HONDA GENERATOR EX7 OWNER'S MANUAL Honda EX7 OWNER’S MANUAL The”e-SPEC"mark symbolizes environmentally 5w responsible technologies applied to Honda power ----~~—- equipment, which contains our wish to “preserve nature for generations to come." Thank you for purchasing a Honda generator. This manual covers operation and maintenance of the EX7 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 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 nstructions 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. AWARNING Honda generator is designed to give safe and dependable service it 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. o The illustration may vary according to the type. CONTENTS _._._. PM? _. EDS-OWN?” 9‘95” N.“ . WIRING DIAGRAM SAFETY INSTRUCTIONS SAFETY LABEL LOCATIO .i CE mark and noise label locations COMPONENT IDENTIFICATION PRE-OPERATION CHECK STARTING THE ENGINE. o Carburetor Modification for HIQI‘I Altitude Operation GENERATOR USE STOPPING THE ENGINE. MAINTENANCE ............ TRANSPORTING/STORAGE TROUBLESHOOTING SPECIFICATIONS“ MAJOR Honda DISTRIBUTOR ADDRESSES .. 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. 0 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 Responsi ility 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 orfoot caught in the generator and it may cause accident. Consult your authoriled Honda dealer for disassembly and service of the generator that are not covered in this manual. 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 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. 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 (3 feet) away from buildings and other equipment during operation. #00 not enclose the generator in any structure. 7 Keep flammable materials away from the generator. Some pans 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. 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. 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. [For Australian model: U type] A No XHAUST ECHAPPEIENT-CMAUD 3. COMPONENT IDENTIFICATION FUEL CAP VENT LEVER CHOKE LEVER SPARK PLUG MAINTENANCE COVER Record the frame serial number in the space below. You will need this serial number when ordering parts. Frame serial number: 12 CONTROL PANEL U type AC RECEFTACLE 13 4. 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: 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). 30 5W-30 - 10W-30 -20 ~10 0 1D 20 30 40"C r—r—r—v—r—r—r—v—r—r—I—r—I 0 20 40 60 80 100°F AMBIENT TEMPERATURE SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range. 14 Loosen the cover screw and remove the left side maintenance cover. Remove the oil filler cap, and wipe the dipstick with a clean rag. Check the oil level by inserting the dipstick in the filler hole without screwing it in. if the oil level is below the end of the dipstick, refill with recommended oil up to the top of the oil filler neck. Reinstall the oil filler cap/dipstick securely. CAUTION: Running the engine with insufficient oil can cause serious engine damage. COVER SCREW OIL FILLER CAP/DIPSTICK LEFT SIDE MAINTENANCE COVER UPPER LEVEL OIL FILLER HOLE NOTE: The Oil Alert System will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, it is still advisable to visually inspect the oil level regularly. 1 5 2. Check the fuel level. If the fuel level is low, refuel the fuel tank until the level as specified. After refueling, tighten the fuel filler cap securely. Use automotive unleaded gasoline with a Research Octane Number of 91 or higher Ia 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. “WARNING '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 limit mark). After refueling, make sure the fuel filler 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. 0Avoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. FUEL FILLER CAP UPPER LIMIT MARK 16 NOTE: 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 warrantw. To avoid this please strictly follow these recommendations: . Only use specified gasoline (see page 16 ). 0 Use fresh and clean gasoline. . To slow deterioration, keep gasoline in a certified fuel container. . If long storage lmore than 30 days) is foreseen, drain fuel tank and carburetor (see pages 38and 39 i. 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. NOTE: - 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. 17 3. Check the air cleaner. Check the air cleaner element to be sure it is clean and in good condition. Loosen the cover screw and remove the left side maintenance cover. Press the latch tab on the top of the air cleaner body, remove the air cleaner cover, check the element. Clean or replace the element if necessaw (see page 35 l. CAUTION: Never run the engine without the air cleaner element. Rapid engine weer will result from contaminants, such as dust and dirt, being drawn through the carburetor, into the engine. COVER SCREW LEI-T SIDE MAINTENANCE COVER AIR CLEANER BODV AIR CLEANER ELEMENT AIR CLEANER COVER LOWER TAB 18 5. STARTING THE ENGINE Before starting the engine disconnect any load from the AC receptacle. 1.Turn the fuel cap vent leverfuily clockwise to the ON position. NOTE: Turn the fuel cap vent lever to the OFF position when transporting the generator. FUEL CAP VENT LEVER 2. Turn the engine switch to the ON position. ENGINE SWITCH 19 3. Move the choke lever to the CLOSED position. NOTE: Do not use the choke when the engine is warm or the air temperature is high. CHOKE LEVER CLOSED CLOSED 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. CAUTION: o 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 iniury. - Do not allow the starter grip to snap back. Return it slowly by hand. STARTER GRIP 20 5. Move the choke leverto the OPEN position as the engine warms up. CHOKE LEVER NOTE: If the engine stops and will not restart, check the engine oil level (see page 14 ) before troubleshooting in other areas. 21 0 Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 1,500 meters (5,000 feet), have your authorized Honda servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life. Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (LOGO-foot) increase in altitude. The ef- fect of altitude on horsepower will be greater than this if no carburetor modification is made. CAUTION: When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications. 22 6. GENERATOR USE Be sure to ground the generator when the connected equipment is grounded. AWARNING 0 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. GROUND TERMINAL __l_ :— EARTH MARK 23 CAUTION: 0 Do not exceed the current limit specified for any one receptacle. 0 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 (200 feet) for cables of 1.5 mm2 (0.0023 inz) and 100 m (330 feet) for cables of 2.5 mm2 (00039 mi). Long extension cables will lower usable power due to resistance in the extension cable. 0 Keep the generator away from other electric cables or wires such as commercial power supply lines. NOTE: - The DC receptacle can be used while the AC power is in use. If you use both at the same time, do not exceed the maximum AC power. Maximum AC power: 0.5 kVA -Most appliance motors require more than their rated wattage for startup. 0Make 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. °Substantial overloading will switch OFF the AC circuit protector. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the AC circuit protector OFF, but will shorten the service life of the generator. 0 Limit operation requiring maximum powerto 30 minutes. Maximum power is: 0.7 kVA 0 For continuous operation, do not exceed the rated power. Rated power is: 0.6 kVA - In either case, the total power requirements (VA) of all appliances connected must be considered. 24 AC applications 1. Start the engine and make sure the output indicator (green) comes on. 2. Confirm that the appliance to be used is switched off, and plug in the appliance. 0 El 0/ ac cchUll’ PROTECTOR ourpur INDICATOR (GREEN) PLUG CAUTION: - Substantial overloading will switch off the circuit protector. Marginal overloading may not switch off the circuit protector, but it will shorten the servi e life of the generator. 0 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 ofl the generator engine switch immediately. Then disconnect the appliance, and examine it for signs of malfunction. 25 AC Circuit Protector The AC circuit protector will automatically switch OFF (push button comes out) if there is a short circuit or a significant overload of the generator at receptacle. If an AC circuit protector switch OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the circuit before resetting the AC circuit protector 0N (pushing the push button in). AC RECEPTACLE AC CIRCUIT PROTECTOR NOTE: If an overloaded circuit trips the AC circuit protector, reduce the electrical load on the circuit, and wait a few minutes before resuming operation. The yellow indicator inside the circuit protector button will pop out to show that the circuit protector has switched off. Push the button in to reset the circuit protector. 26 Output Indicator The Output indicator (green) will remain ON during normal operating conditions. If the output indicator (green) blinks, current to the connected appliancels) will shut off. When this happens, stop the engine and disconnect the appliance(s). Then restart the engine. If the output indicator (green) blinks again, consult your Honda generator dealer. OUTPUT INDICATOR (GREEN) 27 DC application The DC receptacle may be used for charging 12 volt automotive-type batteries only. 1.Connect the charging cable to the DC receptacle of the generator and then to the battery terminals. CMRGING CABLE (SOLD SEPARATELY) AWARNING 0 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. 0 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. CAUTION: - Do not attempt to start an automobile engine with the generator still connected to the battery. The generator may be damaged. 0 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. 28 AWARNING - Batteries produce explosive gases: If ignited, and explosion can cause serious injury or blindness. Provide adequate ventilation when charging. - CHEMICAL HAZARD: Battery electrolyte 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 electrolyte gets into your eyes, flush thoroughly with warm water for at least 15 minutes and call a physician immediately. - POISON: Electrolyte is poison. ANTIDOTE , External: Flush thoroughly with water. 7 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. 2. Start the engine. NOTE: 0 The DC receptacle can be used while the AC power is in use. 0 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. ‘3‘? or; DC CIRCUIT PROTECTOR 29 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 Oil Alert system shuts down the engine, the Oil Alert indicator (red) will come on when you operate the starter, and the engine will not run. lf this occurs, check the engine oil level (see page 14 ). OIL ALER’T INDICATOR (RED) 30 7. STOPPING THE ENGINE To stop the engine in an emergency, turn the engine switch to the OFF position. IN NORMAL USE: 1.Switch off the connected equipment and pull the inserted plug. ENGINE SWITCH 31 3.Turn the fuei cap vent lever fully counterclockwise to the OFF position. FUEL CAP VENT LEVER CAUTION: Be sure the fuel cap vent lever and the engine switch are OFF when stopping, transporting and/or storing the generator. 32 8. MAINTENANCE The purpose of the maintenance and adjustment schedule is to keep the generator in the best 0 erating condition. Inspect or servme as sche uled in the table below. “WARNING 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. - Iniury 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 after stofping the engine. Be careful not to touch the muffler w I e it is hot. et the engine cool before maintenance. CAUTION: Use Honda Genuine parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the generator. Maintenance Schedule REGULAR SERVICE PERIOD (3) Each use First Every Every Every Periormed at every indicated month 3 months 6 months 2 years month or operating hour interval, or or or or whichever comes first. 10 hrs. 50 hrs. 100 hrs. 300 hrs. ITEM Engine oil Check level 0 fl Change 0 0 fl Air cleaner Check 0 Clean 0 (1) Spark plug Check-adjust 0 Replace 0 Valve Clearance Check-adiust O (2] Combustion Clean After every 300 hrs [2) chamber Fuel tank 81 filter Clean Every year (2) Fuel line Check Every 2 years (Replace if necessam (2) NOTE: meervice more frequently when used in dusty areas. lZlThese items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proiieienr. Reier to the Honda shop manual iorservioe procedures. iSlFor commercial use, log hours of operation to determine proper maintenance intervals. 33 1. CHANGING OIL Drain the oil while the engine is still warm to assure rapid and complete draining. CAUTION: Make sure to turn the engine switch and the fuel cap vent lever OFF before draining. 1. Loosen the cover screw and remove the left side maintenance cover. 2. Remove the oil filler cap/dipstick. 3. Drain dirty oil into a container thoroughly. 4. Refill with the recommended oil (see page 14) and check the oil level. 5. Reinstall the oil filler cap/dipstick securely. 6. Reinstall the left side maintenance cover and tighten the cover screw securely. ENGINE OIL CAPACITY: 0.25 L (0.26 us qt, 0.22 Imp qt) COVER SCREW UPPER LEVEL OIL FILLER CAP/ DIPSTICK OIL FILLER HOLE Wash your hands with soap and water after handling used oil. NOTE: Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local sen/ice station for reclamation. Do not throw it in the trash or pour it on the ground. 34 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. [AWARNING Do not use gasoline or low flash point solvents for cleaning. They are flammable and explosive under certain conditions. CAUTION: Never run the generator without the air cleaner. Rapid engine wear may result. 1. Loosen the cover screw and remove the left side maintenance cover. 2.Press the latch tab on the top of the air cleaner body, and remove the air cleaner cover. 3. Wash the element in a non-flammable or high flash point solvent and dry itthoroughly. 4. Soak the element in clean engine oil and squeeze out the excess oil. 5. Reinstall the air cleaner element and the cover. 6.Reinsta|l the air cleaner cover by inserting the lower tabs, and the latch tab. 7. Reinstall the left side maintenance cover and tighten the cover screw securely. COVER SCREW AIR CLEANER ELEMEA;< Stroke 41.8 X 36.0 mm (1.64 in X 1.42 in) Compression ratio 8.0:1 J Engine speed 4,500 rpm _ Cooling system Forced air Ignition system Full transistor Oil capacity 025 L (0.26 US qt, 0.22 Imp qt) Fuel tank capacity 2.1 L (0.55 US gal, 0.46 Imp gal) Spark plug CR4HSB (NGK) U14FSR