Honda EM5500CX Owner's Manual
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Honda EM5500CX Owner's Manual

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Honda
OWNER'S MANUAL
MANUEL DE L'UTILISATEUR
BEDIENUNGSANLEITUNG
MANUAL DE EXPLICACIONES
The''e-SPEC''mark symbolizes environmentally
responsible technologies applied to Honda power
equipment, which contains our wish to ''preserve
nature for generations to come.''
EM3100CX·EM4500CX·EM5500CX
EM4500CXS·EM5500CXS

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  • Page 1 Honda EM3100CX·EM4500CX·EM5500CX EM4500CXS·EM5500CXS OWNER’S MANUAL MANUEL DE L’UTILISATEUR BEDIENUNGSANLEITUNG MANUAL DE EXPLICACIONES 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 2 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.

  • Page 3: Table Of Contents

    STOPPING THE ENGINE ..............37 MAINTENANCE ................39 TRANSPORTING/STORAGE ............46 TROUBLESHOOTING ............... 48 SPECIFICATIONS ................51 INSTALLATION OF KIT PARTS ............57 WIRING DIAGRAM ................64 MAJOR Honda DISTRIBUTOR ADDRESSES ........ . 70...

  • Page 4: Safety Instructions

    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 injuries or property damage can be prevented if you follow all instructions in this manual and on the generator.
  • Page 5 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.
  • Page 6 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 observed. The exhaust system gets hot enough to ignite some materials. −...
  • Page 7 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 dealer for a replacement.

  • Page 8: 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. READ OWNER’S MANUAL...
  • Page 9 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. Exhaust contains poisonous carbon monoxide, a colorless, odorless gas.
  • Page 10 Stop the engine before refueling. 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.

  • Page 11: Ce Mark And Noise Label Locations

    CE mark and noise label locations NOISE LABEL AND CE MARK NOISE LABEL Performance class IP code Dry mass [Example:EM5500CXS] Year of manufacture Manufacturer and address...

  • Page 12: Component Identification

    COMPONENT IDENTIFICATION CONTROL PANEL CHOKE ROD AIR CLEANER FUEL VALVE LEVER OIL FILLER CAP STARTER GRIP FUSE (CXS type) OIL DRAIN BOLT ENGINE SERIAL NUMBER FUEL TANK CAP FUEL GAUGE SPARK PLUG CAP FRAME SERIAL NUMBER MUFFLER Record the frame serial number and the engine serial number in the spaces below.
  • Page 13 CONTROL PANEL (B type) EM3100CX VOLTAGE SELECTOR SWITCH AC CIRCUIT PROTECTORS CIRCUIT BREAKER ENGINE SWITCH 230 V RECEPTACLE 115 V RECEPTACLES GROUND TERMINAL EM4500CX·EM5500CX EM4500CXS·EM5500CXS VOLTAGE SELECTOR SWITCH AC CIRCUIT PROTECTORS (CX type) CIRCUIT BREAKER 230 V RECEPTACLE ENGINE SWITCH 115 V RECEPTACLES...
  • Page 14 (F, G, GW types) EM3100CX·EM4500CX·EM5500CX· AC CIRCUIT PROTECTORS (Except EM3100CX) EM4500CXS·EM5500CXS (CX type) VOLT METER 230 V RECEPTACLES GROUND TERMINAL CIRCUIT BREAKER AUTO THROTTLE SWITCH ENGINE SWITCH (CXS type) (IT type) EM5500CXS AC CIRCUIT PROTECTOR VOLT METER ENGINE SWITCH 230 V RECEPTACLES...
  • Page 15 Auto Throttle System (CXS Type) The Auto Throttle system automatically reduces engine speed when all loads are turned off or disconnected. When appliances are turned on or reconnected, the engine returns to the rated speed. Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator.

  • Page 16: Pre-Operation Check

    PRE-OPERATION CHECK Be sure to check the generator on a level surface with the engine stopped. Check the engine oil level before each use. Using non detergent oil or 2-stroke engine oil could shorten the engine’s service life. Use 4-stroke motor oil that meets or exceeds the requirements for API service category SE or later (or equivalent).
  • Page 17 Check the fuel level. Check the fuel gauge. If the fuel level is low, refuel the fuel tank until the level as specified. After refueling, tighten the fuel tank cap securely. Use automotive unleaded gasoline with a Research Octane Number of 91 or higher (a Pump Octane Number of 86 or higher).
  • Page 18 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.
  • Page 19 Check the air cleaner. Check the air cleaner element to be sure it is clean and in good condition. Unsnap the two air cleaner cover clips, remove the air cleaner cover, and remove the air cleaner element. Clean or replace the element if necessary (see page Never run the engine without the air cleaner element.

  • Page 20: Starting The Engine

    STARTING THE ENGINE Make sure that the circuit breaker is OFF. The generator may be hard to start if a load is connected. CIRCUIT BREAKER...
  • Page 21 Electric starting (CXS type) 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.
  • Page 22 Make sure the auto throttle switch is in the OFF position, or more time will be required for warm up. (F, G, GW, IT types) AUTO THROTTLE SWITCH (B type) AUTO THROTTLE SWITCH...
  • Page 23 Turn the engine switch to the START position and hold it there for 5 seconds or until the engine starts. After the engine starts, let the engine switch return to the ON position. START START ENGINE SWITCH Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.
  • Page 24 If you wish to use the auto throttle system, turn the auto throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes. (F, G, GW, IT types) AUTO THROTTLE SWITCH (B type) AUTO THROTTLE SWITCH...
  • Page 25 Manual starting 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. B type: Set the Voltage Selector Switch to match the voltage requirements for the application.
  • Page 26 CX type: Pull the choke rod to the CLOSED position to start a cold engine. Push the choke rod in the OPEN position to start a warm engine. CXS type: The auto choke will be closed if the engine is cold. If you want to operate the choke manually, pull the choke rod out to the CLOSED position.
  • Page 27 4. CXS type: Make sure the auto throttle switch is in the OFF position, or more time will be required for warm up. (F, G, GW, IT types) AUTO THROTTLE SWITCH (B type) AUTO THROTTLE SWITCH...
  • Page 28 Turn the engine switch to the ON position. (CX type) ENGINE SWITCH (CXS type) ENGINE SWITCH...
  • Page 29 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. The starter grip can be drawn back very quickly before you release it. This may pull your hand forcefully toward the engine and cause an injury.
  • Page 30 8. CXS type: If you wish to use the auto throttle system, turn the auto throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes. (F, G, GW, IT types) AUTO THROTTLE SWITCH (B type) AUTO THROTTLE SWITCH...
  • Page 31 If you always operate the generator at altitudes higher than 1,500 meters (5,000 feet) above 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.

  • Page 32: Generator Use

    GENERATOR USE Be sure to ground the generator when the connected equipment is grounded. 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.
  • Page 33 OFF, but will shorten the service life of the generator. Limit operation requiring maximum power to 30 minutes. Maximum power is: EM3100CX: 3.1 kVA EM4500CX·4500CXS: 4.5 kVA EM5500CX·5500CXS: 5.5 kVA For continuous operation, do not exceed the rated power. Rated power is: 2.8 kVA EM3100CX: EM4500CX·4500CXS: 4.0 kVA EM5500CX·5500CXS:...
  • Page 34 AC Applications 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.
  • Page 35 AC Circuit Protector (Except EM3100CX F, G types) 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 ON (pushing the push button in).
  • Page 36 F, G, GW types (Except EM3100CX) AC CIRCUIT PROTECTOR (For receptacle No.2) AC CIRCUIT PROTECTOR (For receptacle No.1) RECEPTACLE No.1 RECEPTACLE No.2 IT type AC CIRCUIT PROTECTOR (For receptacle No.1) RECEPTACLE No.1...
  • Page 37 Oil Alert System The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase falls below a safe limit, the Oil Alert system will automatically shut down the engine (the engine switch will remain in the ON position).

  • Page 38: Stopping The Engine

    STOPPING THE ENGINE To stop the engine in an emergency, turn the engine switch to the OFF position. IN NORMAL USE: Turn the circuit breaker to the OFF position. CIRCUIT BREAKER Turn the engine switch to the OFF position. (CX type) (CXS type) ENGINE SWITCH...
  • Page 39 Turn the fuel valve lever to the OFF position. FUEL VALVE LEVER...

  • Page 40: Maintenance

    Every 2 years (Replace if necessary) (2) Service more frequently when used in dusty areas. These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.
  • Page 41 CHANGING OIL Drain the oil while the engine is still warm to assure rapid and complete draining. Remove the oil drain bolt and sealing washer, remove the oil filler cap, and drain the oil. Reinstall the drain bolt and sealing washer. Tighten the bolt securely. Refill with the recommended oil (see page ) and check the oil level.
  • Page 42 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. Do not use gasoline or low flash point solvents for cleaning. They are flammable and explosive under certain conditions.
  • Page 43 FUEL SEDIMENT CUP SERVICE Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. The sediment cup prevents dirt or water that may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned.
  • Page 44 SPARK PLUG SERVICE Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
  • Page 45 Make sure that the sealing washer is in good condition, and thread the spark plug in by hand to prevent cross-threading. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.
  • Page 46 FUSE REPLACEMENT (CXS type) If the fuse is blown, the starter motor will not work until it is replaced. Turn the engine switch to the OFF position. Remove the fuse holder cover and replace the fuse. The specified fuse is 10A. FUSE HOLDER COVER If frequent fuse failure occurs, determine the cause and correct the problem before attempting to operate the generator further.

  • Page 47: Transporting/Storage

    TRANSPORTING/STORAGE Transporting 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 OFF. The fuel valve lever should be turned OFF. When transporting the generator: Do not overfill the tank.
  • Page 48 Storage Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.

  • Page 49: Troubleshooting

    Turn off the engine switch and loosen the take the drain screw (see page generator to an Turn the fuel valve to ON. Fuel should flow authorized from the drain when the fuel valve is Honda dealer. turned ON.
  • Page 50 [CXS Type] Starter motor does not turn round; Is the fuse blown? Replace the fuse (see page Is the battery Charge the battery. discharged? If the starter motor still does not turn round, take the generator to an autorized Honda dealer.
  • Page 51 Reset the AC protector ON? circuit protector (see page Check the electrical Take the generator appliance or NO DEFECTS to an authorized equipment for any Honda generator defects. dealer. Replace the electrical appliance or equipment. DEFECTS Take the electrical appliance or...

  • Page 52: Specifications

    SPECIFICATIONS Dimensions and Weight Model EM3100CX Description code EARC Length 681 mm (26.8 in) Width 530 mm (20.9 in) Height 546 mm (21.5 in) Dry mass (weight) 74.5 kg (164.2 lbs) Engine Model GX240 Engine type 4-stroke, overhead valve, single cylinder Displacement 242 cm (14.8 cu-in) ×...
  • Page 53 Noise Model EM3100CX Type B, F, G Sound pressure level (Lp ) 78 dB According to 98/37/EC Microphone point CONTROL PANEL Center 1.60 m 1.0 m Guaranteed sound power level 96 dB ) Tested by 2000/14/EC ‘‘the figures quoted are emission levels and are not necessarily safe working levels.
  • Page 54 Dimensions and Weight Model EM4500CX EM4500CXS Description code EASC EATC Length 681 mm (26.8 in) 877 mm (34.5 in) Width 530 mm (20.9 in) 530 mm (20.9 in) Height 546 mm (21.5 in) 546 mm (21.5 in) Dry mass (weight) 87.8 kg (193.6 lbs) 95.3 kg (210.1 lbs) Engine...
  • Page 55 Noise Model EM4500CX·EM4500CXS Type B, F, G, GW Sound pressure level (Lp ) 80 dB According to 98/37/EC Microphone point CONTROL PANEL Center 1.60 m 1.0 m Guaranteed sound power level 97 dB ) Tested by 2000/14/EC ‘‘the figures quoted are emission levels and are not necessarily safe working levels.
  • Page 56 Dimensions and Weight Model EM5500CX EM5500CXS Description code EAUC EAVC Length 681 mm (26.8 in) 877 mm (34.5 in) Width 530 mm (20.9 in) 530 mm (20.9 in) Height 546 mm (21.5 in) 546 mm (21.5 in) Dry mass (weight) 90.1 kg (198.6 lbs)
  • Page 57 Noise Model EM5500CX·EM5500CXS Type B, F, G, GW, IT Sound pressure level (Lp ) 80 dB According to 98/37/EC Microphone point CONTROL PANEL Center 1.60 m 1.0 m Guaranteed sound power level 97 dB ) Tested by 2000/14/EC ‘‘the figures quoted are emission levels and are not necessarily safe working levels.

  • Page 58: Installation Of Kit Parts

    INSTALLATION OF KIT PARTS STANDARD KIT PARTS Battery Tray Kit (CXS type) × Unscrew the four 6 10 mm flange bolts, and remove the side panel. Route the starter cable under the tank and connect it to the starter solenoid. Connect the ground cable to the generator.
  • Page 59 × Install the battery guards on the frame using the four 8 12 mm flange bolts. Install the battery tray on the battery guards using the four 8 × mm flange bolts. Set the battery on the battery tray and secure with the battery bracket.
  • Page 60 OPTIONAL KIT PARTS 2 Wheel Type Handle Installation Install the right and left handles on the generator upper frame using the handle brackets and four flange bolts. Wheel Kit Installation Apply grease to the axle shaft as shown below, and install the two wheels on the axle shaft using the washers and split pins.
  • Page 61 4 Wheel Type Install the lock plate and four wheels on the wheel shaft using the washers and split pins. Install the left wheel shaft on the left side nearest the engine. × Install the wheel shaft assembly on the generator using eight 8 mm flange bolts and 8 mm flange nuts.
  • Page 62 Hanger Kit Installation Position the hanger at the generator’s balance point as shown below. 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) −...
  • Page 63 [CXS type] Remote Control Kit × Unscrew the four 6 10 mm flange bolts, and remove the side panel. Remove the plug from the 6-pin connector. Connect the remote control cable to the 6-pin connector. Pass the remote control cable through the cord grommet, and fit the grommet into the cutout.
  • Page 64 To avoid accidentally unplugging the remote control cable, secure the cable to the generator frame with the cable ties as shown. CABLE TIES REMOTE CONTROL CABLE Connect the blind connector when not using the remote control. Engine will not start unless the blind connector is connected. PILOT LAMP START SWITCH STOP SWITCH...

  • Page 65: Wiring Diagram

    WIRING DIAGRAM ACOR AC Output Receptacle ACCP AC Circuit Protector ACNF AC Noise Filter Auto Throttle Solenoid ATSw Auto Throttle Switch Auto Throttle Unit AVRe Auto Voltage Regulator Battery Circuit Breaker CBxB Control Box Block Charge Coil Diode DC Winding Engine Block EgCU Engine Control Unit...
  • Page 66 BLACK YELLOW BLUE GREEN WHITE BROWN ORANGE LIGHT BLUE LIGHT GREEN PINK GRAY ENGINE SWITCH EM3100CX·EM4500CX·EM5500CX EM4500CXS·EM5500CXS START...
  • Page 67 EM3100CX·EM4500CX·EM5500CX (B type)
  • Page 68 EM4500CXS·EM5500CXS (B type)
  • Page 69 EM3100CX·EM4500CX·EM5500CX (F, G, GW types)
  • Page 70 EM4500CXS·EM5500CXS (F, G, GW, IT types)

  • Page 71: Major Honda Distributor Addresses

    MAJOR Honda DISTRIBUTOR ADDRESSES For further information, please contact Honda Customer Information Centre at the following address or telephone number: AUSTRIA CYPRUS FRANCE Honda Motor Europe (North) Alexander Dimitriou & Sons Ltd. HONDA RELATIONS CLIENTS Hondastraße 1 162, Yiannos Kranidiotis Avenue...
  • Page 72 381 11 3820 301 ＠ info hondapower.pl http://www.hondasrbija.co.yu LITHUANIA PORTUGAL SLOVAKIA REPUBLIC JP Motor Ltd Honda Portugal, S.A. Honda Slovakia, spol. s r.o. Kubiliaus str. 6 Abrunheira Prievozská 6 - 821 09 Bratislava 08234 Vilnius 2714-506 Sintra Slovak Republic Tel. : ＋...
  • Page 73 SPAIN & TURKEY AUSTRALIA Las Palmas province Anadolu Motor Uretim Ve Honda Australia Motorcycle (Canary Islands) Pazarlama AS (ANPA) and Power Equipment Pty. Ltd Greens Power Products, S.L. Esentepe mah. Anadolu 1954-1956 Hume Highway Avda. Ramon Ciurans, 2 Cad. No: 5...

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