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Thank you for purchasing a Honda generator/welder.
This manual covers the operation and maintenance of the EXWl71S
generator/welder. All information in this publication is based on the latest
product information available at the time of 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/welder and should remain with the generator/welder if it is
resold.
This generator/welder is equipped with a U.S.D.A. qualified spark arrester
which requires periodic maintenance to ensure its effectiveness. It is illegal
in some areas to operate an engine without a spark arrester; check local
laws and regulations.
mm
Indicates a strong possibility of severe personal injury or loss of
life if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage
if instructions are not followed.
NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about your
generator/welder, consult an authorized Honda dealer.
l
Welding is potentially a very hazardous activity. It should only be at-
tempted by a trained welder with a thorough knowledge of proper
welding techniques and safety procedures.
l
Honda generator/welders are designed to give safe operation and
dependable service if operated according to instructions. Read and
understand this Owner’s Manual before operating the generator/welder.
Failure to do so could result in personal injury or equipment damage.
1
CONTENTS
1. GENERATOR/WELDER SAFETY
n......! . . . . . . . . . . . . . . . . . . . ..a................
3
2. COMPONENT IDENTIFICATION . . . . . . . I....................................... 7
3. PRE-OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. STARTING THE ENGINE . . . . . . . . ..a....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. GENERATOR/WELDER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..a................ 25
l
High altitude operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8. TRANSPORTING/STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9. TfIOUBLESHOOTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12. WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
2
1. ,GENERATOR/WELDER SAFETY
TO ENSURE SAFE OPERATION -
Place the generator/welder on a firm, level surface; avoid loose sand or
snow. If the generator/welder is tilted or overturned, fuel spillage and a
fire may result.
To prevent fire hazards and to provide adequate ventilation, keep the
generator/welder at least 1 meter (3 feet) away from buildings and other
equipment during operation. Do not place flammable objects close to the
generator/welder.
Children and pets must be kept away from the area of operation due to a
possibility of electric shock or burns from hot components.
Know how to stop the generator/welder quickly, and understand the
operation of all the controls. Never permit anyone to operate the
generator/welder without proper instruction.
The generator/welder is a potential source of electrical shocks if misus-
ed. Do not operate the generator/welder in rain or snow. Do not let the
generator/welder get wet, and do not operate it with wet hands.
Use adequate eye protection. Eye protection is of the utmost impor-
tance, not only for the operator, but also for any other personnel in the
vicinity while welding is being done. Eye hazards include arc glare,
reflected glare, stray flashes, sparks, and flying bits of molten metal.
Looking at a welding arc with unprotected eyes may produce severe
pain and even temporary blindness.
Use a helmet or hand-held shield with a #lO or darker filter lens.
Filter lenses eliminate the harmful effects of infrared and ultraviolet
radiation from the arc and reduce the glare from the arc light as well.
Wear protective clothing such as leather gloves, cap, sleeves, jacket,
apron, and high-top safety shoes. All outer clothing must be free of oil
and grease.
FACE SHIELD
GLOVES
SAFETY SHOES
APRON
Q Gasoline is extremely flammable and is explosive under certain
conditions.
0 Refuel in a well-ventilated area with the engine stopped. Do not smoke
or allow flames or sparks in the refuelling area or where gasoline is
stored.
0 Do not over-W the fuel tarnk. After refueling, make sure the tank cap is
closed properly and securely.
@ Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may
ignite. If any fuel is spilled, make sure the area is dry before starting the
engine.
e Never run the engine in an enclosed or confined area. Exhaust contains
poisonous carbon monoxide gas; exposure may cause loss of con-
sciousness and may lead to death.
@ Provide adequate ventilation when welding; welding vapors are harmful
to your hc?aHl.
0 The muffler becomes very hou during operation and remains sufficiently
hot to infli6t burns if touched, aven after shutting off the engine. To pre-
vent sewere burns or fire tnazards, let the engine cool before transporting
the generator/welder or storing it indoors.
0 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 utility company workers or others who contact the lines dur-
ing a power outage, and when utility power is restored, the generator
may explode, burn, or cause fires in tine building’s electrical system.
CAUTION: Equipment damage and corrosion from sand, dirt, and water
may occur if the generator is overturned or sinks into a soft surface.
Read these labels before you operate the generator/welder.
HONDA MOTOR CO.. LTD.
MADE IN JAPAN 0
0 BE SURE TO FILL CRANKCASE
CURRENT RANGE
5
WARNING
: TO PKVENT SEVERE EKCTRICAL SHOCK DO NOT INSERT
FINGERS OR OBIECTS INTO THE WELDER TERMINALS.
A
STOP ENGINE BEFORE REFUELING.
PARAR MOTOR ANTES DE ECHAR.
6
2. COMPONENT IDENTIFICATION
FRON
T MAINTENANCE CbVER
I
OIL FILLER CAP- 1
AC RECEPTACLES
w-s... -..
RUBBER
NEGATIVE TERM’INAL
(WELD TERMINAL)
CURRENT
CONTROL
KNOB
~!SITIVE TERMINAL
(WELD TERMINAL)
7
-1
ENGINE SWITCH (Interlocked with fuel valve)
UPPER MAINTENANCE COVER
\
FUEL TANK CAP
I
MAINTENANCE
REAR MAINTENANCE C
\
AIR CLEANER
8
3. PRE-OPERATION CHECK
Check the generator/welder on a level surface with the engine stopped.
Engine Oil
CAUTION: Engine oil is a major factor affecting engine performance and
service life. Nondetergent oils, castor-based oils, and 2-stroke oils are not
recommended because they have inadequate lubricating characteristics.
Use Honda 4-stroke oil or an
equivalent high-detergent, premium
quality motor oil certified to meet or
exceed U.S. automobile manufac-
turer’s requirements for Service
Classification SE ‘or SF. Motor oils
classified SE or SF will show this
designation on the container.
SAE low-40 is recommended for
general, all-temperature use. Other
viscosities shown in the chart may be
&, -iO -is 6 ,b 0
20 30 40°C
used when the average temperature
Ambient temperature
in your area is within the indicated
range.
1. Remove the oil filler cap and wipe the dipstick clean.
2. Check the oil level by inserting the dipstick in the filler neck without
screwing it in.
3. If the level is low, fill to the top of the oil filler neck with the recommend-
ed oil.
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 advisable to visually inspect the oil level
regularly.
OIL FILLER HOLE
UPPER LE
iVEL
- OIL FILLER CAP
9
Fuel
Check the fuel gauge and refill the tank if the fuel level is low. Do not fill
above the UPPER LEVEL line.
Use automotive gasoline with a pump octane number (y) of 86 or
higher, or a research octane number.of 91 or higher (unleaded is preferred
to minimize combustion chamber deposits.)
Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust
or water in the fuel tank. Clean the fuel strainer regularly.
l
Gasoline is extremely flammable and is explosive under certain condi-
tions.
l
Refuel in a well-ventilated area with the engine stopped. Do not smoke
or allow flames or sparks in the refueling area or where gasoline is
stored.
0 Do not overfill the fuel tank. After refueling, make sure the tank cap is
closed properly and securely.
0 Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may
ignite. If any fuel is spilled, make sure the area is dry before starting the
engine.
Fuel tank capacity: 19.0 P (5.0 US Gal., 4.2 Imp Gal.)
FUEL LEVEL GAUGE
FUEL TAiK
CAP
FUEL STRAINER
10
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”:
that containing ethanol, and that 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 cosolkents
and corrosion inhibitors.
NOTE:
l
Fuel system damage or engine performance problems resulting from the
use of such fuels are not covered under Power Equipment Warran-
ties.Honda cannot endorse the use of fuels containing methanol since
evidence of their suitability is as yet incomplete.
l
Before purchasing fuel from an unfamiliar station, try to confirm
whether the fuel contains alcohol, and to what percentage. If you notice
any undesirable operating symptoms after using a gasoline that contains
alcohol, or one that you think contains alcohol, switch to a gasoline that
you know does not contain alcohol.
11
Check the Battery
The electrolyte level must be maintained between the UPPER and LOWER
level marks. If the electrolyte level is near the LOWER mark, add distilled
water.
I
a Protect your eyes, skin, and clothing; battery electrolyte contains
sulphuric acid. Antidote: EXTERNAL - Flush with water. INTERNAL -
Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call a physician immediately. Eyes: Flush
with water and get prompt medical attention.
l Do not smoke or allow flames or sparks near a battery, especially during
charging. Batteries produce explosive gases.
CAUTION:
l Use only distilled water in the battery. Tap water will shorten the service
life of the battery.
l Do not fill the battery above the UPPER LEVEL line. If overfilled, elec-
trolyte may overflow and corrode generator components. Immediately
wash off any spilled electrolyte.
Check the battery terminals to be sure the cables are tightened and free of
corrosion. Remove any corrosion, and coat the terminals and .cable ends
with grease.
UPPER
iOWER LEVEL
NOTE: Use a battery rated at 12V- 18::35 AH or more.
12
I
Air Cleaner
Check the air cleaner element to be sure it is clean and in good condition.
Clean or replace the element if necessary (page 30).
CAUTION: Never run the engine without the air cleaner. Rapid engine wear
will result from contaminants, such as dust and dirt, being drawn through
the carburetor, into the engine.
AIR CLEANER COVER
CLiPS
Al-i CLEANER ELEMENT
13
NOTE: When starting the generator after adding fuel for the first time,
after long-term storage, or after running out of fuel, turn the engine switch
to the
“ON”
position, then wait for 10 to! 20 seconds before starting the
engine.
1. Turn off the AC circuit breaker.
CIRCUIT
BREAKER
2. Make sure the auto-throttle switch is off, or more time will be required
for warm up.
14
3. Turn the engine switch to the START position and hold it there until the
engine starts.
NOTE: Do not use the electric starter for more than 5 seconds at a time. If
the engine fails to start, release the switch and wait 10 seconds before
operating the starter again.
When the engine starts, allow the engine switch to return to the ON
position.
ENGINE
4. If auto-throttle will be used, turn the switch to “AUTO” after the engine
has warmed
up.
15
Counn@ctions for standby powsr~ to a bui8dinag’s enectrican systc?m
must be made by a qu.naRiffied e0ecUrician aund rvwst compPy with
aQU
appBicabPe
laws arid electrica codes. Uunnproper conndctions can allow
electrical cur-
rent
from the geuneraton to bad&m! into %Bae utility $ims. Such
backfeed
may e8ectrocute utility
company workers or others who contact the lines
during a power outage, and whew
utility dower is restored, the generator
may expbde, bum, or cause
fires
in the building’s dectrical system.
Auto-throttle System
With the switch in the AUTO position, engine speed is automatically reduc-
ed to an idle when all loads are turned off or disconnected. When ap-
pliances are turned on or reconnected, the engine resumes the rated speed.
At OFF, the auto-throttle system does not, operate.
NOTE:
l
AUTO is recommended to minimize fuel consumption when no load is
applied.
l
To avoid extended warm-up periods, keep the AUTO switch OFF until
the engine reaches operating temperature.
l
The auto-throttle system will not respond to electrical loads of less than
1 ampere.
l
The system is not-effective for use with an appliances that require only
momentary power.
i
AU D-THROTTLE SWITCH
16
Oil Alert System
The Oil Alert system is designed to prevent engine damage caused by an in-
sufficient amount of oil in the crankcase. Before the oil level in the
crankcase can fall 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 lamp will flash
when you operate the starter, and the engine will not run. If this occurs,
add engine oil (page 9).
17
AC operation
1. Start the engine.
2. Turn the AC/DC (Weld) selector switch to AC position.
CAUTION: Under no circumstances should any type of electrical appliance
be plugged into any of the AC receptacles when the selector is in the DC
(WELD) position. AC voltage is present at the AC receptacles at all times
regardless of the position of the AC/DC (WELD) selector. However, when
this selector is in the DC (WELD) position, the AC voltage is unregulated
and fluctuates considerably.
3. Switch on the AC circuit breaker.
4. Plug in the appliance.
CAUTION:
Do not connect the generator/welder directly to a household circuit. This
could cause damage to the generator or to electrical. wiring and ap-
pliances in the house.
For continuous operation, do not exceed the rated load capacity 4.0
KVA. In either case, be sure to consider the total power requirements of
all connected 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 load on the circuit, and wait a few minutes before
resetting the circuit breaker.
Be sure that all appliances are in good working order before connecting
them to the generator. If an appliance begins to operate abnormally,
becomes sluggish, or stops suddenly, turn off the circuit breaker and the
engine switch immediately. Then disconnect the appliance and examine
it for signs of malfunction
Most appliance and power tool motors require more than the rated
operating current for start-up. To match appliance power needs to
generator capability, allow a sufficient generator power reserve to ac-
comodate motor start-up requirements.
NOTE: Appliance and power tool manufacturers usually list rating informa-
tion near the model number or serial number.
18
AC/DC (WELD) Selector
AC CIRCUIT BREAKER
AC RECEPTACLES
WELDING
Emm
Welding is potentially a very hazardous activity. It should only
be attempted by a trained welder with a thorough knowledge of proper
welding techniques and safety procedures. Be sure to read and follow the
safety rules on pages 3, 4, 5 and 6 of this manual.
1. Put the Engine Switch in the OFF position. Turn the AC circuit breaker
off and remove any plugs from the AC receptacles.
CAUTION: Voltage is present at the welding terminals whenever the
engine is running regardless of the position of the AC/DC (WELD) selector.
AC CIRCUIT. BREAKER
ENGINE SWITCH
19
2. Connect the welding cables to the welqer’s DC terminals (See page 23
and 24).
I
CAUTION:
Failure to use the proper gauge cable may lead to painful burns
and/or damage to equipment. See table 01) page 23.
WELDER’S
DC TERMINALS
3. Start the engine and when it has warmed up fully, turn the Auto-Throttle
Switch to the AUTO position.
SWITCH
20
4. Turn the AC/DC (WELD) selector to the DC (WELD) position.
CAUTION:
l To avoid accidental arcing, one cable end should be firmly attached to
the object to be welded, and the electrode holder at the end of the other
cable should be held in the operator’s hand when the DC (WELD) selec-
tor is turned on.
.
Under no circumstances should any type of electrical appliance be plug-
ged into any of the AC receptacles when the selector is in the DC
(WELD) position. AC voltage is present at the AC receptacle at all times,
regardless of the position of the AC/DC (WELD)‘selector.
However, when this selector is in the DC (WELD) position, the AC
voltage is unregulated and fluctuates considerably.
AC/DC (YELD) selector
21
5. Set the current adjustment knob to theiproper current level for the job
being done (See page 23).
c
CURRiNT ADJUSTMENT KNOB
22
SELECTING THE CORRECT WELDING CURRENT
Measure the thickness of the metal you are welding and then refer to the
table below to select the proper electrode size and current setting.
PLATE THICKNESS
ELECTRODE DIAMETER CURRENT
IN INCHES IN INCHES SETTING
UPTO 3/16
l/16
50- 100
UPTO l/4
3132
100-150
ABOVE II8
1 I8
125-175
ABOVE II4
5132
150-200
NOTE:
Always make a sample weld on a piece of scrap material to be sure
you have chosen the correct electrode and current setting.
WELDING CABLE SELECTION
The table below shows the current carrying capacity of various lengths and
gauges of standard copper welding cable. Whenever possible, refer to the
cable manufacturer’s recommendations.
Always allow a considerable safety margin when selecting welding cables.
The cable’s length and gauge (diameter), along with the’material it is made
from, all combine to determine how much current it can safely carry.
CAUTION: An undersize welding cable will offer unacceptably high
resistance to current flow. This high resistance will shorten the service life
of the generator/welder, and can even make the welding cables become
hot enough to cause painful burns.
LENGTH IN FEET*
I
I
CABLE
CABLE
GAUGE
DIA.
O-50 FT.
50-100 FT.
100-250 FT.
CURRENT, CAPACITY AMPERES
1 .644
250 200
170
2 .604
200 195
NOTE:
The cable lengths given in the table above are the combined lengths of the
negative and positive cables.
23
POLARITY SELECTION
The welding terminals are labeled “+‘I I(positive) and “-” (negative).
Changing the polarity of the cables will affect the weld. The correct polarity
selection is dependent on the type of electrode you are using and the type
of material you are welding; refer to the el,ectrode manufacturer’s recom-
mendations for best results.
For straight polarity, attach the electrode’cable to the negative terminal,
and attach the work cable to the positive, terminal. To change to reverse
polarity, reverse the cables.
STRAIGHT POLARITY
REVERSE POLARITY
WORK CABL
ELECTRODE
WELDING DUTY CYCLE
The duty cycle is the percentage of time that the welder can be operated in
a given 10 minute period.
For example, at a rated output of 130 amperes, the EXW17 1 S’s duty cycle
is 50%. This means that at 130 amperes, welding can be performed for a
total of 5 minutes out of every IO minute period. The duty cycle is longer at
lower operating currents, and shorter at h’igher currents.
Current
170A
Rate 15%
150A
25%
130A
5b%
IIOA
Below 90A
65%
100%
CAUTION:
Do not operate the welder beyond its duty cycle; doing so will
decrease the performance and service life of the generator/welder.
24
6.’ STOPPING THE ENGINE
NOTE: To stop the engine in an emergency, turn the engine switch to the
OFF position.
In normal use:
1. Move the AC circuit breaker to the OFF position.
CIRCUIT BREAKER
2. Turn the engine switch to the OFF position.
ENGINE.SWITCH
25
High altitude operation
At high altitude, the standard carburetor airlfuel mixture will be excessively
rich. Performance will decrease, and fuel consumption will increase.
High altitude performance can be improved1 by installing a smaller diameter
main fuel jet in the carburetor and readjusting the pilot screw. If you always
operate the generator/welder at altitudes higher than 6,000 feet above sea
level, have your authorized Honda Generator/Welder dealer perform these
carburetor modifications.
Even with suitable carburetor jetting, engine horsepower will decrease ap-
proximately 3.5% for each 1,000 foot increase in altitude. The affect of
altitude on horsepower will be greater than this if no carburetor modifica-
tion is made.
CAUTION:
Operation of the generator/welder at an altitude lower than the
carburetor is jetted for may result in reduced performance, overheating,
and seious engine damage caused by an excessively lean air/fuel mixture.
26
7. MAINTENANCE
Periodic maintenance and adjustment are necessary to keep the
generator/welder in good operating condition. Perform the service and in-
spection scheduled in the table on the following page.
m Shut off the engine before performing any maintenance. If the
engine must be run, make sure the area is well ventilated.
Exhaust contains poisonous carbon monoxide gas; exposure may cause
loss of consciousness and may lead to death.
CAUTION: Use only genuine HONDA parts or their equivalent for
maintenance or repair. Replacement parts which are not of equivalent
quality may damage the generator/welder.
Tool kit
The tools supplied with the generator will help you to perform the owner-
maintenance procedures listed on the following page. Always keep this
tool kit with the generator/welder.
10 x 12 mm WRENCH
U
SCREW DRIVER
DRIVER GRIP
PLUG WRENCH HANDLE
IB
PLUG WRENCH
TOOL BAG
27
Maintenance Schedule
I
REGULAR SERVICE PERIOD iFiRST
EVERY
EVERY
EVERY YEAR
EACH USE
MONTH OR 3 MONTHS 6 MONTHS
ITEM Perform at every indicated month or operating 20 HRS OR 50 HRS OR 100 HRS
300o;RS
hour interval, whichever comes first. (31 (31
(31 (31
Engine oil
Air cleaner
Check level
Change
Check
Clean
0
0 0
0
0 (1)
Battery electrolyte
Check level 0
Check level and gravity
0
Sediment cup Clean
0
Spark plug Clean-Reediust
0
1 Spark arrester
Clean
I I I
I 0 I I
I
Valve clearance
Check-Readiust
I
I I
I
I 0 121
I
Fuel tank end filter
Fuel line
Clean
Check
llhlare if nw~ccard
Every 3 Years
1 Of21
NOTE: (1)
Service more frequently when used in dusty areas,
(2)
These items should be serviced by an authorized Honda dealer, unless the owner has the proper tools and is mechanically
proficient.
See the Honda Shop Manual.
(31
For professional commercial use, log hours of operation to determine proper maintenance intervals.
28
Changing Oil
Drain the oil while the engine, is still warm to assure rapid and complete
draining.
1. Open the front maintenance cover.
2. Remove the drain bolt and filler cap, and drain the oil. Retighten the bolt
securely.
3. Refill with the recommended oil (see page 9) and check the level.
4. Close and latch the front maintenance cover.
OIL CAPACITY: l.le (1.16 US qt)
OIL DRAIN BOLT
LEVEL
CAUTION: Used motor oil may cause skin cancer if repeatedly left in con-
tact with the skin for prolonged periods. Although this is unlikely unless
you handle used oil on a daily basis, it is still adviseable to thoroughly wash
your hands with soap and water as soon as possible 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 service station for reclamation. Do not throw it in the trash or pour it
on the ground.
29
Air Cleaner Service
A dirty air cleaner will restrict air flow to ,the carburetor. To prevent car-
buretor malfunction, service the air cleaner regulary (page 28). Service
more frequently when operating the generator/welder in extremely dusty
areas.
raml
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/welder without the air cleaner. Rapid
engine wear will result from contaminants, such as dust and dirt, being
drawn through the carburetor, into the engine.
1.
2.
3.
4.
5.
AIR CLEANER COVER
Open the rear maintenance cover.
Unsnap the clips and remove the
air cleaner cover and air cleaner
element.
Wash the element in a solution of
household detergent and warm
water, then rinse thoroughly, or
wash in nonflammable or high
flash point solvent. Allow the ele-
ment to dry thoroughly.
Soak the element in clean engine
oil and squeeze out the excess oil.
The engine will smoke during in-
itial start-up if too much oil is left
in the element.
Reinstall the air cleaner element,
the cover and the clips.
6. Close and latch the rear mainte-
nance cover.
AIR CLEANER ELEMENT
30
Spark Plug Service
Recommended spark plug: BPR-5ES-11 (NGK)
WlGEPR-Ull (ND)
To ensure proper engine operation, the spark plug must be properly gapped
and free of deposits.
Emtm
The muffler becomes very hot during operation and remains suf-
ficiently hot to inflict burns if touched, even after shutting off the engine.
1.
2.
3.
4.
5.
Remove the spark plug cap.
Clean any dirt from around the spark plug base.
Use the wrench supplied in the tool kit to remove the
PLtiG WRENCH
spark
plug.
PLUG CAP
Visually inspect the spark plug. Discard it if the insulator is cracked or
chipped. Clean the spark plug with a wire brush if it is to be reused.
Measure the plug gap with a feeler gauge. The gap should be 1 .O- 1.1
mm (0.039-0.043 in).
1.0-1.1 mm (0.039-0.043 in)
31
6. Check that the spark plug washer is in good condition, and thread the
spark plug in by hand to prevent cross-threading.
7. After the spark plug is seated, tighten with a spark plug wrench to com-
press the washer.
NOTE: If installing a new spark plug, tighten l/2 turn after the spark plug
seats to compress the washer. If reinstalling a used spark plug, tighten
l/8- l/4 turn after the spark plug seats to compress the washer.
CAUTION:
l
The spark plug must be securely tightened. An improperly tightened
plug can become very hot and may cause engine damage.
l
Use only the recommended spark plugs or equivalent. Spark plugs
which have an improper heat range may cause engine damage.
32
Spark Arrester Maintenance
This generator/welder is equipped with a U.S.D.A. qualified spark arrester
which requires periodic maintenance to ensure its effectiveness. It is illegal
in some areas to operate an engine without a spark arrester; check local
laws and regulations.
m 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. Allow it to cool before proceeding.
CAUTION: The spark arrester must be serviced every 100 hours to main-
tain its efficiency.
1. Remove the right side cover and handle by removing the nine 6 mm
bolts.’
2. Remove the two 5 mm bolts from the spark arrester flange. Remove the
flange, then remove the spark arrester from the muffler.
3. Clean the carbon deposits from the spark arrester screen with a brush.
Check the spark arrester screen for damage. Replace the spark arrester
if the screen is torn or punctured.
4. Reinstall the parts in the reverse order of disassembly. Tighten the bolts
securely.
5 mm PAN SCREW (2)
SPARK
ARRESTER
6 mm BOLTS (9)
Sediment Cup Cleaning
The sediment cup prevents dirt or water which may be in the fuel tank from
entering the carburetor. If the engine has not been run for a long time, the
sediment cup should be cleaned.
1. Open the left side maintenance cover.
2. Turn the engine switch to the OFF position. Remove the sediment cup
by turning it counterclockwise.
3. Clean the cup and O-ring in nonflammable or high flashpoint solvent.
4. Reinstall the O-ring and sediment cup. Tighten securely.
5. Close and latch the left side maintenance cover.
l Gasoline is extremely frammable and is explosive under certain
conditions.
l After installing the sediment cup, check for fuel leaks, and make sure
the area is dry before starting the engine. Fuel vapor or spilled fuel may
ignite.
34
Battery Electrolyte Level Check
Open the left maintenance cover and check the electrolyte level in each
battery cell. Fill the battery with distilled water to the upper level line.
Never overfill the battery. Any corrosion around the positive and negative
terminals should be washed off with a solution of baking soda and warm
water. Dry the terminals and retighten the terminal bolts if necessary, then
coat the terminals with grease.
UPPER LEVEL
L&,,ER LEVEL
l
The battery contains sulfuric acid. Avoid contact with skin, eyes or
clothing.
Antidote: EXTERNAL - Flush with water.
INTERNAL - Drink large quantities of water or milk. Follow
with milk of magnasia, beaten egg or vegetable oil. Call a
physician immediately.
EYES - Flush with water and get prompt medical attention.
l
Batteries produce explosive gases. Keep sparks, flames and cigarettes
away. Always shield the eyes when working near batteries.
CAUTION:
.
.
Use only distilled water in the battery. Tap water will shorten the service
life of the battery.
Do not fill the battery beyond the UPPER level. If overfilled, electrolyte
may overflow and corrode tractor components. Immediately wash off
any spilled electrolyte.
35
Fuse Replacement
The fuse holder is located on the battery dontainer.
1. Turn the engine switch to the OFF posi;tion.
2. Open the left side maintenance cover, ppen the fuse holder cover and
replace the fuse. The specified fuses are 1 A, 5A, IOA.
CAUTION:
l
If frequent fuse failure occurs, determine the cause and correct the pro-
blem before attempting to operate the generator further.
l
Never use a fuse with a different rating from that specified. Serious
damage to the electrical system or fire may result.
FUSE HOLDER
LA-L--J I
36
8. TRANSPORTING/STORAGE
l To prevent severe burns or fire hazards, let the engine cool before
transporting,the generator/welder or storing it indoors.
l When transporting the generator/welder, turn the engine switch and the
fuel valve to the OFF position, and keep the generator/welder level to
prevent fuel spillage. Fuel vapor or spilled fuel may ignite.
Before storing the unit for an extended oeriod:
1. Be sure the storage area is free of
2. Drain the fuel-
a. Open the rear maintenance
cover.
excessive humidity and dust.
b. Turn the engine switch to ON
and then loosen the carburetor
drain screw. Drain the gasoline
from the carburetor and fuel
tank into a suitable container.
mm
Gasoline is extreme-
ly flammable and is explosive
under certain conditions. Per-
form this task in a well ven-
tilated area with the engine
stopped. Do not smoke or allow
flames or sparks in the area dur-
ing this procedure.
c. Tighten the carburetor drain
screw, turn the engine switch
to OFF and close the rear main-
tenance cover.
DRAIN SCREW
3. Once a month, recharge the battery.
CAUTION: When starting the generator after adding fuel for the first time,
after long-term storage, or after running out of fuel turn the engine switch
to the “ON” position, then wait for 10 to 20 seconds before starting the
engine.
37
When the engine will not start:
I
, _.-
1 Is there fuel in the 1
NU
J Refill the fuel
I
tank.
Is the battery
fully charged?
YES
NO
b Charge battery
in the engine?
YES
NO
Add the recom-
- mended oil.
(The oil alert lamp goes on when
cranking the engine)
Is there a spark
NO
Replace the Still No spark
Take the generator
from the spark plug?
spark plug
to an authorized
To check:
HONDA dealer.
Bf any fuel has been
spilled, make sure
the wee is dry
before testing the
spark plug. Fuel
vapor OP spilled fuel
may ignite. Perform
this Pest in a well-
ventilated area.
YES
1) Remove the spark plug cap
and clean any dirt from
around the spark plug.
2) Remove the spark plug and
install the spark plug in the
plug cap.
3) Set the plug side electrode
on the cylinder head.
4) Crank the engine, sparks
should jump across the gap.
the carburetor?
NO
Clean the fuel
To check:
sediment cup.
1) Turn off the enaine switch
does not start,
take the generator
to an authorized
and loosen the drain screw.
2) Fuel should flow from the
drain when the engine
switch is turned on.
38
No electricity at the AC receptacles:
Is the AC circuit
breaker on?
NO
Turn the AC circuit
F breaker on.
Check the electrical
appliance or equip-
ment for any
defects
NO DEFECTS
Take the generator
b to an authorized
Honda dealer.
I’
DEFECTS
. .
l
Take the electrica
appliance or
equipment to an
electrical shop
for repair.
When the welding arc is weak:
Is the cable
size correct?
I
NO
l
Length (page 23)
l
Gauge/piameter
1 YES
+
Is the proper elect-
NO
rode being used?
b Page 23
39
Dimensions
Model
Power product
description code
Length x Width x Height
Dry weight
Engine
Engine Type
Displacement
[Bore x Stroke]
Compression Ratio
Engine Speed (rated r.p.m.1
Cooling System
Ignition System
Oil Capacity
Fuel Tank Capacity
Spark Plug
Generator
EXW171S
EB5
910 x 539 x 695 mm (35.8 x 20.9 x 27.4 in)
137 kg (302.0 lb)
GX340
337 cc (20.6 cu in)
182 x 64 mm (3.2 x 2.5 in)]
8.0 : 1
3600 r.p.m.
Forced air
C.D.I. with electronic advancer
1.1 P (1.16 US qt)
19.0 P (5.0 US gal)
BPR-5ES-11 (NGK), Wl GEPR-Ul 1 (ND)
Rated current
130A
DC
Rated voltage
26.5 V
(WELDING)
Welding current
50-170 A
output
Operating rate
50% 130A
Electrode diameter
3/32, l/8, 5/32 in (2.6-4.0 mm)
Rated Voltage 12ov
Rated Frequency
60 Hz
AC output
Rated Ampere
33.3 A
Rated Output
4.0 KVA
Maximum Output
4.0 KVA
40
11. WIRING DIAGRAM
12. WA
‘-.__
Owner Satisfaction
Your satisfaction and goodwill are important to your dealer and to us. All
Honda warranty details are explained in the Distributor’s Limited Warranty.
Normally, any problems concerning the product will be handled by your
dealer’s service department. If you have a warranty problem that has not
been handled to your satisfaction, we suggest you take the following
action:
l
Discuss your problem with a member of dealership management. Often
complaints can be quickly resolved at that level. If the problem has
already been reviewed with the Service Manager, contact the owner of
the dealership or the General Manager.
l
If your problem still has not been resolved to your satisfaction, contact
the Power Equipment Customer Relations Department of American
Honda Motor Co., Inc.
American Honda Motor Co., Inc.
Power Equipment Customer Relations Department
P.O. Box 50
Gardena, California 90247-0805
Telephone: (2 13) 604-2400
We will need the following information in order to assist you:
- Your name, address, and telephone number
- Product model and serial number
- Date of purchase
- Dealer name and address
- Nature of the problem
After reviewing all the facts involved, you, will be advised of what action
can be taken. Please bear in mind that your problem will likely be resolved
at the dealership, using the dealer’s facilities, equipment, and personnel, so
it is very important that your initial contact be with the dealer.
Your purchase of a Honda product is greatly appreciated by both your
dealer and American Honda Motor Co., Inc. We want to assist you in every
way possible to assure your complete satisfaction with your purchase.
42
Current customer service contact information:
United States, Puerto Rico, and U.S. Virgin Islands:
Honda Power Equipment dealership personnel are trained professionals. They should
be able to answer any question you may have. If you encounter a problem that your
dealer does not solve to your satisfaction, please discuss it with the dealership's
management. The Service Manager or General Manager can help. Almost all problems
are solved in this way.
If you are dissatisfied with the decision made by the dealership's management, contact
the Honda Power Equipment Customer Relations Office. You can write:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST
When you write or call, please provide the following information:
Model and serial numbers
Name of the dealer who sold the Honda power equipment to you
Name and address of the dealer who services your equipment
Date of purchase
Your name, address, and telephone number
A detailed description of the problem
MEMO
43
MEMO
44
45


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