HONDA GENERATOR EM50is-EM65is Um OWNER'S MANUAL Honda EMSOis-EM65is OWNER’S MANUAL SPEC The“e—SPEC"mark symbolizes environmemaliy responsible technologies applied to Honda power "mu...“ equipment, which contains our wish to “preserve nature for generations to come." Thank you for purchasing a Honda generator. This manual covers operation and maintenance of the EMSOis and EM65is generators. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd. resen/es the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the generator and should remain with it if it is resold. Pay special attention to statements preceded by the following words: Indicates a strong possibility of severe personal iniury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. If a problem should arise, or if you have any questions about the generator, consult an authorized Honda dealer. AWARNING Honda generator is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the generator. Failure to do so could result in personal injury or equipment damage. 0 The illustration may vary according to the type. CONTENTS . INSTALLATION OF KIT PARTS. . MAJOR Honda DISTRIBUTOR A 14. (inside of back cover) LEAH wNepwwfig wpw we SAFETY INSTRUCTIONS.... SAFETY LABEL LOCATIONS. CE mark and noise label locations COMPONENT IDENTIFICATION 12 PRE-OPERATION CHECK STARTING THE ENGINE. 0 High altitude operation GENERATOR USE ........ STOPPING THE ENGINE. MAINTENANCE ............ TRANSPORTING/STORAG TROUBLESHOOTING SPECIFICATIONS ...... WIRING DIAGRAM ........................................ ' F, G, and IT Types. L Type ................ R, S, and U Types.. 1. SAFETY INSTRUCTIONS 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 mishaps 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. Never attempt to modify the generator. It can cause an accident as well as damage to the generator and appliances. - Do not connect an extension to the muffler. 0 Do not modify the intake system. 0 Do not adjust the governor. o Do not remove the control panel or do not change the wiring of the control panel. Operator Responsibility 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. Be sure to observe the instructions in this manual for how to use the generator and maintenance information. Ignoring or improperly following the instructions can cause an accident such as an electric shock, and the condition of the exhaust gas may deteriorate. Place the generator on a firm level place before operation. Do not operate the generator with any cover removed. You may get your hand or foot caught in the generator and it may cause accident. Consult your authorized Honda dealer for disassembly and service of the generator that are not covered in this manual. Carbon Monoxide Hazards Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death. If you run the generator in an area that is confined, or even partially enclosed area, the air you breathe could contain dangerous amount of exhaust gas. Never run your generator inside a garage, house, or near open windows or doors. 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. 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 that could result in electrocution. If you get an electric shock, consult a doctor and have medical treatment immediately. Do not connect to a building’s electrical system unless an isolation switch has been installed by a qualified electrician. Fire and Burn Hazards Do not use the generator in areas with a high risk of fire. When installed in ventilated rooms, additional requirements for fire and explosion protection shall be obsen/ed. The exhaust system gets hot enough to ignite some materials. *Keep the generator at least 1 meter (3 feet) away from buildings and other equipment during operation. —Do not enclose the generator in any structure. — Keep flammable materials away from the generator. Some pans of the internal combustion engine are hot and may cause burns. Pay attention to the warnings on the generator. 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. Do not pour the water directly on the generator to put out the fire when it occurs. Use an appropriate fire extinguisher specially designed for electric fire or oil fire. If you inhale fumes produced by an accidental fire with the generator, consult a doctor and have medical treatment immediately. 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. Disposal To protect the environment, do not dispose of the used generator, battery, engine oil, etc. carelessly by leaving them in the waste. Observe the local laws or regulations or consult your authorized Honda generator dealerto dispose of these pans. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash or pour it on the ground. An improperly disposed battew can hurt the environment. Always confirm local regulations for battery disposal. Contact your Honda servicing dealer for a replacement. 2. SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious injury. Read the labels and safety notes and precautions described in this manual carefully. If a label comes off or becomes hard to read, contact your Honda dealer for a replacement. F, G, IT types Gmrmtuoronzwmmrmnrommv : @STOPDENWMALVOEMWTETMKEM O W n: ENEIE m5 RENEHM. ®Ann£1mzmmmmnsmmunm ® van MJFI’ANKBI moron mama. ®rmammumm (g mu: 0 m AMI'ES DE m, 6mm“: in mu "I’ll run mmum I: mxw. (5) sum; AV Mmom rows WNSEPLWLLNIII}, ® “or mm m ”190$me 0 an AV morons" m PM. 8 swum marrow EMEN rmwsu 0 Honda generator is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner's Manual before operating the generator. Failure to do so could result in personal iniury or equipment damage. - Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death. ~ If you run the generator in an area that is confined, or even partially enclosed area, the air you breathe could contain a dangerous amount of exhaust gas. 'Never run your generator inside a garage, house or near open windows or doors. ' Do not connect to a building's electrical system unless an isolation switch has been installed by a qualified electrician. 0 Connections lor standby power to a building’s electrical system must be made by a qualified electrl an and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and when utility power is restored, the generator may explode. burn, or cause fires in the building's electrical system. a $10? was 5mm: BEFORE newsuuo. ® mire LE Morsua Avml DE mm LE Mm. ® von AUFI'ANKEN moron ABSTELLEN. ® ARRESTARE IL MOTORS PRIMA DI FARE RIFOWENTO. ® STOP DE MOTOR ALWHENS BL! TE TAMKEM & (amtuwronmresnsnmsrm ® assueus o moron ANTES n: amen. @nmm: m mm mm row moomxuo vs mun, © sum: AV moron" FéflE mumummme. ® s-ror morons" m ammmrvm-uc, ® su AV moms!" ran PAFVLLING. ® SAMMUTA MOD‘I'I'ORI ENNEN TANKKAUSTA. 0 Stop the engine before refueling. 0 Gasoline is extremely flammable and explosive under certain conditions. Refuel in a well ventilated area with the engine stopped. - Keep away from cigarette, smoke and sparks when refueling the generator. Always refuel in a well ventilated location. 0 Wipe up spilled gasoline at once. j A hot exhaust system can cause serious burns. Avoid contact if the engine has been running. 8. R, U. L types 10 n: um um mans-um I nsv- mi nun-um , was .memuumhmmxmm: Iriluumnlfllzunuumnm '22.}? um mm mm Irma» n m urn-um I: as .m- u mu Wm mass m at: limo: mu. lmmsn'mmlmsul 11mm u: rmmsam-L AAYENCIM I mousmmsmmmunmm In: «no as mm In new: u sm- n: ma ratmn A u msmmbl 'Elénmu n: w n: I.“ Mum-sun: m-Iw'm mmm - 133...” u PM mm mm: mm um mm mm "mum-7M ms mums mufiwvwfl‘wn HOT-EXHAUST ECHAPPEMENT-CHAUD - CE mark and noise label locations NOISE HEEL AND CE MARK 11 3. COMPONENT IDENTIFICATION CONTROL PANEL (See page: 13 thru 15) SPARK PLUG INSPEC‘HON COVER WHEEL " BATTERY my (Inslde malntenanm oovor) FUSE (IMHO maimenanu cover) AIR CLEANER STAND FUEL TANK CAP FUEL GAUGE GROUND TERMINAL OIL DRAIN PLUG OIL FILLER CAP/DIPSTICK 12 (U WI») OIL ALERT INDICATOR OVERLDAD INDICATOR I—MONITOR BUTTON AC RECEPTACLES i-MONITOR ENGINE SWITCH WEL VALVE LEVER ECO THROTTLE SWITCH 15 Record the frame serial number in the space below. You will need this serial number when ordering parts. Frame serial number: 16 Eco Throttle ON: Engine speed is kept at idle automatically when the electrical appliance is disconnected and it returns to the proper speed by the electrical load when electrical appliance is connected. This position is recommended to minimize the fuel consumption while in operation. NOTE: oWhen high electrical load appliances is connected simultaneously, turn the Eco Throttle switch to the OFF position to reduce voltage changes. 0 Eco Throttle system does not operate sufficiently if the electrical appliance requires the momentary electric power. OFF: Eco Throttle system does not operate. Engine speed is kept over rated speed. (L we) on W \ OFF OFF ECO THROTTLE swncu (F. G. IT mm) (s, U. n types) OFF ON ON 17 Oil Alert system The Oil Alert system is designed to prevent the 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 comes on and the Oil Alert system automatically will stop the engine (the engine switch will remain in the ON position). The i-Monitor display will show “OIL" on the screen and the Oil Alert indicator will illuminate. If the engine stops or the Oil Alert indicator comes on when you turn the engine switch to the START position or pull the starter grip, check the engine oil level (see page 22) before troubleshooting in other areas. Even when the oil is added to the engine, the generator will not restart until the Oil Alert indicator is reset. To reset the Oil Alert indicator, turn the engine switch to the OFF position, add the proper amount of oil (see page 40 l, and then turn the engine switch back to the ON position. OIL ALERT INDICATOR (RED) (r, 6, IT typos) (s, u. n, Ltypes) LO} OUTPUT OVERLOAD 'OLL INDICATOR ALARM ALERT L4 HE 3:le ahpm «a " blink‘/ 18 i-Monitor The i-Monitor is a user interface that allows the operator to view (when the generator is running) total operating time in hours, generator output, engine RPM, battery voltage, and error messages. The different display modes are selected by pressing the i—Monitor button. i-Monitor at Start Up During start up, the i-Monitor display and all three indicators will simultaneously blink once. The condition of the i»Monitor display and all three indicators can be checked with the aid of an observer. Once the generator is running, the Output indicator (green) and the i- Monitor display will remain lit. Backlight blinks When turning the engine switch to the ON position with having not start the engine over 30 seconds, display starts to blink. Please start the engine or turn the engine switch to the OFF position. i-Monitor Display The i-Monitor display is divided into two screens. The single~digit screen display the i-Monitor mode which is represented by a number 1 through 4. The four-digit screen displays the four mode values total operating hours, power output, engine RPM and battery Voltage or any activated error messages. I—MONITOR BUTTON 12E EZVA SINGLE-DIG" SCREEN DISH-AV FOUR-DIGIT SCREEN DISPLAV 19 i-Monitor Display Mode 1 A Total Operating Hours This mode displays the total operating hours of the generator‘ When the generator is running, the total operating time accumulates. If the total operating time is less than one hour, the numeric display will be "0.” When the operating time is one hour or greater. the display will be ”1” or ”2” and so on. Base the generator's maintenance schedule on the accumulated time displayed. HE a:VA ahpm «a l 99l©l i—Monitor Display Mode 2 — Power Output This mode displays an approximate generator output on the display screen. The output is expressed in VA (volt amperesl. The output value is not an exact measurement and should be regarded as a reference only. Power output will not display until a load is connected to the generator. lib] a:VA ahpm Hm E dflflfll©| i~Monitor Display Mode 3 — Engine RPM When the i-Monitor is in this mode, the engine’s speed, expressed in revolutions-per-minute (RPM), is displayed. llfl E‘:VA Eiirpm HIE 3 Efiflfll©i 20 i—Monitor Display Mode 4 — Battery Voltage This mode displays the battery condition, expressed in Volts DC. % :35l©l i-Monitor Low Battery Message If the engine switch is turned to the START position and “ban” is shown on the i-Monitor display, the battery voltage is too low to operate the engine's electric starter. Use the recoil starter to start the generator. Have the battery recharged and checked (see pages 50 thru. 52). 1:8 a:vA sham HIE b8ttl©l i-Monitor System Error Messages If the generator has a system malfunction, it will show an error message on the i-Monitor display. If an error message displays, contact an authorized Honda generator dealer. T ?r OUTPUT OVERL'OAD OIL OVERLOAD INDICATOR INDICATOR ALARM ALERY ”13 all] 2:“ azmm we l©l E -D l l©l ERRORMESSAGE (Example: EN) 21 4. PRE-OPERATION CHECK CAUTION: Be sure to check the generator on a level surface with the engine stopped. 1. Check the engine oil level. CAUTION: Using non detergent oil or 2-stroke engine oil could shorten the engine's service life. Use high-detergent, premium quality 4-stroke engine oil, certified to meet or exceed U.S. automobile manufacturer’s requirements for API service category SE or later (or equivalentl. Select the appropriate viscosity for the average temperature in your area. SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range. -20 -10 0 10 20 30 40°C l_'—T_'_l_'—1_'—l—V_T_-'—l 0 20 40 60 80 100°F AMBIENT TEMPERATURE 22 Remove the oil filler cap, and wipe the dipstick with a clean rag. Check the oil level by inserting the dipstick in the filler hole without screwing it in. If the oil level is below the end of the dipstick, refill with recommended oil up to the top of the oil filler neck. CAUTION: Running the engine with insufficient oil can cause serious engine damage. NOTE: The Oil Alert System will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, it is still advisable to visually inspect the oil level regularly. UPPER LEVEL DIP STICK OIL FILLER CAP 23 2. Check the fuel level. If the fuel level is low, refill to the shoulder of the fuel strainer. After refueling, tighten the fuel filler cap securely. Use automotive unleaded gasoline with a Research Octane Number of 91 or higher (3 Pump Octane Number of 86 or higher). Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. [AWARNING . 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. . Do not overfill the fuel tank. After refueling, make sure the fuel filler cap is closed properly and securely. . Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. if any fuel is spilled, make sure the area is dry before starting the engine. oAvoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. FUEL TANK CAP MAXIMUM FUEL LEVEL FULL o i EMPTV 0 FUEL GAUGE 24 NOTE: Gasoline spoils very quickly depending on factors such as light exposure, temperature and time. In worst cases, gasoline can be contaminated within 30 days. Using contaminated gasoline can seriously damage the engine (carburetor clogged, valve stuck). Such damage due to spoiled fuel is disallowed from coverage by the warranty. To avoid this please strictly follow these recommendations: 0 Only use specified gasoline lsee page 24). - Use fresh and clean gasoline. 0 To slow deterioration, keep gasoline in a certified fuel container. - If long storage (more than 30 days) is foreseen, drain fuel tank and carburetor. Gasolines Containing Alcohol If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by Honda. There are two types of ”gasohol": one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors. NOTE: 0Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete. - Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol, if it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating symptoms while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol. 25 3. Check the air cleaner. Loosen the cover screws and remove the air cleaner cover. Remove the foam air filter from the air cleaner housing. Check the foam air filter to be sure it is clean and in good condition. If the foam airfilter is dirty, clean it as described on page 48. Replace the foam air filter if it is damaged. Reinstall the foam airfilter in the air cleaner housing. FOAM AIR FILTER AIR CLEANER COVER COVER SCREWS CAUTION: Never run the engine without the form air filter. Rapid engine wear will result from contaminants, such as dust and dirt, being drawn through the carburetor, into the engine. 26 5. STARTING THE ENGINE Electric starting CAUTION: When starting the generator after adding fuel for the first time, after long-term storage, or after running out of fuel, turn the fuel valve lever to the ON position, then wait for 10 to 20 seconds before starting the engine. Before starting the engine disconnect any load from the AC receptacle. 1 . L type only: Set the Voltage Selector Switch to match the voltage requirements for the application. we a 120/240V / F 120V ONLY VOLTAGE SELECTOR SWITCH 2. Turn the fuel valve leverto the ON position on 6 OFF FUEL VALVE LEVER 27 3.Make sure the Eco Throttle switch is in the OFF position, or more time will be required for warm—up. (L W) ON OFF Eco mam-n1 swrrcu zoo TH 1'I'LE swrrcu (F, G, rr typos) (S. U. R types) 28 4. Turn the engine switch to the START position and hold it there until the engine starts. (F. G. IT types) (S, U. E l- (was) 0 OFF N START REMOTE O ENGINE SWITCH CAUTION: Do not use the starter motor ior more than 5 seconds. If the engine fails to start, release the key, and wait at least 10 seconds before operating the starter motor again. NOTE: When the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged. 5. After the engine starts, let the engine switch return to the ON position. (F. G. IT types) (8, U. R. L mm) o F N OF START REMOTE O ENGINE SWITCH 29 6,lf you wish to use the Eco Thronle system, turn the Eco Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes. Eg/ (l mu! °" ON OFF E00 THROTILE swrrcu Eco mam-rm swrrcu W / (F. G, IT types) OFF on (S, U, R typci) 30 Manual starting CAUTION: When starting the generator after adding fuel for the first time, after long-term storage, or after running out of fuel, turn the fuel valve lever to the ON position, then wait for 10 to 20 seconds before starting the engine. Before starting the engine disconnect any load from the AC receptacle. 1. L type only Set the Voltage Selector Switch to match the voltage requirements for the application. Va 7— 120/240V “i:— 120V ONLV t VOLTAGE SELECTOR SWITCH 2. Tu rn the fuel valve lever to the ON position. OFF FUEL VALVE LEVER 31 3‘ Make sure the Eco Throttle switch is in the OFF position, or more time will be required for warm-up. (L M») ON OFF E00 mnonLE swrrcu ECO THROTTLE SWITCH (F, G, IT types) 0" (S' U. H :vpes] 32 4. Turn the engine switch to the ON position. IF, 6. IT W995) (S, U, R, Ltvpesl o F N OF START REMOTE O 5.Pull the starter grip lightly until you feel resistance, then pull the starter grip briskly toward in the direction of the arrow as shown below. ENGINE SWITCH CAUTION: o The starter rope can be drawn back very quickly before you release it. This may pull your hand forcefully toward the engine and cause an iniury. - Do not allow the starter grip to snap back. Return it slowly by hand. ~ Do not let the starter rope rub against the generator body, or the rope will wear out prematurely. STARTER GRIP 33 6.lf you wish to use the Eco Throttle system, turn the Eco Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes. (L two) ON OFF sco 111mm: swrrcu eco THROTTLE swn'cu U 1/ (F s, l'l'types) J//0N (S, U, R lvPOs) ECO TPRO‘I'I'LE OFF ON 34 0 High altitude operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by specific modifications to the carburetor. If you always operate the generator at altitudes higher than 1,500-meter (5,000 feet) above sea level, have your authorized Honda dealer perform these carburetor modifications. Even with suitable carburetorjetting, engine horsepower will decrease approximately 3.5% for each 300-meteri1,000-foot) increase in altitude. The affect of altitude on the horse power will be greater than this if no carburetor modification is made. CAUTION: Operation of the generator at an altitude lower than the carburetor is ietted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture. 35 6. GENERATOR USE Be sure to ground the generator when the connected equipment is grounded. [AWARIHNG . Do not connect to a building's electrical system unless an isolation switch has been installed by a qualified electrician. c Connections for standby power to a building’s electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage, and when utility power is restored. the generator may explode, burn, or cause fires in the building’s electrical system. GROUND TERMINAL EARTH MARK 36 CAUTlON: . Do not exceed the current limit specified for any one receptacle. - Do not connect the generator to a household circuit. This could cause the damage to the generator or to electrical appliances in the house. 0 Do not modify or use the generator for other purposes than it is intended for. Also observe the following when using the generator. . Do not connect an extension to the exhaust pipe. 0 When an extension cable is required, be sure to use a tough rubber sheathed flexible cable (IEC 245 or equivalent). 0 Limit length of extension cables; 60 m (200 feet) for cables of 1.5 mm2 (0.0023 in2) and 100 m (330 feet) for cables of 2.5 mm2 (0.0039 inl). Long extension cables will lower usable power due to resistance in the extension cable. - Keep the generator away from other electric cables or wires such as commercial power supply lines. NOTE: 0 Make sure the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes. Limit operation requiring maximum powerto 30 minutes. Maximum power in parallel operation is: EM65is: 6,500 VA EM50is: 5,000 VA For continuous operation, do not exceed the rated power. Rated power in parallel operation is: EM65is: 5,500 VA EM50is : 4,500 VA In either case, the total power requirements (VA) of all appliances connected must be considered. 37 AC Application 1. L type only: Turn the voltage selector switch to either position. Voltage selector Used receptacles switch position 120/240V 120V and 120/240V 120V ONLY 120V [1% E F— 120]sz q:— I20V ONLY t VOLTAGE SELECTOR swrrcn 2. Start the engine and make sure the green output indicator comes on. 3. Confirm that the appliance to be used is switched off, and plug in the appliance. OUTPUY INDICATOR (GREEN) 38 CAUTION: - Substantial overloading that continuously lights the Overload indicator (red) may damage the generator. Marginal overloading that temporarily lights the Overload indicator (red) may shorten the service life of the generator. 0 Be sure that all appliances are in good working order before connecting them to the generator. Electrical equipment (including lines and plug connections) should not be defective. If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn off the generator engine switch immediately. Then disconnect the appliance, and examine it for signs of malfunction. 39 AC Receptacle Selection (L Type only) The generator has separate main power producing circuits. These two circuits supply power to different receptacles shown when the voltage selector switch is in the 120/240 V 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 when the 120/240 V locking plug receptacle is used for 120 V. The total rated ampere draw is: EMSOis: 37.5A/EM65is: 45.8A Model Main power Receptacles powered Power distribution circuit by each main circuit (rated ampere) EMSOis Main Circuitl 1, 3 and 4 1 + 3 + 4:18.8A Main Circuit ll 2 and 5 2 + 5 =18.8A EMGSis Main Circuitl 1, 3 and 4 1 + 3 + 4: 22.9A Main Circuit ll 2 and 5 2 + 5 = 22.9A ©120sz ©12W30A ©120V20A / / / / // / Q / / ©120/240V30A ///‘f; ? G) Izo/zaov 30A Output and Overload Indicators The Output indicator (green) will remain 0N during normal operating conditions. if the generator is overloaded (see page 37), or if there is a short in the connected appliance, the Output indicator (green) will go OFF, the overload indicator (red) will go ON and current to the connected appliance will be shut off. Stop the engine if the Overload indicator (red) comes ON and investigate the overload source. NOTE: The Overload indicator (red) also lights in the following cases: . When the inverter is overheated; the current to the connected appliance will be shut off. Check to see if the air intake is obstructed. . Before connecting an appliance to the generator, check that it is in good order, and that its electrical rating does not exceed that of the generator. Then connect the power cord of the appliance, and start the engine. F, e, and rr mm L. R, s, and u Types OUTPUT INDICATOR OVERLOAD ouwur INDICATOR OVERLOAD (GREEN) INDICATOR (RED) (GREEN) INDIcATOR (RED) {a m] T “J @ £3 ‘5“ OUTPUT OVERLOAD OIL INDICATOR ALARM ALERT NOTE: When an electric motor is staned, both the Overload indicator (red) and the Output indicator (green) may go on simultaneously. This is normal if the Overload indicator (red) goes off after about five (5) seconds. If the Overload indicator (red) stays on, consult your Honda generator dealer. 41 Ac Circuit Protectors The AC circuit protectors will automatically switch OFF (push button comes out) if there is a short circuit or a significant overload of the generator at receptacle. 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 0N (pushing the push button in). AC URCUIT PROTECTORS 3% CIRCUIT PROTECTOR CIRCUIT PROTECTOR CIRCUIT PROTECTOR (For receptacle No, 1) (For receptacle Mar 2) (For receptacl- No. 3) AC RECEPTACLE AC RECEPTACLE AC RECEPTACLE No. 1 No. 2 No. 3 42 “we CIRCUIT PROTECTOR CIRCUIT PROTECTOR (For receptacle No‘ 2) (For neoplacle No. 3) AC RECEPTACLE AC RECEPTACLE AC RECEPTACLE No. 1 Na‘ 2 No. 3 IT type CIRCUIT PROTECTOR CIRCUIT PROTECTOR (For rmptaclo No. 2] (For noeptacla No. 3) AC RECEPTACLE AC RECEPTACLE AC RECEPTACLE No. 1 No. 2 N0, 3 43 7. STOPPING THE ENGINE To stop the engine in an emergency, turn the engine switch to the OFF position. IN NORMAL USE: 1. Switch off the connected equipment and pull the inserted plug. W //2 2. Turn the engine switch to the OFF position. (F. G, n typos) (S, U, R, LWP“) on OFF sum REMOTE O 3. Tu rn the fuel valve lever to the OFF position. ENGINE SWITCH FUEL VALVE LEVER 8. MAINTENANCE The purpose of the maintenance and adjustment schedule is to keep the generator In the best 0 eratlng condition. Inspect or sewlce as sche uled In the table below. A‘AWARHING Make sure the engine is off before you begin any maintenance or re airs. This will ellm ate several potential hazards: - arbon monox‘de poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. oBurns from hot parts. Let the engine and exhaust system cool before touching. o Inigry from moving parts. Do not run the engine unless instructed to 0 so. The muffler becomes very hot during operation and remains hot for a while after sto ping the engine. Be careful not to touch the muffler while it is hot. at the engine cool before maintenance. Maintenance Schedule REGULAR SERVICE PERIOD (3) Each use First Every Every Every Item month 3months 6 months year Perform at every indicated month or or or or or operating hour interval, 20hrs. so hrs. 100 hrs. acorns. whichever comes first. Engine oil Check level 0 Chance 0 0 Air cleaner Check 0 Clean 0 (I) Sediment cup Clean 0 Spark plug Check—adiust 0 Replace 0 Valve Clearance Check-adiust o (2) Combustion Clean After every 500 hrs. (2) chamber Fuel tank a lilter Clean I | l o (2) l Fuel tube Check Everv 2 ears (Replace il necessary) (2) NOTE: (“Service more frequently when used in dusty areas. (ZlThese 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. (3lFor commercial use, log hours of operation to determine proper maintenance intervals. 1. CHANGING OIL Drain the oil while the engine is still warm to assure rapid and complete draining. 1.0pen and remove the oil maintenance cover. 2. Remove the oil filler cap and oil drain plug to drain the oil. 3. Install the oil drain plug, and tighten it securely. 4. Refill with the recommended oil (see page 22 ) and check the oil level. 5. Reinstall, close and latch the oil maintenance cover. ENGINE OIL CAPACITY: 1.1 L (1.2 US qt, 1.0 Imp qt) UPPER lEVEI. SEALING WASHER m on DRAIN PLUG OIL FILLER CAP/DIPSTICK Wash your hands with soap and water after handling used oil. NOTE: Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash or pour it on the ground. 46 2. 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. “WARNING Do not use gasoline or low flash point solvents for cleaning. They are flammable and explosive under certain conditions. CAUTION: Never run the generator without the air cleaner. Rapid engine wear may result. 1. Loosen the cover screws and remove the air cleaner cover. FOAM AIR FILTER AIR CLEANER COVER COVER SCREWS 2. Remove the foam air filter. 47 3. Clean the foam airfilter in warm soapy water, rinse, and allow to dry thoroughly, or clean in non-flammable solvent and allow to dry. FOAM AIR FILTER 4. Dip the foam air filter in clean engine oil, and then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the filter. ‘ 1. Soakl l2. Squeezel l3. Gill '4. Squeeze Do not twist. Do not twist. @a»@ea 5.Wipe dirt from the air cleaner housing and cover using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor. 6. Reinstall the foam air filter. 7. Reinstall the air cleaner cover and tighten the cover screw securely. 3. FUEL SEDIMENT CUP SERVICE [AWAHNlNC Gaso he is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 1. Turn the engine switch to the OFF position. 2. Turn the fuel valve lever to the OFF position. 3. Remove the sediment cup by turning it counterclockwise. 4. Wash the sediment cup in non-flammable solvent, and dry it thoroughly. 5. Reinstall a new O-ring and sediment cup. 49 4. SPARK PLUG SERVICE RECOMMENDED SPARK PLUG: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1. Loosen the cover screw and remove the spark plug inspection covert SPARK PLUG INSPECTION COVER COVER SCREW 2. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. 3. Remove the spark plug with a spark plug wrench. SPARK PLUG WRENCH 50 4. Visually inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor condition, or if the electrode is worn. Clean the spark plug with a wire brush if it is to be reused. 5. Measure the plug gap with a feeler gauge. Correct as necessary by carefully bending the side electrode. The gap should be: 0.7’0.8 mm (002870.031 in) 0.7 7 0.5 mm (0.023, 0.031 in) SEALING WASHER PLUG GAP 6. Install the spark plug carefully, by hand, to avoid cross-threading. 7.After a new spark plug has been seated by hand, it should be tightened 1/2 turn with a wrench to compress its sealing washer, If a used plug is being reinstalled, it should only require 1/8 to 1/4 turn after being seated. CAUTION: oThe spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the generator. 0 Never use a spark plug with an improper heat range. 8. Reinstall the spark plug inspection cover and tighten the cover screw. 51 6. FUSE REPLACEMENT If the fuse is blown, the starter motor won't operate. In the event of fuse failure, locate the cause of failure and repair it before you continue Operation. if the fuse continues to fail, discontinue generator use and consult an authorized Honda generator dealer. 1.Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse. 2.Lift handle upward. Lock levers will lock and secure handle into place. 3. Loosen the cover screw and remove the maintenance cover. \ g‘ MAINTENANCE COVER ' F DOVER SCREW 52 4. Remove the fuse holder cover and pull the fuse out. 5. Replace the fuse with a fuse of the same type and rating. Specified fuse: 1A, 15A FUSES (IA) FUSE (15A) FUSE HOLDER FUSE HOLDER COVER //////////// CAUTION: 0 If frequent fuse failure occurs, determine the cause and correct the problem before attempting to operate the generator further. - Never use a fuse with a different rating from that specified. Serious damage to the electrical system or fire may result. 6. Install the fuse holder cover and the battery maintenance cover in the reverse order of removal. Never operate the generator without the battery maintenance cover in place, as poor engine and generator performance will result. 53 7. BATTERY REMOVAL/INSTALLATION AWARNING 0 Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness. Provide adequate ventilation when charging. 0 CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin. even through clothing, may cause severe burns. Wear a face shield and protective clothing. 0 Keep flames and sparks away, and do not smoke in the area. ANTIDOTE: If electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately. . POISON: Electrolyte is poison. ANTIDOTE —External: Flush thoroughly with water. —lnternal: Drink large quantities of water or milk. Follow ith milk of magnesia or vegetable oil, and call a physician immediately. ' KEEP OUT OF REACH OF CHILDREN. Removal: 1.Turn the engine switch to the OFF position. 2. Lift handle upward. Lock levers will lock and secure the handle into place. 3. Loosen the cover screw and remove the battery maintenance cover. 4. Remove the negative (—) cable from the battery negative (7) terminal, and then remove the positive (+) cable from the battery positive (+)terminal. 5. Unhook the battery holder band from the bottom hook of the generator. POSI'HVE (+) CABLE NEGA11VE (a) CABLE BATl'EflY HOLDER BAND 54 6. Remove the battery from the battery tray. Installation: 1. Make sure that the engine switch is turned OFF. 2. Connect the battery positive (+) cable to the battery positive (+) terminal, then the battery negative (—) cable to the battery negative (—l terminal. Tighten the bolts and nuts securely. 3. Install the battery holder band. 4. install the battery maintenance cover, and tighten the cover screw. Never operate the generator without the battery maintenance cover in place, as poor engine and generator performance will result. CAUTION: When disconnecting the battery cable, be sure to disconnect at the battery negative (- l terminal first. To connect, connect at the positive (+) terminal first, then at the negative (—) terminal. Never dis/ connect the battery cable in the reverse order, or it causes a short circuit when a tool contacts the terminals. Charging: The battery is rated at 11.2 Ah (ampere hours). Charging current should equal 10% of the battery’s ampere hour rating. A battery charger should be used that can be adjusted to deliver1.1 amps. A‘AWARNWC The battery gives off explosive gasses; keep sparks, flames and cigarettes away from the battery while charging. Provide adequate ventilation when charging. - The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. —lf electrolyte gets on your skin, flush with water. —lf electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. —lf swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. 1.Connect the battery charger following the manufacturer's instructions. 2. Charge the battery. 3. Clean the outside of the battery and the battery tray compartment with a solution of baking soda and water. 55 This symbol on the battery means that this product must not be treated as household waste. NOTE: An improperly disposed of battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal. 56 9. TRANSPORTING/ STORAGE To prevent fuel spillage when transporting or during temporary storage, the generator should be secured upright in its normal operating position, with the engine switch OF. The fuel valve lever should be turned OFF. AWAHNING When transporting the generator: 0 Do not overfill the tank. . Do not operate the generator while it is on a vehicle. Take the generator off the vehicle and use it in a well ventilated place. - Avoid a place exposed to direct sunlight when putting the generator on a vehicle. If the generator is left in an enclosed vehicle for many hours, high temperature inside the vehicle could cause fuel to vaporize resulting in a possible explosion. - Do not drive on a rough road for an extended period with the generator on board. If you must transport the generator on a rough road, drain the fuel from the generator beforehand. CAUTION: When you are to lift up your generator with your assistant by hands, take care not to lift it up by holding the handle of the generator. Be sure to lift up the generator by holding the under frame as shown. X F re» _ r s o 3 @ D UNDER FRAME HANDLE 57 Before storing the unit for an extended period: 1. Be sure the storage area is free of excessive humidity and dust. 2. Drain the fuel. AWARNING 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. a. Place a suitable gasoline container below the carburetor drain hose. b.Turn the fuel valve lever to the ON position. Loosen the carburetor drain screw and drain the gasoline from the fuel tank and carburetor. DRAIN SCREW c. After all the fuel has drained into the container, tighten the carburetor drain screw securely and turn the fuel valve to the OFF position. d.Remove the sediment cup, and empty it and reinstall. 3. Change the engine oil (see page 46). 4. Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug. 5. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion. 58 6. Remove the maintenance cover and disconnect the battery negative (alterminal (see page 54 ). Cover the battery cable negative terminal with vinyl tape. Once a month, recharge the battery (see page 55 l. 7. Reinstall the maintenance cover. 8. Store the generator in clean area. 59 10. TROUBLESHOOTING When the engine will not start: Is there fuel in NO Refillthe fuel the tank? tank (see page YES 24). Is the engine NO Turn the engine switch on? switch on. i YES ls the fuel vale N0 Tu rn the fuel lever on? valve lever on. i YES Is the enough oil N0 Add the in the en ine? recommended YES oil (see page 22). Is the spark plug N0 Clean, readjust in good gap and dry the condition? spark plug. Replace it if necessary (see YES page 50 ). ls the fuel NO Clean the fuel reaching the sediment cup carburetor? (see page 49). YES To check: If the engine still 1)Turn off the fuel valve does not start, lever and loosen the take the drain screw. generator to an 2)Turn on the fuel valve authorized lever. Fuel should flow Honda dealer. from the drain. 60 Appliance does not operate: G, F, and IT types only: Is the AC circuit protector ON? N0 YES Is the Output indicator ON.7 NO YES ind icator ON? Is the Overload N0 Turn the AC circuit protector 0N. YES Check the electrical appliance or equipment for any defects. NO DEFECTS Take the generator to an authorized Honda dealer. DEFECTS Take the generator to an authorized Honda dealer. 0 Replace the electrical appliance or equipment. - Take the electrical appliance or equipment to an electrical shop for repair. 61 11 . SPECIFICATIONS Dimensions and Weight [extended handle] Model EM50is Description code EAJJ Length 810 mm (31.9 in) [extended handle] [1,155 mm (45.5 in)] Width 672 mm (26.5 in) Height 692 mm (27.2 in) [709 mm (27.9 inl] Dry mass 98.9 kg (2180 lbs) Engine Model GX340K1 Engine type 4-stroke, overhead valve, single cylinder Displacement 337 cm3 (20.6 cu-in) Bore >< Stroke 82.0 X 64.0 mm (3.22 in X 2.52 in) Compression ratio 8.0:1 Engine speed (Eco Throttle ON) 2,400,3'300 rpm Cooligq system Forced air Ignition system Full transistor Oil capacity 1.1 L (1.2 US qt, 1.0 Imp qt) Fuel tank capacity 16.5 L (4.36 US gal, 3.63 Imp gal) Spark plug BPRSES (NGK) W16EPR-U (DENSO) Battery 12V11.2AH/10HR Generator Model EMSOis Type F, G, IT Rated Voltage (V) 230 AC Rated Frequency (Hz) 50 output Rated Ampere (A) 19.6 Rated Output (kVA) 4.5 Max Output (kVA) 5.0 Model EMSOis Type S l R U L Rated Voltage (V) 220 240 120/240 AC Rated Frequency (Hz) 60 l 50 50 60 output Rated Ampere (A) 20.5 18.8 375/133 Rated Output (kVA) 4.5 Max Output (kVA) 5.0 62 Noise Model EM50is Type F, G, IT S, L, U,B CONTROL Com" PANEL \ Microphon- point Sound pressure level leAl According to 98/37/EC team 81 dB Guaranteed sound power level (LWAl Tested by 2000/14/EC at Eco Throttle Switch turn on 96 dB ”the figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes, and the length of time for which an operator is exposed to the noise. Also the permissible exposure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk". NOTE: Specifications are subject to change without notice. Dimensions and Weight [extended handle] Model EM65is Description code EAHJ Length 810 mm (31.9 inl [extended handle] [1,155 mm (45.5 in)! Width 672 mm (26.5 in) Height 692 mm (27.2 in) [709 mm (27.9 inll Dry mass 98.9 kg (218.0 lbs) Enqine Model GX390K1 Engine type 4—stroke, overhead valve, single cylinder Displacement 3892 cm3 (23.74 cu-in) Bore >< Stroke 88.0 X 64.0 mm (3.46 in X 2.52 in) Compression ratio 8.0:1 Engine speed (Eco Throttle 0N) 2400—3500 rpm Cooling system Forced air Ignition system Full transistor Oil capacity 1.1 L (1.2 US qt, 1.0 Imp qt) Fuel tank capacity 16.5 L (4.36 US gal, 3.63 Imp gal) Spark plug BPRSES (NGKl W16EPR-U (DENSO) Battery 12V11.2AH/10 HR Generator Model EM65is Type F, G, IT Rated Voltage (V) 230 AC Rated Frequency (Hz) 50 output Rated Ampere (A) 239 Rated Output (kVA) 5.5 Max Output (kVA) 6.5 Model EM65is Type S l R U L Rated Voltage (V) 220 240 120/240 AC Rated Frequency (Hz) 60 l 50 50 60 output Rated Ampere (A) 25.0 22.9 45.8/22.9 Rated Output (kVA) 5.5 Max Output (kVA) 6.5 64 Noise Model EM65is Type F, G, IT S, L, U, H Sound pressure level (LpAl According to 93/37/EC 32 dB 7 Microphone porn: CONTROL PANEL 1,60m Guaranteed sound power level lLWA) Tested by 2000/14/EC at 97 dB —— Eco Throttle Switch turn on “the figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes, and the length of time for which an operator is exposed to the noise. Also the permissible exposure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk". NOTE: Specifications are subject to change without notice. 65 12. INSTALLATION OF KIT PARTS SAFETY 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. [AWARIHMG Improper assembly can cause an unsafe condition that can lead to serious injury or death. Follow the procedures and precautions in the assembly instructions carefully. Some of the most important safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing this assembly. Only you can decide whether or not you should perform a given task. A‘AWARI‘HNG Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. 66 Important Safety Precautions 0 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: Cl Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely. - Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate several potential hazards: D Carbon monoxide poisoning from engine exhaust. Operate outside away from open windows or doors. I] Burns from hot parts. Let the engine and exhaust system cool before touching. El Injury from moving parts. Do not run the engine unless the instruction tells you to do so. Even then, keep your hands, fingers, and clothing away. Do not run the engine when any protective guard or shield is removed. - To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. Use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel related parts. 67 STANDARD KIT PARTS Wheel Kit Installation Do not operate the generator without the wheel kit installed. The wheel kit provides an air space between the ground and the generator air intake. NOTE: If the wheel kit is not installed, it may be possible for dirt and debris to be drawn into the generator air intake, possibly causing generator damage. Always operate the generator with the wheel kit installed. 1. Install the two wheels on the axle shaft using the washers and cotter pins. 2.]nstall the axle assembly on the generator using four 8 X 16 mm flange bolts. 3.|nsta|l the two stands on the under frame using four 8 X 16 mm flange bolts. TORQUE: 24~29 N-m (2.4-3.0 kgf-m , 17a22 lbf-ftl INSIDE 8 X I6 mm FLANGE BOLT [4) STAND (Zl WHEEL (2] 20 mm WASHER (2) 8X 15 mm 4.0 x23 mm COTTER PIN [2) FLANGE BOLT (4) 68 Handle Installation Install the handle assembly on the generator upperframe using the 12 mm washers, spring washers and handle holder bolts. TORQUE: 24—29 N-m (2.4—3.0 kgf-m ,17—22Ibf-ft) HANDLE HOLDER BDLY [2) SPRING WASHER ‘2) 12 mm WASHER (2) HANDLE ASSEMBLY Operation must be checked after attaching a handle. To extend handle: Raise the handle to the horizontal position. The handle will click into place when locked. HANDLE LEVER HANDLE 69 Rear Bar Installation Install the rear bar on the generator frame using the two 8 X 45 mm flange bolts. TORQUE: 24—29 N-m (2.4-3.0 kgf-m , 17-22 Ibf-ft) 8X45 mm FLANGE BOLT (2) REAR BAR 70 Battery The battery is either standard parts or optional parts (or this generator. Battery Part Number: 31500-MCR-D02 1. Remove the maintenance cover (see page 52 ). 2. (Standard parts type) The battery is disconnected and strapped into the battery tray for shipment. Remove the battery strap from the bottom hook, and then remove the battery. Remove the red cable and the black cable from the twist clip, and set the battery. (Optional parts type) Remove the battew strap from the bottom hook. Remove the red cable and the black cable from the twist clip, and set the battery. 3. Remove the protective cover from the battery positive (+l terminal, connect the red cable to the battery positive (+ l terminal. 4. Connect the black cable to the battery negative (—) terminal. 5. To secure the battery, hook other clasp of the battery strap onto the bottom hook of the generator. 6. Install the maintenance cover in the reverse order of removal. Never operate the generator without the maintenance cover in place, as poor engine and generator performance will result. TWIST CLIP RED CABLE (POSITIVE (+) CABLE) BAI'I'ERV STRAP . I . . \ \f A» BLACK CABLE [NEMTIVE (7) CABLE) 71 OPTIONAL KIT PARTS Remote Control Kit 1. Remove the maintenance cover (see page 52 )l 2. Remove the plug from the 6—pin connector. 3. View the back of the maintenance cover and locate the knockout near the top center of the cover. Carefully remove the knockout. KNOCKOUT 72 4. Pass the remote control cable through the supplied wire grommet and fit the grommet into the maintenance cover knockout. 5. Plug the remote control cable into the 6-pin connector. 6. Install the maintenance cover and tighten the cover screw. REMOTE OONTROL CABLE REMOTE OON'IROL CABLE REMOTE ODNTROL BOX MAINTENANCE COVER GROMMET 7. To avoid accidentally unplugging the remote control cable, secure the cable to the generatorframe with a cable tie as shown. CABLE 11: § 0 Never operate the generator without the battery maintenance cover in place, as poor engine and generator performance will result. 0 When the remote control is not being used, replace the plug on the connector. 73 Starting the engine with remote control: 1. B, L types only: Determine the voltage requirements and adjust the voltage selector switch, as needed. 2.Turn the fuel valve lever to the ON position. 3. Turn the engine switch to the REMOTE (far left) position. (F, 6, rr types) I .0“ Koo» [8, U. R. Ltyposl 0N OFF START REMOTE O 4.Press and hold the start button until the engine pilot lamp illuminates. The start button will automatically be disabled after the engine starts. FUEL VALVE LEVER ENGINE SWITCH CAUTION: Do not use the starter motor for more than 5 seconds. If the engine fails to start, release the key, and wait at least 10 seconds before operating the starter motor again. (B.F.G,I1’tvvos} sum mo“ (s u. n. uypes) ° (Co/3°) \ / ’7 :09 O . :lom g m sum E PILOT LAMP 74 Stopping the engine with remote control: 1. Press the stop button. (F1 6, I'I'twos) (S, U. R, L mm) STOP BU'I'I'DN 2. Turn the engine switch to the OFF position. 3. Turn the fuel valve leverto the OFF position. (F, 6, IT types) (S,U, R, Ltyw) ON OFF START REMOTE Q FUEL VALVE LEVER ENGINE SWITCH 75 Hanger Kit Installation 1. Position the hanger at the generator’s balance point as shown below. 2. Fit the end tabs of the hanger through the bracket slots, and bolt the brackets to the hanger and tighten securely. TORQUE: 24-29 N-m (2.4—3.0 kgf-m , 17—22 lbf-ft) 8X 16 mm FLANGE BOLT (4) ‘7 HANGER BRACKET (2) FUEL TANK HANGER GENEATOH SIDE 76 13. MAJOR Honda DISTRIBUTOR ADDRESSES AUSTRALIA Hnndn Anm-III Motorcycle mu Pawn! Equip-mm Pty. Ltd 1954-1956 Hume Highway Campbellfield Victoria 3061 Tel. : [0109270 :1 11 Fax : (as) 9270 1132 79 14. WIRING DIAGRAM INDEX (See inside of back cover) ABBREVIATIONS Symbol Part name Symbol Part name ACCP Ac Circuit Protector PL Output Indicator ACOR AC Output Receptacle RCB Remote Control Block BAT Battery RcBX Remote Control Box CCM Choke Control Motor RTM Red Tape Mark CPB Control Panel Block (R) R Type D Diode SP Spark Plug EcoSw Eco Throttle Switch SSW Stop Button EgB Engine Block StM Starter Motor ESw Engine Switch StSw Start Button ETS Engine Temperature Sensor SW Slave Winding FrB Frame Block (S) S Type FuB Fuse Box TCM Throttle Control Motor 1F) F Type (U) U Type Ge Generator VSSw Voltage Selector Switch GeB Generator Block WTM White Tape Mark GCU Generator Control Unit GT Ground Terminal (G) G, GW Types WIRE COLOR CODE IgC Ignition Coil lgPG Ignition Pulse Generator BI BLACK IU Inverter Unit Y YELLOW IUB Inverter Unit Block Bu BLUE (IT) IT Type G GREEN MW Master Winding R RED OAL Oil Alert Indicator W WHITE OI Overload Indicator Br BROWN OLSw Oil Level Switch 0 ORANGE OP Optional Lb LIGHT BLUE Lg LIGHT GREEN P PINK Gr GRAY 80 SWITCH CONNECTIONS ENGINE SWITCH SUB ACC BAT REM REMOTE START ECOTHROTTLE SWITCH COM (-) SW ON ‘9' 7 OFF .9 ‘9 81 RECEPTACLE Type 83 77777 mi? 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