Yamaha EM1600 Owner`s manual

Owner's Manual
GENERATOR
EM1600X • EM1800X • EM2200X
©1983 Honda Motor Co., Ltd. — All Rights Reserved
Thank you for purchasing a Honda generator.
This manual covers
2200X generators.
product information
Honda Motor Co.,
notice and without
operation and maintenance of the EM1600X, 1800X and
All information
in this publication is based on the latest
available at the time of approval for printing.
Ltd reserves the right to make changes at any time without
incurring any obligation.
No part of this publication
may be reproduced without
This manual should be considered a permanent
should remain with the generator when it is sold.
Pay special attention
NOTE:
Indicates a possibility
are not followed.
permission.
part of the generator and
to statements preceded by the following
m
Indicates a strong possibility
life if instructions are not followed.
CAUTION:
instructions
written
words:
of severe personal injury or loss of
of personal injury or equipment damage if
Gives helpful information.
If a problem should arise, or if you have any questions about the generator,
consult an authorized Honda dealer.
B
Honda generators are 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.
1
CONTENTS
CONTENTS
1. GENERATOR SAFETY ....................
L ..............
2. COMPONENT IDENTIFICATION
............................
3. PRE-OPERATION CHECK .................................
4. STARTING THE ENGINE ..................................
l
High altitude operatioty ..................................
5. GENERATOR USE .......................................
6. STOPPING THE ENGINE ..................................
MAINTENANCE
.........................................
i: TRANSPORTING/STORAGE
...............................
9. TROUBLESHOOTING
....................................
10. WIRING DIAGRAM
......................................
ll.SPEClFlCATlONS
........................................
12. WARRANTY SERVICE ....................................
2
3
4
6
8
10
11
14
15
24
25
27
29
30
1. GENERATOR
SAFETY
To ensure safe operation l
l
l
l
l
l
l
l
Place the generator at least 1 m (3 ft) away from buildings or other equipment during operation.
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. Never permit anyone to operate the generator without proper
instructions.
Keep children and pets away from the generator when it is in operation.
Keep away from rotating parts while the generator is running.
The generator is a potential source of electrical shocks when misused; do
not operate with wet hands.
Do not operate the generator in rain or snow and do not let it get wet.
When charging a battery l
l
Battery electrolyte contains sulphuric acid. Protect your eyes, skin and
clothing. In case of contact, flush thoroughly with water and get prompt
medical attention, especially if your eyes are affected.
Batteries generate hydrogen gas which can be highly explosive. Do not
smoke or allow flames or sparks near a battery, especially during charging.
3
2. COMPONENT
IDENTIFICATION
FUEL GAUGE
(Except EM1600XI
AIR
CLEANER
VOLTAGE
METER
(Except EM1600X)
ENGINE
SWITCH
PILOT LAMP
(Except EM1600X)
\-
\
\
GRIP
BREAKER
OIL ALERT
LAMP
\
/
/
DC CIA/CUIT
BREAKER
DC TERMINALS
v
KNOB
\
OIL ~LLER
AGE ADJUSTMENT
(Except EM1600XI
CAP
FUEL
CAP
FUEL
TANK
TANK
\
-SPARK
PLUG
I
EXHAUST
OUTLET
MUFFLER
5
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 US. automobile manufacturers’
requirements for Service Classification SE or SF. (Motor oils classified SE
or SF will show this designation on the container.)
SAE low-40
is recommended for general, all-temperature
use. Other
viscosities 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 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 below the end of the dipstick, add oil to the upper level
mark on the dipstick.
NOTE: The Oil Alert System will automatically stop the engine before
the oil level falls below the safe limit. However, to avoid the inconvenience
of an unexpected shutdown, it is still advisable to visually inspect the oil
level regularly.
UPPER
\
LEVEL
LOWER
6
LEVEL
2. Check the fuel level
Check the fuel gauge (EM1800X and EM2200X only), and refill the tank
if the fuel level is low.
Use low lead or unleaded automotive gasoline 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.
Clean the fuel filler screen regularly.
CAUTION: .Gasoline substitutes are not
harmful to fuel system components.
recommended;
they
may be
Gasoline is extremely flammable and explosive under certain conditions.
Refuel in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the area where the generator
is refueled or where gasoline is stored.
Do not overfill the tank and make sure the fuel tank cap is securely
closed after refueling.
Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel
may ignite. If any fuel is spilled, make sure the area is dry before starting
the engine.
FUEL GAUGE
(EMlEOOX and EM2200X
\
only)
FUEL
TANK
CAP
FUEL FILLER
SCREEN
7
4. STARTING
THE ENGINE
(1) Disconnect any load from the DC
terminals and make sure that the AC
circuit breaker is in the OFF position.
AC CIRCUIT
BREAKER
DC TERMINALS
(2) Turn on the fuel valve.
(3) Turn on the engine switch.
ON
8
(4) Move the choke lever to the CLOSED
position.
(5) Pull the starter rope lightly until
resistance is felt, then pull briskly.
CAUTION: Do not allow the starter
grip to snap back. Return it slowly
hand.
by
NOTE: Make sure the pilot lamp comes
on. If not, check the bulb filament.
(6) Move the choke lever to the OPEN
position as the engine warms up.
9-
Oil Alert System
Before the oil level in the crankcase can fall below a safe limit, the Oil Alert
System will automatically shut off the engine. The Oil Alert Lamp will light
when the recoil starter grip is pulled.
To restart, add enough recommended engine oil to bring the oil level to the
upper level mark on the dipstick (See page 6), and restart the engine.
ENGINE
SWITCH
OIL ALERT
LAMPE
NOTE: The engine switch will remain in the ON position
stopped by the Oil Alert System.
if the engine is
High altitude operation
At high Altitude, the standard carburetor air-fuel mixture will be excessively
rich. 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. If you always
operate the generator at altitudes higher than 6,000 feet above sea level,
have your authorized Honda Generator dealer perform these carburetor
modifications.
Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 1,000 foot increase in altitude. The affect of
altitude on horsepower will be greater than this if no carburetor modification is
made.
CAUTION: Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and
serious engine damage caused by an excessively lean air/fuel mixture.
5. GENERATOR
USE
m
To prevent electrical shock from faulty appliances, the generator
should be grounded. Connect a length of heavy wire between the generator’s
ground terminal and an external ground source.
GROUND
TERMINAL
CAUTION:
l
Limit operation requiring maximum poyver (1.6 KVA for the EM1600X;
1.8 KVA for the EM1800X and 2.2 KVA for the EM2200X) to 30 minutes.
For continuous operation, do not exceed the rated power (1.4 KVA for the
EM1600X; 1.5 KVA for the EM1800X and 2.0 KVA for EM2200X).
l
Do not exceed the current limit specified for any one receptacle.
l Do not connect the generator to a household circuit.
This could cause
damage to the generator or to electrical appliances in the house.
NOTE: The EM1600X, 1800X and 2200X generate both AC and DC power.
If you use both at the same time, be sure not to exceed the total rated power
(1.4 KVA for the EM1600X; 1.5 KVA for the EMl800X and 2.0 KVA for the
EM2200X) for AC and DC combined.
Most appliance motors require more than their rated wattage for start-up.
AC applications
1. Start the engine and make sure the pilot lamp comes on. If not, check the
filament.
2. Switch on the AC Circuit Breaker.
NOTE: Although voltage adjustment is usually not required, fine adjustments may be made by turning the voltage adjustment knob. Use the
generator at the specified voltage (12OV).
3. Plug in the appliance; always three-pronged plugs,
CAUTION:
Be sure that appliances do not exceed the generator’s rated
load capacity for more than 30 minutes and that they never exceed the
maximum load capacity. Substantial overloading will switch off the circuit
breaker. Marginal overloading may not switch off the circuit breaker, but
it will shorten the service life of the generator.
Be sure that 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 circuit breaker and the
generator engine switch immediately. Then disconnect the appliance and
examine it for signs of malfunction.
NOTE: If an overloaded circuit causes the AC circuit breaker to switch
off, reduce the electrical load on the circuit and wait a few minutes before
resetting the circuit breaker.
VOLT
-+f
’
METER
!I
AC CIRCUIT
BREAKER
I
~V~L~GE
ADJUSTMENT
12
, PILOT
KNOB\
)
LAMP
DC application
The DC terminals may be used for charging 12 volt automotive-type
only.
batteries
m
Batteries produce explosive gases. Keep sparks, flames, and
cigarettes away. To prevent the possibility
of creating a spark near the
battery, connect charging cables first to the battery, then to the generator,
and disconnect cables at the generator first.
CAUTION:
l
Do not attempt to start an automobile engine while the generator is still
connected to the battery. The generator may be damaged.
l
Connect the positive battery terminal to the positive generator terminal. Do
not reverse the charging cables, or serious damage to the generator and/or
battery may occur.
NOTE:
The DC terminals may be used while the AC power is in use.
l
An overloaded DC circuit will trip the DC circuit protector (push button
comes out). If this happens, wait a few minutes before pushing in the
circuit protector to resume operation.
l
DC CIRCUIT
BREAKER
POSITIVE
TERMINAL
(RED)
(BLACK)
13
6. STOPPING
THE ENGINE
(1) Turn
off the AC circuit breaker and
disconnect any charging leads at the
DC terminals.
(21 Turn the engine switch to the OFF
position.
(3) Turn the fuel
position.
14
valve to the
OFF
-
7.
MAINTENANCE
The purpose of the maintenance and adjustment schedule is to keep the
generator in the best operating condition.
Inspect or service as scheduled in the table on the next page.
B
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:
placement
generator.
Use genuine HONDA parts or their equivalent. The use of reparts which are not of equivalent quality may damage the
Tool kit
The tools supplied are necessary for performing
simple adjustments and repairs.
Always keep the tool kit with the generator.
some periodic maintenance,
15
Maintenance Schedule
Air cleaner
(Replace
NOTE
if necessary)
(1) : 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.
Changing oil
Drain the oil while
draining.
the engine is still warm to assure rapid and complete
1. Remove the drain plug and filler cap, and drain the oil. Retighten the plug
securely.
2. Refill with the recommended oil (see page 6) and check the level.
01 L CAPACITY:
0.6 II (0.63 USqt)
OIL FILLER
OIL DRAIN
PLUG
Used motor oil may cause skin cancer if repeatedly left in contact
with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly
wash your hands
with soap and water as soon as possible after handling used oil.
CAUTION:
NOTE: Please dispose of used motor oil in a manner that is compatible with
the environment. We suggest you take it in a sealed container to your local
service station for reclamantion. Do not throw it in the trash or pour it on the
ground.
17
Air cleaner service
A dirty air cleaner will restrict air flow to the carburetor, To prevent carburetor malfunction, service the air cleaner regularly (page 16)). Service more
frequently when operating the generator in extremely dusty areas.
m
Never use gasoline or low flash point solvents for cleaning the air
cleaner element. A fire or explosion could result.
CAUTION:
Never run the genetrator
wear will result.
without
the air cleaner. Rapid engine
1. Unsnap the air cleaner cover springs, remove the air cleaner cover and
remove the element.
2. Wash the element in a non-flammable or high flash point solvent and dry
it thoroughly.
3. Soak the element in clean engine oil and squeeze out the excess oil.
4. Reinstall
COVER
SPRINGS
18
the air cleaner
element
and the cover.
ELEMENT
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 fuel valve OFF. Remove the filter cup.
2. Clean the cup thoroughly.
3. Reassemble. Do not damage the rubber gasket.
bw
After installing the filter cup, check for fuel leaks and make sure
the area is dry before starting the engine.
RUBBER
GASKET
FILTER
CUP
19
Spark plug service
Recommended spark plug:
BPGES, BPRGES (NGK)
W20EP-U, W20EPR-U (ND)
To ensure proper engine operation,
and free of deposits.
the spark plug must be properly
gapped
1. Remove the spark plug cap.
2. Clean any dirt from around the spark plug base.
3. Use the wrench supplied in the tool kit to remove the spark plug.
PLUG
WRENCH
SPARK
PLUG CAP
4. Visually inspect the spark plug. Discard it if the insulator is cracked or
chipped. Clean the spark plug with a wire brush if it is to be reused.
5. Measure the plug gap with a feeler gauge.
The gap should be 0.7-0.8
mm (0.028~0.031
in). Correct as
necessary by carefully bending the side electrode.
0.7-m
mm
(0.028~0.031
20
in)
6. Attach the plug washer and thread the plug in by hand to prevent cross
threading.
7. After a new spark plug has been seated by hand, it should be tightened l/2
turn with a wrench to compress its washer.
If a used plug is being reinstalled, it should only require l/8 to l/4 turn
after being seated,
CAUTION:
The spark plug must be securely tightened. An improperly
can become very hot and possibly damage the generator.
l
Never use a spark plug with an improper heat range.
l
tightened
plug
21
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 the five 6 mm bolts to remove the muffler protedtor.
PROTECTOR
bolts
2. Remove the two 8 mm bolts at the exhaust pipe and the 8 mm bolt at the
muffler stay.
Remove the muffler and the spark arrester.
Two 8 mm bolts
MUFFLER
22
.
3. Use a brush to remove carbon deposits from the spark arrester screen.
NOTE: Inspect
necessary.
the spark arrester screen for holes or tears.
Replace if
4. Check the exhaust pipe gasket and replace if damaged. Reinstall
muffler and the protector.
the
23
8. TRANSPORTING/STORAGE
B
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. Replace the filter cup and tighten securely.
d. Loosen the carburetor drain screw and drain the gasoline from the
carburetor into a suitable container.
3. Slowly pull the starter grip until resistance is felt. At this point, the piston
is coming up on its compression stroke and both the intake and exhaust
‘valves are closed. Storing the engine in this position will help to protect it
from internal corrosion.
24
9. TROUBLESHOOTING
When the engine will
not start:
Refill the fuel
tank.
Is there fuel in the
tank?
YES
in the engine?
YES
NO
Turn the engine
switch on.
NO
Turn the fuel
valve on.
Replace the
spark plug
R!!!re
is no spilled fuel around the
spark plug. Spilled fuel
may ignite.
YES
Add the recommended oil.
NO
(The oil alert lamp goes on when
pulling the starter grip)
Take the generator
to an authorized
HONDA dealer.
Still Nospark
l) Remove the spark plug cap and
and clean any dirt from around
the spark plug.
2) Remove the spark plug and install the spark plug in the plug
cap.
3) Set the plug side electrode on
the cylinder head:
4) Pull the recoil starter, sparks
should jump across the gap.
-
I
NO
the carburetor?
YES
To check
1) Turn off the fuel valve and
remove the drain screw.
2) Fuel should flow from the
drain when the fuel valve is
turned on.
.
25
No electricity
at the AC receptacles:
NO
Turn the AC circuit
breaker on.
YES
Check the electrical
appliance or equipment for any defects
NO DEFECTS
+
DEFECTS
)
No electricity
Turn the DC circuit
breaker on.
on?
YES
)
26
- Replace the electrical appliance or
equipment.
* Take the electrical
appliance or equipment to an electrical shop for
repair.
at the DC terminals:
NO
breaker
Take the generator
to an authorized
Honda dealer.
Take the generator
to an authorized
Honda dealer.
‘R I
I
I
1
I
WIR
B
”
Lb
b
I
Lb
“r
I LIGHT
_I
BLUE
X
V
A
rs
G
8
.
11. SPECIFICATIONS
Dimensions
Length x Width x Height
505 x 420 x 420 mm
(19.9 x 16.5 x 16.5 in)
Dry Weight
EM 1600X, 1800X: 41.5 kg (91.5 lb)
: 44.0 kg (97.0 lb)
EM2200X
Enoine
Model
Engine Type
Displacement
[Bore x Stroke]
Compression Ratio
Engine Speed
Cooling System
Ignition System
Oil Capacity
Fuel Tank Capacity
Spark Plug
HONDA GX140
4-Stroke, O.H.V, 1 cylinder
(25” tilted)
144 cm3 (8.8 cuin)
64 x 45 cm (2.5 x 1.8 in)
8.75 : 1
3600 rpm
Forced air cooled
Transistor Magnet Ignition
0.611(0.63 USqtI
11 .OQ(2.9 USgal)
BPGES, BPRGES (NGK),
W20EP-U, W20EPR-U (ND)
Generator
Rated voltage
Rated frequency
Rated ampere
AC output
Rated output
Maximum output
DC output
120v
60Hz
EM1600X:
EM1800X:
EM2200X:
EM1600X:
EM1800X:
EM2200X:
11.7 A
12.5 A
16.7 A
1.4 kVA (14OOW)
1.5 kVA (15OOW)
2.0 kVA (2OOOW)
EM1600X:
EM1800X:
EM2200X:
1.6 kVA (16OOW)
1.8 kVA (18OOW)
2.2 kVA (22OOW)
Only for charging 12 V automotive
batteries.
Maximum charging output = 8.3 A
29
12. WARRANTY
Owner
SERVICE
Satisfaction
Your satisfaction
and goodwill are important ‘to your dealer and to us. All
Honda warranty details are explained in the Distributor’s
Limited Warranty.
Normally, any problems concerning the product will be handled by your
dealer’s service department.
If you have a warranty problem that has not
been handled to your satisfaction,
we suggest you take the following
action:
l
l
Discuss your problem with a member of dealership management. Often
complaints
can be quickly resolved at that level. If th‘e problem has
already been reviewed with the Service Manager, contact the owner of
the dealership or the General Manager.
If your problem still has not been resolved to your satisfaction,
contact
the Customer Relations Department of American Honda Motor Co., Inc.
American Honda Motor Co., Inc.
Honda Power Equipment Division
Customer Service Office
4900 Marconi Drive
Alpharetta, GA 30005-2600
TeleDhone: (770) 497-6400
- Your name, address, and telephone
- Product model and serial number
-
number
Date of purchase
Dealer name and address
- Nature of the problem
After reviewing
all the facts involved,
you will be advised of what action
can be taken. Please bear in mind that your
at the dealership,
using the dealer’s facilities,
problem
will likely be resolved
equipment,
and personnel,
so
it is very important
be with the dealer.
that your initial contact
Your purchase of a Honda product is greatly appreciated by both your
dealer and American Honda Motor Co., inc. We want to assist you in every
way possible to assure your complete satisfaction
with your purchase.
30
MEMO
31
32
POM53284
P/N 31ZB1010
00X31-ZB1-0100
KINKOS
Printed on
Recycled Paper
75.2002.08
PRINTED IN U.S.A.