Honda EX4000S, Owner'S Manual

Page 1: ...GENERATOR OWNER S MANUAL MANUEL DE L UTILISATEUR BEDIENUNGSANLEITUNG MANUAL DE EXPLICACIONES EX4000S EX4500S ...

Page 2: ...SATEUR Notice originale BEDIENUNGSANLEITUNG Originalbetriebsanleitung MANUAL DE EXPLICACIONES Manual original The e SPEC mark symbolizes environmentally responsible technologies applied to Honda power equipment which contains our wish to preserve nature for generations to come ...

Page 3: ...ain with it if it is resold Pay special attention to statements preceded by the following words Indicates a strong possibility of severe personal injury 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 gener...

Page 4: ... STARTING THE ENGINE 22 High altitude operation 6 GENERATOR USE 25 7 STOPPING THE ENGINE 30 8 MAINTENANCE 31 9 TRANSPOTING STORAGE 43 10 TROUBLESHOOTING 45 11 OPTIONAL PARTS 47 12 SPECIFICATIONS 51 13 WIRING DIAGRAM 53 MAJOR Honda DISTRIBUTOR ADDRESSES inside of back cover EC Declaration of Conformity CONTENT OUTLINE inside of back cover CONTENTS ...

Page 5: ...ot 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 manu...

Page 6: ... 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 malfun...

Page 7: ...topping 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...

Page 8: ...ler to dispose of these parts 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 battery can hurt the environment Always confirm local regulations for battery disposal Contact your Honda servicing d...

Page 9: ... 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 EXHAUST CAUTION READ OWNER S MANUAL CONNECT CAUTION FUEL CAUTION HOT CAUTION ...

Page 10: ...us 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 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 c...

Page 11: ...9 Gasoline is highly flammable and explosive Turn the engine off and let it cool before refueling A hot exhaust system can cause serious burns Avoid contact if the engine has been running ...

Page 12: ...0 CE mark and noise label locations EX4000S B F G GW IT types CE MARK AND NOISE LABEL NOISE LABEL Manufacturer and address Performance class IP code Sales agency and address Year of manufacture Dry mass ...

Page 13: ... Frame serial number ________________________ AC CIRCUIT PROTECTOR ENGINE SWITCH Interlocked with fuel valve VOLTMETER AUTO THROTTLE SWITCH VOLTAGE ADJUSTMENT KNOB MUFFLER AC RECEPTACLES DAMPER RUBBER DC CIRCUIT PROTECTOR DC TERMINALS FRAME SERIAL NUMBER OIL DRAIN BOLT GROUND TERMINAL FRONT MAINTENANCE COVER OIL FILLER CAP DIP STICK ...

Page 14: ...IT PROTECTOR G GW type IT type ENGINE SWITCH Interlocked with fuel valve VOLTMETER VOLTAGE ADJUSTMENT KNOB AUTO THROTTLE SWITCH 230V RECEPTACLES DC CIRCUIT PROTECTOR DC TERMINALS AC CIRCUIT PROTECTOR ENGINE SWITCH Interlocked with fuel valve VOLTMETER AUTOTHROTTLE SWITCH DC CIRCUIT PROTECTOR 230V RECEPTACLES DC TERMINALS AC CIRCUIT PROTECTOR VOLTAGE ADJUSTMENT KNOB ...

Page 15: ...ROTTLE SWITCH 230V RECEPTACLES AC CIRCUIT PROTECTOR VOLTAGE SELECTOR SWITCH 115V RECEPTACLES L type PILOT LAMP L type only VOLTMETER ENGINE SWITCH Interlocked with fuel valve AC CIRCUIT PROTECTOR DC TERMINALS DC CIRCUIT PROTECTOR 120V RECEPTACLES 120 240V RECEPTACLES VOLTAGE SELECTOR SWITCH ...

Page 16: ...14 UPPER MAlNTENANCE COVER FUEL TANK CAP AIR CLEANER REAR MAINTENANCE COVER SPARK PLUG ...

Page 17: ...ended to minimize the fuel consumption while in operation Auto throttle system does not work when the electrical load is less than 1 A Auto throttle system does not operate sufficiently if the electrical appliance requires the momentary electric power Warming up the engine with this system on may require a longer period than usual OFF Auto throttle system does not operate AUTO THROTTLE SWITCH OFF ...

Page 18: ...e Recommended oil Use 4 stroke motor oil that meets or exceeds the requirements for API service category SE or later or equivalent Always check the API service label on the oil container to be sure it includes the letters SE or later or equivalent 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 indic...

Page 19: ... the top of the oil filler neck with the recommended oil 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 ...

Page 20: ...ns 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 there should be no fuel in the filler neck After refueling make sure the fuel tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite I...

Page 21: ...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 Fuel system damage or ...

Page 22: ...nsnap the clips and remove the air cleaner cover Check the element Clean or replace the element if necessary page 33 CAUTION Never run the engine without the air cleaner element Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor into the engine AIR CLEANER COVER AIR CLEANER ELEMENT ...

Page 23: ... 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 Internal Drink large quantities of water or milk Follow with milk of magnesia or vegetable oil and call a physician immediately KEEP OUT OF REACH OF CHILDREN CAUTION Use only distilled water in the battery Tap water will shorten the s...

Page 24: ... engine switch 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 and DC terminals 1 Turn off the AC circuit protector 2 Make sure the auto throttle switch is off or more time will be required for warming up OFF AC CIRCUIT PROTECTOR OFF AUTO THROTTLE SWITCH OFF OFF ...

Page 25: ...t 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 4 After the engine starts let the engine switch return to ON 5 Turn the auto throttle switch to AUTO after the engine is warmed up OFF ON START OFF ON START ENGINE SWITCH AUTO THROTTLE SWITCH START ON ON ...

Page 26: ...ove sea level have your authorized Honda dealer perform these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 300 meter 1 000 foot increase in altitude The effect 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 car...

Page 27: ...ny 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 CAUTION Limit operation requiring maximum power See page 51 to 30 minutes For continuous operation do not exceed the rated power See page 51 In either case the total wattage of all appliances connected must be consider...

Page 28: ...to the exhaust pipe When an extension cable is required be sure to use a tough rubber sheathed flexible cable IEC 245 or equivalent Limit length of extension cables 60 m for cables of 1 5 mm2 and 100 m for cables of 2 5 mm2 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 supp...

Page 29: ...stantial overloading will switch off the circuit protector Marginal overloading may not switch off the circuit protector but it will shorten the service life of the generator Be sure that all appliances are in good working order before connecting them to the generator If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn off the circuit protector and the generator en...

Page 30: ...disconnect the vehicle s grounded battery cable Reconnect the vehicle s grounded battery cable after the charging cables are removed This procedure will prevent the possibility of a short circuit and sparks if you make accidental contact between a battery terminal and the vehicle s frame or body CAUTION Do not attempt to start an automobile engine with the generator still connected to the battery ...

Page 31: ...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 Internal Drink large quantities of water or milk Follow with milk of magnesia or vegetable oil and call a physician immediately KEEP OUT OF REACH OF CHILDREN 2 Start the engine NOTE The DC terminals may be used whil...

Page 32: ...OPPING THE ENGINE To stop the engine in an emergency turn the engine switch OFF IN NORMAL USE 1 Turn off the AC circuit protector 2 Turn off the engine switch OFF AC CIRCUIT PROTECTOR OFF OFF ENGINE SWITCH OFF ...

Page 33: ...heir equivalent The use of replacement parts which are not of equivalent quality may damage the generator Maintenance Schedule NOTE 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures 3 For commercial use log hours of operation ...

Page 34: ...16 and check the level 4 Reinstall the oil filler cap securely 5 Close and latch the front maintenance cover 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 gro...

Page 35: ...under certain conditions CAUTION Never run the generator without the air cleaner Rapid engine wear will result 1 Open the rear maintenance cover 2 Unsnap the clips remove the air cleaner cover and air cleaner element 3 Wash the element in a non flammable or high flash point solvent and dry it thoroughly 4 Soak the element in clean engine oil and squeeze out the excess oil 5 Reinstall the air clean...

Page 36: ...nd the spark plug base 4 Use the plug wrench to remove the spark plug 5 Visually inspect the spark plug Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped Clean the sark plug with a wire brush if it is to be reused 6 Measure the plug gap with a feeler gauge The gap should be 0 7 0 8 mm 0 028 0 031 in Correct as necessary by carefully bending the side electro...

Page 37: ... turn with a wrench to compress its washer If a used plug is being reinstalled it should only require 1 8 to 1 4 turn after being seated 9 Close and latch the rear maintenance cover CAUTION The spark plug must be securely tightened An improperly tightened plug can become very hot and possibly damage the engine Never use a spark plug with an improper heat range ...

Page 38: ...t cup should be cleaned 1 Make sure that the engine switch is in the OFF position 2 Open the left maintenance cover 3 Loosen the nut and remove the nut sediment cup and gasket 4 Clean the sediment cup in non flammable solvent thoroughly 5 Reinstall the gasket sediment cup and nut then tighten the nut securely 6 Close and latch the left side maintenance cover After installing the sediment cup check...

Page 39: ... the fuse holder cover and replace the fuse The specified fuses are two 5A and 10A CAUTION 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 FUSE HOLDER COVER 10A 5A 5A ...

Page 40: ...as been running the muffler will be very hot Allow it to cool before proceeding 1 Remove the nine 6 mm bolts the handle and right side cover 2 Remove the two 5 mm pan screws and remove the spark arrester RIGHT SIDE COVER HANDLE 6 mm BOLTS SPARK ARRESTER 5 mm PAN SCREW ...

Page 41: ...Use a brush to remove carbon deposits from the spark arrester screen NOTE Inspect the spark arrester screen for holes or tears Replace if necessary 4 Reinstall the spark arrester right side cover and handle ...

Page 42: ... 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 Internal Drink large quantities of water or milk Follow with milk of magnesia or vegetable oil and call a physician immediately KEEP OUT OF REACH OF CHILDREN Removal 1 Make sure that th...

Page 43: ...le to the battery negative terminal Tighten the bolts and nuts securely 3 Install the terminal cover and battery set plate then tighten the wing nuts 4 Close and latch the left maintenance cover CAUTION When disconnecting the battery cable be sure to disconnect at the battery negative terminal first To connect connect at the positive terminal first then at the negative terminal Never dis connect t...

Page 44: ...te gets in your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous If 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 compart...

Page 45: ...rting the generator turn the engine switch OFF and keep the generator level to prevent fuel spillage Fuel vapor or spilled fuel may ignite NOTE To transport the generator hold the holding part shaded areas in the figure below HOLDING PART ...

Page 46: ...er 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 c Tighten the carburetor drain screw turn the engine switch to OFF and close the rear maintenance cover 3 Once a month recharge the battery CAUTION When starting the generator after adding fuel for the first time after long term storage ...

Page 47: ... there fuel in the tank Is the engine switch on Refill the fuel tank Is there enough oil in the engine Is the spark plug in good condition Is the fuel reaching the carburetor If the engine still does not start take the generator to an authorized Honda dealer Turn the engine switch on Add the recommended oil Clean readjust gap and dry the spark plug Replace it if necessary Clean the fuel sediment c...

Page 48: ...heck the electrical appliance or equipment for any defects Turn the AC circuit protector on Take the generator to an authorized Honda dealer Replace the electrical appliance or equipment Take the electrical appliance or equipment to an electrical shop for repair NO DEFECTS DEFECTS ...

Page 49: ...connect the jumper coupler from the 9 P coupler 3 Connect the 9 P coupler of the remote control panel to the 9 P coupler disconnected in step 2 4 Install the remote control panel with four screws 5 Connect the remote control cable coupler to the remote control panel coupler JUMPER COUPLER 9 P COUPLER 9 P COUPLER REMOTE CONTROL PANEL REMOTE CONTROL PANEL COUPLER REMOTE CONTROL CABLE COUPLER ...

Page 50: ...sition to start the engine OFF Flip the knob down to this position to stop the engine Starter button To start the engine press this button in with the engine switch in the ON position NOTE Turn the remote control switch OFF to start and stop the engine with the controls on the generator REMOTE CONTROL ENGINE SWITCH PILOT LAMP STARTER BUTTON ...

Page 51: ...p to ON 7 Depress the starter button until the pilot lamp is on CAUTION When a remote controller is installed be sure to set the remote control switch in the OFF position before starting the machine locally CAUTION Do not use the starter motor for more than 5 seconds If the engine fails to start release the button and wait at least 10 seconds before operating the starter motor again ON REMOTE CONT...

Page 52: ...ter the engine is warmed up STOPPING THE ENGINE WlTH REMOTE CONTROL 1 Turn the AC circuit protector to the OFF position 2 Turn the remote control engine switch to the OFF position 3 Turn the remote control switch to the OFF position AUTO THROTTLE SWITCH OFF AUTO OFF AUTO ...

Page 53: ...cooling Ignition system Transistor magneto ignition Oil capacity 1 1 L 1 16 US qt 0 97 Imp qt Fuel tank capacity 16 4 L 4 33 US gal 3 61 Imp gal Spark plug BPR5ES NGK W16EPR U DENSO Battery 12 V 18 Ah 10Hr Model EX4000S EX4500S Type G GW F IT B L AC output Rated voltage 230 V 115 230 V 120 240 V Rated frequency 50 Hz 50 Hz 60 Hz Rated current 15 2 A 30 4 15 2 A 33 3 16 7 A Rated output 3 5 kVA 3 5...

Page 54: ... 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 Model EX4000S EX4500S Type G GW B F IT L Sound pressure level at the workstati...

Page 55: ... Control Box block Charge Coil Choke solenoid Diode DC Diode DC Noise Filter DC Protector DC Terminal DC Winding Engine Block Engine Switch Exciter Winding Frame Block Fuel Cut Solenoid Fuse Fuel Valve Field Winding Generator Block Ground Terminal Ignition Coil Main Winding Oil Level Switch Optional Parts Pilot Lamp Remote Control Box Remote Control Switch Solenoid Control Unit Assembly SM SP TS T...

Page 56: ...54 RECEPTACLE Shape Type G GW B F IT L ...

Page 57: ...WIRING DIAGRAM SCHÉMA DE CABLAGE SCHALTPLAN DIAGRAMA DE CONEXIONES ...

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Page 61: ...tre d informations clients Honda à l adresse ou numéro de téléphone suivants ADRESSEN DER WICHTIGSTEN Honda HAUPTHÄNDLERS Weitere Informationen erhalten Sie gerne vom Honda Kundeninformationszentrum unter der folgenden Adresse oder Telefonnummer DIRECCIONES DE LOS PRINCIPALES CONCESIONARIOS Honda Para obtener más información póngase en contacto con el Centro de información para clientes Honda en l...

Page 62: ... la Ruelle Cedex Tel 02 38 81 33 90 Fax 02 38 81 33 91 http www honda fr com espaceclient honda eu com BELGIUM Honda Motor Europe North Doornveld 180 184 1731 Zellik Tel 32 2620 10 00 Fax 32 2620 10 01 http www honda be BH_PE HONDA EU COM CZECH REPUBLIC BG Technik cs a s U Zavodiste 251 8 15900 Prague 5 Velka Chuchle Tel 420 2 838 70 850 Fax 420 2 667 111 45 http www honda stroje cz GERMANY Honda ...

Page 63: ...ervice hondaireland ie POLAND Aries Power Equipment Sp z o o ul Wroclawska 25 01 493 Warszawa Tel 48 22 861 43 01 Fax 48 22 861 43 02 http www ariespower pl http www mojahonda pl info ariespower pl RUSSIA Honda Motor RUS LLC 21 MKAD 47 km Leninsky district Moscow region 142784 Russia Tel 7 495 745 20 80 Fax 7 495 745 20 81 http www honda co ru postoffice honda co ru ITALY Honda Italia Industriale ...

Page 64: ...dolu Motor Uretim ve Pazarlama AS Esentepe mah Anadolu Cad No 5 Kartal 34870 Istanbul Tel 90 216 389 59 60 Fax 90 216 353 31 98 http www anadolumotor com tr antor antor com tr Tenerife province Canary Islands Automocion Canarias S A Carretera General del Sur KM 8 8 38107 Santa Cruz de Tenerife Tel 34 922 620 617 Fax 34 922 618 042 http www aucasa com ventas aucasa com taller aucasa com UKRAINE Hon...

Page 65: ... DESCRIPTION DE TABLE DES MATIERES EU Konformitätserklärung INHALTSÜBERSICHT DESCRIPCIÓN GENERAL DEL CONTENIDO DE LA Declaración de Conformidad CE 1 see specification page 1 voir page de spécifications 1 Siehe Spezifikationen Seite 1 consulte la página de las especificaciones ...

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Page 69: ...KS 36ZB7620 00X36 ZB7 6200 K1 Honda Motor Co Ltd 2009 150 2009 09 Printed in Japan N 西 独 仏 英 C ...