Owner`s Manual EX5500
Contents
1. 2 Check the fuel level Use any regular grade automotive gasoline unleaded gasoline is preferred with a pump octane rating of 86 or higher Never use an oil gasoline mixture or dirty gasoline Avoid getting dirt dust or water in the fuel tank CAUTION Gasoline substitutes are not recommended they may be harmful to the fuel system components Fuel tank capacity 16 5 2 4 36 US gal e Gasoline is extremely flammable and explosive under certain conditions Refuel in a well ventilated area with the engine stopped e Do not smoke or allow flames or sparks in the area where the generator is refueled or where gasoline is stored e Do not overfill the tank and make sure the filler cap is securely closed after refueling e 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 TANK CAP 3 Check the coolant level If there is no coolant in the reserve tank check the cooling system for leaks and repair if necessary Add coolant to the radiator then check the coolant level in the reserve tank after the engine reaches operating temperature Never remove the radiator cap when the engine is hot The coolant is under pressure and severe scalding could result When the engine is at operating temperature the coolant level should be between the MIN and MAX marks on the reserve tank If the level is near the MI2. VOLTAGE ADJUSTMENT VOLTMETER AIR CIRCUIT BREAKERS 13 6 STOPPING THE ENGINE To stop the engine in an emergency move the engine switch to OFF In normal use 1 Turn the circuit breakers OFF CIRCUIT BREAKERS N _ Woy 7 0 Pt 2 Turn the engine switch OFF ENGINE SWITCH 14 3 Turn the fuel valve OFF FUEL VALVE KNOB 15 7 MAINTENANCE The purpose of the maintenance schedule and adjustment is to keep the generator in the best operating condition Inspect or service as scheduled in the table on the next page 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 Use only genuine HONDA parts or their equivalent The use of replacement parts which are not of equivalent quality may damage the generator 16 Maintenance Schedule REGULAR SERVICE PERIOD Perform at every indi cated month or oper ating hour interval whichever occurs Every 6 months Every or 2 years 100 Hrs Air cleaner element Fuel filter cleaning Spark plug maintenance Valve clearance adjustment Combustion chamber and valve cleaning Oil filter change Radiator coolant Battery inspection Fuel fine inspection Replace if necessary NOTE 1 Service more frequently when used in dusty areas 2 These items shoul
3. Equipment Owner s Manual EX5500 Click here to save this ttt ttt manual to your computer l LE LLLI i a 2 8 TTT G G E LLL LL TE EE EET ELT ET LE LE T_T LLL LL LII I TT IJIlLLLLLLLLLL HONDA MOTOR CO LTD 1982 _ 1 Thank you for purchasing a Honda generator This manual covers operation and maintenance of the EX5500 generator All information in this publication is based on the latest product information available at the time of approval for printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the generator and remain with the generator when sold Pay special attention to statements preceded by the following words CEES indicates a strong possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about the generator consult an authorized Honda dealer The 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
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5. clean if necessary 4 Install the spark arrester and arrester cap on the muffler 5 Tighten two 5 mm pan screws to the arrester cap 24 8 TRANSPORTING STORAGE DIT 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 FILTER CUP 25 26 d Drain the carburetor by loosening the drain screw Drain the gasoline into a suitable container DRAIN SCREW Once a month recharge the battery 9 TROUBLESHOOTING A When the engine will not start 1 Is there enough fuel 2 Is the fuel valve on 3 Is gasoline reaching the carburetor To check loosen the drain screw with the fuel valve on PIN If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Fuel vapor or spilled fuel may ignite ae DRAIN SCREW 4 15 the reset button pushed in 5 Are the circuit breakers off 6 15 the engine switch on 7 Is the fuse good 8 15 there a spark at the spark plug Page 28 27 ger en ee a Remove the s
6. generator Failure to do so could result in personal injury or equipment damage 5 CONTENTS Lee bat 1 Z COMPONENT IDENTIFICATION 2 eae eee ea ge aaa 4 asss s EERE 8 sus sz ann ee 12 OPPIN NOINE PD 14 16 TRANSPORTING STORAGE 25 19 TROUBLESHOOTING 27 Lube gee ee hee eee tena oataeas 29 30 12 INSTALLATION OF 31 1 GENERATOR SAFETY V WARNING To ensure safe operation Place the generator at least 1m 3ft away from buildings or other equipment when operating the generator Operate the generator on a level surface If the generator is tilted fuel spillage may result Exhaust gas contains poisonous carbon monoxide Never run the generator in an enclosed area Be sure to provide adequate ventilation Know how to stop the generator quickly and understand operation of all the controls 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 2 COMPONENT IDENTIFICATION AIR CLEANER COOLANT
7. 18 3NISN3 1121304 OC 32018 ISNVd 3 HY18S 3XOH2 GiON3108 YOLOW TOBLNOD a 4 t Y HOLIMS S ud CE 4 4 6 9 v D i m yr igi co Bi t 10114 9 9 s 9 zt ss FLA 54 D TD EH jia ra 484 rer HOLIMS od a T 100 iNO05 H ionau waive G0 7 H ee rer ee H nig MO Er s 21 a s III a ii ir VL pL rez p 1N3SNOO 512018 HO1VH3N39 F 30 12 INSTALLATION OF OPTIONAL PARTS Remote control kit The generator may be adapted for remote control operation by use of an optional kit 1 Unscrew the two 6 x 10 mm flange bolts and 6 x 8 mm screws attaching the control panel Remove the control panel 10 mm FLANGE BOLTS 6 x 8 mm SCREWS 2 Position the relay box on back of the control panel with the studs inserted through the holes in the relay box flange Install a 4 mm nut and lock washer on each stud and tighten securely 3 Remove the 6 P coupler with a jumper wire from the wire harness female coupler Connect the relay box 6 P male coupler to the wire harnes
8. N mark add coolant to bring it up to the MAX mark Coolant Recommendation Use high quality ethylene glycol antifreeze that is specifically formulated for use in aluminum engines Mix the antifreeze with low mineral drinking water or distilled water A 50 50 mixture of ethylene glycol antifreeze and water is recommended for most temperatures and provides good corrosion protection A higher concentration of antifreeze decreases cooling efficiency and is recommended only if additional protection against freezing is needed A concentration of less than 4096 antifreeze will not provide proper corrosion protection CAUTION The use of unsuitable antifreeze hard water or salt water may cause corrosion damage that will shorten the life of the engine LOWER LEVEL m RESERVE TANK 6 4 Check the battery The electrolyte level must be maintained between the UPPER and LOWER level marks If the electrolyte level is near the LOWER mark add distilled water V WARNING e The battery contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Eyes Flush with water and get prompt medical attention Batteries produce explosive gases Keep sparks flames and cigarettes away Always shield the eyes when working near batteries CAUTION Use on
9. RESERVE TANK GROUND TERMINAL 4 COOLANT DRAIN PLUG ENGINE OIL DRAIN PLUG ENGINE OIL FILLER CAP FUEL TANK CAP p cue ENGINE OIL FILTER FUEL GAUGE BATTERY MUFFLER RADIATOR CONTROL BOX VOLTAGE LAMP ADJUSTMENT KNOB PILOT LAMP COOLANT LAMP VOLTMETER RESET BUTTON REMOTE CONTROL SWITCH FUEL VALVE KNOB CIRCUIT AC RECEPTACLES BREAKERS AUTO THROTTLE ENGINE SWITCH SWITCH 3 PRE OPERATION CHECK CAUTION Be sure to check the generator on a level surface with the engine stopped 1 Check the engine oil level CAUTION Engine oil is a major factor affecting engine performance and service life Non detergent or vegetable oils are not recommended Use Honda 4 stroke oil or an equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufacturer s requirements for Service Classification SE or SF Motor oils classified SE or SF will show this designation on the container SAE 10W 40 is recommended for general all temperature use If single viscosity oil is used select the appropriate viscosity for the average temperature in your area Remove the oil filler cap and check the oil level If the level is low fill to the top of the oil filler neck with the recommended oil Total oil capacity 1 4 1 48 US qt N ME WM FILLER HOLE N OIL FILLER CAP 30 20 10 O 10 20 30 40 C ad 20 0 20 40 60 80 100 F
10. d be serviced by an authorized Honda dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 17 Toll The tools supplied are necessary for performing some periodic maintenance simple adjustments and repairs Always keep the kit with the generator ET Engine oil and oil filter change Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the drain plug and filler cap and drain the oil Retighten the plug securely and reinstall the filler cap 2 Remove the oil filter with a filter wrench and let the remaining oil drain out 3 Apply a thin coat of engine oil to the filter rubber seal and screw it in by hand until you feel it seat against the engine then turn it 3 4 of a turn more 4 Fill the crankcase with the recommended oil See page 4 and check the level Recheck the level after running the engine for a few minutes Total oil oe 40 1 48 US at i OIL FILLER CAP SN Air cleaner service A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly page 23 Service more frequently when operating the generator in extremely dusty areas Never use gasoline or low flash point solvents for cleaning the air cleaner elements A fire or explosion could result CAUTION Never run the generator without the air cleane
11. ly distilled water in the battery Tap water will shorten the service life of the battery Do not fill the battery beyond the UPPER level If overfilled electrolyte may overflow and corrode generator components Immediately wash off any spilled electrolyte Check the battery terminals to be sure the cables are tightened and free of corrosion Remove any corrosion and coat the terminals and cable ends with grease UPPER LEVEL DISTILLED WATER 2 UPPER L EVEL CAP 4 STARTING THE ENGINE 1 Turn the fuel valve ON FUEL VALVE KNOB 2 Make sure that the circuit breakers are OFF The generator may be hard to start if a load is connected CIRCUIT BREAKERS po 3 Make sure the auto throttle switch is off or more time will be required for warm up AUTO THROTTLE SWITCH 4 Turn the engine switch to START and hold there until the engine starts Do not use the electric starter for more than 5 seconds at a time If the engine fails to start release the switch and wait 10 seconds before operating the starter again NOTE e When the speed of the starter motor drops after a period of time it is an indication that the battery should be recharged NOTE It is normal for the oil lamp to remain lit during starting tf the oil level is OK the lamp will go off when the engine is running If the oil level is low the oil lamp will stay on the engine may start but will not conti
12. nue to run 10 5 After the engine starts let the engine switch return to ON ENGINE SWITCH 6 Warm up the engine for 2 3 minutes Turn the auto throttle switch to AUTO after the engine has warmed up AUTO THROTTLE SWITCH 11 5 GENERATOR USE To prevent electrical shock from faulty appliances the generator should be grounded Connect a length of heavy wire between the ground terminal and the ground source CAUTION Limit operation requiring maximum power 5 5 KVA to 30 minutes For continuous operation do not exceed the rated power of 5 0 KVA In either case the total wattage of all appliances connected must be considered Connections for standby power to household circuits must be made by qualified electrician and must comply with all applicable laws and electrical codes Improper installation may result in personal injury or damage to equipment or property Auto throttle system With the switch in the AUTO position engine speed is automatically reduced to an idle when all loads are turned off or disconnected When appliances are turned on or reconnected the engine resumes the rated speed At OFF the auto throttle system does not operate NOTE AUTO is recommended to minimize fuel consumption The auto throttle system will not respond to electrical loads of less than 1 ampere The system is not effective for use with appliance that requires only momen
13. o compress the washer If you are reusing a plug it should only take 1 8 1 4 turn after the plug seats Reinstall the top cover CAUTION 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 PLUG GAP 0 9 1 0 mm 0 035 0 039 in PLUG WRENCH 22 a A UMEMEDEMDDDDUGMDGLIGHLLLLULLLURXLLUlKES CL o 1 i L L EN Fuse replacement If the fuse is blown the engine wil not start until it is replaced 1 Pull the lock levers out and open the top cover 2 Turn the engine switch OFF 3 Remove the fuse holder and replace the fuse Use only a 10A fuse 4 Close the top cover CAUTION e f frequent fuse failure occurs determine the cause and correct the problem before attempting to operate the generator further e Never use a fuse with a rating other than 10A Serious damage to the electrical system or a fire may result 12 FUSE HOLDER 23 Spark arrester maintenance YT if the generator has been running the muffler will be very hot Allow it to cool before proceeding CAUTION The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Loosen two 5 mm pan screws on the arrester cap 2 Remove the arrester cap then pull out spark arrester taking care not to damage the wire mesh 3 Check the muffler exhaust port for carbon deposits
14. park plug cap Clean any dirt from around the spark plug base then remove the spark plug Install the spark plug in the plug cap Turn the engine switch on Grounding the side electrode to any engine ground crank the engine to see if sparks jump across the gap e If there are no sparks replace the plug If OK try to start the engine according to the instructions 9 If the engine still does not start take the generator to the dealer When the engine starts but stops immediately 15 there enough oil in the crankcase If not the oil lamp will go on b Is there enough coolant in the radiator is the engine overheated If not the coolant lamp will go C No electricity at the output receptacles Are the circuit breakers on 28 10 SPECIFICATIONS Dimension Engine Model Engine Type Displacement Bore x Stroke Compression Ratio Engine Speed Ignition System Capacity Cooling System Capacity Fuel Tank Capacity Spark plug Generator Length x Width x Height Dry weight Rated voltage Rated frequency 60Hz SSCS AC output 965 x 590 x 730 mm 38 0 x 23 2 x 28 7 in 175 kg 385 9 Ib Honda GX360 4 Stroke O H C 2 cylinder 359 21 9 cu in 58 x 68 2 3 x 2 7 in 8 5 1 3 600 C D I 1 4 1 48 US at 2 0 2 11 US at 16 5 2 4 36 US gal BPR6HS 10 NGK 120 240 V 29 11 WIRING DIAGRAM HOLS 320
15. r Rapid engine wear may result 1 Pull the lock levers out and open the top cover 2 Unscrew the wing nut and remove the air cleaner cover 3 Remove the urethane and paper elements WING NUT AIR CLEANER ELEMENTS URETHANE AND PAPER 19 4 Carefully check both elements for holes or tears and replace as required Damaged elements will pass dirt into the system Always clean the filter housing and air passages before installing clean elements 5 Foam element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in high flash point solvent and allow to dry Dip the element in clean engine oil and squeeze out all the excess The engine will smoke during initial start up if too much oil is left in the foam 6 Paper element Tap the element lightly several times on a hard surface to remove excess dirt or blow compressed air through the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers Clean in warm soapy water and rinse Dry using compressed air blown from the inside out or shake the element and allow it to air dry thoroughly Or clean in high flash point solvent remove immediately and allow to dry the outside of the paper with a light aerosol oil such as WD 40 The engine will smoke during initial start up if too much oil is used 7 Reinstall the elements and air cleaner cover with the arrow on the cover aligned with the arrow on the frame Tighten
16. s female coupler 4 Insert the relay box 6 P female coupler in the hole in the sub panel below the control panel and install with the two self tapping screws and coupler holder 4x 10 mm SELF TAPPING SCREWS COUPLER HOLDER CONTROL PANEL N j P ix d Q a N HOLE IN SUB PANEL RELAY BOX t 4 mm NUT 31 5 Reinstall the control panel with the 6 x 10 mm flange bolts and 6 x 8 mm screws 6 Connect the remote contro 6 P male coupler to the 6 P coupler on the sub panel i 6 P FEMALE COUPLER REMOTE CONTROL CABLE 7 Connect the remote control 6 P male coupler to the switch box 32 Remote control operation STARTING 1 Turn the fue valve on 2 Turn the auto throttle switch off 3 Turn the ignition switch key off or remove it from the generator 4 Turn the relay switch on Er zm 5 Flip the remote control engine switch knob up to ON ENGINE SW 9 LO STAAT 33 6 Depress the starter button until the pilot lamp is ENGINE SW 34 TAT TTC eee rere Sper bres ert ere re errs l LE LL d JG Jd LLL ll LLLL ACCES PEFEERHEHREEREEPEERHE PFTPEPETT EFFETITTTE TI Li bL LEE E TL TEL EET Lyd td LLL SNAN EDENN EDEN MEN et LLL ERN l LL xuma LLL gll
17. tary power To avoid extended warm up periods keep the switch OFF until the engine reaches operating temperature Engine Protection Circuit If the oi or coolant level runs low during operation the protection circuit will automatically stop the engine to prevent damage If this occurs add oil or coolant as required push the reset button in then restart the engine OIL LAMP RESET BUTTON CAUTION f engine idle speed 15 set too low the protection circuit cannot be activated while idling The correct idle speed 15 2200 200 rpm 1 2 COOLANT LAMP a x a O t J J A unt PUE M 1 Start the engine and make sure that the pilot lamp comes 2 Switch on the circuit breakers 3 Plug in the appliance NOTE Connect 120V appliances to the 120V receptacles You can use both 120V 240V appliances with the 120V 240V receptacle CAUTION Be sure that appliances do not exceed the rated load for more than 30 minutes and never exceed the maximum load Substantial over loading will switch off the circuit breaker Lesser overloading will not switch off the circuit breaker and will shorten the service life of the generator NOTE This generator is equipped with an AVR Automatic Voltage Regulator Though voltage adjustment is not required fine adjustments may be made by turning the voltage adjustment knob Use the generator at the specified voltage
18. the wing nut securely 8 Reinstall the top cover URETHANE ELEMENT 20 Fuel filter service The filter prevents dirt or water which may be in the fuel tank from entering the carburetor If the engine has not been run for a long time the filter should be cleaned 1 Turn the two lock pins and open the carburetor cover 2 Turn the fuel valve OFF Remove the filter cup 3 Clean the cup thoroughly 4 Reassemble Do not damage the O ring 5 Close the carburetor cover and lock with the lock pins After installing the filter cup check for fuel leaks and make sure the area is dry before starting the engine FILTER CUP 21 eet Spark plug service Recommended spark plug BPR6HS 10 NGK To ensure proper engine operation the spark plug must be properly gapped and free of deposits o AWN J 8 Pull the lock levers out and open the top cover Remove the spark plug cap Use the wrench supplied the tool kit to remove the spark plug Visually inspect the spark plug Discard it if the insulator is cracked or chipped Measure the plug gap with a feeler gauge The gap should be 0 9 1 0 mm 0 035 0 039 in Correct as necessary by bending the side electrode Attach the plug washer Thread the plug in by hand to prevent cross threading Tighten a new spark plug 1 2 turn with the wrench t
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