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Thank you for purchasing a Honda generator. This manual covers operation and maintenance of the EX800 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
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CONTENS CONTENTS ................................... 3 1. GENERATOR SAFETY ............................ 4 2. COMPONENT IDiNTlFlCATlON ................................. 6 3. PRE-OPERATION CHECK ................................... 8 4. STARTING THE ENGINE ....................................... 11 5. GENERATOR USE ................................... 14 6. STOPPING THE ENGINE ......................................... 15 7. MAINTENANCE ............................... 23 .8. TR
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1. GENERATOR SAFETY To ensure safe operation - l Place the generator at least 1 m (3 ft) away from buildings or other equip- ment when operating the generator. l Operate the generator on a level surface. If the generator is tilted, fuel spillage may result. l Exhaust gas contains poisonous carbon monoxide. Never run the generator in an enclosed area. Be sure to provide adequate ventilation. l Know how to stop the generator quickly and understand operation of all the controls. Never per
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2., COMPONENT IDENTIFICAT.ION CIRCUIT BREAKERS TOP COVER L ALERT SWITCH PILOT LAMP FREQUENCY METER C RECEPTACLES GOVERNOR ADJUSTMENT TERMINAL \ dlL FILLER
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CA ,RRYING HANDLE FUEL TANK CAP FUEL GAUGE \. I RIGHT SI DE COVER \ EXHAUST MUFFLER OUTLET COVER
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3. IPRE-QPERATBON 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. Usfe 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
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2. Check the fuel level. Check the fuel gauge, and refill the tank.if the fuel level is low. Use low lead or unleaded automotive gasoline with a pump octane rating of 86 or higher. Never use an oil/gasoline mixture or dirty gakoline. 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. l Gasoline is extremely flammable and explosive under certain conditions. Refuel in a well ventilated
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4. STARTING THE ENGINE 1. Disconnect any load from the AC receptacles or DC terminals. 2. Move the engine switch to “ON”. 3. Turn the choke.lever to CLOSE. 8
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4. Pull the starter rope lightly until resistance is felt, then pull briskly, LAMP CAUTION: Do not allow the starter grip to snap back against the generator. Return it gently to prevent damage to the housing. NOTE: Make sure the pilot lamp comes on. If not, the filament may be burnt out. 5. Turn the choke lever to OPEN as the engine warms up. 9
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5. GENERATOR USE l 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. l 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 u
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Oil alert system The oil alert system automatically stops the engine before the oil level becomes too low. If this occurs, the oil alert switch will pop out. Add the recommended oil (see page 6), and press the switch in to allow restarting. OIL ALERT SWITCH 11
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AC operation 1. Start the engine and make sure the pilot lamp comes on. If not, the fila- ment may be burnt out. 2. Plug in the appliance. 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 gen- erator. 3. Check the frequency meter to verify that the gene
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DC operation The DC terminals may be used for charging 12 volt automotive-type batteries only. - l Batteries produce explosive gases. Keep sparks, flames, and cigarettes away. To prevent the possibility of creating a spark near the battery, connect the charging cord first to the battery, then to the generator, and disconnect the cord first at the generator. l Disconnect the vehicle’s grounded battery cable first, and after charging, reconnect the grounded cable last. This procedure will
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6. STOPPING THE ENGINE To stop the engine in an emergency, move the engine switch to OFF. In normal use: 1. Tur? ‘off the electrical appliance or disconnect the charging cord from the generator. 2. Move the engine switch to OFF. 14
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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. m Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. The exhaust con- tains poisonous carbon monoxide gas. CAUTION: Use only genuine HONDA parts or their equivalent. The use of replacement parts which are not of equivalent quality
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Maintenance Schedule REGULAR SERVICE First Every Every Every Perform at every indi- month 3 months 6 months year cated month or oper- Daily or or or or ating hour interval, 20 Hrs. 50 Hrs. 100 Hrs. 300 Hrs. whichever occurs Inspection l Engine oil Change . l ’ Combustion chamber and Fuel line inspection (Replace if necessary) Spark arrester Clean every 100 operating hours. NOTE (1) : Service more frequently when used in dusty areas. (2) : These items should be serviced by an au
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Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining. 1. Remove the oil filler cap, and drain the oil. 2. Refill with the recommended oil (see page 6) and check the level. OIL CAPACITY: 0.45 Q (0.48 US qt) .LER OIL DRAIN BOLT 17
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Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent car- buretor malfunction, service the air cleaner regularly (page 16). Service more frequently when operating the generator in extremely dusty areas. B Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. CAUTION: Never run the generator without the air cleaner. Rapid engine wear.may result. 1. Unsnap the air cleaner case springs,
