Honda Power Equipment EW171 User Manual
I -
t
.
m The aenerator is a potential source of electrical shock
if misused. Do notexpose the generator to moisture, rain or snow. Do
not let the generator get wet, and do not operate it with wet hands.
Thank you for purchasing a Honda generator/welder. We want to help you get
the best results from your new generator/welder and to operate it safely. This
manual contains the information on how to do that; please read it carefully.
This owner’s manual describes the operation and maintenance of the EWI 71
Honda 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 it if it is resold.
Safety Messages
Your safety and the safety of others is very important. We have provided
important safety messages in this manual and on the generator/welder.
Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others.
Each safety message is preceded by a safety alert symbol Band one of three
words: DANGER, WARNING, or CAUTION.
These mean
.
D ’
m You WILL be KILLED or SERIOUSLY HURT if you don’t
follow instructions.
A -
!
m You CAN be KILLED or SERIOUSLY HURT if you don’t
follow instructions.
* L
m You CAN be HURT if you don’t follow instructions.
.
0
Each message tells you what the hazard is, what can happen, and what you
can do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
(1
you don’t follow instructions.
The purpose of these messages is to help prevent damage to your generator/
welder, other property, or the environment.
Your generator/welders or other property could be damaged if
1
CONTENTS
SAFETY
Safety
Safety Information
COMPONENT IDENTIFICATION
CONTROLS
Engine Switch
Recoil
Fuel Valve
Choke
Circuit
Oil Alert System
Auto-throttle system
AC/DC (Weld) Selector Switch
Welding
Welding Current Adjust System
GENERATOR USE
Connections to a Building’s Electrical System
AC
Welding
Selecting the Correct Welding Current
Welding
Welding
Polarity Selection
High Altitude Operation
Auto-throttle System
PREOPERATION
Engine Oil
Fuel
STARTING THE
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Label Locations
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Starter ......................................................................................
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Rod
Breaker ....................................................................................
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Cable Terminal
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Operation
................................................................................................
Cable Selection
Duty Cycle..
Recommendation
......................................................................................
CHECK..
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ENGINE/STOPPING THE
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ENGINE
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4
4
6
8
10
10
10
11
11
12
12
13
13
14
14
15
15
16
17
17
18
18
19
19
20
21
21
22
24
2
MAINTENANCE..
Maintenance
Tool Kit
Engine Oil Change
Air Cleaner
Fuel Sediment Cup Cleaning
Spark Plug
Spark Arrester
TRANSPORTING/STORAGE
TROUBLESHOOTING..
WIRING
SPECIFICATIONS
INSTALLATION OF OPTIONAL PARTS
WARRANTY
INDEX
................................................................................................
DIAGRAM
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Schedule
Service
Service
Maintenance
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SERVICE
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25
25
26
27
28
29
30
31
32
34
36
37
38
41
42
3
SAFETY
SAFETY LABEL LOCATION
These labels warn you of potential hazards that can cause serious injury.
Read them carefully.
If a label comes off or becomes hard to read, contact your Honda Generator
dealer for a replacement.
STOP fR61llf BffORf RffUflll6.
NconrRolfu au’tt 1’1 A WI fllllf ill fSSfnct
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\ niPAllolJf sun L’APPARfIL.
ARRhfR Lt YOTtUR WI Of RflAlRI Ii PL
0 fSCAPf.
PARAR NOTOR ANIfS Of fCHAR.
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PARA CONRUSTlBLt UfRRANAOO
I
‘WARNING
ATTENTION NE PAS UTILISER DANS UN ENOROIT FERME A CAUSE DU
4
DO NOT USE INDOORS. EXHAUST GAS CONTAINS POISONOUS
h
CARBON MONOXIDE.
RISQUE D’EMPOISONNEMENT DU GAZ.
NO LO USE EN LUGARES CERRADOS PORDUE EL MONOXIDE
DE CARBON0 ES VENENOSO.
”
EW 17 1
HONDA MOTOR CO., LTD.
CAUTION
n
BE SURE TO FILL CRANKCASE
WITH RECOMMENDED OIL
BEFORE USING.
FOR DETAILED EXPLANATION.
SEE THE OWNER’S MANUAL.
\
CURRENT RANGE
50 - 170 Amps DC
RATED CURRENT
130 A -26.5 V-DC
MAD IN JAPAN @
AC OUTPUT
>
5
SAFETY INFORMATION
Honda generator/welder are designed to give safe and dependable service if
operated according to instructions. Read and understand this owner’s manual
before operating your generator/welder. You can help prevent accidents by
being familiar with your generator’s controls, and by observing safe operating
procedures.
Operator Responsibility
l
Know how to stop the generator/welder quickly in case of emergency.
l
Understand the use of all generator/welder controls, output receptacles,
and connections.
l
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
l
Exhaust contains poisonous carbon monoxide, a colorless and odorless
gas. Breathing exhaust can cause loss of consciousness and may lead to
death.
l
If you run the generator/welder in an area that is confined, or even partially
enclosed, the air you breathe could contain a dangerous amount of
exhaust gas. To keep exhaust gas from building up, provide adequate
ventilation.
Electric Shock Hazards
The generator/welder produce enough electric power to cause a serious
shock or electrocution if misused.
Using a generator/welder or electrical appliance in wet conditions, such as
rain or snow, or near a pool or sprinkler system, or when your hands are
wet, could result in electrocution. Keep the generator/welder dry.
If the generator/welder is stored outdoors,unprotected from the weather,
check all electrical components on the control panel, before each use.
Moisture or ice can cause a malfunction or short circuit in electrical
components which could result in electrocution.
Do not connect to a building’s electrical system unless an isolation switch
has been installed by a qualified electrician.
6
Fire and Burn Hazards
The exhaust system gets hot enough to ignite some materials.
- Keep the generator/welder at least 1 mater (3 feet) away from buildings
and other equipment during operation.
- Do not enclose the generator/welder in any structure.
- Keep flammable materials away from the generator/welder.
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.
Let the engine cool before storing the generator/welder indoors.
Gasoline is extremely flammable and is explosive under certain conditions.
Do not smoke or allow flames or sparks where the generator/welder is
refueled or where gasoline is stored. Refuel in a well-ventilated area with
the engine stopped.
Fuel vapors are extremely flammable and may ignite after the engine has
started. Make sure that any spilled fuel has been wiped up before starting
the generator/welder.
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 #I 0 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
7
COMPONENT IDENTIFICATION
FUEL GAUGE
ENGINE SWITCH
CHOKE ROD
WELDING CURRENT
ADJUSTMENT KNOB
/ WELDING CABLE
FUEL
VALVE
AIR
CLEANER
3
-3c
/
RECOIL
STARTER GRIP
B
AUTO THkOlTLE
SWITCH
I
ENGINE SERIAL NUMBER
‘ITCH
Ai2 RECEPTACLES
FUEL TANK CAP
MU\FFLER
SERIAL NUMBER
l
Record the engine and frame serial numbers for your future reference.
Refer to these serial numbers when oidering parts, and when making
technical or warranty inquiries (see page 41)
Frame serial number:
Engine serial number:
9
CONTROLS
Engine Switch
To start and stop the engine.
Switch position:
OFF:
ON:
To stop the engine.
To run the engine.
ENGINE SWITCH
Recoil Starter
To start the engine, pull the starter grip lightly until resistance is felt, then pull
Do not allow the starter to snap back against the engine.
Return it gently to prevent damage to the starter.
10
Fuel Valve
The fuel valve is located between the fuel tank and carburetor. When the valve
fuel lever is in the ON position, fuel is allowed to flow from the fuel tank to the
carburetor. Be sure to return the fuel lever to OFF position after stopping the
engine.
Choke Rod
The choke is used to provide an enriched fuel mixture when starting a cold
engine. It can be opened and closed by operating the choke rod manually. Pull
the rod out toward CLOSED to enrich the mixture.
11
Circuit Breaker
The circuit breaker will automatically switch OFF if there is a short circuit or a
significant overload of the generator at the receptacle. If the circuit breaker is
switched OFF automatically, check that the applicance is working properly
and does not exceed the rated load capacity of the circuit before switching the
circuit breaker ON again.
The circuit breaker may be used to switch the generator power ON or OFF.
AC CIRCUIT BREAKER
Oil Alert System
The Oil Alert system is designed to prevent engine damage caused by an
insufficient 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 start. If this occurs, add engine oil (p. 21).
12
Auto-throttle System
The auto-throttle system automatically reduces engine speed when AC loads
are turned off or disconnected, or DC welding is discontinued. When AC loads
are turned on or reconnected, or DC welding is resumed, the engine returns
to the rated speed.
AUTO:
Recommended to minimize fuel consumption and further reduce
noise levels when no load is applied to the generator/welder.
OFF:
The auto-throttle system does not operate.
Recommended to minimize warm up time when the engine is started.
AUTO-THROTTLE
:
AC/DC (Weld) Selector Switch
A AC/DC (Weld) selector switch is located on the control panel.
psieq
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) selector is
turned on.
l
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 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.
C (WELD) SELECTOR SWITCH
13
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