Generator Safety

Safety Information

• Honda generators are designed to provide safe and dependable service if operated according to instructions
• Read and understand the owner's manual thoroughly before operating the generator.
• It is important to be familiar with the generator's controls and observe safe operating procedures to prevent accidents.
• Know how to quickly stop the generator in an emergency.
• Understand the function of all generator controls, output receptacles, and connections.
• Ensure anyone operating the generator receives proper instruction and children are supervised.

Carbon Monoxide Hazards

• Exhaust contains poisonous carbon monoxide, a colorless and odorless gas that can lead to loss of consciousness and death
• When using the generator in an enclosed or partially enclosed space, ensure adequate ventilation to prevent buildup of exhaust gas

Electrical Shock Hazards

• The generator produces enough electric power to cause serious shock or electrocution if misused
• Using the generator or electrical appliances in wet conditions or with wet hands can result in electrocution
• The generator should be kept dry.
• Before each use, check all electrical components on the control panel, especially if the generator is stored outdoors, unprotected from the weather.
• Do not connect the generator to a building's electrical system unless a qualified electrician has installed an isolation switch.

Fire and Burn Hazards

• The exhaust system becomes hot enough to ignite materials so keep the generator at least 1 meter (3 feet) away from buildings and other equipment and do not enclose it in any structure.
• Keep flammable materials away from the generator.
• Be careful not to touch the muffler while it is hot
• Let the engine cool before storing the generator indoors.
• Gasoline is extremely flammable and explosive under certain conditions.
• Do not smoke or allow flames or sparks when refueling or where gasoline is stored.
• Refuel in a well-ventilated area with the engine stopped.
• Ensure any spilled fuel is wiped up before starting the generator because fuel vapors are extremely flammable and may ignite.

Component Identification

• Record the engine and frame serial numbers for future reference when ordering parts or making technical or warranty inquiries.

Controls - Engine Switch

• To start and stop the engine use the engine switch:
  • OFF is to stop the engine.
  • ON is to run the engine.

Controls - Recoil Starter

• To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly.
• Do not allow the starter to snap back against the engine.
• Return it gently to prevent damage to the starter.

Controls - Choke Lever

• The choke is used to provide an enriched fuel mixture when starting a cold engine.
• Operate the choke lever manually to open and close it.
• Move the lever to the CLOSED position to enrich the mixture.

Controls - Pilot Lamp

• The pilot lamp illuminates when the generator is operating normally indicating it is producing electrical power.
• The frequency meter should be displaying 60Hz if the pilot light is illuminated.

Controls - Ground Terminal

• The generator ground terminal is connected to the frame, the metal non-current carrying parts, and the ground terminals of each receptacle.
• Consult a qualified electrician, electrical inspector, or local agency for applicable local codes or ordinances before using the ground terminal.

Controls - Oil Alert System

• The Oil Alert system prevents engine damage from insufficient oil in the crankcase.
• The Oil Alert system will automatically stop the engine before the oil level falls below a safe limit.
• The engine switch will remain in the ON position.
• Check the engine oil level before troubleshooting if the engine stops and will not restart.

Controls - AC Circuit Protector

• The AC circuit protector automatically shuts off the AC receptacle circuit when the generator is overloaded
• The AC circuit protector shuts off when there is a problem with the electrical load or the connections between the electrical load and the generator are improper.

DC Terminals

• The DC terminals may ONLY be used for charging 12 volt automotive type batteries.
• There are colored red to identify the positive (+) terminal and black to identify the negative (-) terminal.
• The battery must be connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal)

DC Circuit Protector

• The DC circuit protector automatically shuts off the DC battery charging circuit when the generator is overloaded or when there is a problem with the battery, or the connections between the battery and the generator are improper.

Generator Use - Electrical Connections

• Connections for standby power to a building's electrical system must be made by a qualified electrician.
• Connections must isolate the generator power from utility power and comply with all applicable laws and electrical codes.
• Improper connections to a building's electrical system can allow electrical current from the generator to backfeed into the utility lines which may electrocute workers who contact the lines during a power outage and the utility company/qualified electrician should be consulted.

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.
• If the generator is tested by a receptacle tester, it will not show the same ground circuit condition as for a home receptacle.

Generator Use - Special Requirements

• Federal or State OSHA regulations, local codes, or ordinances may apply to the intended use of the generator so a qualified electrician, electrical inspector, or the local agency having jurisdiction, should be consulted.
• Generators may be required to be registered with local utility companies in some areas.
• Additional regulations may be observed if the generator is used at a construction site.

AC Operation

• Start the engine and make sure the pilot lamp comes on. If not, the filament may be burnt out.
• Plug in the appliance.
• Overloading will switch off the circuit protector and substantial overloading may not switch off the circuit protector, but it will shorten the service life of the generator.
• Ensure 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 generator engine switch immediately. Then disconnect the appliance and examine it for signs of malfunction.
• Reduce the electrical load on the circuit and wait a few minutes before resuming operation if an overloaded circuit trips the AC circuit protector.
• The green indicator inside the circuit protector button will pop out to show that the circuit protector has switched off
• Push the button in to reset the circuit protector.

DC Operation - Battery Cables

• DC terminals may ONLY be used for charging 12 volt automotive-type batteries.
• Before connecting charging cables to a battery that is installed in a vehicle, disconnect the vehicle's ground cable from the battery.
• The battery gives off explosive gases so keep sparks, flames and cigarettes away.
• Adequate ventilation should be provided when charging or using batteries.
• Connect the positive (+) battery cable to the battery positive (+) terminal and connect the other end of the positive (+) battery cable to the generator positive (+) terminal.
• Connect the negative (-) battery cable to the battery negative (-) terminal and connect the other end of the negative (-) battery cable to the generator negative (-) terminal.
• Start the generator.
• Do not start the vehicle while the battery charging cables are connected and the generator is running because the vehicle or the generator may be damaged.
• If an overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit protector the DC circuit protector push button will extend out.
• In the event that this happens, wait a few minutes before pushing in the circuit protector to resume operation. Contact your authorized Honda generator dealer and discontinue charging if the circuit protector continues to go OFF.

DC Operation - Disconnecting Battery Cables

• Stop the engine.
• Disconnect the negative (-) battery cable from the generator negative (-) terminal and disconnect the other end of the negative (-) battery cable from the battery negative (-) terminal.
• Disconnect the positive (+) battery cable from the generator positive (+) terminal and disconnect the other end of the positive (+) battery cable to the battery positive (+) terminal.
• Connect the vehicle ground cable to the battery negative (-) terminal.

High Altitude Operation

• The standard carburetor air-fuel mixture will be excessively rich at high altitude, so performance will decrease, and fuel consumption will increase.
• High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw.
• Modification should be performed by an authorized Honda generator dealer if always operating the engine at altitudes higher than 6,000 feet above sea level.
• Engine horsepower will decrease approximately 3.5% for each 1,000 foot increase in altitude, even with suitable carburetor jetting.
• A lower altitude used generator jetted for high altitude will experience a reduction in performance and may overheat and seriously damage the engine because the lean air-fuel mixture will reduce performance.

Pre-Operation Check - Engine Oil

• Engine oil is a major factor affecting engine performance and service life.
• The use of non-detergent and 2-stroke engine oils will damage the engine and are not recommended.
• Check the oil level BEFORE EACH USE with the generator on a level surface with the engine stopped.
• 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 SG, SF/CC, CD. Motor oils classified SG, SF/CC, CD will show this designation on the container.
• SAE 10W-30 is recommended for general, all-temperature use however other viscosities are shown in the chart may be used when the average temperature in your area is within the indicated range.
• Remove the oil filler cap and wipe the dipstick clean then check the oil level by inserting the dipstick into the filler neck without screwing it in.
• Fill to the top of the oil filler neck with the recommended oil if the oil level is low.

Pre-Operation Check - Fuel Recommendation

• Check the fuel level gauge.
• Refill the tank if the fuel level is low, do not fill above the shoulder of the fuel strainer.
• Gasoline is extremely flammable and is explosive under certain conditions.
• Refuel in a well-ventilated area with the engine stopped and 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 which means there should be no fuel in the filler neck.
• After refueling, ensure the tank cap is closed properly and securely.
• Avoid repeated or prolonged contact with skin or breathing of vapor and keep out of reach of children.
• The fuel tank capacity is 2.8 l (0.74 US gal, 0.62 Imp gal).
• Use gasoline with a pump octane rating of 86 or higher.
• Using unleaded gasoline is recommended.
• It will produce fewer engine and spark plug deposits and extends exhaust system life.
• Never use stale or contaminated gasoline or oil/gasoline mixture, getting dirt or water in the fueltank should be avoided.
• Light "spark knock" or "pinging" (metallic rapping noise) may be heard while operating under heavy loads, this is no cause for concern.
• Change brands of gasoline if spark knock or pinging occurs at a steady engine speed, under normal load.
• See an authorized Honda generator dealer if spark knock or pinging persists.
• Running the engine with persistent spark knock or pinging can cause engine damage and is misuse, and the Distributor's Limited Warranty does not cover parts damaged by misuse.

Oxygenated Fuels

• Some gases are collectively referred to as oxygenated fuels.
• Some areas of the United States and Canada use oxygenated fuels to help reduce emissions to meet clean air standards.
• It is important to ensure that the oxygenated fuel is unleaded and meets the minimum octane rating requirement.
• Before using an oxygenated fuel, try to confirm what the fuel's contents are.
• Some states/provinces require this information to be posted on the pump.
• The EPA approved percentages of oxygenates are
  • ETHANOL - 10% by volume. Gasoline containing up to 10% ethanol by volume may be marketed under the name "Gasohol".
  • MTBE - 15% by Volume. You may use gasoline containing up to 15% MTBE by volume.
  • METHANOL - 5% by Volume. Gasoline containing up to 5% methanol by volume may be used as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system.
• A fuel may not contain more than 5% methanol, because doing so may cause starting and/ or performance problems and may also damage metal, rubber, and plastic parts of your fuel system.
• Try another service station or switch to another brand or gasoline if any undesirable operating symptoms are noticed.
• Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.

Starting the engine

• The generator may be hard to start if a load is connected.
• Move the choke lever to the CLOSE position.
• Move the engine switch to the ON position.
• Pull the starter grip until compression is felt, then pull briskly.
• Do not allow the starter grip to snap back and return it slowly by hand instead.
• Move the choke lever to the OPEN position as the engine warms up.

Stopping the engine

• In an emergency, move the engine switch to the OFF position.
• Turn off any AC electrical appliance and disconnect DC battery charging cables if in normal use.
• Move the engine switch to the OFF position.

Maintenance

• Periodic maintenance and adjustment is necessary to keep the generator in good operating condition.
• Perform the service and inspection at the intervals shown in the Maintenance Schedule.
• Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance & if the engine must be run, make sure the area is well ventilated.
• Use only genuine HONDA parts or their equivalent for maintenance or repair and replacement parts which are not of equivalent quality may damage the generator.

Maintenance Schedule

• 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.
• For professional commercial use, log hours of operation to determine proper maintenance intervals.

Maintenance - Engine Oil Change

• Drain the oil while the engine is warm to assure complete and rapid draining.
  1. Remove the oil filler cap.
  2. Turn the engine switch OFF and tilt the generator to drain the oil.
  3. Refill with the recommended oil (see page 20 and check the oil level). Oil capacity: 0.35 ℓ (0.37 US qt, 0.31 Imp qt)
• Dispose of used motor oil and the oil containers in a manner that is compatible with the environment
• Take it in a sealed container to your local service station or recycling center for reclamation; do not throw it in the trash or pour it on the ground.

Maintenance - Air Filter 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.
  1. Unsnap the air cleaner case spring, and remove the cleaner case and air cleaner element.
  2. Wash the element in a solution of household detergent and warm water, then rinse thoroughly, or wash in nonflammable or high flash point solvent.
  3. Allow the element to dry thoroughly.
  4. Soak the element in clean engine oil and squeeze out the excess oil.
• The engine will smoke during initial startup if too much oil is left in the element.
• Reinstall the air cleaner element and cleaner case.
• Gasoline or flammable solvent used to clean the filter element can cause a fire or explosion. Use only soapy water or nonflammable solvent.
• The generator should never be run without the air cleaner because rapid engine wear will result.

Maintenance - Spark Plug Service

• Recommended spark plugs:
  • BMR-4A (NGK)
  • W14MR-U (NIPPONDENSO)
• The spark plug must be properly gapped and free of deposits to ensure proper engine operation.
• The muffler will be very hot if the engine has been running be careful not to touch the muffler.

1. Remove the spark plug cap.
2. Clean any dirt from around the spark plug base.
3. Use the proper size plug wrench to remove the spark plug.

• Visually inspect the spark plug and discard it if the insulator is cracked or chipped, and if not clean the spark plug with a wire brush if it is to be reused.

4. Measure the plug gap with a feeler gauge.

• Correct as necessary by carefully bending the side electrode.
• The gap should be: 0.60.7 mm (0.0240.028 in)

5. Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading.
6. 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.
• If reinstalling a used spark plug, tighten 1/8-1/4 turn after the spark plug seats to compress the washer.
• The spark plug must be securely tightened and an improperly tightened spark plug can become very hot and could damage the engine. Never use spark plugs which have an improper heat range, and use only the recommended spark plugs or equivalent.

Maintenance - Spark Arrestor

• If the generator has been running, the muffler will be very hot. Allow to cool before proceeding.
• The spark arrester must be serviced every 100 hours to maintain its efficiency.
  1. Remove the fuel tank cap.
  2. Remove the four 5 mm pan-screws, and then remove the rear cover and retighten the fuel tank cap.
  3. Remove the two 6 mm bolts, and then remove the muffler protector.
• Remove the three 6 mm bolts that hold the muffler, then move the muffler to the right and up as far as possible & then carefully remove the spark arrester from the muffler.
• Check for carbon deposits around the exhaust port and the spark arrester.
• Use a brush to remove carbon deposits from the spark arrester screen.
• The spark arrester screen should be inspected for holes or tears and replaced if necessary.
• The spark arrester must be free of breaks and holes and if so, replace if necessary.
• Install the spark arrester and the muffler in a reverse order.
• Check the exhaust pipe gasket and replace if damaged.
• Reinstall the muffler and the protector.

Transporting/Storage

• Turn engine switch and the fuel valve OFF when transporting the generator.
• Keep the generator level to prevent fuel spillage, as fuel vapor or spilled fuel may ignite.
• Contact with a hot engine or exhaust system can cause serious burns or fires, so let the engine cool before transporting or storing the generator.
• It is important to take care not to drop or strike the generator when transporting
• Do not place heavy objects on the generator.
• Be sure the storage area is free of excessive humidity and dust, when preparing the unit for an extended period.

Recommended Storage Service Procedure

• Use gasoline conditioners that are formulated to extend storage life.
• Contact your authorized Honda generator dealer for conditioner recommendations.
• Drain the carburetor by loosening the drain screw and drain the gasoline into a suitable container.
• Gasoline is extremely flammable and is explosive under certain conditions, so it is important to perform this task in a well ventilated area with the engine stopped and do not smoke or allow flames or sparks in the area during this procedure.
• With the engine switch ON, remove the fuel filler cap.
• Loosen the drain screw and drain the fuel into a suitable container and then retighten the screw.
• Move the engine switch to OFF.
• In addition to the steps above, pouring about a tablespoon of clean engine oil is recommended. - Crank the engines several revolutions to distribute the oil, then reinstall the spark plug. Slowing pull the starter grip until resistance is felt and storing the engine in this position has the advantage of helping to protecting the engine from internal corrosion. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed.

Troubleshooting

• Fuel tank, engine switch, engine oil and spark plug issues are checked and resolved as part of the troubleshooting diagnostic flow.

Wiring Diagram

• A wiring diagram for the unit is provided for service and repair purposes.

Specifications

• A specifications reference table is provided for the unit for dimensions, engine and generator statistics