Honda GXE2.0S, Manual

Page 1: ...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 you...

Page 2: ...0 2 dummyhead dummyhead How to use this manual REVISION HISTORY No Date of revision Contents of revision 1 February 2021 Newly published ...

Page 3: ...CONTENTS dummyhead dummyhead SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 CONTROL UNIT 6 POWER UNIT 7 WIRING DIAGRAMS 8 INDEX ...

Page 4: ... manual Of course it is not practical or possible to warn you about all the hazards associated with servicing these products You must use your own good judgment Honda Motor Co Ltd 2021 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These...

Page 5: ...the hole Metric bolts nuts and screws may be not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it will be explained specifically in the text without the use of the symbols Replace the part s w...

Page 6: ...iagnostic Trouble Code EACV Electric Air Control Valve EBT Engine Block Temperature ECT Engine Coolant Temperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward FI Fuel Injection GND Ground HI High HST Hydrostatic Transmission HO2S Heated Oxygen sensor IAB Intake Air Bypass IAC Idle Air Control IAT Intake Air Temperature I D Inside...

Page 7: ...e this manual SOC State of Charge STD Standard SW Switch TBW Throttle By Wire TDC Top Dead Center TP Throttle Position VST Variable Speed Transmission VTEC Variable Valve Timing Valve Lift Electronic Control Abbreviated term Full term ...

Page 8: ...MEMO dummyhead dummyhead ...

Page 9: ...1 1 1 dummytext 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 DIMENSIONAL DRAWINGS 1 4 P T O DIMENSIONAL DRAWINGS 1 5 ...

Page 10: ... CHARGER 1 Model GXE2 0S Type M1 V1 V2 V3 Overall length Motor 233 mm 9 2 in 216 mm 8 5 in Control unit 351 mm 13 8 in Overall width Motor 224 mm 8 8 in Control unit 299 mm 11 8 in Overall height Motor 194 mm 7 6 in Control unit 127 mm 5 0 in 1 251 mm 9 9 in 2 Mass weight 16 5 kg 36 4 lbs 1 22 9 kg 50 5 lbs 2 15 8 kg 34 8 lbs 1 22 2 kg 48 9 lbs 2 Model CV7285Z Type JM AM EM BM SWM Overall length 2...

Page 11: ...View from P T O shaft end Cooling system Forced air Breather system Air opened type Stopping system Regenerative braking resistant consumption Rotor sensor Hall IC rotation sensor thermistor temperature sensor built in Control unit Type 3 phase square wave drive Control system PWM Pulse Width Modulation Maximum 3 phase output current 80 A Cooling system Air cooled Battery pack Type DP72104Z Li ion...

Page 12: ... 13 8 299 11 8 12 5 0 49 10 5 0 41 125 5 4 94 127 5 0 105 5 4 15 10 5 0 41 125 5 4 94 12 5 0 49 10 5 0 41 105 5 4 15 10 5 0 41 251 9 9 62 2 4 80 3 1 55 2 2 49 1 9 M type 233 9 2 V type 216 8 5 106 4 2 62 2 4 M8 x 1 25 2 places M8 x 1 25 2 places M5 2 places M5 2 places M6 x 1 0 2 places M6 x 1 0 ...

Page 13: ...places Φ8 4 0 33 41 5 1 63 3 9 4 0 0 15 0 16 M12 x 1 25 23 6 0 93 Φ13 0 5 Φ15 0 6 Φ22 0 9 4 000 4 018 0 1575 0 1582 140 5 5 40 5 1 59 37 1 5 65 1 2 56 60 2 4 62 2 4 75 3 0 65 1 2 56 50 2 0 50 2 0 31 1 2 68 2 7 25 1 0 M8 x 1 25 9 places 24 5 0 96 17 0 7 18 0 7 Φ16 8 0 66 Φ22 0 9 TAPER 1 5 Φ17 000 17 003 0 6693 0 6694 M8 x 1 25 Unit mm in Φ6 x 5 dowel holes 2 places ...

Page 14: ...MEMO dummyhead dummyhead ...

Page 15: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 2 LUBRICATION SEAL POINTS 2 2 TOOLS 2 3 HARNESS ROUTING 2 4 ...

Page 16: ... lbf ft Rotor fan bolt M5 x 0 8 5 9 0 6 4 4 Stator bolt M6 x 1 0 10 1 0 7 Motor harness stay bolt M6 x 1 0 10 1 0 7 Cooling fan nut M12 x 1 25 59 6 0 44 Fastener lever wire bolt M6 x 1 0 10 1 0 7 Battery connector stay bolt M5 x 0 8 5 9 0 6 4 4 Item Thread Dia Torque values N m kgf m lbf ft Screw 3 mm 1 0 0 1 0 7 4 mm 2 0 0 2 1 5 5 mm 4 2 0 4 3 1 6 mm 9 0 9 6 6 Bolt and nut 5 mm 5 2 0 5 3 8 6 mm 1...

Page 17: ...2 3 dummyhead dummyhead SERVICE INFORMATION TOOLS Special tools used in this manual can be ordered using normal Honda parts ordering procedures Cooling fan holder 070PB 8A00100 Rotor guide 070PG 8A00100 ...

Page 18: ...NT CONNECTOR CONNECTOR COVER JOINT CONNECTOR HARNESS CLIP POWER CABLE MAIN WIRE HARNESS HARNESS CLIP HARNESS CLIP ROTOR SENSOR 8P Black CONNECTOR MAIN WIRE HARNESS Clamp at the white tape position PDU 3P Gray CONNECTOR DLC 4P 3 PHASE WIRE HARNESS PDU 33P Black CONNECTOR PDU 3P Black CONNECTOR ROTOR SENSOR WIRE HARNESS POWER CABLE BATTERY 4P White CONNECTOR ...

Page 19: ...ARNESS SPEED CHANGE SWITCH 2P Blue CONNECTOR ERROR INDICATOR 2P Black CONNECTOR HARNESS CLIP HARNESS CLIP POWER CABLE POWER SWITCH 2P Black CONNECTOR START STOP SWITCH POWER INDICATOR 2P Black CONNECTOR ALERT INDICATOR 2P Black CONNECTOR Route the branch wire for the error indicator over the main wire harness as shown Assemble without interference with the frame ...

Page 20: ... HARNESS BAND 5 10 mm 0 2 0 4 in ROTOR SENSOR WIRE HARNESS 3 PHASE WIRE HARNESS Cut the band end Center Make sure to tighten the harness band securely in position ROTOR SENSOR built into stator ROTOR SENSOR WIRE HARNESS 3 PHASE WIRE HARNESS 3 PHASE WIRE HARNESS GROMMET Red White Blue SENSOR WIRE HARNESS GROMMET Inside of motor housing P T O side Do not bite the stator side wire tube into the gromm...

Page 21: ...3 1 3 dummytext 3 MAINTENANCE MAINTENANCE SCHEDULE 3 2 BEFORE OPERATION CHECK 3 3 WIRE HARNESS CHECK 3 3 DRAIN HOLE CLEANING 3 3 MOTOR SET SPEED CHECK 3 3 ...

Page 22: ...in 1 rpm low speed If the Power Pack makes an unusual sound have it inspected by your servicing dealer 4 Replace if necessary Item REGULAR SERVICE PERIOD 1 Refer to page Each use Every 5 years or 250 hrs Exterior Check 3 3 Switch applicable type Check 3 3 LED applicable type Check 3 3 Power cable Check 3 3 Motor wire harness Check 3 3 Set of wire harnesses Check 2 4 3 3 Battery fastener Check 3 3 ...

Page 23: ... it does not come loose during operation or become damaged Check the setting condition of the battery pack and If it feels loose the fastening components must be checked page 5 3 DURING THE TEST RUN Check that the following All indicators 7 light when the power pack is turned on All switches 8 work start and stop properly WIRE HARNESS CHECK Remove the under frame page 6 4 Check each connecting par...

Page 24: ...MEMO dummyhead dummyhead ...

Page 25: ...4 1 4 dummytext 4 TROUBLESHOOTING TROUBLESHOOTING INFORMATION 4 2 DTC TROUBLESHOOTING 4 6 ...

Page 26: ...DTC in its memory and the fail safe function stops the system except for Warning items It is necessary to retrieve the DTC and other system conditions with Dr H for diagnosis Dr H INFORMATION Refer to the Instruction Manual for the Dr H for the connection method to a personal computer and for the step up method How to connect Dr H to power unit Stop the power unit system all the indicators are tur...

Page 27: ...discharging Flash When detects protection function item or Protectionstate continued 10 seconds have elapsed from protection detection or 5 seconds have elapsed from pressing check button or Cancels protection function Cell low temperature protection at discharging Flash Cell high temperature protection at charging Flash Cell low temperature protection at charging Flash Error Level 1 C FET high te...

Page 28: ...er unit turns off START STOP switch failure Stop Flash CAN communication interruption Stop Flash Rotor sensor failure Stop Flash Output pulse abnormality Stop Flash FET thermistor shorted opened Stop Flash Motor thermistor shorted opened Stop Flash Error FET overtemperature abnormality Stop Flash Motor overtemperature abnormality Stop Flash Motor lock failure Stop Flash Overcurrent abnormality ove...

Page 29: ...tion Power off Charging Stay on Charging completed Stay on Error Charger output overvoltage Stay on When detects protection function item or Protection state continued AC plug disconnection Power off Charger output current abnormality CC charging Stay on Charger output current abnormality pre charge Stay on Charger output low voltage abnormality CC charging Stay on Charger output low voltage abnor...

Page 30: ... abnormality permanent failure Battery cannot supply power 1 Battery connectors at battery pack and power cable Any foreign material short circuit failure or other problem in connector 2 Battery cell voltage connected with Dr H Excessive voltage difference between respective cells 3 Battery indicator single part ERROR Red indicator of battery pack flashes pressing check button 4 PDU battery pack i...

Page 31: ...emperature is 130 C 266 F or more 3 Battery indicator single part ERROR Red indicator of battery pack flashes pressing check button 4 PDU battery pack installed on power unit Motor operation by performing the starting procedure Damaged battery 5 Battery pack Replace battery pack 3A412 Battery thermistor opened permanent failure Line open circuit failure due to thermistor damaged resulting in batte...

Page 32: ...icator of battery pack flashes pressing check button Abnormal battery cell voltage due to PDU malfunction 3 PDU battery pack installed on power unit Motor operation by performing the starting procedure 4 PDU power unit indicator battery pack installed on power unit ERROR Red or ALERT Orange indicator of power unit flashes Abnormal battery cell voltage due to battery charger malfunction 5 Battery c...

Page 33: ...ery indicator battery pack installed on charger ERROR Red indicator of battery pack stays on during charging 4 Charger indicator battery pack installed ERROR Red indicator of charger stays on during charging Damaged battery 5 Battery pack Replace battery pack 3A424 Discharge overcurrent protection Excessive current flows in battery so that does not activate battery pack by itself 1 Battery current...

Page 34: ... or not 3 Battery charger battery pack installed Charger does not start charging 4 Charger indicator battery pack installed ERROR Red indicator of charger stays on during charging FET heats due to high temperature around battery 5 Battery peripheral area installed on charger Peripheral temperature is more than 50 C 122 F Charger cooling fan stops due to foreign object interference or fan motor con...

Page 35: ...r unit ALERT Orange indicator of power unit flashes during discharging POWER button pressed to ON Battery cannot be discharged due to high ambient temperature 5 Battery peripheral area installed on power unit Peripheral temperature is more than 50 C 122 F Battery cannot be discharged due to excessive load 6 Driven mechanism Mechanical lock or excessive overload Damaged battery 7 Battery pack Repla...

Page 36: ...or less Damaged battery 6 Battery pack Replace battery pack 3A443 Battery cell low temperature protection at discharging Battery cell overcools resulting in battery not being activated by itself 1 Battery cell temperature connected with Dr H Cell temperature is 20 C 4 F or less 2 Battery indicator single part ALERT Orange indicator of battery pack flashes pressing check button PDU malfunction 3 PD...

Page 37: ...TOP switch malfunction Loosely connected connector 1 START STOP switch connector Loose or poor connection Loosely connected connector terminals 2 START STOP switch connector terminal Loose or poor contact Open circuit in switch wire 3 Switch wires between switch and PDU Open circuit Damaged PDU 4 PDU Replace PDU 3A106 Regenerative resistance circuit malfunction Damaged PDU 1 PDU Replace PDU 3A107 ...

Page 38: ...essive overload Improper installation of PDU on frame 4 PDU PDU mounting condition Damaged PDU 5 PDU Replace PDU 3A132 Motor excessively overheating OT2 Overload operation 1 PDU connected with Dr H Current value is 35 A or more in motor running status abnormal High ambient temperature around product 2 Motor peripheral area Peripheral temperature Lock or overload by driven system 3 Driven mechanism...

Page 39: ... in motor running status abnormal High ambient temperature around product 2 Motor peripheral area Peripheral temperature Lock or overload by driven system 3 Driven mechanism Mechanical lock or excessive overload Improper installation of PDU on frame 4 PDU PDU mounting condition Damaged PDU 5 PDU Replace PDU 3A172 Power on to running inhibition POWER button is pressed ON with START STOP switch in S...

Page 40: ...MEMO dummyhead dummyhead ...

Page 41: ...5 1 5 dummytext 5 COVER BATTERY TRAY COVER BATTERY TRAY REMOVAL INSTALLATION 5 2 BATTERY FASTENING COMPONENT CHECK 5 3 ...

Page 42: ...myhead dummyhead COVER COVER BATTERY TRAY COVER BATTERY TRAY REMOVAL INSTALLATION Remove the battery pack page 7 2 1 2 4 5 6 7 3 8 10 9 13 12 14 15 11 16 5 9 N m 0 6 kgf m 4 4 lbf ft 10 N m 1 0 kgf m 7 lbf ft ...

Page 43: ...e it 3 FASTENER WIRE Looking at the fastener wire from the side as shown check to see if the wire is correctly bent into a curve with the indicated measurements If the length is longer the wire has straightened out and requires replacing Parts Remarks 1 BATTERY TRAY COVER 2 SPECIAL BOLT 6 x 12 mm 2 3 HOLE CAP 2 4 BATTERY MOUNT RUBBER 4 INSPECTION page 5 3 5 BATTERY TRAY 6 BOLT 8 x 20 mm 2 7 BATTER...

Page 44: ...MEMO dummyhead dummyhead ...

Page 45: ...6 1 6 dummytext 6 CONTROL UNIT CONTROL COVER REMOVAL INSTALLATION 6 2 SWITCH INSPECTION 6 3 PDU REMOVAL INSTALLATION 6 4 ...

Page 46: ...6 2 dummyhead dummyhead CONTROL UNIT CONTROL UNIT CONTROL COVER REMOVAL INSTALLATION Remove the battery tray page 5 2 NOTE Route the wire harness properly page 2 4 1 2 3 4 8 6 9 11 13 12 7 6 15 14 5 10 ...

Page 47: ... be continuity with the switch pressed and should be no continuity with the switch released Parts Remarks 1 CONTROL COVER 2 START STOP SWITCH INSPECTION page 6 3 3 BOLT 6 x 20 mm 4 SPECIAL BOLT 6 x 12 mm 2 5 POWER CABLE INSTALLATION Pass through the frame before installing the control base 6 and assemble securely 6 CONTROL BASE 7 BOLT 6 x 12 mm 4 8 SPECIAL BOLT 6 x 12 mm 5 9 PDU COVER 10 POWER SWI...

Page 48: ...6 4 dummyhead dummyhead CONTROL UNIT PDU REMOVAL INSTALLATION Remove the control base page 6 2 NOTE Route the wire harness properly page 2 4 3 9 1 11 6 7 2 5 4 12 10 8 ...

Page 49: ...d CONTROL UNIT Parts Remarks 1 PDU 2 BOLT 6 x 16 mm 4 3 POWER CABLE 4 BATTERY CONNECTOR CAP 5 MOTOR WIRE HARNESS 6 MAIN WIRE HARNESS 7 FRONT FRAME 8 BOLT 6 x 10 mm 3 9 FRAME 10 HARNESS CLIP 11 UNDER FRAME 12 BOLT 6 x 10 mm 4 ...

Page 50: ...MEMO dummyhead dummyhead ...

Page 51: ...7 1 7 dummytext 7 POWER UNIT BATTERY PACK REMOVAL INSTALLATION 7 2 P T O FLANGE REMOVAL INSTALLATION 7 3 MOTOR DISASSEMBLY ASSEMBLY 7 4 STATOR INSPECTION 7 6 ...

Page 52: ...ctor REMOVAL Disconnect the battery connector 1 of the power cable from the battery pack 2 Pull the fastener lever 3 toward you to release the lock lever pin 4 and then remove the battery pack INSTALLATION Insert the claw 5 of the battery pack into the battery hook 6 securely and set it onto the tray Hook the lever pin and turn the fastener lever over the battery pack to secure it Connect the batt...

Page 53: ...5 1 10 11 12 7 8 9 13 Parts Remarks 1 BOLT 8 x 40 mm 4 Applicable type 2 P T O FLANGE Applicable type 3 DOWEL PIN 6 x 10 mm 2 Applicable type 4 NUT 8 mm 2 5 MOTOR BRACKET STAY 6 BOLT 8 x 125 mm 2 7 HARNESS GROMMET 8 HARNESS GROMMET HOLDER 9 BOLT 6 x 10 mm 2 10 MOTOR HARNESS STAY 11 BOLT 6 x 14 mm 2 12 HARNESS BAND 13 MOTOR ...

Page 54: ... Remove the following Motor wire harness connectors page 6 4 P T O flange page 7 3 3 2 4 5 9 6 8 5 9 N m 0 6 kgf m 4 4 lbf ft 12 13 14 15 11 7 16 17 Bearing part 1 10 N m 1 0 kgf m 7 lbf ft 59 N m 6 0 kgf m 44 lbf ft 18 GREASE NEW 19 10 N m 1 0 kgf m 7 lbf ft 10 ...

Page 55: ...PB 8A00100 Tighten the four 6 mm bolts of the tool to 12 N m 1 2 kgf m 9 lbf ft 5 COOLING FAN 6 MOTOR HOUSING FAN SIDE INSPECTION Check the dust seal and bearing in the housing for wear or damage 7 BOLT 5 x 12 mm 4 8 ROTOR FAN 9 WOODRUFF KEY 13 x 12 mm 10 ROTOR SHAFT TOOL ROTOR GUIDE 070PG 8A00100 page 7 5 11 HOUSING PACKING 12 SOCKET BOLT 6 x 16 mm 4 13 MOTOR HARNESS STAY 2 14 SOCKET BOLT 6 x 40 ...

Page 56: ...minals of the stator side 3P Gray connector Measure the insulation resistance between each connector terminal and the motor housing and rotor shaft with 1 000 VDC range in a insulation resistance tester Replace the stator assembly if the coil resistance is out of specification or if the insulation resistance is abnormal CONNECTION Red White Blue Red White Blue STANDARD 66 5 73 5 mΩ 20 C 68 F RESIS...

Page 57: ...8 1 8 dummytext 8 WIRING DIAGRAMS WIRING DIAGRAM 8 2 ...

Page 58: ... Bl P Bu R Bu W Bu Bl P R Bu Bl V Lb P Y R Bl Y Bl Bl Bl Bl Bl Bl P Y Bu Bl Bl W G Lg Lb V R R W Bu Bu Bu Bu G G G Lg Bl Y Bu Bl W Bl W Bl W Bl W Bl W Bl Y Y Bu Bu R Y R Bl Y R G Bl W Bu W Bu Bl R Bu FREE PUSH Black Brown Yellow Orange Blue Light blue Green Light green Red Pink White Gray Beige Violet SPEED CHANGE SWITCH Momentary FREE PUSH POWER SWITCH Momentary START STOP START STOP SWITCH Alter...

Page 59: ...OUBLESHOOTING 4 6 H HARNESS ROUTING 2 4 L LUBRICATION SEAL POINTS 2 2 M MAINTENANCE SCHEDULE 3 2 MAINTENANCE STANDARDS 2 2 MOTOR DISASSEMBLY ASSEMBLY 7 4 MOTOR SET SPEED CHECK 3 3 P P T O DIMENSIONAL DRAWINGS 1 5 P T O FLANGE REMOVAL INSTALLATION 7 3 PDU REMOVAL INSTALLATION 6 4 S SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 STATOR INSPECTION 7 6 SWITCH INSPECTION 6 3 T TOOLS 2 3 TORQUE VALUES 2 ...