generator eg3600cx·eg4500cx eg5500cx·eg5500cxs

generator eg3600cx·eg4500cx eg5500cx·eg5500cxs

DIC197 Black

00X32-Z30-6000_EG4000CX_H1-4

GENERATOR

EG3600CX

·

EG4500CX

EG5500CX

·

EG5500CXS

32Z30600

00X32-Z30-6000

CX

CXS o

Honda Motor Co., Ltd. 2010

11000.2005.09

Printed in China

OWNER'S MANUAL

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Honda

EG3600CX·EG4500CX

EG5500CX·EG5500CXS

OWNER’S MANUAL

The‘‘e-SPEC’’mark symbolizes environmentally responsible technologies applied to Honda power equipment, which contains our wish to ‘‘preserve nature for generations to come.’’

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Thank you for purchasing a Honda generator.

This manual covers operation and maintenance of the EG3600CX·

EG4500CX·EG5500CX·EG5500CXS generators.

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 written permission.

This manual should be considered a permanent part of the generator and should remain with it if it is resold.

Pay special attention to statements preceded by the following words:

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

Gives helpful information.

If a problem should arise, or if you have any questions about the generator, consult an authorized Honda dealer.

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.

The illustrations herein are mainly based on: RGH type

The illustration may vary according to the type.

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CONTENTS

1. SAFETY INSTRUCTIONS ...................................................................

. 3

2. SAFETY LABEL LOCATIONS .............................................................

. 7

3. COMPONENT IDENTIFICATION .....................................................

. 10

4. PRE-OPERATION CHECK

5. STARTING THE ENGINE

................................................................

. 13

.................................................................

. 20

High altitude operation

6. GENERATOR USE ............................................................................

. 29

7. STOPPING THE ENGINE .................................................................

. 36

8. MAINTENANCE ................................................................................

. 38

9. TRANSPORTING/STORAGE ...........................................................

. 47

10. TROUBLESHOOTING

11. SPECIFICATIONS

......................................................................

.............................................................................

. 51

. 54

12. INSTALLATION OF KIT PARTS .......................................................

. 56

13. WIRING DIAGRAM ..........................................................................

MAJOR Honda DISTRIBUTOR ADDRESSES ..............

. 59

. inside back cover

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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. The most common hazards are discussed below, along with the best way to protect yourself and others.

Never attempt to modify the generator. It can cause an accident as well as damage to the generator and appliances.

Do not connect an extension to the muffler.

Do not modify the intake system.

Do not adjust the governor.

Do not remove the control panel or do not change the wiring of the control panel.

Operator Responsibility

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles, and connections.

Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the generator without parental supervision.

Be sure to observe the instructions in this manual for how to use the generator and maintenance information. Ignoring or improperly following the instructions can cause an accident such as an electric shock, and the condition of the exhaust gas may deteriorate.

Place the generator on a firm level place before operation.

Do not operate the generator with any cover removed. You may get your hand or foot caught in the generator and it may cause accident.

Consult your authorized Honda dealer for disassembly and service of the generator that are not covered in this manual.

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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.

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.

Keep the generator dry.

If the generator is stored outdoors, unprotected from the weather, check all of the electrical components on the control panel before each use. Moisture or ice can cause a malfunction or short circuit in electrical components that could result in electrocution.

If you get an electric shock, consult a doctor and have medical treatment immediately.

Do not connect to a building’s electrical system unless an isolation switch has been installed by a qualified electrician.

(RGH type):

4

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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.

− Keep the generator at least 1 meter away from buildings and other equipment during operation.

Do not enclose the generator in any structure.

− Keep flammable materials away from the generator.

Some parts of the internal combustion engine are hot and may cause burns. Pay attention to the warnings on the generator.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors.

Do not pour the water directly on the generator to put out the fire when it occurs. Use an appropriate fire extinguisher specially designed for electric fire or oil fire.

If you inhale fumes produced by an accidental fire with the generator, consult a doctor and have medical treatment immediately.

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.

Allow the engine to cool if the generator has been in operation.

Refuel only outdoors in a well ventilated area with the engine off.

Do not overfill the fuel tank.

Never smoke near gasoline, and keep other flames and sparks away.

Always store gasoline in an approved container.

Make sure that any spilled fuel has been wiped up before starting the engine.

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Disposal

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.

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 reclamation. Do not throw it in the trash or pour it on the ground.

An improperly disposed battery can hurt the environment. Always confirm local regulations for battery disposal. Contact your Honda servicing dealer for a replacement.

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2.

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.

RGH type:

READ OWNER’S MANUAL

EXHAUST CAUTION

CONNECT CAUTION

UH type:

RGH type:

HOT CAUTION

UH type:

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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. Breathing carbon monoxide 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.

Do not connect to a building’s electrical system unless an isolation switch has been installed 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. Improper connections can allow electrical current from the generator to backfeed into the utility lines.

Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and when utility power is restored, the generator may explode, burn, or cause fires in the building’s electrical system.

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A hot exhaust system can cause serious burns.

Avoid contact if the engine has been running.

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3.

COMPONENT IDENTIFICATION

CX type

FUEL GAUGE

CONTROL PANEL

CHOKE KNOB

FUEL VALVE LEVER

OIL FILLER CAP

SEDIMENT CUP AIR CLEANER

ENGINE SERIAL NUMBER

FUEL TANK CAP

STARTER GRIP

OIL DRAIN BOLT

SPARK PLUG

FRAME SERIAL NUMBER

MUFFLER

Record the frame serial number and the engine serial number in the spaces below. You will need these serial numbers when ordering parts.

Frame serial number:

Engine serial number:

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CXS type

CONTROL PANEL

CHOKE KNOB

FUEL VALVE LEVER

FUEL GAUGE

FUSE

SEDIMENT CUP AIR CLEANER

ENGINE SERIAL NUMBER

OIL FILLER CAP

STARTER GRIP

OIL DRAIN BOLT

FUEL TANK CAP

BATTERY TRAY

SPARK PLUG

FRAME SERIAL NUMBER

MUFFLER

Record the frame serial number and the engine serial number in the spaces below. You will need these serial numbers when ordering parts.

Frame serial number:

Engine serial number:

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CONTROL PANEL

EG3600CX, EG4500CX, EG5500CX: UH types

ENGINE SWITCH

240V RECEPTACLES

DC CIRCUIT PROTECTOR

DC TERMINALS

AC CIRCUIT BREAKER

EG4500CX: RGH type

ENGINE SWITCH

GROUND TERMINAL

EG5500CXS:

RGH, UH types

230V RECEPTACLES

DC CIRCUIT

PROTECTOR

ENGINE

SWITCH

VOLT METER

AC CIRCUIT BREAKER

DC TERMINALS

GROUND TERMINAL

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4.

PRE-OPERATION CHECK

Be sure to check the generator on a level surface with the engine stopped.

1.

Check the engine oil level before each use.

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). Always check the API service label on the oil container to be sure it includes the letters SE or later (or equivalent).

AMBIENT TEMPERATURE

SAE 10W-30 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.

13

10/07/22 15:03:02 32Z30R00_016 a.

Remove the oil filler cap and wipe the dipstick clean.

b.

Check the oil level by inserting the dipstick in the filler hole c.

without screwing it in.

If the oil level is low, fill to the upper limit of the oil filler neck with the recommended oil.

Running the engine with insufficient oil can cause serious engine damage.

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.

OIL FILLER CAP

UPPER LIMIT

DIPSTICK

OIL FILLER HOLE

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2.

Check the fuel level.

Check the fuel gauge. If the fuel level is low, refuel the fuel tank until the level as specified.

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.

Avoid getting dirt or water in the fuel tank.

Gasoline is extremely flammable and is 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 engine is refueled or where gasoline is stored.

Do not overfill the fuel tank (there should be no fuel above the upper level mark (red) on the fuel strainer). After refueling, make sure the fuel tank cap is closed properly and securely.

Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

Avoid repeated or prolonged contact with skin or breathing of vapor.

KEEP OUT OF REACH OF CHILDREN.

FUEL GAUGE FUEL TANK CAP UPPER LEVEL MARK (RED)

FULL EMPTY

FUEL

STRAINER

UPPER

LEVEL

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Gasoline spoils very quickly depending on factors such as light exposure, temperature and time.

In worst cases, gasoline can be contaminated within 30 days.

Using contaminated gasoline can seriously damage the engine

(caburetor clogged, valve stuck).

Such damage due to spoiled fuel is disallowed from coverage by the warrantry.

To avoid this please strictly follow these recommendations:

Only use specified gasoline (see page 15 ).

Use fresh and clean gasoline.

To slow deterioration, keep gasoline in a certified fuel container.

If long storage (more than 30 days) is foreseen, drain fuel tank and carburetor (see page 49 ).

Gasolines 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.

Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has cosolvents and corrosion inhibitors.

Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty.

Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete.

Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol, if it does, confirm the type and percentage of alcohol used.

If you notice any undesirable operating symptoms while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

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3.

Check the air cleaner.

Check the air cleaner element to be sure it is clean and in good condition.

Unsnap the two air cleaner cover clips, remove the air cleaner cover, and remove the air cleaner element.

Clean or replace the air cleaner element if necessary (see page 41 ).

Never run the engine without the air cleaner element. Rapid engine wear will result from contaminants, such as dust and dirt, being drawn through the carburetor, into the engine.

AIR CLEANER ELEMENT

AIR CLEANER COVER

CLIP

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4.

Check the battery fluid (CXS type).

Your generator’s engine charging system charges the battery while the engine is running. However, if the generator is only used periodically, the battery must be charged monthly to maintain the battery service life.

The battery contains sulfuric acid (battery fluid), which is highly corrosive and poisonous. Getting battery fluid in your eyes or on your skin can cause serious burns.

Wear protective clothing and eye protection when working near the battery.

KEEP CHILDREN AWAY FROM THE BATTERY.

Emergency Procedures

Eyes

− Flush with water from a cup or other container for at least fifteen minutes. (Water under pressure can damage the eye.) Call a physician immediately.

Skin

− Remove contaminated clothing. Flush the skin with large quantities of water. Call a physician immediately.

Swallowing

− Drink water or milk. Call a physician immediately.

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The battery fluid level must be kept between the UPPER and LOWER level marks. If the battery fluid level is below the LOWER level, sulfation and battery plate damage will occur.

If rapid loss of battery fluid is experienced, or if your battery seems to be weak causing slow operation of the starter motor, see your authorized Honda generator dealer.

1.

Locate the battery. Check the battery fluid level with the generator on a level surface. Remove the battery cell caps.

2.

Inspect the battery fluid level of each cell.

The battery fluid level must be kept between the UPPER and LOWER

3.

level marks, and battery fluid should cover all the plates.

If any plates are not covered, remove the battery and add distilled water as necessary.

For battery installation, refer to the Battery Tray Kit (see page 56 ).

BATTERY BATTERY CELL CAPS

UPPER LEVEL

LOWER LEVEL

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5.

STARTING THE ENGINE

Make sure that the AC circuit breaker is in the OFF position. The generator may be hard to start if a load is connected.

O F F

O F F

AC CIRCUIT BREAKER

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Electric starting (CXS type)

When starting the generator after adding fuel for the first time, after long-term storage, or after running out of fuel, turn the fuel valve lever to the ON position, then wait for 10 to 20 seconds before starting the engine.

1.

Turn the fuel valve lever to the ON position.

ON

O N

FUEL VALVE LEVER

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2.

Pull the choke knob to the CLOSED position to start a cold engine.

Push the choke knob to the OPEN position as the engine warms up.

CHOKE KNOB

C L O S E D

O P E N

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3.

Turn the engine switch to the START position and hold it there for 5 seconds or until the engine starts.

After the engine starts, let the engine switch return to the ON position.

O N

ON

START

START

ENGINE SWITCH

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.

When the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged.

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Manual starting

When starting the generator after adding fuel for the first time, after long-term storage, or after running out of fuel, turn the fuel valve lever to the ON position, then wait for 10 to 20 seconds before starting the engine.

1.

Turn the fuel valve lever to the ON position.

ON

O N

FUEL VALVE LEVER

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2.

Pull the choke knob to the CLOSED position to start a cold engine.

Push the choke knob to the OPEN position as the engine warms up.

CHOKE KNOB

C L O S E D

O P E N

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3.

Turn the engine switch to the ON position.

(CX type)

ON

ON

(CXS type)

ON

ENGINE SWITCH

O N

ENGINE SWITCH

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4.

Pull the starter grip lightly until you feel resistance, then pull the starter grip briskly toward in the direction of the arrow as shown below.

The starter grip can be drawn back very quickly before you release it. This may pull your hand forcefully toward the engine and cause an injury.

Do not allow the starter grip to snap back. Return it slowly by hand.

Do not let the starter rope rub against the generator body, or the rope will wear out prematurely.

D i r e c t i o n t o p u l l

STARTER GRIP

5.

Push the choke knob to the OPEN position as the engine warms up.

CHOKE KNOB

O P E N

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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 specific modifications to the carburetor. If you always operate the generator at altitudes higher than 1,500 meters 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 increase in altitude. The affect of altitude on the horsepower will be greater than this if no carburetor modification is made.

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.

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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 installed 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. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage, and when utility power is restored, the generator may explode, burn, or cause fires in the building’s electrical system.

(RGH type):

GROUND TERMINAL

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Do not exceed the current limit specified for any one receptacle.

Do not connect the generator to a household circuit. This could cause the damage to the generator or to electrical appliances in the house.

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 an extension to the exhaust pipe.

When an extension cable is required, be sure to use a tough rubber sheathed flexible cable (IEC 245 or equivalent).

Limit length of extension cables; 60 m for cables of 1.5 mm and 100 m for cables of 2.5 mm . Long extension cables will lower usable power due to resistance in the extension cable.

Keep the generator away from other electric cables or wires such as commercial power supply lines.

30

Make sure the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

Limit operation requiring maximum power to 30 minutes.

Maximum power is:

EG3600CX:

EG4500CX:

EG5500CX:

EG5500CXS:

3.6 kVA

4.5 kW

4.5 kVA

5.5 kVA

5.5 kW

(UH type)

(RGH type)

(UH type)

(UH type)

(RGH type)

5.5 kVA (UH type)

For continuous operation, do not exceed the rated power.

Rated power is:

EG3600CX:

EG4500CX:

EG5500CX:

EG5500CXS:

3.2 kVA

4.0 kW

4.0 kVA

5.0 kVA

5.0 kW

5.0 kVA

(UH type)

(RGH type)

(UH type)

(UH type)

(RGH type)

(UH type)

For the RGH type, it is when the power factor is 1.0.

In either case, the total power requirements (VA) of all appliances connected must be considered.

Most appliance motors require more than their rated wattage for startup.

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AC Applications

Substantial overloading will switch off the AC circuit breaker.

Marginal overloading may not switch off the AC 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. Electrical equipment (including lines and plug connections) should not be defective. 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.

1.

Start the engine (see page 20 ).

2.

Switch the AC circuit breaker ON.

3.

Confirm that the appliance to be used is switched off, and plug in the appliance.

RGH type: UH type:

AC CIRCUIT BREAKER AC CIRCUIT BREAKER

ON

ON

ON

PLUG PLUG

Most motorized appliances require more than their rated power for startup.

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DC application

The DC receptacle may be used for charging 12 volt automotive-type batteries only.

To prevent the possibility of creating a spark near the battery, connect charging cable first to the generator, then to the battery.

Disconnect cable first at the battery.

Before connecting charging cable to a battery that is installed in a vehicle, disconnect the vehicle’s battery cable. Reconnect the vehicle’s battery cable after the charging cables are removed. This procedure will prevent the possibility of a short circuit and sparks if you make accidental contact between a battery terminal and the vehicle’s frame or body.

Do not attempt to start an automobile engine with the generator still connected to the battery. The generator may be damaged.

Connect the positive battery terminal to the positive charging cord.

Do not reverse the charging cables, or serious damage to the generator and/or battery may occur.

POSITIVE DC TERMINAL

(RED)

NEGATIVE DC TERMINAL

(BLACK)

32

BATTERY

NEGATIVE (

)

TERMINAL

BATTERY POSITIVE (

)

TERMINAL

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1.

Before connecting the battery charging cable to a battery that is installed in a vehicle, disconnect the vehicle battery ground cable from the negative ( − ) battery terminal.

2.

Connect the red lead of battery charging cable into the positive ( + )

DC terminal of the generator.

3.

Connect the black lead of battery charging cable into the negative

( − ) DC terminal of the generator.

4.

Connect the red lead of the battery charging cable to the positive

( + ) battery terminal and the black lead to the negative ( − ) battery terminal.

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Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness. Provide adequate ventilation when charging.

CHEMICAL HAZARD: Battery fluid contains sulfuric acid. Contact with eyes or skin, even through clothing, may cause severe burns.

Wear a faceshield and protective clothing.

Keep flames and sparks away, and do not smoke in the area.

ANTIDOTE: If battery fluid gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately.

POISON: Battery fluid is poison.

ANTIDOTE

External: Flush thoroughly with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia or vegetable oil, and call a physician immediately.

KEEP OUT OF REACH OF CHILDREN.

5.

Start the engine.

The DC terminal can be used while the AC power is in use.

An overload 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.

DC CIRCUIT PROTECTOR

OFF

ON

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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 falls below a safe limit, the Oil Alert system will automatically shut down the engine (the engine switch will remain in the ON position).

If the engine stops and will not restart, check the engine oil level (see page 14 ) before troubleshooting in other areas.

Automatic Engine Stop Function

Oil Alert Function

During operation, the engine will automatically stop if there is not enough oil in the tank. Moreover, if the generator is on a slope, the oil alert function may operate, and stop the engine.

Overspeed Detection Function

To protect the engine from exceeding the engine load, the engine will automatically stop if the engine speed becomes abnormal.

Abnormal Voltage Detection Function

The engine will automatically stop during generation when it detects abnormal voltage.

If the engine stops, inspect the amount of engine oil, and a while, then try to restart the engine. When the engine will not start at all, take your generator to the dealer.

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7.

STOPPING THE ENGINE

To stop the engine in an emergency, turn the engine switch to the OFF position.

IN NORMAL USE:

1.

Turn the AC circuit breaker to the OFF position.

AC CIRCUIT BREAKER

OFF

2.

Turn the engine switch to the OFF position.

(CX type) (CXS type)

O F F

O F F

OFF

O F F

OFF

ENGINE SWITCH

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3.

Turn the fuel valve lever to the OFF position.

FUEL VALVE LEVER

OFF

O F F

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8.

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 below.

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine.

Burns from hot parts. Let the engine and exhaust system cool before touching.

Injury from moving parts. Do not run the engine unless instructed to do so.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before maintenance.

Use Honda Genuine parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the generator.

38

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Maintenance Schedule

REGULAR SERVICE PERIOD (3)

Performed at every indicated month or operating hour interval, whichever comes first.

ITEM

Engine oil

Air cleaner

Sediment cup

Spark plug

Check Level

Change

Check

Clean

Clean

Check-adjust

Replace

Clean

Spark arrester

(UH type)

Valve clearance

Combustion chamber

Fuel tank and filter

Check-adjust

Clean

Fuel tube

Battery fluid

(CXS type)

Clean

Check

Check

Each use

First month or

20 Hrs.

Every

3 months or

50 Hrs.

Every

6 months or

100 Hrs.

Every year or

300 Hrs.

Page

(1)

After every 500 Hrs. (2)

Every 2 years (Replace if necessary) (2)

(2)

(2)

18

14

40

17

41

42

43

43

45

(1) Service more frequently when used in dusty areas.

(2) These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

Tools

A box wrench and wrench handle are supplied with the generator.

Use the supplied tools to perform maintenance tasks. Using an incorrect tool may damage the generator.

Power Plug

This generator is bundled with power plugs corresponding to the number of outlets equipped on the generator.

(except UH type)

39

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1.

CHANGING OIL

Drain the oil while the engine is still warm to assure rapid and complete draining.

1.

Remove the oil drain bolt and sealing washer, remove the oil filler cap, and drain the oil.

2.

Reinstall the drain bolt and new sealing washer. Tighten the bolt securely.

3.

Refill with the recommended oil (see page 13 ) and check the oil level.

Oil capacity:

1.1 L

SEALING

WASHER

UPPER LIMIT

OIL FILLER CAP OIL DRAIN BOLT

Wash your hands with soap and water after handling used oil.

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 reclamation. Do not throw it in the trash or pour it on the ground.

40

10/07/22 15:06:09 32Z30R00_043

2.

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. They are flammable and explosive under certain conditions.

Never run the engine without the air cleaner element. Rapid engine wear will result.

1.

Unsnap the two air cleaner cover clips, remove the air cleaner cover, and remove the air cleaner element.

AIR CLEANER ELEMENT

AIR CLEANER

COVER

AIR CLEANER

ELEMENT

CLIP

2.

Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly, or wash in nonflammable or high flashpoint solvent. Allow the air cleaner element to dry thoroughly.

3.

Soak the air cleaner element in clean engine oil and squeeze out the excess oil. The engine will smoke during initial startup if too much

4.

oil is left in the air cleaner element.

Reinstall the air cleaner element and the cover.

properly hooked improperly hooked

AIR CLEANER

ELEMENT

AIR CLEANER

COVER

CLIP

41

10/07/22 15:06:18 32Z30R00_044

3.

FUEL SEDIMENT CUP SERVICE

Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.

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.

1.

Type with electric starter:

Turn the engine switch to the OFF position and remove the key.

KEY

Type without electric starter:

Turn the engine switch to the OFF position.

2.

Turn the fuel valve lever to the

O F F p o s i t i o n . R e m o v e t h e

3.

sediment cup and O-ring.

Clean the sediment cup in

4.

nonflammable or high flash point solvent.

Reinstall the new O-ring and

5.

sediment cup.

Turn the fuel valve lever to the ON position and check for leaks.

FUEL VALVE LEVER

O-RING

(Replace)

OFF

OFF

SEDIMENT CUP

After installing the sediment cup, be sure to tighten it securely. Check for fuel leaks and make sure the area is dry before starting the engine.

42

10/07/22 15:06:28 32Z30R00_045

4.

SPARK PLUG SERVICE

Recommended spark plug:

BPR5ES (NGK)

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

1.

2.

Remove the spark plug cap.

Clean any dirt from around the spark plug base.

3.

Use a spark plug wrench to remove the spark plug.

SPARK PLUG WRENCH

SPARK PLUG CAP

4.

Visually inspect the spark plug.

Discard it if the insulator is

5.

cracked, chipped, or fouled. Clean the spark plug with a wire brush if it is to be reused.

Measure the plug gap with a feeler gauge.

Correct as necessary by carefully bending the side electrode.

The gap should be:

0.7

− 0.8 mm

SIDE ELECTRODE

0.7

0.8 mm

SEALING WASHER

43

10/07/22 15:06:33 32Z30R00_046

6.

Make sure that the sealing washer is in good condition, and thread the spark plug in by hand to prevent cross-threading.

7.

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 to

1/4 turn after the spark plug seats.

8.

Reinstall the spark plug cap on the spark plug securely.

The spark plug must be securely tightened. An improperly tightened plug can become very hot and possibly damage the generator.

Never use a spark plug with an improper heat range.

44

10/07/22 15:06:43 32Z30R00_047

5.

SPARK ARRESTER CLEANING (UH type)

If the generator has been running, the muffler will be very hot.

Allow it to cool before proceeding.

The spark arrester must be serviced every 100 hours to maintain its efficiency.

1.

Loosen the screw by the exhaust port of the muffler and remove the spark arrester.

SPARK ARRESTER

SCREW

2.

Use a brush to remove carbon deposits from the spark arrester screen.

Inspect the screen for breaks or tears and replace it if necessary.

SPARK ARRESTER SCREEN

3.

Install the spark arrester in the reverse order of removal.

45

10/07/22 15:06:51 32Z30R00_048

6.

FUSE REPLACEMENT (CXS type)

If the fuse is blown, the starter motor will not work until it is replaced.

1.

Turn the engine switch to the OFF position and remove the key before checking or replacing the fuse.

2.

Remove the fuse holder cover and pull the fuse out.

3.

Replace the fuse with a fuse of the same type and rating.

Specified fuse:

10 A

FUSE HOLDER COVER

FUSE (10 A)

If frequent fuse failure occurs, determine the cause and correct the problem before attempting to operate the generator further.

Never use a fuse with a different rating from that specified. Serious damage to the electrical system or fire may result.

4.

Install the fuse holder cover in the reverse order of removal.

46

10/07/22 15:07:00 32Z30R00_049

9.

TRANSPORTING/STORAGE

Transporting

To prevent fuel spillage when transporting or during temporary storage, the generator should be secured upright in its normal operating position, with the engine switch OFF.

The fuel valve lever should be turned OFF.

When transporting the generator:

Do not overfill the tank.

Do not operate the generator while it is on a vehicle. Take the generator off the vehicle and use it in a well ventilated place.

Avoid a place exposed to direct sunlight when putting the generator on a vehicle. If the generator is left in an enclosed vehicle for many hours, high temperature inside the vehicle could cause fuel to vaporize resulting in a possible explosion.

Do not drive on a rough road for an extended period with the generator on board. If you must transport the generator on a rough road, drain the fuel from the generator beforehand.

To transport the generator, hold the holding part (shaded areas in the figure below).

HOLDING PART

47

10/07/22 15:07:03 32Z30R00_050

Take care not to drop or strike the generator when transporting.

Do not place heavy objects on the generator.

When transporting the generator by loading it on to a vehicle, secure to the generator frame as shown.

48

10/07/22 15:07:09 32Z30R00_051

Storage

1.

Place a suitable gasoline container below the carburetor, and use a funnel to avoid spilling fuel.

2.

Loosen the carburetor drain screw and drain the gasoline from the carburetor.

Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.

DRAIN SCREW

3.

After all the gasoline has drained into the container, tighten the drain screw securely.

4.

Place a suitable gasoline container below the sediment cup, and use a funnel to avoid spilling gasoline.

49

10/07/22 15:07:16 32Z30R00_052

5.

Remove the sediment cup (see page 42 ), and then turn the fuel valve lever to the ON position.

6.

Allow the gasoline to drain completely, and then install the sediment cup (see page 42 ).

ON

FUEL VALVE LEVER

O N

7.

Change the engine oil (refer to page 40 ).

8.

Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder. Turn the engine several revolutions slowly with the recoil starter to distribute the oil, then reinstall the spark plug.

9.

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.

Align the notch on the starter pulley with the hole at the top of recoil starter.

50

10/07/22 15:07:28 32Z30R00_053

10.

TROUBLESHOOTING

When the engine will not start:

Is there fuel in the tank?

NO

YES

Is the engine switch ON?

NO

Refill the fuel tank (see page

15 ).

YES

Turn the engine switch ON (see page 23 for electric starting or 26 for manual starting).

Add the recommended oil (see page 13 ).

Is there enough oil in the engine?

YES

Is the spark plug in good condition?

NO

NO

YES

Clean, readjust gap and dry the spark plug.

Replace it if necessary (see page 43 ).

Is the fuel reaching the carburetor?

YES

If the engine still does not start, take the generator to an authorized

Honda dealer.

NO

Clean the fuel sediment cup

(see page 42 ).

To check:

1) Turn off the engine switch and loosen the drain screw (see page 49 ).

2) Turn the fuel valve lever to ON. Fuel should flow from the drain when the fuel valve lever is turned on.

51

10/07/22 15:07:34 32Z30R00_054

[CXS Type]

Starter motor does not turn round;

YES

Is the fuse blown?

NO

YES

Is the battery discharged?

NO

If the starter motor still does not turn round, take the generator to an autorized Honda dealer.

Replace the fuse (see page 46 ).

Charge the battery.

52

10/07/22 15:07:42 32Z30R00_055

No electricity at the AC receptacles:

Is the AC circuit breaker ON?

NO

YES

Check the electrical appliance or equipment for any defects.

NO DEFECTS

Turn the AC circuit breaker ON (see page 31 ).

Take the generator to an authorized

Honda dealer.

DEFECTS

Replace the electrical appliance or equipment.

Take the electrical appliance or equipment to an electrical shop for repair.

No electricity at the DC terminals:

Is the DC circuit protector ON?

NO

YES

Take the generator to an authorized

Honda dealer.

Push the DC circuit protector ON (see page 34 ).

53

10/07/22 15:08:04 32Z30R00_056

11.

SPECIFICATIONS

Dimensions and Weight

Model

Type

Description code

Length

Width

Height

Dry mass (weight)

Engine

Model

Engine Type

Displacement

[Bore × Stroke]

Compression ratio

Engine speed

Cooling system

Ignition system

Oil capacity

Fuel tank capacity

Spark plug

EG3600CX

UH

EBHC

71.0 kg

681 mm

530 mm

571 mm

EG4500CX

RGH UH

EBFC

82.5 kg

GX270H GX340H1

4-stroke, overhead valve, single cylinder

270 cm

77.0

× 58.0 mm

8.3:1

82.0

337 cm

× 64.0 mm

8.0:1

3,000 rpm

Forced air

Transistorized magneto ignition

1.1 L

24.0 L

BPR5ES (NGK)

Generator

Model

Type

AC output

Rated voltage

Rated frequency

Rated current

Rated output

Maximum output

DC output

:

EG3600CX

UH

240 V

EG4500CX

RGH

230 V

UH

240 V

13.3 A

3.2 kVA

50 Hz

17.4 A

4.0 kW *

3.6 kVA 4.5 kW * 4.5 kVA

Only for charging 12 V automotive batteries.

Maximum changing output = 8.3 A

16.7 A

4.0 kVA

It is when the power factor is 1.0.

Specifications may vary according to the types, and are subject to change without notice.

54

10/07/22 15:08:23 32Z30R00_057

Dimensions and Weight

Model

Type

Description code

Length

Width

Height

Dry mass (weight)

* 1: Without battery

Engine

Model

Engine Type

Displacement

[Bore × Stroke]

Compression ratio

Engine speed

Cooling system

Ignition system

Oil capacity

Fuel tank capacity

Spark plug

EG5500CX

UH

EBCC

681 mm

84.0 kg

530 mm

571 mm

EG5500CXS

RGH UH

EBDC

844 mm

87.0 kg * 1

GX390H1

4-stroke, overhead valve, single cylinder

389 cm

88.0

× 64.0 mm

8.0:1

3,000 rpm

Forced air

Transistorized magneto ignition

1.1 L

24.0 L

BPR5ES (NGK)

Generator

Model

Type

AC output

Rated voltage

Rated frequency

Rated current

Rated output

Maximum output

DC output

2:

EG5500CX

UH

240 V

EG5500CXS

RGH

230 V

UH

240 V

50 Hz

20.8 A

5.0 kVA

5.5 kVA

21.7 A

5.0 kW

5.5 kW

2

2

20.8 A

5.0 kVA

5.5 kVA

Only for charging 12 V automotive batteries.

Maximum changing output = 8.3 A

It is when the power factor is 1.0.

Specifications may vary according to the types, and are subject to change without notice.

55

10/07/22 15:08:30 32Z30R00_058

12.

INSTALLATION OF KIT PARTS

STANDARD KIT PARTS

Battery Tray Kit (CXS type)

1.

Install the battery guard pipe on the frame.

Set the battery tray on the battery guard pipe and tighten the bolts.

2.

Route the starter cable under the tank and connect it to the starter solenoid.

3.

Connect the battery ground cable to the generator rear housing.

4.

Set the battery on the battery tray and secure with the battery set bolt.

Connect the starter cable to the battery positive ( + ) terminal first, then to the negative ( − ) terminal. When disconnecting, disconnect at the battery negative ( − ) terminal first.

5.

Install the battery guard plate on the battery guard pipe.

56

10/07/22 15:08:36 32Z30R00_059

STARTER SOLENOID STARTER CABLE

(Positive)

CABLE TIE

BATTERY

GROUND CABLE

(13)

(12)

(3)

(2)

(1)

(8)

(5)

(6)

(7)

(4)

(9)

(14)

(11)

(15)

(10)

(1) BATTERY SET BOLT

(2) BATTERY SET PLATE

(3) 6 mm FLANGE NUT

(4) BATTERY GROUND CABLE

(5) STARTER CABLE

(6) CABLE TIE

(7) 6 × 12 mm BOLT

12

1

2

1

1

2

1

(8) BATTERY GUARD PIPE

(9) BATTERY TRAY

(10) BATTERY GUARD PLATE

(11) BATTERY BOX

(12) 6 × 30 mm FLANGE BOLT

(13) WASHER

(14) 8 × 12 mm FLANGE BOLT

(15) 6 × 12 mm FLANGE BOLT

1

1

8

8

2

1

2

2

57

10/07/22 15:08:44 32Z30R00_060

INSTALLATION OF KIT PARTS

OPTIONAL KIT PARTS

Four Wheel Kit Installation

1.

Install the lock plate and four wheels on the wheel shaft using the plain washers and split pins.

Install the front wheel shaft on the front side nearest the engine.

2.

Install the wheel shaft assembly on the generator using eight 8 × 16 mm hex bolts.

TORQUE:

24 − 29 N·m (2.4

− 3.0 kgf·m , 17 − 22 lbf·ft)

8

×

16 mm HEX BOLT (8)

GENERATOR

SIDE

LONGER

REAR WHEEL SHAFT

WHEEL (4)

8 mm

FLANGE NUT (8)

FRONT WHEEL SHAFT

LOCK PLATE

58

20 mm PLAIN WASHER (5)

4

×

28 mm SPLIT PIN (4)

10/07/22 15:08:50 32Z30R00_061

13.

WIRING DIAGRAM

Fu

FW

GeB

GND

GT

IgC

J/B

MW

DC D

DC CP

DC T

DC W

ESw

EX W

FCS

FrB

OAU

OLSw

PoC

RgRc

SP

St

TrMU

VM

INDEX

(See inside back cover)

EG4500CX (RGH type) .......................................................................

. W − 1

EG5500CXS (RGH type) .....................................................................

. W − 2

EG3600CX·EG4500CX·EG5500CX (UH type)

EG5500CXS (UH type)

...................................

. W − 3

.......................................................................

. W − 4

ABBREVIATIONS WIRE COLOR CODE

Symbol

AC O

BAT

AC CB

ChC

D

D-AVR

Part name

AC Outlet

Battery

AC Circuit Breaker

Charge Coil

Diode

Digital-Automatic

Voltage Regulator

DC Diode

DC Circuit Protector

DC Terminal

DC Winding

Engine Switch

Exciter Winding

Fuel Cut Solenoid

Frame Block

Fuse

Field Winding

Generator Block

Ground

Ground Terminal

Ignition Coil

Junction Box

Main Winding

Oil Alert Unit

Oil Level Switch

Power Coil

Regulator Rectifier

Spark Plug

Starter

Tr-Mag Unit

Volt Meter

Bl

Y

Bu

G

R

W

Br

Lg

Gr

Lb

O

P

BLACK

YELLOW

BLUE

GREEN

RED

WHITE

BROWN

LIGHT GREEN

GRAY

LIGHT BLUE

ORANGE

PINK

59

10/07/22 15:08:58 32Z30R00_062

SWITCH CONNECTIONS

ENGINE SWITCH

EG3600CX·EG4500CX·EG5500CX

IG E

OFF

ON

G

EG5500CXS

IG E BAT

OFF

ON

ST

RECEPTACLE

FS

ST

Shape

G FS

Type

RGH

RGH

UH

60

10/07/22 15:09:11 32Z30R00_066

W

1

10/07/22 15:09:20 32Z30R00_067

W

2

10/07/22 15:09:29 32Z30R00_068

W

3

10/07/22 15:09:39 32Z30R00_069

W

4

10/07/22 15:09:43 32Z30R00_071

MAJOR Honda DISTRIBUTOR ADDRESSES

For further information, please contact Honda Customer Information

Centre at the following address or telephone number:

10/07/22 15:09:46 32Z30R00_072

RUSSIA

Honda Motor RUS LLC

21. MKAD 47 km., Leninsky district.

Moscow region, 142784 Russia

Tel. : + 7 (495) 745 20 80

Fax : + 7 (495) 745 20 81 http://www.honda.co.ru

postoffice @ honda.co.ru

AUSTRALIA

Honda Australia Motorcycle and

Power Equipment Pty. Ltd

1954-1956 Hume Highway

Campbellfield Victoria 3061

Tel. : (03) 9270 1111

Fax : (03) 9270 1133

DIC197 Black

00X32-Z30-6000_EG4000CX_H1-4

GENERATOR

EG3600CX

·

EG4500CX

EG5500CX

·

EG5500CXS

32Z30600

00X32-Z30-6000

CX

CXS oHonda Motor Co., Ltd. 2010

11000.2005.09

Printed in China

OWNER'S MANUAL

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