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Honda EG6500CXS - User Manual

Honda EG6500CXS
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A Few Words About Safety
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 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.
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.
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.
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 man-
ual and other service materials carefully.
Failure to properly follow instructions and precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
82Z30000.book 1 ページ 2010年6月25日 金曜日 午後5時50分

Other manuals for Honda EG6500CXS

Questions and Answers

Summary

How to Use This Manual

A Few Words About Safety

Explains safety precautions for using the manual and performing service.

Service Information

Information for qualified technicians, warnings about training and tools.

Safety Messages

Provides safety messages and explains signal words (DANGER, WARNING, CAUTION).

Important Safety Precautions

Essential safety practices like reading instructions, using safety equipment, and engine safety.

1. Specifications

Generator

Generator specifications including rated output, frequency, and voltage.

Specifications

Details technical specifications like dimensions, weights, and engine data.

Engine

Engine specifications including displacement, bore, stroke, and ignition system.

Characteristics

Performance characteristics like voltage/frequency variation and fuel consumption.

2. Service Information

Torque Values

Lists specified torque values for engine and frame fasteners.

Service Information

Maintenance Standards

Maintenance standards for EG5500CX/EG6500CX/EG5500CXS/EG6500CXS engines.

Torque Values

Specific torque values for engine and frame bolts and nuts.

Generator Side (MH, RH, KH, UH, SH, SKH, RGH Type)

Wiring diagram for the generator side for various types.

Generator Side (RHH Type)

Wiring diagram for the generator side specifically for RHH type.

Generator Side (LDH, LTH Type)

Wiring diagram for the generator side for LDH/LTH types.

Control Panel Side (CX-RHH Type)

Wiring details for the control panel side of CX-RHH type generators.

Control Panel Side (CXS-RHH Type)

Wiring details for the control panel side of CXS-RHH type generators.

Control Panel Side (CX-MH Type)

Wiring details for the control panel side of CX-MH type generators.

Control Panel Side (CXS-MH Type)

Wiring details for the control panel side of CXS-MH type generators.

Control Panel Side (CX-RH, KH, SH Type)

Wiring details for the control panel side of CX-RH/KH/SH types.

Control Panel Side (CXS-RH, KH, SH Type)

Wiring details for the control panel side of CXS-RH/KH/SH types.

3. Maintenance

Maintenance Schedule

Schedule for regular service intervals based on time or usage.

Valve Clearance Check;Adjustment

Procedure for checking and adjusting valve clearance.

Maintenance

Maintenance Schedule

Regular service intervals for various maintenance items.

Engine Oil Level Check

Step-by-step guide for checking engine oil level with diagrams.

Engine Oil Change

Detailed procedure for changing engine oil, including torque specs.

Valve Clearance Check;Adjustment

Step-by-step guide for measuring and adjusting valve clearance.

4. Troubleshooting

Troubleshooting

Hard Starting

Continues troubleshooting for hard starting, focusing on compression issues.

Engine Speed Does Not Stabilize

Troubleshooting guide for unstable engine speed.

Engine Does Not Stop When Combination; Engine Stop Switch Is Turned Off

Troubleshooting steps for when the engine fails to stop.

Engine Does Not Stop When Engine Oil Level Is Low

Troubleshooting guide for engine not stopping due to low oil level.

5. Fuel System

Fuel System

Carburetor Removal;Installation

Instructions for removing and installing the carburetor and related components.

Carburetor Disassembly;Assembly

Detailed procedure for disassembling and reassembling the carburetor.

6. Governor System

Governor System

Governor Adjustment

Procedure for adjusting governor speed using pinch bolts and limiting screws.

7. Generator;Charging System

Generator;Charging System

Generator System Troubleshooting

Troubleshooting steps for "No DC Output" issues, checking windings and diodes.

Charging System Troubleshooting (CXS Type Only)

Troubleshooting steps for charging system issues on CXS models.

Flywheel;Fuel Cut;Charge Coil;Power Coil Removal;Installation

Procedure for removing and installing flywheel, coils, and related parts.

Generator Removal

Steps for removing the generator from the engine, including brush holder removal.

Generator Installation

Procedure for installing the generator, including alignment and torque specs.

Generator Disassembly;Assembly

Detailed steps for disassembling and assembling the generator rotor and stator.

8. Ignition System

Ignition System

Ignition System Troubleshooting

Troubleshooting guide for "No Spark at Spark Plug" issues.

Spark Test

Guide on how to perform a spark test to check for spark.

Ignition Coil Inspection

Procedures for inspecting ignition coil primary and secondary resistance.

9. Starting System

Starting System

Starting System Troubleshooting (CXS Type Only)

Troubleshooting guide for starter motor not operating on CXS models.

Starter Motor Removal;Installation (CXS Type Only)

Steps for removing and installing the starter motor on CXS models.

Starter Motor Disassembly;Assembly (CXS Type Only)

Detailed procedure for disassembling and assembling the starter motor on CXS models.

Starter Motor Inspection (CXS Type Only)

Inspects starter motor solenoid, brush length, and brush continuity on CXS models.

10. Other Electrical

Control Panel Disassembly;Assembly

Detailed procedure for disassembling and assembling the control panel.

Other Electrical

Control Panel Disassembly;Assembly CX-RHH type

Exploded view and steps for control panel disassembly/assembly for CX-RHH type.

Control Panel Disassembly;Assembly CXS-RHH type

Exploded view and steps for control panel disassembly/assembly for CXS-RHH type.

Control Panel Disassembly;Assembly CX-RH, KH, SH type

Exploded view and steps for control panel disassembly/assembly for CX-RH/KH/SH types.

Control Panel Disassembly;Assembly CXS-RH, CXS-KH, CXS-SH type

Exploded view and steps for control panel disassembly/assembly for CXS-RH/KH/SH types.

Control Panel Disassembly;Assembly CX-UH type

Exploded view and steps for control panel disassembly/assembly for CX-UH type.

Control Panel Disassembly;Assembly CXS-UH type

Exploded view and steps for control panel disassembly/assembly for CXS-UH type.

Control Panel Disassembly;Assembly CX-MH type

Exploded view and steps for control panel disassembly/assembly for CX-MH type.

Control Panel Disassembly;Assembly CXS-MH type

Exploded view and steps for control panel disassembly/assembly for CXS-MH type.

Control Panel Disassembly;Assembly CX-LDH, LTH type

Exploded view and steps for control panel disassembly/assembly for CX-LDH/LTH types.

Control Panel Disassembly;Assembly CXS-LDH, CXS-LTH type

Exploded view and steps for control panel disassembly/assembly for CXS-LDH/LTH types.

Control Panel Disassembly;Assembly CX-SKH type

Exploded view and steps for control panel disassembly/assembly for CX-SKH type.

Control Panel Disassembly;Assembly CXS-SKH type

Exploded view and steps for control panel disassembly/assembly for CXS-SKH type.

Control Panel Disassembly;Assembly CX-RGH type

Exploded view and steps for control panel disassembly/assembly for CX-RGH type.

Control Panel Disassembly;Assembly CXS-RGH type

Exploded view and steps for control panel disassembly/assembly for CXS-RGH type.

11. Muffler

Muffler

Muffler Removal;Installation

Detailed procedure for muffler removal/installation with safety caution.

12. Engine Removal;Installation

Engine Removal;Installation

Engine Removal;Installation

Steps for removing and installing the engine, including rubber mounts and bolts.

13. Cylinder Head

Cylinder Head

Cylinder Head Removal;Installation

Steps for removing and installing the cylinder head, including torque specs.

Cylinder Head Disassembly;Assembly

Detailed steps for disassembling and assembling cylinder head valve components.

Cylinder Head;Valves Inspection

Procedures for checking cylinder compression and cylinder head warpage.

14. Cylinder Block

Bearing;Oil Seal Replacement

Steps for replacing bearings and oil seals in the cylinder block.

Cylinder Block

Crankshaft;Camshaft;Balancer Weight (Except EG3600;EG4000);Piston Removal;Installation

Procedure for removing and installing crankshaft, camshaft, balancer weight, and piston.

Governor Disassembly;Assembly

Detailed steps for disassembling and assembling the governor system components.

Piston Disassembly;Assembly

Procedure for disassembling and assembling the piston, rings, and pin.

Cylinder Block Inspection

Inspection of camshaft holder I.D., cylinder barrel, and cylinder sleeve I.D.

15. Technical Features

Technical Features

16. Wiring Diagrams

Wiring Diagrams

Summary

How to Use This Manual

A Few Words About Safety

Explains safety precautions for using the manual and performing service.

Service Information

Information for qualified technicians, warnings about training and tools.

Safety Messages

Provides safety messages and explains signal words (DANGER, WARNING, CAUTION).

Important Safety Precautions

Essential safety practices like reading instructions, using safety equipment, and engine safety.

1. Specifications

Generator

Generator specifications including rated output, frequency, and voltage.

Specifications

Details technical specifications like dimensions, weights, and engine data.

Engine

Engine specifications including displacement, bore, stroke, and ignition system.

Characteristics

Performance characteristics like voltage/frequency variation and fuel consumption.

2. Service Information

Torque Values

Lists specified torque values for engine and frame fasteners.

Service Information

Maintenance Standards

Maintenance standards for EG5500CX/EG6500CX/EG5500CXS/EG6500CXS engines.

Torque Values

Specific torque values for engine and frame bolts and nuts.

Generator Side (MH, RH, KH, UH, SH, SKH, RGH Type)

Wiring diagram for the generator side for various types.

Generator Side (RHH Type)

Wiring diagram for the generator side specifically for RHH type.

Generator Side (LDH, LTH Type)

Wiring diagram for the generator side for LDH/LTH types.

Control Panel Side (CX-RHH Type)

Wiring details for the control panel side of CX-RHH type generators.

Control Panel Side (CXS-RHH Type)

Wiring details for the control panel side of CXS-RHH type generators.

Control Panel Side (CX-MH Type)

Wiring details for the control panel side of CX-MH type generators.

Control Panel Side (CXS-MH Type)

Wiring details for the control panel side of CXS-MH type generators.

Control Panel Side (CX-RH, KH, SH Type)

Wiring details for the control panel side of CX-RH/KH/SH types.

Control Panel Side (CXS-RH, KH, SH Type)

Wiring details for the control panel side of CXS-RH/KH/SH types.

3. Maintenance

Maintenance Schedule

Schedule for regular service intervals based on time or usage.

Valve Clearance Check;Adjustment

Procedure for checking and adjusting valve clearance.

Maintenance

Maintenance Schedule

Regular service intervals for various maintenance items.

Engine Oil Level Check

Step-by-step guide for checking engine oil level with diagrams.

Engine Oil Change

Detailed procedure for changing engine oil, including torque specs.

Valve Clearance Check;Adjustment

Step-by-step guide for measuring and adjusting valve clearance.

4. Troubleshooting

Troubleshooting

Hard Starting

Continues troubleshooting for hard starting, focusing on compression issues.

Engine Speed Does Not Stabilize

Troubleshooting guide for unstable engine speed.

Engine Does Not Stop When Combination; Engine Stop Switch Is Turned Off

Troubleshooting steps for when the engine fails to stop.

Engine Does Not Stop When Engine Oil Level Is Low

Troubleshooting guide for engine not stopping due to low oil level.

5. Fuel System

Fuel System

Carburetor Removal;Installation

Instructions for removing and installing the carburetor and related components.

Carburetor Disassembly;Assembly

Detailed procedure for disassembling and reassembling the carburetor.

6. Governor System

Governor System

Governor Adjustment

Procedure for adjusting governor speed using pinch bolts and limiting screws.

7. Generator;Charging System

Generator;Charging System

Generator System Troubleshooting

Troubleshooting steps for "No DC Output" issues, checking windings and diodes.

Charging System Troubleshooting (CXS Type Only)

Troubleshooting steps for charging system issues on CXS models.

Flywheel;Fuel Cut;Charge Coil;Power Coil Removal;Installation

Procedure for removing and installing flywheel, coils, and related parts.

Generator Removal

Steps for removing the generator from the engine, including brush holder removal.

Generator Installation

Procedure for installing the generator, including alignment and torque specs.

Generator Disassembly;Assembly

Detailed steps for disassembling and assembling the generator rotor and stator.

8. Ignition System

Ignition System

Ignition System Troubleshooting

Troubleshooting guide for "No Spark at Spark Plug" issues.

Spark Test

Guide on how to perform a spark test to check for spark.

Ignition Coil Inspection

Procedures for inspecting ignition coil primary and secondary resistance.

9. Starting System

Starting System

Starting System Troubleshooting (CXS Type Only)

Troubleshooting guide for starter motor not operating on CXS models.

Starter Motor Removal;Installation (CXS Type Only)

Steps for removing and installing the starter motor on CXS models.

Starter Motor Disassembly;Assembly (CXS Type Only)

Detailed procedure for disassembling and assembling the starter motor on CXS models.

Starter Motor Inspection (CXS Type Only)

Inspects starter motor solenoid, brush length, and brush continuity on CXS models.

10. Other Electrical

Control Panel Disassembly;Assembly

Detailed procedure for disassembling and assembling the control panel.

Other Electrical

Control Panel Disassembly;Assembly CX-RHH type

Exploded view and steps for control panel disassembly/assembly for CX-RHH type.

Control Panel Disassembly;Assembly CXS-RHH type

Exploded view and steps for control panel disassembly/assembly for CXS-RHH type.

Control Panel Disassembly;Assembly CX-RH, KH, SH type

Exploded view and steps for control panel disassembly/assembly for CX-RH/KH/SH types.

Control Panel Disassembly;Assembly CXS-RH, CXS-KH, CXS-SH type

Exploded view and steps for control panel disassembly/assembly for CXS-RH/KH/SH types.

Control Panel Disassembly;Assembly CX-UH type

Exploded view and steps for control panel disassembly/assembly for CX-UH type.

Control Panel Disassembly;Assembly CXS-UH type

Exploded view and steps for control panel disassembly/assembly for CXS-UH type.

Control Panel Disassembly;Assembly CX-MH type

Exploded view and steps for control panel disassembly/assembly for CX-MH type.

Control Panel Disassembly;Assembly CXS-MH type

Exploded view and steps for control panel disassembly/assembly for CXS-MH type.

Control Panel Disassembly;Assembly CX-LDH, LTH type

Exploded view and steps for control panel disassembly/assembly for CX-LDH/LTH types.

Control Panel Disassembly;Assembly CXS-LDH, CXS-LTH type

Exploded view and steps for control panel disassembly/assembly for CXS-LDH/LTH types.

Control Panel Disassembly;Assembly CX-SKH type

Exploded view and steps for control panel disassembly/assembly for CX-SKH type.

Control Panel Disassembly;Assembly CXS-SKH type

Exploded view and steps for control panel disassembly/assembly for CXS-SKH type.

Control Panel Disassembly;Assembly CX-RGH type

Exploded view and steps for control panel disassembly/assembly for CX-RGH type.

Control Panel Disassembly;Assembly CXS-RGH type

Exploded view and steps for control panel disassembly/assembly for CXS-RGH type.

11. Muffler

Muffler

Muffler Removal;Installation

Detailed procedure for muffler removal/installation with safety caution.

12. Engine Removal;Installation

Engine Removal;Installation

Engine Removal;Installation

Steps for removing and installing the engine, including rubber mounts and bolts.

13. Cylinder Head

Cylinder Head

Cylinder Head Removal;Installation

Steps for removing and installing the cylinder head, including torque specs.

Cylinder Head Disassembly;Assembly

Detailed steps for disassembling and assembling cylinder head valve components.

Cylinder Head;Valves Inspection

Procedures for checking cylinder compression and cylinder head warpage.

14. Cylinder Block

Bearing;Oil Seal Replacement

Steps for replacing bearings and oil seals in the cylinder block.

Cylinder Block

Crankshaft;Camshaft;Balancer Weight (Except EG3600;EG4000);Piston Removal;Installation

Procedure for removing and installing crankshaft, camshaft, balancer weight, and piston.

Governor Disassembly;Assembly

Detailed steps for disassembling and assembling the governor system components.

Piston Disassembly;Assembly

Procedure for disassembling and assembling the piston, rings, and pin.

Cylinder Block Inspection

Inspection of camshaft holder I.D., cylinder barrel, and cylinder sleeve I.D.

15. Technical Features

Technical Features

16. Wiring Diagrams

Wiring Diagrams

Honda EG6500CXS Specifications

General IconGeneral
AC Output120/240V
Displacement389 cc
EngineHonda GX390
Rated Power5.5 kVA
Maximum Power6.5 kVA
DC Output12V
Starting SystemElectric

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