Honda EW171, Owner'S Manual

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Page 2: ...eep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the generator and should remain with the generator if resold The information and specifications included in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinueor changespecificationsor design at any time...

Page 3: ...ormation is intendedto help you avoid damage to your generatodwelder other property or the environment We suggest you read thewarranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is aseparate document that should have been givento you by your dealer When your generator welder needs scheduled maintenance keep in mind that your tlonda servicing ...

Page 4: ...rator welder You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the generator welder Safety Messages preceded by a safety alert symbolA a n d one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT...

Page 5: ...ld Selector Switch 15 Welding Cable Terminal 16 Welding Current Adjust System 16 GENERATOFUWELDER USE 17 Connections to a Building Electrical System 17 Welding 19 AC Operation 18 Selecting the Correct Welding Current 19 Welding Cable Selection 20 Welding Duty Cycle 20 Polarity Selection 21 High Altitude Operation 21 Auto throttle System 22 PREOPERATICIN CHECK 23 Engine Oil 23 Fuel Recommendation 2...

Page 6: ...ation 29 Maintenance Schedule 33 Engine Oil Change 34 Air Cleaner Service 35 Spark Plug Service 37 TRANSPORTING STORAGE 39 WIRING DIAGRAM 43 SPECIFICATIONS 44 INSTALLATION OF OPTIONALPARTS 45 INDEX 49 Fuel Sediment Cup Cleaning 36 Spark Arrester Maintenance 38 TROUBLESHOOTING 41 WARRANTY SERVICE INFORMATION 48 4 ...

Page 7: ...R FUEL LEAKS lCFNTR6LER RU IL H Y A H I FUlTE HI ESSEHCE STOP EH61NE BEFORE REFUELIHG ARRETER LE YOTEUR AVANT DE REFAIRE LE PLEIN REP HDUE SUR L APPAREIL 0 ESCAPE PARAR MOTOR ANTES OE ECHAR MIHSPECCIOHAR PARA COMBUSTIEU OERRAMAOO Itor pARNING CARBON MONOXIDE DO NOT USE INDOORS EXHAUST GAS CONTAINS POISONOUS I RISOUE D EMPOISONNEMENT DU GAZ NE PAS UTlLlSER DANS UN ENDROIT FERME A CAUSE DU I IATENCl...

Page 8: ...E U T o N 1RATE o Jk7 E PSDC 1i G E 4 C8lz WITH RECOMMENDEDOIL FREQUENCY 60 Hz FOR DETAILED EXPLANATION SEE THE OWNER S MANUAL DUTY CYCLE 50 130 A GASOLINE PETROL WELDER OUT PUT AC OUTPUT BE SURE TO FILL CRANKCASE CURRENT RANGE 130 A 26 5 V DC 6 ...

Page 9: ...ncy 0 Understand the use of all generator welder controls output receptacles and connections 0 Be sure that anyone who operates the generator welder receives proper instruction Do not let children operate the generator welder without parental supervision Carbon Monoxide Hazards Exhaust contains poisonous carbon monoxide a colorless and odorless gas Breathingexhaust can cause loss of consciousness ...

Page 10: ...rician Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials Keepthe generator welderat least 1 meter 3feet away from buildings Do not enclose the generator welder in any structure Keep flammable materials away from the generator welder and other equipment during operation The mufflerbecomesvery hotduring operation and remainshotfor awhile after stopping the engine Be c...

Page 11: ...elding arc with unprotected eyes may produce severe pain and event ternporary blindness Use a helmet orhand heldshieid with a 10 or darker filter lens Filter lenses eliminate the harmful effects of infrared and ultraviolet radiation from the arc and reducethe glare from the arc light as well Wear protective clothing such asleathergloves cap sleeves jacket apron and high topsafety shoes All outer c...

Page 12: ...COMPONENT IDENTIFICATION FUEL GAUGE WELDING CURRENT ADJUSTMENT KNOB WELDING CABLE RECEPTACLES GlNE OIL FILLER CAP STARTER GRIP ENGINE OIL DRAIN PLUG AUTO THROTTLE SWITCH ENGINESERIAL NUMBER 10 ...

Page 13: ...cord the engine and frame serial numbers for yo lr f fure reference Refer to these serial numbers when ordering parts and when making technical or warranty inquiries see page 48 Frame serial number Engine serial number 11 ...

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Page 15: ... fuel tankto the carburetor Be sure to return the fuel lever to the OFF position after stopping the engine L VALVE LEVER Choke Rod The choke is used to provide an enriched fuel mixture when starting a cold engine It can be opened and closed by operatingthe chokerod manually Pull the rod out toward CLOSED to enrich the mixturefor cold starting CHOKE ROD 13 ...

Page 16: ...cuit breaker ON again The circuit breaker may be used to switch the generator power ON or OFF Oil Alert System The Oil Alerta system is designed to prevent engine damage caused by an insufficientamountof oil inthe crankcase Beforethe oil levelinthe crankcase can fall below a safe limit the Oil Alert System will automatically stop the engine the engine switch will remain in the ON position If the e...

Page 17: ... AC DC Weld selector switch is located on the control panel To avoid accidental arcing one cable end should befirmly attachedto the object to bewelded andthe electrode holder at the end of the other cable should be held inthe operator s hand DCvoltage ispresent at the welding terminals at all times regardless of the position of the AC DC WELD selector Under no circumstances shouldanytypeof electri...

Page 18: ...e proper gauge cable may lead to painful burns and ordamageto equipment See table on page20 Welding Current Adjust System For best results it is essential that current be adjusted properly according to the thickness of the materials to be welded and the methodof welding See Page 19 CURRENT ADJUSTMENT KNOB 16 ...

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Page 20: ... appliances Do not exceed the current limit specified for any one receptacle Substantial overloading will switch off the circuit breaker Marginal overloading may not switch off the circuit breaker but it will shorten the service life of the generator welder If an overloaded circuit causes the AC circuit breaker to switch off reduce the electrical loadonthe circuit andwait afew minutesbeforeresetti...

Page 21: ...he proper gauge cable may lead to painful burns and or damageto equipment See table on page 20 3 Start the engine and when it has warmed up fully turn the Auto Throttle 4 Turn the AC DC WELD selector to the DC WELD position 5 Setthe currentadjustmentknobto the propercurrent levelfor thejob being Switch to the AUTO position done See page 20 Selecting theCorrect Welding Current Measurethe thickness ...

Page 22: ...o cause painful burns LENGTH IN FEET 1 CABLE 1 CABLE 0 50 FT 150 100 FT llO0 250 FT GAUGE DIA CURRENT CAPACITY AMPERES 1 170 200 250 644 2 195 200 604 NOTE The cable lengthsgiven in the table above are the combined lengths of the negative and positive cables Welding Duty Cycle The duty cycle is the percentage of time that the welder can be operated in a given 10 minute period Forexample ata ratedo...

Page 23: ... A very rich mixture will also foul the sparkplug and cause hard starting Highaltitudeperformancecanbeimprovedbyspecificmodificationstothe carburetor If yolu always operate your generator welder at altitudes above 1 500 meters 5 00Ofeet have an authorized Hondaservicingdealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 3...

Page 24: ...t allow the engine to reach normal operating rpm when they are connected to the generator Turn the auto throttle to the OFF position and connect the appliance to the generator If the engine still will not reach normaloperating speed check that the appliance does not exceed the rated load capacity of the generator welder To avoid extended warm up periods keep the switch OFF until the engine reaches...

Page 25: ... ways checktheAPlSE RVlCElabelon the TEMP 20 0 20 40 60 80 1 O O F oil container to be sure it includes 30 20 10 o IO 20 30 40 C the letters SJ AMBIENT TEMPERATURE SAE 1OW 30is recommended for general all temperature use Other viscosities shown in the chart may be used whenthe average temperature in your area is within the indicated range 1 Remove the oil filler cap and wipe the dipstick clean 2 C...

Page 26: ...k cap is closedproperly and securely Becareful notto spill fuelwhen refueling Spilledfuel or fuel vapor may ignite If any fuel isspilled makesuretheareaisdrybefore starting the engine 0 Avoid repeated or prolonged contact with skin or breathingof vapor 0 KEEP OUT OF REACHOFCHILDREN Fueltank capacity 4 50 US gal 17 0 e 3 74 Imp gal FUEL TANK CAP FUEL FILTER SCREEN Use gasoline with a pump octane ra...

Page 27: ... using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing upto 10 ethanol byvolume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by...

Page 28: ...Pull the starter grip lightly until resistance is felt then pull briskly INOTlCEl Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter or housing 7 Push the choke rod to the OPEN position as the Engine warms up 8 If you wish to use the auto throttle system turn the auto throttle switch to the AUTO position after the engine has warmed up fo...

Page 29: ... nance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your generator undersevere conditions such as sustained high load or high temperature operation or u...

Page 30: ...poisoning from engine exhaust Besurethere isadequateventilationwheneveryou operatethe engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Readthe instructionsbeforeyou begin and makesure you havethe tools and skills required To reduce the possibility of fire or explosion be careful when working...

Page 31: ... and California CleanAir Acts EPA and California regulations require all manufacturers 20 furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission contro...

Page 32: ... any of thefollowing symptoms haveyour engineinspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption 30 ...

Page 33: ...ndquality may impair the effectiveness of your emission control system A manufacturerof an aftermarketpart assumesthe responsibilitythat the part will notadverselyaffectemissionperformance The manufactureror rebuilder of the part mustcertifythat useofthe partwill notresultin afailure ofthe engine to comply with emission regulations Maintenance 8Follow the maintenanceschedule on page 33 Remember th...

Page 34: ...ion relating to the engine s emission durability period The descriptive term indicates the useful lifeperiodfor the engine semissioncontrol system Seeyour Emission Control Warranty for additional information Descriptive Term Applicable to Emission Durability Period Moderate 50 hours 0 65 cc Intermediate 300 hours 0 65 cc Extended 125 hours 0 65 cc 125 hours greater than 65 cc 250 hours greater tha...

Page 35: ...ster Clean I I Clean Adjust Check Adjust Clean chamber l l I I I I Fuel tank and filter Clean Every 3 months 50 Hrs or 0 1 0 I Fuel tube Check Every 2 years Replace if necessary 2 NOTE Emissionrelated items 1 Service morei requentlywhen used in dusty areas 2 TheseitemsshouldbeservicedbyanauthorizedHondagenerator dealer unless the owner 3 Forprofessionalcommercialuse log hours of operationia determ...

Page 36: ... recommended oil see page 23 and check the level Oil capacity 1 I6 US qt 1 1 l 0 97 Imp qt drain the oil OIL DRAIN PLUG CAP UPPER LIMIT Y Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggestyoutake it inasealed containerto your localservice station or recycling center for reclamation Do notthrow ...

Page 37: ... COVER 1 Unsnap the air cleaner cover clips removethe air cleaner cover and remove the element 2 Wash the element in a solutionof household detergent and warm water then rinsethoroughly or wash in ncnflammable or high flash point solvent Allow the element to dry thoroughly CLI6 AIR CLEANER ELEMENT 3 Soak the element in clean engine oil and squeezeout the excess oil The engine willsmoke during init...

Page 38: ...r a long time the sediment cup should be cleaned 1 Turnthe fuelvalve leverto the OFFposition Removethe sediment cup 0 ring and filter 2 Clean the sediment cup O ring and filter in nonflammableor high flash point solvent 3 Reinstallthe filter O ring and sediment cup 4 Turn the fuel valvelever ON and checkfor leaks FUEL VALVE LEVER FUEL FILTER SEDIMENT CUP 36 ...

Page 39: ...will be very hot Be Careful not to touch the muffler 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use a spark plug wrench to remove the spark plug PLUG WRENCH PLUG CAP 4 Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it isto be reused 5 Measure the plug gap with a feeler gauge Correct as ...

Page 40: ...ug can become veryhot and could damagethe engine Never use spark plugs which have an improperheat range Useonly therecommended spark plugsor equivalent Spark Arrester Maintenance If the generator welder hasbeen running the muffler will be very hot Allow it to cool before proceeding The spark arrester must be servicedevery 100 hours to maintain its efficiency Clean the spark arrester as follows 1 L...

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Page 42: ...uring this procedure DRAl N SCREW 2 Change the engine oil 3 Removethe spark plug and pour about a tablespoon of clean engine oil intothe cylinder Crankthe engine several revolutionsto distribute the oil then reinstall the spark plug 4 Slowly pull the starter grip until resistance is felt At this point the piston is coming upon its compression stroke and both the intake and exhaust valves are close...

Page 43: ... 2 Remove the spark plug and installthespark plug in the plug cap 3 Set the plug side electrodeonthe cylinder head 4 Crank the engine sparks should jump across the gap YES 7 Isthe fuel reaching the carburetor To check NO ment cup I Clean the fuel sedi I I IYES Ifthe engine still1does not start take the gen eratodwelder to an authorized Honda aenerator dealer 1 Turn off the fuel DRAIN SCREW valve a...

Page 44: ...ny defects L an authorized Honda gene NO DEFECTS DEFECTS plianceor equipment Take the electrical appliance or equipment to anelectrical shop for repair When the welding arc is weak I s thecable size cor lection see page 20 rect NO Check the welding cable se YES Gauge Diameter w Check the electrode diameter being used see page 20 YES aenerator dealer 42 ...

Page 45: ...WIRING DIAGRAM 43 ...

Page 46: ...acity BPR5ES NGK W16EPR U DENSO Spark plug 4 5 US gal 1 7 0e 3 74 Imp gal Generator Rated current 26 5 V 130 A DC 50 170 A Welding current WELDING Ratedvoltage output 50 130 A Duty cycle Electrode diameter Rated voltage 3 32 1 8 5 32 in 2 6 4 0 mm 60 Hz Rated frequency 120v Output Rated amperage 33 3 A Rated output 4 0 KVA Tune up Specifications ITEM MAINTENANCE SPECIFICATION Spark plug gap No oth...

Page 47: ...tion 8 x 16 m m FLANGE BOLT 4 HANGER I NOTICE I 0 Position the hanger at the generator s balance point in the middle of Fit the end tabs of the hanger through the bracket slots and bolt the the fuel tank brackets to the hanger HAMGER FUEL TANK CAP 45 ...

Page 48: ...Install the four wheels on the axle shaft 2 Install the axle assembly on the generator using four bolts and nuts WHEEL STOPPER Inside Longer k I 1 Shorter end end 1 NOTE Install the shaft with wheel stopper facing engine side 46 ...

Page 49: ... wheels on the axle shaft 2 Installthe axle assembly on the generatodwelder using four boltsand nuts 3 Install the two stands using four bolts and nuts 4 Install right and left handleson the generator upper frameusing brackets and six bolts 47 ...

Page 50: ...d with the decision made by the dealership s manage ment contactthe Honda Power Equipment CustomerRelations Office You can write to American Honda MotorCo Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When youwrite or call please give us this information Model and serial number see page 11 0 Name of dealer who sold...

Page 51: ...em 17 High Altitude Operation 21 Polarity Selection 21 Selecting the Correct Welding Current 19 Welding 19 Welding Cable Selection 20 Welding Dut yCycle 20 INSTALLATIONOF OPTIONAL PARTS 45 MAINTENANCE 27 Air CleanerService 35 Air Index 32 Emission Control System Information 29 Engine Oil Change 34 Fuel Sediment Cup Cleaning 36 Importanceof Maintenance 27 Maintenance Safety 28 Maintenance Schedule ...

Page 52: ...INDEX SPECIFICATIONS 44 STOPPING THE ENGINE 26 TRANSPORTING STORAGE 39 TROUBLESHOOTING 41 WARRANTY SERVICE INFORMATION 48 WIRING DIAGRAM 43 STARTING THE ENGINE STOPPINGTHE ENGINE 26 50 ...

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