- Industrial & lab equipment
- Honda
- EG5500CXS
- Manual
- 14 Pages
Honda EG5500CXS, EG6500CXS Manual 14 Pages
The Honda EG5500CXS is a powerful and reliable generator designed to provide backup power in a variety of applications. It features a robust engine, a durable construction, and a user-friendly design. This generator can power essential appliances and equipment, such as lights, refrigerators, and small tools, during power outages or when accessing electricity is limited. Its compact size and portability make it ideal for camping, tailgating, or other outdoor activities.
Honda EG5500CXS, EG6500CXS Manual
The Honda EG5500CXS is a powerful and reliable generator designed to provide backup power in a variety of applications. It features a robust engine, a durable construction, and a user-friendly design. This generator can power essential appliances and equipment, such as lights, refrigerators, and small tools, during power outages or when accessing electricity is limited. Its compact size and portability make it ideal for camping, tailgating, or other outdoor activities.
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How to use this manual A Few Words About Safety How to use this manual SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight while servicing this product can result in faulty operation, damage to the product, or injury to others. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure that the hoist hook is securely attached to the product. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never store gasoline in an open container. • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts. 0-1 How to use this manual INTRODUCTION This supplement covers the construction, function, and servicing procedures of the Honda EG5500CXS/ EG6500CXS Generator. OUTLINE OF CHANGES SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 FUEL SYSTEM 5 GOVERNOR SYSTEM 6 GENERATOR/CHARGING SYSTEM 7 IGNITION SYSTEM 8 STARTING SYSTEM 9 OTHER ELECTRICAL 10 preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment. MUFFLER 11 ENGINE REMOVAL/INSTALLATION 12 SAFETY MESSAGES CYLINDER HEAD 13 CYLINDER BLOCK 14 TECHNICAL FEATURES 15 WIRING DIAGRAMS 16 For service information that is not covered in this supplement, please refer to the EG5500CXS/ EG6500CXS base shop manual (part number 82Z3000). All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing these products. You must use your own good judgement. You will find important safety information in a variety of forms, including: · Safety Labels – on the product. · Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: INDEX The marked sections contain no changes. They are not covered in this supplement. Note this supplement is applicable only to the engine serial numbers listed in the table shown below. Model Engine serial number GX390H1 GCAFH-0372947 and subsequent You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. · Instructions – how to service these products correctly and safely. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: September 2013 0-2 How to use this manual SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use marine grease (water resistant urea based grease). Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use automatic transmission fluid. ( 0-3 x )( ) page 1-1 Indicates the diameter, length, and quantity of metric bolts used. Indicates the reference page. OUTLINE OFthis CHANGES How to use manual Item Starter Motor After Before Harness Clip Base 0-4 MEMO 2. SERVICE INFORMATION 2 MAINTENANCE STANDARDS ·····················2-2 CABLE/HARNESS ROUTING ······················ 2-2 2-1 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Part Starter motor Item Brush length Mica depth Unit: mm (in) Service limit 4.0 (0.16) 0.5 (0.02) Standard 10.5 (0.41) 1.5 (0.06) CABLE/HARNESS ROUTING (+) BATTERY CABLE TERMINAL HARNESS BAND STARTER SOLENOID CABLE TERMINAL Do not secure the starter cable at harness band Terminal number Wire color Bl W STARTER SOLENOID CONNECTOR 2-2 Terminal number Wire color Bl/W 9. STARTING SYSTEM STARTER MOTOR REMOVAL/ INSTALLATION·············································9-2 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ··················································· 9-3 STARTER MOTOR INSPECTION ················ 9-4 9-1 9 STARTING SYSTEM STARTER MOTOR REMOVAL/INSTALLATION STARTING SYSTEM Disconnect the starter motor wires and battery (+) cable from the starter motor. Remove the fan cover (Base shop manual : page 7-9). BOLT (8 x 35 mm) STARTER MOTOR WASHER STARTER SOLENOID WIRE BATTERY POSITIVE (+) CABLE SPRING WASHER NUT (6 mm) 2.5 N·m (0.3 kgf·m, 2 lbf·ft) 9-2 STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ASSEMBLY Remove the starter motor (page 9-2). BRUSH HOLDER BRUSH ASSEMBLY: SPRING (4) Install the brush holder, brush springs, positive brushes, negative brushes, and two screws SCREW (2) to the center bracket as shown. NEGATIVE BRUSH (2) BRUSH SPRING HOUSING ASSEMBLY: Make sure there is no obstruction on the magnets. POSITIVE BRUSH SCREW (5 x 30 mm) (3) POSITIVE BRUSH (2) CENTER BRACKET BRUSH HOLDER ARMATURE SNAP RING NUT (6 mm) SCREW (5 x 13 mm) (2) 2.5 N·m (0.3 kgf·m, 2 lbf·ft) (LEFT HAND THREADS) STARTER SOLENOID WASHER (2) SCREW (5 x 20 mm) (2) NEGATIVE BRUSH (2) SCREW (5 x 20 mm) BRUSH SPRING (4) 5 N·m (0.5 kgf·m, 4 lbf·ft) POSITIVE BRUSH (2) SPRING WASHER SNAP RING SEAL STARTER SOLENOID WIRE WASHER NUT (6 mm) 3.7 N·m (0.4 kgf·m, 3 lbf·ft) CENTER BRACKET DRIVE PINION GEAR REDUCTION GEAR OVERRUNNING CLUTCH/PINION GEAR DRIVE SIDE HOUSING 9-3 STARTING SYSTEM STARTER MOTOR INSPECTION STARTER SOLENOID Connect the positive (+) lead of a 12V battery to the solenoid terminal [1] and the negative (-) lead to the solenoid wire terminal [2]. Measure the resistance between the starter motor solenoid terminals as shown. Continuity should exist when the battery is connected and not exist when the battery is disconnected. [2] [1] BRUSH LENGTH Measure the brush length. If the negative brush length is less than the service limit, replace the center bracket. If the positive brush length is less than the service limit, replace the center bracket. STANDARD: 10.5 mm (0.41 in) SERVICE LIMIT: 4.0 mm (0.16 in) BRUSH CONTINUITY CHECK Check for continuity between the positive (+) brushes [1] and negative (-) brushes [2]. There should be continuity between both the positive brushes. There should be continuity between both the negative brushes. There should be no continuity from either positive brush to either negative brush. If the correct continuity of the positive (+) brushes is not obtained, replace the center bracket (page 9-3). If the correct continuity of the negative (-) brushes is not obtain, replace the negative (-) brushes. ARMATURE MICA DEPTH Visually inspect the commutator surface for dust, rust, or other damage. If necessary, wipe it with a clean lintfree cloth. If rusted or damaged, dress with a fine emery cloth. When the mica is clogged, or its depth is smaller than the service limit value, recut the grooves using a hacksaw blade or a small file. STANDARD: 1.5 mm (0.06 in) SERVICE LIMIT: 0.5 mm (0.02 in) 9-4 [1] [2] [2] [1] STARTING SYSTEM ARMATURE CONTINUITY CHECK COMMUTATOR TO SHAFT Check for continuity between the commutator and the armature shaft. Replace the armature if continuity exists between any of the commutator segments and the armature shaft (page 9-3). ARMATURE CONTINUITY CHECK COMMUTATOR SEGMENTS Check for continuity between segments. If an open circuit (no continuity) exists between any two segments, replace the armature (page 9-3). OVERRUNNING CLUTCH • Do not apply oil or grease to the pinion gear [1] and dumper clutch [2]. • Do not use non-flammable solvent for cleaning the pinion gear and dumper clutch. Check the pinion gear operation by holding the pinion gear shaft [3] and turning the pinion gear. The pinion gear should turn clockwise freely and should not turn counterclockwise. If the pinion gear operation is not smooth, apply grease to the pinion gear shaft or replace the overrunning clutch if necessary. [1] Check the pinion gear for wear or damage, and replace the overrunning clutch if necessary. If the pinion gear is worn or damaged, the flywheel ring gear must be inspected. [2] [3] 9-5 STARTING SYSTEM STARTER SOLENOID WIRE Check the starter solenoid wire for continuity. 9-6 INDEX INDEX CABLE/HARNESS ROUTING ········································2-2 MAINTENANCE STANDARDS·······································2-2 STARTER MOTOR DISASSEMBLY/ASSEMBLY ··········9-3 C M STARTER MOTOR INSPECTION·································· 9-4 STARTER MOTOR REMOVAL/INSTALLATION ··········· 9-2 S 2 10-1
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Key Features
- Powerful engine
- Reliable performance
- Durable construction
- User-friendly design
- Portable and compact
- Quiet operation
- Fuel-efficient operation
- Easy maintenance
- Extended runtime
- Automatic voltage regulation