING PRECAUTIONS Before operating the generator for the first time, review chapters GENERATOR SAFETY BEFORE OPERATION (see page 6) and (see page 20). For your safety, do not operate the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.
OPERATION STARTING 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. Do not place flammable objects close to the engine. Operating this generator less than 3 feet (1 meter) from a building or other obstruction can cause overheating and damage the generator.
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OPERATION 4. To start a cold engine, move the CHOKE LEVER choke lever to the CLOSED position. To restart a warm engine, leave the choke lever in the OPEN position. CLOSED OPEN 5. Turn the engine switch to the ON position. ENGINE SWITCH 6.
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OPERATION 7. If the choke lever was moved to CHOKE LEVER the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up. OPEN...
OPERATION STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. 1. Turn off or disconnect all appliances that are connected to the generator. 2.
If the GFCI system fails the test, the generator must be repaired by an authorized Honda servicing dealer before use. 1. Unplug all tools and appliances from the generator. 2. Start the engine (see page 23).
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• The RESET button should be flush with the base. • If the RESET button is not flush with the TEST button, contact an authorized Honda generator dealer. 6. Check the GFCI LED to see if it is correctly functioning.
OPERATION AC OPERATION If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is in the appliance or the rated load capacity of the generator has been exceeded. Substantial overloading may damage the generator.
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AC CIRCUIT BREAKER AC CIRCUIT PROTECTORS PLUG *: Except EG4000CL 5. Turn on the appliance. Do not exceed the current limit specified for any of the receptacles. If an overloaded circuit causes the AC circuit breaker or AC circuit...
Make sure the electrical rating of the tool or appliance does not exceed the maximum power rating of the generator. Maximum power is: EG4000CL: 4.0 kVA EG5000CL: 5.0 kVA EG6500CL: 6.5 kVA For continuous operation, do not exceed the rated power.
VOLTAGE SELECTOR SWITCH TERMINAL TERMINAL *: Except EG4000CL Power Producing Circuits This generator is equipped with two power generating circuits. When the voltage selector switch is in the 120V/240V position, each of the two power producing circuits supplies power to specific receptacles.
You must, however, make sure the load on any receptacle does not exceed its available power shown below and the total load does not exceed the total current available. Total Current Available: 30.0 A (EG4000CL) 37.5 A (EG5000CL) 45.8 A (EG6500CL)
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Divide the load between the two sets of receptacles shown below. Balancing is necessary because each set of receptacles is powered by only one power producing circuit that can produce a maximum of amps(*). 15.0 A (EG4000CL) 18.8 A (EG5000CL) 22.9 A (EG6500CL) Set of...
OPERATION STANDBY POWER Connections to a Building’s Electrical System Connections for standby power to a building’s 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.
OPERATION Special Requirements There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction. •...
Remember that an authorized Honda 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, Honda Genuine parts or their equivalents for repair and replacement.
SERVICING YOUR GENERATOR 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. Improper maintenance can cause an unsafe condition.
— (1) Service more frequently when used in dusty areas. (2) These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.
SERVICING YOUR GENERATOR REFUELING With the engine stopped, check the fuel gauge. Refill the fuel tank if the fuel level is low. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks, and flame away when refueling.
SERVICING YOUR GENERATOR UPPER LEVEL MARK (RED) FUEL GAUGE FUEL TANK CAP FUEL FILTER UPPER LEVEL FULL EMPTY MARK (RED) After refueling, reinstall the fuel tank cap securely. FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher.
SERVICING YOUR GENERATOR ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. 1. Remove the oil filler cap. 2. Check the oil level. If it is below the upper limit, fill with the recommended oil (see page 44) to the upper limit.
SERVICING YOUR GENERATOR ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap, 12×15 mm drain plug, and sealing washer.
AMBIENT TEMPERATURE The SAE oil viscosity and service category are in the API label on the oil container. Honda recommends that you use API service category SJ or later (or equivalent) oil.
SERVICING YOUR GENERATOR AIR CLEANER SERVICE 1. Unsnap the air cleaner cover clips and open the air cleaner cover. 2. Free the hooks from the setting pins on the air cleaner case and remove the air cleaner cover to the right side of the frame pipe, taking care not to damage the air cleaner cover.
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SERVICING YOUR GENERATOR 5. Reinstall the air cleaner element in the air cleaner case. 6. 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 clearance between the air cleaner cover and air cleaner case.
SERVICING YOUR GENERATOR AIR CLEANER ELEMENT CLEANING A dirty air cleaner element will restrict air flow to the carburetor, reducing engine performance. If you operate the generator in very dusty areas, clean the air cleaner element more frequently than specified in the Maintenance Schedule. 1.
SERVICING YOUR GENERATOR SPARK PLUG SERVICE Recommended spark plugs: BPR5ES (NGK) To ensure proper engine operation, the spark plug must be properly gapped 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. 1.
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SERVICING YOUR GENERATOR 3. Visually inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked, chipped, or fouled. 4. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode.
SERVICING YOUR GENERATOR SPARK ARRESTER SERVICE The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester. Clean the spark arrester as follows: 1.
SERVICING YOUR GENERATOR SEDIMENT CUP CLEANING The sediment cup prevents dirt or water that 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. 1.
STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your generator trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your generator’s function and appearance, and will make the engine easier to start when you use the generator again.
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After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting. Use gasoline stabilizers that are formulated to extend storage life. Follow the manufacturer’s instructions for use. Contact your authorized Honda generator dealer for stabilizer recommendations.
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STORAGE Draining the Fuel Tank and Carburetor Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Stop the engine and keep heat, sparks, and flame away when refueling. • Handle fuel only outdoors. •...
STORAGE 3. Remove the sediment cup (see page 51), and then turn the fuel valve lever to the ON position and drain the fuel from the fuel tank. 4. After all the fuel has drained into the container, tighten the carburetor drain bolt securely.
STORAGE STORAGE PRECAUTIONS If your generator will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.
TRANSPORTING Do not lay the generator on its side when moving, storing, or operating it. Oil or fuel may leak and damage the engine or your property. If the generator has been running, allow the engine to cool for at least 15 minutes before loading the generator on the transport vehicle.
(see page 48). Spark plug wet with fuel Dry and reinstall spark plug. (flooded engine). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.
(see page 54). gasoline, or refueled with bad Refuel with fresh gasoline gasoline. (see page 40). Fuel filter restricted, Take the generator to an carburetor malfunction, authorized Honda servicing ignition malfunction, valves dealer, or refer to the shop stuck, etc. manual.
Check AC load and reset AC circuit protector (see page 16). Faulty power tool or Replace or repair power tool or appliance. appliance. Stop and restart the engine. Faulty generator. Take the generator to an authorized Honda servicing dealer, or refer to the shop manual.
TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER FRAME SERIAL NUMBER Record the engine and frame serial numbers and date purchased in the spaces below. You will need this information when ordering parts and when making technical or warranty inquiries. Engine serial number: Frame serial number: Date purchased:...
High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 5,000 feet (1,500 meters), have your authorized Honda servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.
The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards. Tampering and Altering Tampering is a violation of Federal and California law.
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• Afterburning (backfiring). • Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your new Honda engine were designed, built, and certified to conform with applicable emission regulations. We recommend the use of Honda Genuine parts whenever you have maintenance done.
TECHNICAL & CONSUMER INFORMATION Air Index (Models sold in California) An Air Index Information 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.
TECHNICAL & CONSUMER INFORMATION Wiring Diagram Abbreviations Wire color code Symbol Part name BLACK YELLOW AC O AC Outlet BLUE AC CB AC Circuit Breaker GREEN Control Box Block D-AVR Digital-Automatic WHITE Voltage Regulator BROWN D-CDI Digital-CDI LIGHT GREEN Engine Switch GRAY Engine Block LIGHT BLUE...
TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Dealer Locator Information To find an authorized Honda Servicing Dealer anywhere in the United States, visit our website: http://powerequipment.honda.com/dealer-locator Honda Publications Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.
TECHNICAL & CONSUMER INFORMATION Customer Service Information Honda Power Equipment dealership personnel are trained professionals. They should be able to answer any question 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.
INITIAL USE INSTRUCTIONS ENGINE OIL The generator is shipped WITHOUT OIL in the engine. 1. Place the generator on a level surface. 2. Remove the oil filler cap. 3. Add enough oil to bring the oil level to the upper limit of the oil filler neck.
INITIAL USE INSTRUCTIONS FUEL Add fuel to the generator in a well-ventilated area. Never refuel the engine inside a building where gasoline fumes may reach 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.
Please Register Your Generator If your dealer did not collect registration information from you, please take a few minutes and register your purchase with Honda. This allows us to contact you with any important updates regarding your generator. Please note registration is not required to obtain warranty service.
OPTIONAL PARTS HANDLE INSTALLATION Install the right and left handles on the generator upper frame using the handle brackets and four 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 RIGHT UPPER HANDLE ASSY RIGHT HANDLE BRACKET LEFT HANDLE BRACKET...
OPTIONAL PARTS WHEEL KIT INSTALLATION 1. Install the two wheels on the axle shaft using the plain washers and split pins. 2. Install the axle assembly on the generator using four 8×16 mm flange bolts and 8 mm flange nuts. 3.
INDEX Abnormal Voltage Detection Function..........18 AC Applications .................. 31 AC Circuit Breaker................15 AC Circuit Protectors ................16 AC OPERATION................... 29 AC Receptacle Selection ..............32 AIR CLEANER ELEMENT CLEANING ..........47 AIR CLEANER SERVICE ..............45 Air Index ....................65 ARE YOU READY TO GET STARTED?..........
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GFCI OPERATION CHECK ..............27 Ground Fault Circuit Interrupter (GFCI) Receptacle ......17 Ground Terminal ................19 HANDLE INSTALLATION ..............74 Honda Publications................69 IMPORTANT SAFETY INFORMATION ..........6 INITIAL USE INSTRUCTIONS ............71 IS YOUR GENERATOR READY TO GO?..........20...
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INDEX MAINTENANCE SAFETY..............38 MAINTENANCE SCHEDULE .............. 39 NO POWER AT THE AC RECEPTACLES..........60 Oil Alert Function................18 Oil Alert System.................. 18 OPERATION..................22 Operator Responsibility ............... 6 OPTIONAL PARTS ................74 Overspeed Detection Function ............18 Power Producing Circuits..............32 QUICK REFERENCE INFORMATION......
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INDEX SAFE OPERATING PRECAUTIONS............ 22 SAFETY LABEL LOCATIONS..............9 SEDIMENT CUP CLEANING............... 51 Safety Precautions................38 Serial Number Location ..............61 SERVICING YOUR GENERATOR ............37 SPARK ARRESTER SERVICE.............. 50 SPARK PLUG SERVICE............... 48 Special Requirements ................ 36 Specifications..................66 STANDBY POWER ................
QUICK REFERENCE INFORMATION Fuel Type Regular unleaded gasoline with an ethanol content of no more than 10% and a pump octane rating of 86 or higher (page 41) Engine Oil Type SAE 10W-30, API SJ or later (or equivalent), for general use (page 44) Spark Plug Type...
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31Z30610 N FM 00X31-Z30-6100 Printed in China...