Owner’s Manual EX5500 00X31 -ZAO-6000
Thank you for purchasing a Honda generator. This manual covers operation and maintenance of the EX5500 generator. 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 This manual should be considered a permanent remain with the generator when sold.
CONTENTS CONTENTS 1. GENERATOR SAFETY ....................... 2. COMPONENT IDENTIFICATION .................. 3. PRE-OPERATION CHECK ...................... 4. STARTING THE ENGINE ...................... 5:GENERATOR USE .......................... 6. STOPPING THE ENGINE ....................... 7. MAlNTENAi)lCE ........................... 8. TRANSPORTING/STORAGE .................... . 9. TROUBLESHOOTING ........................ 10. SPECIFICATIONS .......................... ......................... 11.
I. GENERATOR SAFETY To ensure safe operation l l l l l l l Place the generator at least 1 m (3 ft) away from buildings or other equipment when operating the generator. Operate the generator on a level surface. If the generator is tilted, fuel spillage may result. Exhaust gas contains poisonous carbon monoxide. Never run the generator in an enclosed area. Be sure to provide adequate ventilation. Know how to stop the generator quickly and understand operation of all the controls.
2. COMPONENT AIR IDENTIFICATION CLEANER TOP COVER LOCK L .
CONTROL BOX VOLTAGE ADJUSTMENT KNOB PILOT LAMP VOLTMETER RESET BUTTON r 1 Cl RCUIT BREAKERS AUTO-THROTTLE SWITCH REMOTE CONTROL SWITCH FUEL VALVE KNOB AC RECEPTACLES ENGINE SWITCH 3
3. PRE-OPERATION CAUTION: stopped. CHECK- Be sure to check the generator on a level surface with the engine 1. Check the engine oil level. CAUTION: Engine oil is a major factor affecting engine performance service life. Non-detergent or vegetable oils are not recommended. and 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.
2. Check the fuel level. Use any regular grade automotive gasoline (unleaded gasoline is preferred) with a pump octane rating of 86 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 harmful to the fuel system components. Fuel tank capacity: recommended; they may be 16.5 P (4.36 US gal 1 mm!! Gasoline is extremely flammable and explosive under certain conditions.
3. Check the coolant level. If there is no coolant in the reserve tank, check the cooling system for leaks and repair if necessary. Add coolant to the radiator, then check the coolant level in the reserve tank after the engine reaches operating temperature. M Never remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. When the engine is at operating temperature, the coolant level should be between the MIN and MAX marks on the reserve tank.
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. l l The batterv contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL - Flush with water. INTERNAL Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. Eyes: Flush with water and get prompt medical attention.
4. STARTING 1. Turn the fuel , 8 valve - - THE IENGINE ON.
2. Make sure that the circuit breakers are OFF. The generator may be hard to start if a load is connected. CIRCUIT-BREAKERS ( 0II c 0 c - 9 3. Make sure the auto-throttle warm up.
4.Turn the engine switch to START and hold it there until the engine starts. 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. NOTE: When the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged l NOTE: It is normal for the oil lamp to remain lit during starting.
5. After the engine starts, let the engine-switch ENGINE return to ON. SWITCH 6. Warm up the engine for 2-3 minutes. AUTO after the engine has warmed up.
5. GENERATOR USE M To 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. CAUTION: Limit operation requiring maximum power (5.5 KVA) to 30 minutes. For continuous operation, do not exceed the rated power of 5.0 KVA. In either case, the total wattage of all appliances connected must be considered.
Operation 1. Start the engine and make sure that the pilot 2. Switch on the circuit breakers. 3. Plug in the appliance. lamp comes on. NOTE: Connect 120V appliances to the 120V receptacles. You can use both 12OV/24OV appliances with the 12OV/24OV receptacle. CAUTION: Be sure that appliances do not exceed the rated load for more than 30 minutes, and never exceed the maximum load. Substantial. overloading will switch off the circuit breaker.
6. STOPPING THE ENGINE To stop the engine in an emergency, move the engine switch to OFF. In normal use: 1. Turn the circuit breakers OFF. CIRCUIT BREAKERS I I 2. Turn the engine switch OFF.
3. Turn the fuel valve OFF.
7. MAINTENANCE The purpose of the maintenance schedule and adjustment generator in the best operating condition. Inspect or service as scheduled in the table on the next page. is to keep the 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: replacement generator. Use only genuine HONDA parts or their equivalent.
Maintenance Schedule orm at every indiating hour interval, whichever occurs NOTE (1 J : 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.
Toll kit The tools supplied are necessary for performing simple adjustments and repairs. Always keep the kit with the generator. some periodic maintenance, Engine oil and oil filter change Drain the oil while the engine is still warm to assure rapid and complete draining. 1. Remove the drain plug and filler cap, and drain the oil. Retighten the plug securely, and reinstall the filler cap. 2. Remove the oil filter with a filter wrench and let the remaining oil drain out. 3.
Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly (page 23). Service more frequently when operating the generator in extremely dusty areas. N Never use gasoline or low flash point solvents for cleaning the air cleaner elements. A fire or explosion could result. CAUTION: Never run the generator without wear may result. the air cleaner. Rapid engine 1. Pull the lock levers out and open the top cover. 2.
4. Carefully check both elements for holes or tears and replace as required. Damaged elements will pass dirt into the system. Always clean the filter housing and air passages before installing clean elements. 5. Foam element: Clean in warm soapy water: rinse and allow to dry thoroughly. Or clean in high flash-point solvent and allow to dry. Dip the element in clean engine oil and squeeze out all the excess. The engine will smoke during initial start-up if too much oil is left in the foam. 6.
Fuel filter service The filter 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 filter should be cleaned. 1. Turn the two lock pins and open the carburetor cover. 2. Turn the fuel valve OFF. Remove the filter cup. 3. Clean the cup thoroughly. 4. Reassemble. Do not damage the O-ring. 5. Close the carburetor cover and lock with the lock pins.
Spark plug service Recommended spark plug: BPRGHS-10 (NGK) To ensure proper engine operation, and free of deposits. the spark plug must be properly gapped 1. 2. 3. 4. Pull the lock levers out and open the top cover. Remove the spark plug cap. Use the wrench supplied in the tool kit to remove the spark plug. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. 5. Measure the plug gap with a feeler gauge. The gap should be 0.9-1.0 mm (0.035-0.039 in).
Fuse replacement If the fuse is blown, the engine will not start until it is replaced. 1. Pull the lock levers out and open the top cover. 2. Turn the engine switch OFF. 3. Remove the fuse holder and replace the fuse. Use only a 10A fuse. 4. Close the top cover. CAUTION: If frequent fuse failure occurs, determine the cause and correct the problem before attempting to bperate the generator further. Never use a fuse with a rating other than 10A. Serious damage to the electrical system or a fire may result.
Spark arrester maintenance m If the generator has been running, Allow it to cool before proceeding. the muffler will be very hot. CAUTION: The spark arrester must be serviced every 100 hours to maintain its efficiency. 1. Loosen two 5 mm pan screws on the arrester cap. 2. Remove the arrester cap, then pull out spark arrester taking care not to damage the wire mesh. 3. Check the muffler exhaust port for carbon deposits; clean if necessary. 4. Install the spark arrester and arrester cap on the muffler. 5.
8. TRANSPORTING/STORAGE m 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. 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 fuel valve OFF, remove and empty the filter cup. b. Turn the fuel valve ON and drain the gasoline in the fuel tank into a suitable container. c.
d. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. -- P DRAIN 3. Once a month, recharge the battery.
9. TROUBLESHOOTING A. When the engine will not start: 1. Is there enough fuel? 2. Is the fuel valve on? 3. Is gasoline reaching the carburetor? To check, loosen the drain screw with the fuel valve on. bw If any fuel is spilled, make sure the area is dry before testing the spark plug or starting the engine. Fuel vapor or spilled fuel may ignite. DRAIN SCREW I 4. Is the reset button pushed in? 5. Are the circuit breakers off? 6. Is the engine switch on? 7. Is the fuse good? 8.
a. Remove the spark plug cap. Clean any dirt from around the spark plug base, then remove the spark plug. b. Install the spark plug in the plug cap. c. Turn the engine switch on. d. Grounding the side electrode to any engine ground, crank the engine to see if sparks jump across the gap. e. If there are no sparks, replace the plug. If OK, try to start the engine according to the instructions. 9. If the engine still does not start, take the generator to the dealer. B.
10. SPEClFlCATlONS Dimension Length x Width x Height 965x590x730mm (38.0 x 23.2 x 28.7 in) Dry weight 175 kg (385.9 lb) Engine Model Engine Type Displacement [Bore x Stroke] Compression Ratio Engine Speed Ignition System Oil Capacity Cooling System Capacity Fuel Tank Capacity Spark plug Honda GX360 4Stroke, O.H.C. 2 cylinder 359 cm3 (21 .Q cu in) (58 x 68 mm (2.3 x 2.7 in)1 8.5 :1 3,600 rpm C.D.I. 1.4 P (1.48 US qt) 2.0 P (2.11 us qt) 16.5 P (4.
c = -
12. INSTALLATION OF OPTIONAL PARTS Remote control kit The generator may be adapted for remote control operation by use of an optional kit. 1. Unscrew the two 6 x 10 mm flange bolts and 6 x 8 mm screws attaching the control panel. Remove the control panel. 6 x 10 mm FLANGE BOLTS 2. Position the relay box on the back of the control panel with the studs inserted through the holes in the relay box flange. Install a 4 mm nut and lock washer on each stud and tighten securely. 3.
5. Reinstall the control panel with the 6 x 10 mm flange bolts and 6 x 8 mm screws. 6. Connect the remote control 6-P male coupler to the 6-P coupler on the sub panel. 6-P FEMALE COUPLER RE CO CA 7. Connect the remote control 32 6-P male coupler to the switch box.
Remote control operation (STARTING) . i. Turn the fuel valve on. 2. Turn the auto-throttle switch off. 3. Turn the ignition switch key off or remove it from the generator. 41 Turn the relay switch on. 5. Flip the remote control engine switch knob up to ON.
6. Depress the starter button until the pilot lamp is on.
