Owner’s Manual
Generator
EM500 l EM600
Q1997 American Honda Motor Co., Inc. - All Rights Reserved
I
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Printed on
Aecvcled Paper
Thank you for purchasing a Honda generator.
This manual covers operation and maintenance of the EM500 and EM600
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. reserves 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
remain with the generator when sold.
Pay special attention to statements preceded by the following words:
B Indicates a strong possibility of severe personal injury or
loss
of
life 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.
B The 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.
CONTENTS
CONTENTS
1. GENERATOR SAFETY
...................................
1
2. COMPONENT IDENTIFICATION
...........................
2
3. PRE-OPERATION CHECK
.................................
4
4. STARTING THE ENGINE
................................. 7
5. GENERATOR USE
.......................................
8
6. STOPPING THE ENGINE
.................................
11
7. MAINTENANCE
......................................... 12
8. TRANSPORTING/STORAGE
...............................
21
9. TROUBLESHOOTING
....................................
22
10. SPECIFICATIONS
........................................
24
ll.WIRING DIAGRAM
......................................
25
1. GENERATOR SAFETY
E
To ensure safe operation -
l
Place the generator at least 1 m (3 ft) away from buildings or other equip-
ment when operating the generator.
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Operate the generator on a level surface.
If the generator is tilted, fuel spillage may resuit.
l
Exhaust gas contains poisonous carbon monoxide.
Never run the generator in an enclosed area.
Be sure to provide adequate ventilation.
l
Know how to stop the generator quickly and understand operation of all
the controls. Never permit anyone to operate the generator without proper
instructions.
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Keep children and pets away from the generator when it is in operation.
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Keep away from rotating parts while the generator is running.
l
The generator is a potential source of electrical shocks when misused; do
not operate with wet hands.
l
Do not operate the generator in rain or snow and do not let it get wet.
When charging a battery -
l
Battery electrolyte contains sulphuric acid. Protect your eyes, skin and
clothing. In case of contact, flush thoroughly with water and call a doctor
if your eyes were exposed.
l
Batteries generate hydrogen gas which can be highly explosive. Do not
smoke or allow flames or sparks near a battery, especially while charging it.
1
2. COMPONENT IDENTIFICATION
CIRCUIT BREAKERS
OIL ALERT LAMP
(EM600 ONLY)
PILOT LAMP
SPARK PLUG CAP
DC RECEPTACLE
FREQUENCY
METER
AC RECEPTACLE
EXHAUST OUTLET
RiCOlL STARTER
2
CARRYING HANDLE \
FUEL TANK CAP
/
THROTTL
GROUND
.AIR CLEANER
COVER
3
3. 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: Engine oil is a major factor affecting engine performance and
service life. Non-detergent or vegetable oils are not recommended.
Use Honda 4.stroke oil, or an equivalent high detergent, premium quality
motor’ oil certified to meet or exceed U.S. automobile manufacturer’s
requirements for Service Classification SE or SF. (Motor oils classified SE
or SF will show this designation on the container.)
SAE low-40 is recommended for general, all-temperature use. Other
viscosities shown in the chart may be used when the average temperature
in your area is within the indicated range.
Remove the oil filler cap and check the oil level.
If the level is low, fill to the top of the oil filler neck with the recom-
mended oil.
CAUTION: Running the engine with insufficient oil can cause serious
engine damage.
I JPPER LEVEL
OIL FILLER CAP FILLER HOLE
-20 0 20 40 60 80 100°F
-30 -20 -10 0 10 20 30 40°C
NOTE:
l
The oil alert lamp (EM600 only) will light during operation before the
engine oil level becomes too low. If this occurs, stop the engine and fill to
the top of the filler neck with the recommended oil (page 4).
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The oil alert lamp should always light when starting, but should go out
after the engine is running if there is sufficient oil. If the lamp does not
light at all, replace the bulb.
OIL
ALERT
LAMP
5
2. Check the fuel level.
Use low lead or unleaded automotive gasoline with a pump octane rating of
88 or higher.
Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust
or water in the fuel tank.
CAUTION: Gasoline substitutes are not recommended; they may be
harmf.ul to the fuel system components.
l
Gasoline is extremely flammable and explosive under certain conditions.
Refuel in a well ventilated area with the engine stopped.
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Do not smoke or allow flames or sparks in the area where the generator
is refueled or where gasoline is stored.
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Do not overfill the tank and make sure the filler cap is securely closed
after refueling.
l
Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may
ignite. If any fuel is spilled, make sure the area is dry before starting the
engine.
FUEL FILLER
HOLE
+
?
---=
----
__
-- ---
--
-- --
--
*- --_
-
- -
- -
-
- -
--
-
6
4. STARTING THE ENGINE
1. Disconnect the load from the AC or DC receptacle.
2. Move the engine switch to “ON”.
ENGINE
3. Pull the starter rope lightly until resistance is felt,
then pull briskly.
CAUTION: Do not allow the starter grip to snap back against the generator.
Return it gently to prevent damage to the housing.
NOTE:
Make sure the pilot lamp comes on. If not, the filament may be burnt
out.
7
5. GENERATOR USE
H?IlEQT
o prevent electrical shock from faulty appliances, the generator
should be grounded. Connect a length of heavy wire between the ground
terminal and the ground source.
GROUND TERMINAL
CAUTION:
l
Limit operation requiring maximum power (EM500: 500VA, EM600:
600VA) to 30 minutes.
For continuous operation, do not exceed the rated power of 4OOVA
(EM5001 and 450VA (EM600).
l
Do not exceed the current limit specified for any one receptacle.
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Do not connect the generator to a household circuit. This could cause
damage to the generator or to electrical appliances in the house.
NOTE:
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The EM500/EM600 generate both AC and DC power, but they cannot be
used at the same time.The interlock selector switch prevents simultaneous
use.
l
Most appliance motors require more than their rated wattage for start-up.
If the required starting wattage exceeds lOOW, the AC circuit will be over-
loaded.
AC operation
1. Start the engine and make sure the pilot lamp comes on. If not, the fila-
ment may be burnt out.
2. Move the selector switch to the AC position.
3. Plug in the appliance.
CAUTION: Be sure that appliances do not exceed the rated load for more
than 30 minutes, and never exceed the maximum load. Substantial over-
loading will switch off the circuit breaker. Lesser overloading will not
switch off the circuit breaker and will shorten the service life of the gen-
erator.
4. Check the frequency meter to verify that the generator is operating at
60Hz. If it is not, turn the throttle knob to increase or decrease engine
speed until the correct frequency is obtained (meter bar next to 60 will
vibrate).
NOTE:
l
An overloaded AC circuit will trip the AC circuit breaker. If this occurs,
wait a few minutes before pushing the circuit breaker to resume operation.
/
FREOUENCY METER
TilROTTLE KNOB
9
DC operation
Start the engine and move the selector switch to the
DC position. The DC
receptacle may be used for charging 12 volt automotive-type batteries only.
m Batteries produce explosive gases. Keep sparks, flames, and
cigarettes away. To prevent the possibility of creating a spark near the
battery, connect the charging cord first to the battery, then to the generator,
and disconnect the cord first at the generator.
B Disconnect the vehicle’s grounded battery cable first, and after
charging, reconnect the grounded cable last. This procedure will prevent the
possibility of a short circuit and sparks if your tools accidentally make con-
tact between a battery terminal and the vehicle’s frame or body.
CAUTION:
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Do not attempt to start an automobile engine with the generator still
connected to the battery. The generator may be damaged.
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Connect the positive battery terminal to the positive charging cord. Do
not reverse the charging cables, or serious damage to the generator and/or
battery may occur.
NOTE:
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An overloaded DC circuit will trip the DC circuit breaker (push button
comes out). If this happens, wait a few minutes before pushing the circuit
breaker to resume operation.
IVEl
6. STOPPING THE ENGINE
To stop the engine in an emergency, move the engine switch to OFF.
In normal use:
1. Turn off the electrical appliance or disconnect the charging cord from the
generator.
2. Move the engine switch to OFF.
l
High altitude operation
At high altitude, the standard carburetor air-fuel mixture will be excessively
rich. Performance will decrease, and feul consumption will increase.
High altitude performance can be improved by installing a smaller diameter
main fuel jet in the carburetor and readjusting the pilot screw. If you always
operate the generator at altitudes higher than 6,000 feet above sea level,
have your authorized Honda Generator dealer perform these carburetor
modifications.
Even with suitable carburetor jetting, engine horsepower will decrease
approximately 3.5 % for each 1,000 foot increase in altitude. The effect of
altitude on horsepower will be greater than this if no carburetor modification
t
in made.
CAUTION: Operation of the generator at an altitude lower than the
t
carburetor is jetted for may result in reduced performance, overheating,
and serious engine damage caused by an excessively lean air/fuel
mixture.
11
7. MAINTENANCE
The purpose of the maintenance schedule and adjustment is to keep the
generator in the best operating condition.
Inspect or service as scheduled in the table on the next page.
m Shut off the engine before performing any maintenance. If the
engine must be run, make sure the area is well ventilated. The exhaust
contains poisonous carbon monoxide gas.
CAUTION: Use only genuine HONDA parts or their equivalent. The use of
replacement parts which are not of equivalent quality may damage the
generator,
Tool kit
The screwdriver and spark plug wrench stored under the generator will enable
you
to perform the owner-maintenance procedures listed on page 13. The
10 mm socket end of the spark plug wrench can also be used to turn the
ground terminal nut.
Always keep the tool kit with the generator.
VI- COMBINATION SCREWDRIVER
PLUG WRENCH / 10 mm WRENCH /
SCREWDRIVER HANDLE
Maintenance Schedule
REGULAR SERVICE
Perform at every indi-
cated month or oper-
ating hour interval,
whichever occurs
Daily
First Every Every Every
month
3 months 6 months year
2O’Ars.
5O’irs. 1 OZ-irs. 3OCZirs.
Inspection
0
Engine oil ’
Change
0 0
Air cleaner
Inspection
0
element
Cleaning
l (1)
Fuel filter cleaning
0
Spark plug maintenance
a
Valve clearance adjustment
l
(2)
Combustion chamber and
valve cleaning
l
(2)
Fuel line inspection
0
(Replace if necessary)
Spark arrester
Clean every 100 operating hours.
NOTE (1) : Service more frequently when used in dusty areas.
(2) : These items should be serviced by an authorized Honda dealer, unless the
owner has the proper tools and is mechanically proficient. See the Honda
Shop Manual.
13
Changing oil
Drain the oil while the engine is still warm to assure rapid and complete
draining.
1. Remove the oil filler cap, and drain the oil.
2. Refill with the recommended oil (see page 4) and check the level.
OIL CAPACITY: 0.35P (0.37 US qt)
OIL FILLER CA+
CAUTION: Used motor oil may cause skin cancer if repeatedly left in
contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to
thoroughly wash your hands with soap and water as soon as possible
after handling used oil.
NOTE: Please dispose of used motor oil in a manner that is compatible with
the environment. We sug.gest 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.
14
Air cleaner service
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly (page 13). Service
more frequently when operating the generator in extremely dusty areas.
E
m Never use gasoline or low flash point solvents for cleaning the air
cleaner element. A fire or explosion could result.
I
CAUTION: Never run the generator without the air cleaner. Rapid engine
wear may result.
1. Loosen the cover bolt, remove the air cleaner cover and remove the ele-
ment.
2. Wash the element in a non-flammable or high flash point solvent and dry it
thoroughly.
3. Soak the element in clean engine oil and squeeze out the excess oil.
4. Reinstall the air cleaner element and the cover.
!&
Y
15
Spark plug service
Recommended spark plug: BPMR4A-10 (NGK)
W14MPR-UIO (ND)
To ensure proper engine operation, the spark plug must be properly gapped
and free of deposits.
1. Remove the spark plug cap.
2. Use the wrench supplied in the tool kit to remove the spark plug.
3. Visually inspect the spark plug. Discard it if the insulator is cracked or
chipped. Clean the spark plug with a wire brush if it is to be reused.
4. Measure the plug gap with a feeler gauge.
The gap should be 0.9-1.0 mm (0.035-0.039 in). Correct as necessary by
bending the side electrode.
0.9 mm-l .O mm
(0.035-0.039 in)
16
5. Attach the plug washer. Thread the plug in by hand to prevent cross-
threading.
6. Tighten a new spark plug l/2 turn with the wrench to compress the washer.
If you are reusing a plug, it should only take l/8-1/4 turn after the plug
seats.
CAUTION:
l
The spark plug must be securely tightened. An improperly tightened plug
can become very hot and possibly damage the generator.
l
Never use a spark plug with an improper heat range.
17
Spark arrester maintenance
B If the generator has been running, the muffler will be very hot.
Allow it to cool before proceeding.
CAUTION: The spark arrester must be serviced every 100 hours to maintain
its efficiency.
1. Remove the four left side cover screws, and remove the cover.
SCREW
2. Remove the mounting bolt for the muffler, the mounting bolt for the
choke bimetal strip, and the two nuts that attach the exhaust pipe to the
engine. Remove the muffler and exhaust pipe.
3. Remove the two screws that attach the heat shield to the muffler. Remove
the heat shield.
4. Remove the two bolts that attach the exhaust pipe to the muffler. Remove
the exhuast pipe from the muffler carefully to avoid damaging the spark
arrester screen.
18
Automatic choke adjustment
1. Loosen the automatic choke setting bolt.
2. Push the choke valve arm at the carburetor so the choke valve is closed.
3. Adjust distance “A” to 3 mm (0.12 in) by relocating the bimetal strip.
Retighten the bolt securely.
NOTE:
l
Recheck distance A after tightening the bimetal strip.
l
Hard starting or lack of power will result if not adjusted properly.
CHOKE VALVE ARM
SETTING BOLT
CARBURETOR
AUTOMATIC CHOKE
BIMETAL STRIP
20
8. TRANSPORTING/STORAGE
B When transporting the generator, turn the engine switch OFF and
keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may
ignite.
I
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 -
?
a. With the engine switch ON, remove the fuel filler cap.
b. Loosen the drain screw and drain the fuel into a suitable container.
Retighten the screw.
c. Move the engine switch to OFF.
DRAIN
3. Pull the starter grip until resistance is felt; the piston is coming up on its
compression stroke. At this position, the exhaust and intake valves are
closed, and this will help protect the engine from corrosion.
21
d. Grounding the side electrode to the cover, pull the recoil starter to see
if sparks jump across the gap.
SPARK PLUG
e. If there are no sparks, replace the plug.
If OK, try to start the engine according to the instructions.
6. If the engine still does not start, take the generator to the dealer.
B. No electricity at the AC receptacles:
1. Is the AC circuit breaker on?
2. Check the electrical appliance or equipment for any defects.
C. No electricity at the DC receptacles:
1. Is the DC circuit breaker on?
2. Check the electrical appliance or equipment for any defects.
23
10. SPECIFICATIONS
Dimensions
Length x Width x Height EM500: 355 x 250 x 325 mm
(14.0 x 9.84 x 12.8 in)
EM600: 365 x 250 x 325 mm
(14.4 x 9.84 x 12.8 in)
Dry Weight
EM500: 18.0 kg (39.7 lb)
EM600: 19.0 kg (41.9 lb)
Engine
Engine Type 4-stroke, side valve, 1 cylinder
Displacement
[Bore x Stroke]
Compression Ratio
Engine Speed
Cooling System
Ignition System
Oil Capacity
Fuel Tank Capacity
Spark Plug
59.8 cc (3.65 cu in)
[46x 36 mm (1.81 x 1.42 in)]
5.5 : 1
3.600 r.p.m.
Forced air cooling
C.D.I.
0.35 c! (0.37 us qt)
2.0 Q (0.5 US gal)
BPMR4A-10 (NGK), W14MPRUlO (ND)
Generator
Rated Frequency
1 EM500: 3.3 A
I
Ratea Ampere
EM600: 3.8 A
I
AP n,,+n,,t
Rated Output
EM500: 400 VA (400 W)
EM600: 450 VA (450 W)
Maximum Output
EM500: 500 VA (500 W)
EM600: 600 VA (600 WI
DC output
Only for charging 12 V automotive
batteries.
Maximum charging output = 8.3 A
24
I.C
mr
B/Y~B/Y~
r--P-
I I I E.kY
I
I
AVR
I
[EM6001
0. ^
u
.
26
Part Name
AVR
Automatic Voltage Regulator
D
DC Diode
E.R.
Rotor Exciter Winding
E.S.
Stator Exciter Winding
ESw
Engine Switch
EW
Exciter Winding
FM
Frequency Meter
C.B
Circuit Breaker
FW
Field Winding
GT
Ground Terminal
IC
Ignition Coil
klw
Ignition Winding
LW
Lamp Winding
MW
Main Winding
A0
AC Output Receptacle
DO
DC Output Receptacle
PC
Pulser Coil
PL
Pilot Lamp
SP
Spark Plug
B
L
Br
G
Gr
Lg
R
W
Y
Color
Black
Blue
Brown
Green
Gray
Light green
Red
White
Yellow
Y
MEMO
28
~ Warranty Service
Owner Satisfaction
Your satisfaction and goodwill are important to your dealer and to us. All
Honda warranty details are explained in the Distributor’s Limited Warranty.
Normally, any problems concerning the product will be handled by your
dealer’s service department. If you have a warranty problem that has not
been handled to your satisfaction, we suggest you take the following action:
l
Discuss your problem with a member of dealership management. Often
complaints can be quickly resolved at that level. If the problem has
already been reviewed with the Service Manager, contact the owner of
the dealership or the General Manager.
0 If your problem still has not been resolved to your satisfaction, contact the
Power Equipment Customer Relations Department of American Honda
Motor Co., Inc.
American Honda Motor Co., inc.
Power Equipment Customer Relations Department
P.O. Box 50
Gardena, California 90247-0805
Telephone: (2 13) 604-2400
We will need the following information in order to assist you:
-Your name, address, and telephone number
-Product model and serial number
-Date of purchase
-Dealer name and address
-Nature of the problem
After reviewing all the facts involved, you will be advised of what action can
be taken. Please bear in mind that your problem will likely be resolved at the
dealership, using the dealer’s facilities, equipment, and personnel, so it is
very important that your initial contact be with the dealer.
Your purchase of a Honda product is greatly appreciated by both your dealer
and American Honda Motor Co., Inc. We want to assist you in every way
possible to assure your complete satisfaction with your purchase.
29
Current customer service contact information:
United States, Puerto Rico, and U.S. Virgin Islands:
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. The Service Manager or 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:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST
When you write or call, please provide the following information:
• Model and serial numbers
• Name of the dealer who sold the Honda power equipment to you
• Name and address of the dealer who services your equipment
• Date of purchase
• Your name, address, and telephone number
• A detailed description of the problem