Honda EX4000S Owner's Manual
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Honda EX4000S Owner's Manual

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GENERATOR
EX4000S ・ EX4500S
OWNER'S MANUAL
MANUEL DE L'UTILISATEUR
BEDIENUNGSANLEITUNG
MANUAL DE EXPLICACIONES

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  • Page 1 GENERATOR EX4000S ・ EX4500S OWNER'S MANUAL MANUEL DE L'UTILISATEUR BEDIENUNGSANLEITUNG MANUAL DE EXPLICACIONES...
  • Page 2 Honda EX4000S • EX4500S OWNER’S MANUAL Original instructions MANUEL DE L’UTILISATEUR 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 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 4: Table Of Contents

    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...

  • Page 5: Safety Instructions

    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 injuries or property damage can be prevented if you follow all instructions in this manual and on the generator.
  • Page 6 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 a dangerous amount of exhaust gas. Never run your generator inside a garage, house, or near open windows or doors.
  • Page 7 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 8 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 dealer to dispose of these parts.

  • Page 9: 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 10 • 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 11 • 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: Ce Mark And Noise Label Locations

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

  • Page 13: Component Identification

    3. COMPONENT IDENTIFICATION ENGINE SWITCH (Interlocked with fuel valve) VOLTMETER AUTO THROTTLE SWITCH AC CIRCUIT PROTECTOR VOLTAGE OIL FILLER ADJUSTMENT CAP/DIP STICK KNOB MUFFLER FRONT MAINTENANCE COVER AC RECEPTACLES OIL DRAIN BOLT DAMPER RUBBER GROUND TERMINAL FRAME SERIAL NUMBER DC CIRCUIT PROTECTOR DC TERMINALS Record the frame serial number in the space below.
  • Page 14 F type VOLTAGE VOLTMETER ADJUSTMENT KNOB AUTO THROTTLE ENGINE SWITCH SWITCH (Interlocked with fuel valve) 230V RECEPTACLES AC CIRCUIT PROTECTOR DC TERMINALS DC CIRCUIT PROTECTOR G, GW type IT type ENGINE SWITCH ENGINE SWITCH (Interlocked with VOLTMETER (Interlocked with VOLTMETER fuel valve) VOLTAGE fuel valve)
  • Page 15 B type ENGINE SWITCH (Interlocked with fuel valve) VOLTMETER AUTO THROTTLE SWITCH AC CIRCUIT 230V RECEPTACLES PROTECTOR VOLTAGE 115V RECEPTACLES SELECTOR SWITCH L type PILOT LAMP (L type only) VOLTMETER AUTO THROTTLE SWITCH VOLTAGE SELECTOR SWITCH ENGINE SWITCH (Interlocked with fuel valve) 120/240V RECEPTACLES AC CIRCUIT...
  • Page 16 FUEL TANK CAP UPPER MAlNTENANCE COVER AIR CLEANER SPARK PLUG REAR MAINTENANCE COVER...
  • Page 17 Auto throttle AUTO: Engine speed is kept at idle automatically when the electrical appliance is disconnected and it returns to the rated speed when electrical appliance is connected. NOTE: • This position is recommended to minimize the fuel consumption while in operation.

  • Page 18: Pre-Operation Check

    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. Recommended oil Use 4-stroke motor oil that meets or exceeds the requirements for API service category SE or later (or equivalent).
  • Page 19 Open the front maintenance cover. 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 low, fill to the top of the oil filler neck with the recommended oil.
  • Page 20 2. Check the fuel level. Check the fuel level. Refill the fuel tank if the fuel level is low. 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). Never use stale or contaminated gasoline or an oil/gasoline mixture.
  • Page 21 Gasoline 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 22 3. Check the air cleaner. Check the air cleaner element to be sure it is clean and in good condition. Open the rear maintenance cover. Unsnap 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.
  • Page 23 4. Check the battery. The electrolyte level must be maintained between the UPPER and LOWER level marks. If the electrolyte level is near the LOWER mark, add distilled water. • Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness.

  • Page 24: Starting The Engine

    5. STARTING THE ENGINE CAUTION: When starting the generator after adding fuel for the first time, after long-term storage, or after running out of fuel, turn the engine switch to the “ON” position, then wait for 10 to 20 seconds before starting the engine.
  • Page 25 3. Turn the engine switch to START and hold it there until the engine starts. START START 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.

  • Page 26: High Altitude Operation

    High altitude performance can be improved by specific modifications to the carburetor. If you always operate the generator at altitudes higher than 1,500 m (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 27: Generator Use

    6. 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 insalled 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 28 CAUTION: • 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 generators in parallel. • Do not connect an extension to the exhaust pipe. •...
  • Page 29 AC applications 1. Start the engine and make sure the pilot lamp (L type only) comes on. 2. Choose the proper voltage by changing the voltage selector switch (B and L types only). 3. Switch on the AC circuit protector. NOTE: •...
  • Page 30 DC application (Except B type) The DC terminals may be used for charging 12 volt automotive-type batteries only. 1. Connect the charging cables to the battery terminals and then to the DC terminals of the generator. DC CIRCUIT PROTECTOR NEGATIVE TERMINAL (BLACK) POSITIVE...
  • Page 31 • Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness. Provide adequate ventilation when charging. • 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. •...

  • Page 32: Stopping The Engine

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

  • Page 33: Maintenance

    (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 to determine proper maintenance intervals.
  • Page 34 Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining. 1. Open the front maintenance cover. 2. Remove the oil drain bolt and oil filler cap, and drain the oil. Retighten the bolt securely. 3.
  • Page 35 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.
  • Page 36 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. Open the rear maintenance cover. 2. Remove the spark plug cap. 3. Clean any dirt from around the spark plug base. 4.
  • Page 37 7. Attach the plug washer and thread the plug in by hand to prevent cross threading. 8. After a new spark plug has been seated by hand, it should be tightened 1/2 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.
  • Page 38 Sediment cup Gasoline is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in the area. The sediment cup prevents dirt or water which 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 39 Fuse replacement If the fuse is blown, the engine will not start until it is replaced. 1. Turn the engine switch OFF. 2. Open the left side maintenance cover, and open the fuse holder cover and replace the fuse. The specified fuses are two 5A and 10A. CAUTION: •...
  • Page 40 Spark arrester maintenance (Equipped Type only) If the generator has 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. RIGHT SIDE COVER HANDLE 6 mm BOLTS 2.
  • Page 41 3. 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 Battery removal/installation • Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness. Provide adequate ventilation when charging. • CHEMICAL HAZARD: Battery electrolyte contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.
  • Page 43 4. Remove the negative (–) cable from the battery negative (–) terminal, and then remove the positive (+) cable from the battery positive (+) terminal. 5. Remove the battery. POSITIVE (+) CABLE NEGATIVE (–) CABLE BATTERY Installation: 1. Make sure that the engine switch is turned OFF. 2.
  • Page 44 Charging: The battery is rated at 18 Ah (ampere hours). Charging current should equal 10% of the battery’s ampere hour rating. The battery gives off explosive gasses; keep sparks, flames and cigarettes away from the battery while charging. Provide adequate ventilation when charging.

  • Page 45: Transpoting/Storage

    9. TRANSPOTING/STORAGE 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. NOTE: To transport the generator, hold the holding part (shaded areas in the figure below).
  • Page 46 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. Open the rear maintenance cover. b. Turn the engine switch to ON and then loosen the carburetor drain screw.

  • Page 47: Troubleshooting

    To check: 1) Turn off the engine switch and loosen the drain screw. 2) Fuel should flow from the drain when the engine switch is turned If the engine still does not start, take the generator to an authorized Honda dealer.

  • Page 48: No Electricity At The Ac Receptacles

    Turn the AC circuit protector on? protector on. NO DEFECTS Check the electrical Take the generator appliance or to an authorized equipment for any Honda dealer. defects. • Replace the electrical DEFECTS appliance or equipment. • Take the electrical appliance or...

  • Page 49: Optional Parts

    11. OPTIONAL PARTS Remote Control Kit The remote control kit is available as optional part to control the generator remotely. (Installation) 1. Remove the shield cover on the front cover. 2. Disconnect 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.
  • Page 50 Remote Control Box REMOTE CONTROL ENGINE SWITCH PILOT LAMP STARTER BUTTON Pilot lamp The lamp must be on while the engine is rotating. Remote control engine switch ON: Flip the knob up to this position 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.
  • Page 51 STARTING WlTH REMOTE CONTROL 1. Make sure the engine switch is OFF. 2. Turn the auto throttle switch to OFF. 3. Turn off the AC circuit protector. 4. Remove the engine switch key from the generator. 5. Turn the remote control switch to ON. 6.
  • Page 52 8. After the engine starts, turn the auto-throttle switch to AUTO after the engine is warmed up. AUTO THROTTLE SWITCH AUTO AUTO 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.

  • Page 53: Specifications

    12. SPECIFICATIONS Dimensions Model EX4000S • EX4500S Description code Length × Width × Height 910 × 530 × 695 mm (35.8 × 20.9 × 27.4 in) Dry mass [weight] 122 kg (269 lb) Engine Model Honda GX340K1 Engine Type 4-stroke, O.H.V., 1 cylinder...
  • Page 54 Noise Model EX4000S EX4500S Type G, GW, B, F, IT Sound pressure level at the workstation 72 dB (A) (2006/42/EC) Microphone point CONTROL PANEL Center 1.60 m 1.0 m Uncertainty 2 dB (A) Measured sound power level 89 dB (A)

  • Page 55: Wiring Diagram

    13. WIRING DIAGRAM INDEX (See inside of back cover) L Type..................... W-1 B Type ....................W-2 F, G, GW, IT Types ................W-3 ABBREVIATIONS Symbol Part name Symbol Part name AC CP AC Circuit Protector Starter Motor ACOR AC Output Receptacle Spark Plug AC, NF AC Noise Filter...
  • Page 56 RECEPTACLE Shape Type G,GW...
  • Page 57 WIRING DIAGRAM SCHÉMA DE CABLAGE SCHALTPLAN DIAGRAMA DE CONEXIONES...

  • Page 61: Major Honda Distributor Addresses

    For further information, please contact Honda Customer Information Centre at the following address or telephone number: ADRESSES DES PRINCIPAUX CONCESSIONNAIRES Honda Pour plus d’informations, s’adresser au Centre d’informations clients Honda à l’adresse ou numéro de téléphone suivants: ADRESSEN DER WICHTIGSTEN Honda-HAUPTHÄNDLERS...
  • Page 62 AUSTRIA CROATIA FINLAND Honda Motor Europe (North) Hongoldonia d.o.o. OY Brandt AB. Hondastraße 1 Jelkovecka Cesta 5 Tuupakantie 7B 2351 Wiener Neudorf 10360 Sesvete — Zagreb 01740 Vantaa Tel. : +43 (0)2236 690 0 Tel. : +385 1 2002053 Tel. : +358 20 775 7200...
  • Page 63 MALTA SLOVAKIA REPUBLIC The Associated Motors Honda Slovakia, spol. s r.o. Company Ltd. Prievozská 6 821 09 Bratislava New Street in San Gwakkin Tel. : +421 2 32131112 Road Fax : +421 2 32131111 Mriehel Bypass, Mriehel QRM17 http://www.honda.sk...
  • Page 64 SWEDEN UNITED KINGDOM Honda Nordic AB Honda (UK) Power Equipment Box 50583 - Västkustvägen 17 470 London Road 20215 Malmö Slough - Berkshire, SL3 8QY Tel. : +46 (0)40 600 23 00 Tel. : +44 (0)845 200 8000 Fax : +46 (0)40 600 23 19 http://www.honda.co.uk...

  • Page 65: Ec Declaration Of Conformity" Content Outline

    "EC Declaration of Conformity" CONTENT OUTLINE "CE-Déclaration de conformité" DESCRIPTION DE TABLE DES MATIERES "EU-Konformitätserklärung" INHALTSÜBERSICHT DESCRIPCIÓN GENERAL DEL CONTENIDO DE LA "Declaración de Conformidad CE" *1: see specification page. *1: Siehe Spezifikationen-Seite é á *1: voir page de sp cifications gina de las *1: consulte la p...
  • Page 69 Honda Motor Co., Ltd. 2009 36ZB7620 150.2009.09 英 仏 独 西 00X36-ZB7-6200 Printed in Japan...

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