Honda EB6500X Owner's Manual
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Honda EB6500X Owner's Manual

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  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever.
  • Page 3 Congratulations on your selection of a Honda generator. We are certain you will be pleased with your purchase of one of the finest generators on the market. We want to help you get the best results from your new generator and to operate it safely.
  • Page 4 A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS GENERATOR SAFETY ................Safety Label Locations ............... Important Safety Information ............COMPONENT IDENTIFICATION .............. CONTROLS ....................10 Engine Switch ..................10 Starter Grip ..................10 Fuel Valve Lever ................. 11 Choke Rod ................... 11 Voltage Selector Switch (Dual Voltage System) ......
  • Page 6 WIRING DIAGRAM ................. . 52 SPECIFICATIONS ..................54 ASSEMBLY ....................57 WARRANTY SERVICE INFORMATION ..........65 DEALER LOCATOR INFORMATION ..........65 CUSTOMER SERVICE INFORMATION ..........65 Honda PUBLICATIONS ..............66 INDEX ...................... . 67...

  • Page 7: Generator Safety

    GENERATOR SAFETY SAFETY LABEL LOCATION These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda generator dealer for a replacement.

  • Page 8: Important Safety Information

    IMPORTANT SAFETY INFORMATION Honda generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating procedures.
  • Page 9 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.

  • Page 10: Component Identification

    COMPONENT IDENTIFICATION ENGINE SWITCH CONTROL PANEL CHOKE ROD AIR CLEANER FUEL VALVE LEVER STARTER GRIP OIL FILLER CAP/DIPSTICK ENGINE SERIAL NUMBER OIL DRAIN PLUG CONTROL PANEL 120 ONLY 120/240 − ＊ 1: Except EB3800X VOLTAGE SELECTOR SWITCH GFCI TEST BUTTON AC CIRCUIT PROTECTORS GFCI RESET BUTTON 120/240V AC...
  • Page 11 LIFTING HANGER TRANSPORT HANDLE FUEL TANK CAP FUEL GAUGE SPARK PLUG CAP FRAME SERIAL NUMBER STAND MUFFLER WHEEL Record the engine and frame serial numbers and date of purchase for your future reference. Refer to these serial numbers when ordering parts and when making technical or warranty inquiries (see page Engine serial number: Frame serial number:...

  • Page 12: Controls

    CONTROLS Engine Switch To start and stop the engine. Switch position: OFF: To stop the engine. To run the engine. ENGINE SWITCH Starter Grip To start the engine, pull the starter grip lightly until resistance is felt, and then pull briskly. Do not allow the starter grip to snap back against the engine.

  • Page 13: Fuel Valve Lever

    Fuel Valve Lever The fuel valve is located between the fuel tank and carburetor. When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the OFF position after stopping the engine.

  • Page 14: Voltage Selector Switch (Dual Voltage System)

    Voltage Selector Switch (Dual Voltage System) The voltage selector switch switches the main power carrying windings of the generator to produce ‘‘120V ONLY’’ or ‘‘120/240V’’. If a 240V appliance is connected to the 4-prong receptacle, the switch must be in the ‘‘120/240V’’ position. If only a 120V appliance is being connected to any of the 120V 3-prong receptacles, select the ‘‘120V ONLY’’...

  • Page 15: Oil Alert System

    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 can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position).

  • Page 16: Circuit Breaker

    Circuit Breaker The circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle, or if the ground fault circuit interrupter (GFCI) detects a ground fault current. Check the following if the circuit breaker switches OFF automatically: When the GFCI RESET button is extended (page 18): −...

  • Page 17: Circuit Protector

    Circuit Protector The circuit protectors will automatically switch OFF if there is a short circuit or a significant overload of the generator at the 20A 120V, 30A 120V locking plug, or 120/240V locking plug receptacle. If a 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 circuit protector ON.

  • Page 18: Ground Fault Circuit Interrupter (Gfci)

    Ground Fault Circuit Interrupter (GFCI) Using the generator in rain, snow or near water can lead to death from electric shock. Keep the generator dry. All receptacles on the generator are protected by a ground fault circuit interrupter (GFCI) for protection against the shock hazard of ground fault current.
  • Page 19 Observe the following precautions to ensure proper GFCI operation and to reduce shock hazards: Use grounded 3-conductor extension cords, tools, and appliances, or double-insulated tools and appliances. Inspect cords and plugs, and replace if damaged. Do not use cord lengths greater than 164 feet (50 meters), and do not use multiple tools and appliances with built-in noise filters.
  • Page 20 Press the GFCI TEST button. The RESET button should extend, and the circuit breaker should switch to the OFF position. If the GFCI and circuit breaker do not function as described, take the generator to an authorized Honda generator dealer for repair. GFCI RESET BUTTON GFCI TEST BUTTON...
  • Page 21 ON position. The circuit breaker will not remain in the ON position if the RESET button is extended. If the GFCI and circuit breaker do not function as described, take the generator to an authorized Honda generator dealer for repair. GFCI RESET BUTTON CIRCUIT BREAKER...

  • Page 22: Generator Use

    Ground System Honda portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire.

  • Page 23: Ac Applications

    Limit operation requiring maximum power to 30 minutes. Maximum power is: EB3800X: 3.8 kVA EB5000X: 5.0 kVA EB6500X: 6.5 kVA For continuous operation (longer than 30 minutes), do not exceed the rated power. Rated power is: EB3800X: 3.3 kVA EB5000X: 4.5 kVA...

  • Page 24: Ac Operation

    AC Operation Check GFCI operation before each use (see page 18 ). Start the engine (see page Turn the voltage selector switch to either position. With the voltage selector switch in the ‘‘120/240V’’ position, you can use the 120V and 120/240V receptacles simultaneously. If you are NOT using the 120/240V receptacle but require more power from the 120V locking plug receptacle, then select the ‘‘120V ONLY’’...

  • Page 25: Ac Receptacle Selection

    AC Receptacle Selection The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle ＃ 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EB3800X: ○ ○ 120V 30A 120V 20A (in total) 120V 20A (in total) ○...
  • Page 26 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 120V ONLY 27.5A at 120V 20A at 120V 20A at 120V 20A at 120V None 120V/240V 13.8A at 120V 13.8A at 120V 13.8A at 120V 4A-4B...
  • Page 27 The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle ＃ 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EB5000X: ○ ○ 120V 30A 120V 20A (in total) 120V 20A (in total) & 120/240V 30A ○...
  • Page 28 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 120V ONLY 30A at 120V 20A at 120V 20A at 120V 30A at 120V None 120V/240V 18.8A at 120V 18.8A at 120V 18.8A at 120V 4A-4B...
  • Page 29 The control panel, shown below, has a voltage selector switch and four receptacles. Receptacle ＃ 4, the 240-volt receptacle, has two powered terminals, 4A and 4B. EB6500X: ○ ○ 120V 30A 120V 20A (in total) 120V 20A (in total) ○ ○...
  • Page 30 Voltage Selector Switch The power available to each receptacle depends on the position of the voltage selector switch. Switch Position Receptacle Available Power 120V ONLY 30A at 120V 20A at 120V 20A at 120V 30A at 120V None 120V/240V 22.9A at 120V 20A at 120V 20A at 120V 4A-4B...

  • Page 31: Auto Throttle System

    Auto Throttle System With the switch in the AUTO position, engine speed is automatically reduced when ALL loads are turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to rated speed. In the OFF position, the Auto Throttle system does not operate. The Auto Throttle system will not respond to electrical loads of less than 1 ampere or intermittent loads such as a staple gun.

  • Page 32: High Altitude Operation

    High Altitude Operation At high altitude, the standard carburetor air/fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

  • Page 33: Pre-Operation Check

    PRE-OPERATION CHECK Engine Oil Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped. Use 4-stroke motor oil that m e e t s o r e x c e e d s t h e requirements for API service c a t e g o r y S J o r l a t e r ( o r equivalent).

  • Page 34: Refueling

    Refueling With the engine stopped, check the fuel level gauge. Refill the fuel tank if the fuel level is low. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop engine and keep heat, sparks, and flame away. Refuel only outdoors.

  • Page 35: Fuel Recommendations

    Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty. After refueling, reinstall the fuel tank cap securely. Fuel Recommendations This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher.

  • Page 36: Starting The Engine/Stopping The Engine

    STARTING THE ENGINE/STOPPING THE ENGINE Starting the Engine For your safety, do not operate the generator in an enclosed area such as a garage. Your generator’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.
  • Page 37 Stopping the Engine In an emergency: To stop the engine in an emergency, move the engine switch to the OFF position. In normal use: Turn the AC circuit breaker to the OFF position. Move the engine switch to the OFF position. Turn the fuel valve lever to the OFF position.

  • Page 38: Maintenance

    Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions. If...

  • Page 39: Maintenance Safety

    Remember that your servicing dealer knows your generator best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, Honda Genuine parts or their equivalents for repair or replacement.

  • Page 40: Maintenance Schedule

    Every 2 years (Replace if necessary)(2) Service more frequently when used in dusty areas. These items should be serviced by an authorized Honda generator dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop Manual.

  • Page 41: Engine Oil Change

    Engine Oil Change Drain the oil while the engine is warm to assure rapid and complete draining. Place a suitable container below the engine to catch the oil, then remove the oil drain plug and sealing washer, remove the oil filler cap/dipstick, and drain the oil.

  • Page 42: Air Cleaner Service

    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. Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine, causing rapid engine wear.

  • Page 43: Fuel Sediment Cup Cleaning

    Fuel Sediment Cup Cleaning 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. Turn the fuel valve lever to the OFF position. Remove the sediment cup, O-ring, and filter.

  • Page 44: Spark Plug Service

    Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. An incorrect spark plug can cause engine damage.

  • Page 45: Spark Arrester Maintenance

    Check that the spark plug 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: Transporting/Storage

    TRANSPORTING/STORAGE When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Contact with a hot engine or exhaust system can cause serious burns or fires.
  • Page 47 Change the engine oil (page 39 ). After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting. Use gasoline stabilizers that are formulated to extend storage life. Contact your authorized Honda generator dealer for stabilizer recommendations.
  • Page 48 Storage Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

  • Page 49: Troubleshooting

    If the engine still the drain screw. (page 46) does not start, take Turn the fuel valve to ON. Fuel should the generator to an flow from the drain when the fuel valve authorized Honda is turned ON. generator dealer.
  • Page 50 The GFCI RESET button and equipment, and in- is extended again. spect the GFCI operation. (refer to page 18) Take the generator to an au- thorized Honda generator dealer. The GFCI RESET button Replace the electrical ap- is not extended. pliance or equipment.

  • Page 51: Technical Information

    The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit.
  • Page 52 The emission control systems on your Honda engine were designed, built, and certified to conform with applicable emission regulations. We recommend the use of Honda Genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.

  • Page 53: Air Index

    Air Index (Models certified for sale in California) An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines.

  • Page 54: Wiring Diagram

    WIRING DIAGRAM EB3800X...
  • Page 55 EB5000X, EB6500X...

  • Page 56: Specifications

    Refer to page 42 Valve clearance IN: 0.15 ± 0.02 mm (cold) See your authorized EX: 0.20 ± 0.02 mm (cold) Honda dealer. Other specifications No other adjustments needed. Specifications may vary according to the types, and are subject to change without notice.
  • Page 57 Refer to page 42 Valve clearance IN: 0.15 ± 0.02 mm (cold) See your authorized EX: 0.20 ± 0.02 mm (cold) Honda dealer. Other specifications No other adjustments needed. Specifications may vary according to the types, and are subject to change without notice.
  • Page 58 Dimensions Model EB6500X Type California type Non-California type (AC, ACH type) (AN, ANH type) Description code EALC Length 41.9 in (1,064 mm) Width 27.2 in (691 mm) Height 30.4 in (773 mm) Dry mass [weight] 220.7 lbs (100.1 kg) 219.6 lbs (99.6 kg)

  • Page 59: Assembly

    ASSEMBLY 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.
  • Page 60 Important Safety Precautions 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: □ Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.
  • Page 61 Unpacking Remove the generator and loose parts box from the carton. Compare the loose parts with the inventory list below. Tools Required: 14 mm wrench (2), pliers Loose Parts (Wheel kit, hanger and handle) Check all loose parts against the following list. Contact your dealer if any of the loose parts shown below are not included with your generator.
  • 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: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) −...
  • Page 63 Handle Installation Install the right and left handles on the generator upper frame using the brackets and 6 flange bolts. TORQUE: 17 22 lbf·ft (24 29 N·m , 2.4 3.0 kgf·m) − − − 8 16 mm FLANGE BOLT (4) ×...
  • Page 64 Wheel Kit Installation Install the two wheels on the axle shaft using the washers and cotter pins. Install the axle assembly on the generator using four 8 × 16 mm flange bolts and 8 mm flange nuts. Install the two stands on the under frame using four 8 ×...
  • Page 65 Engine Oil The generator is shipped WITHOUT OIL in the engine. Place the generator on a level surface. Add enough of the recommended oil to bring the oil level to the top of the oil filler neck. AMBIENT TEMPERATURE Use a 4-stroke motor oil that meets the requirements for API service category SJ or OIL FILLER HOLE...
  • Page 66 BEFORE OPERATION Before using your generator, you should become familiar with information contained in the following chapters and sections: GENERATOR SAFETY (page CONTROLS (page GENERATOR USE (page STARTING THE ENGINE (page STOPPING THE ENGINE (page...

  • Page 67: Warranty Service Information

    WARRANTY SERVICE INFORMATION DEALER LOCATOR INFORMATION To find an authorized Honda Servicing Dealer anywhere in the United States: Visit our website: www.hondapowerequipment.com CUSTOMER SERVICE INFORMATION Servicing dealership personnel are trained professionals. They should be able to answer most questions 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.

  • Page 68: Honda Publications

    Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. Available through your Honda dealer or through Helm Inc. at 1 888- 292-5395 or visit www.hondapowerequipment.com Parts Catalog This manual provides complete, illustrated parts lists. Available through your Honda dealer.

  • Page 69: Index

    INDEX ASSEMBLY ....................57 COMPONENT IDENTIFICATION .............. CONTENTS ....................CONTROLS ....................10 Auto Throttle System ............... 13 Choke Rod ................... 11 Circuit Breaker ..................14 Circuit Protector ................. 15 Engine Switch ..................10 Fuel Valve Lever ................
  • Page 70 Emission Control System Information ..........49 TRANSPORTING/STORAGE ..............44 TROUBLESHOOTING ................47 WARRANTY SERVICE INFORMATION ..........65 CUSTOMER SERVICE INFORMATION ..........65 DEALER LOCATOR INFORMATION ..........65 Honda PUBLICATIONS ..............66 WIRING DIAGRAM ................. . 52...
  • Page 71 00X31Z226050...

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