EXW171S
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
life if instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage
if instructions are not followed.
Indicates a strong possibility of severe personal injury or loss of
NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about your
generator/welder, consult an authorized Honda dealer.
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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.
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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.
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CONTENTS
1. GENERATOR/WELDER SAFETY
n......! . . . . . . . . . . . . . . . . . . . ..a................
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
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High altitude operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8. TRANSPORTING/STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9. TfIOUBLESHOOTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12. WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 misused. 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 importance, 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 consciousness 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 prevent 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 during 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.
0 BE SURE TO FILL CRANKCASE
HONDA MOTOR CO.. LTD.
CURRENT RANGE
MADE IN JAPAN 0
5
WARNING
: TO PKVENT SEVERE EKCTRICAL SHOCK DO NOT INSERT
FINGERS OR OBIECTS INTO THE WELDER TERMINALS.
6
A
STOP ENGINE BEFORE REFUELING.
PARAR MOTOR ANTES DE ECHAR.
2. COMPONENT IDENTIFICATION
w-s... -..
RUBBER
T MAINTENANCE CbVER
FRON
AC RECEPTACLES
OIL FILLER CAP- 1
NEGATIVE TERM’INAL
(WELD TERMINAL)
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CURRENT
CONTROL
KNOB
~!SITIVE TERMINAL
(WELD TERMINAL)
7
-1
’ ENGINE SWITCH (Interlocked with fuel valve)
UPPER MAINTENANCE COVER
REAR MAINTENANCE C
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FUEL TANK CAP
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MAINTENANCE
\
AIR CLEANER
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
used when the average 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 recommended oil.
&, -iO -is 6 ,b 0
Ambient temperature
20 30 40°C
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 CAP ’
OIL FILLER HOLE
UPPER LE
iVEL
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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.
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Gasoline is extremely flammable and is explosive under certain conditions.
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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.)
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FUEL LEVEL GAUGE
FUEL TAiK
CAP
FUEL STRAINER
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:
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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.
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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.
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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.
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.
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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.
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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
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