Honda Power Equipment EW171 Welding System User Manual
Contents
1. eatin 19 Auto throttle System 20 cS 21 21 Fuel Recommendation 22 24 MAINLE rel e 25 Maintenance Schedule sese nena nna rennen annes 25 26 A 27 Nir Cleaner SeFVICE icon si acaa 28 uel Sediment Cup Cleaning pp 29 Spark Plug 5 30 park Arrester Maintenance 31 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 ENGINE BEFORE REFUELING CONTROLER QU IL N Y A NI FUITE NI ESSENCE REPANDUE SUR L APPAREIL ARR TER LE MOTEUR AVANT DE REFAIRE LE P BINSPECEIONAR PARA COMBUSTIBLE DERRAMADO 0 ESCAPE PARAR MOTOR ANTES DE ECHAR AN USING THE GENERATOR IN RAIN SNOW OR NEAR WATER CAN LEAD ELECTRIC SHOCK KEEP i UID LICENSED ELECTRICIAN OWNERS MANUAL CAREFULLY DO NOT USE INDOORS EXHAUST GAS CONTAINS POISONOUS WARNING CARBON MONOXIDE NE PAS UTILISER DANS UN ENDROIT FERME A CAUSE DU ATTE2. Power Equipment Owner s Manual GENERATOR WELDER EW171 ii GR RR RR RR ER manual to your LLL LL LE E TL LLL LLLA LL LT te aa aaa Hitze E R ATT ttt E ONDA MOTOR C LT EEEEREEREEHEEEEEEEREEHEEEE The generator 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 S TE Nrp sa e Thank you for purchasing a Honda generator welder We want to help you 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 EW171 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 s
3. 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 10 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 COMPONENT IDENTIFICATION WELDING CURRENT FUEL GAUGE ADJUSTMENT KNOB OIL ALERT LAMP WELDING CABLE TERMINALS ENGINE SWITCH YA AY CIRCUIT h J BREAKER A E y g WELDING AC 5 22 Afo SELECTOR S ELS SWITCH FUEL IAA VALVE AIR CLEANER AC RECEPTACLES ENGINE OIL FILLER CAP RECOIL STARTER GRIP ENGINE OIL DRAIN PLUG AUTO THROTTLE SWITCH ENGINE SERIAL NUMBER FUEL TANK CAP SPARK PLUG FRAME SERIAL NUMBER MUFFLER e Record the engine and frame serial numbers for your future reference Refer to these serial numbers when ordering parts and when making technical or warranty inquiries see page 41 Frame serial number Engine serial number
4. 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 Turn the fuel valve to the OFF position Remove the sediment cup O ring and filter 2 Clean the sediment cup O ring and filer in nonflammable or high flash point solvent 3 Reinstall the filter O ring and sediment cup FUEL VALVE SEDIMENT CUP SEDIMENT CUP 29 s An NMPNNQ Spark Plug Service Recommended spark plugs BPR5ES NGK W16EPR U NIPPONDENSO To ensure proper engine operation the spark plug must be properly gapped and free of deposits If the engine has been running the muffler will be very hot Be careful not to touch the muffler 1 Remove the spark plug cap 2 Clean and dirt from around the spark plug base 3 Use the wrench supplied in the tool kit to remove the spark plug PLUG WRENCH SPEM 8 lt lt PLUG 2 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 is to be reused 5 Measure the plug gap with a feeler gauge Correct as necessary by carefully bending the side electrode The gap should be 0 70 0 80 mm 0 028 0 031 in 0 7 0 8 mm 0 028 0
5. from all combine to determine how much current it can safely carry NOTICE 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 CABLE CABLE GAUGE DIA LENGTH IN FEET 0 50 FT 50 100 FT 100 250 FT CURRENT CAPACITY AMPERES 250 200 w NOTE The cable lengths given 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 For example ata rated output of 130 amperes the EW171 s duty cycle is 5096 This means that at 130 amperes welding can be performed for a total of 5 minutes out of every 10 minute period The duty cycle is longer at lower operating currents and shorter at highter currents 150A NOTICE Do not operate the welder beyond its duty cycle doing so will decrease the performance and service life of the generator welder 18 Polarity Selection The welding terminals are labeled 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 electrode manufacturer s recommendations f
6. 031 in 30 7 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 8 After the spark plug is seated tighten with a spark plug wrench to compress the washer lf installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer The spark plug must be securely tightened An improperly tightened spark plug can become very hot and could damage the engine Never use spark plugs which have an improper heat range Use only the recommended spark plugs or equivalent Spark Arrester Maintenance If the generator welder has been running the muffler will be very hot Allow it to cool before proceeding The spark arrester must be serviced every 100 hours to maintain its efficiency Clean the spark arrester as follows 1 Loosen the screw by the exhaust port of the muffler and remove the spark arrester 2 Use a brush to remove carbon deposits from the spark arrester screen Inspect the screen for breaks or tears and replace it if necessary 3 Install the spark arrester in the reverse order of removal SPARK ARRESTER ES Uu SCREEN E c SPARK ARRESTER TRANSPORTING STORAGE When transporting the generator welder turn the engine switch and the fuel valve OFF and keep the generator welder level to prevent fuel
7. circuit breaker Marginal overloading may not switch off the circuit breaker but it will shorten the service life of the generator welder e 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 e 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 accomodate motor start up requirements NOTICE Appliance and power tool manufacturers usually list rating information near the model number or serial number AC CIRCUT BREAKER E S AC DC WELD d 16 Welding 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 and 5 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 NOTICE Voltage is pres
8. in the OFF position or more time will be required for warm up 5 Move the engine switch to the ON position 6 Pull the starter grip lightly until resistance is felt then pull briskly NOTICE 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 for 2 or 3 minutes Stopping the Engine In an emergency 1 To stop the engine in an emergency turn the engine switch to the OFF position In normal use 1 Turn the AC circuit breaker to the OFF position 2 Move the engine switch to the OFF position 3 Turn the fuel valve to the OFF position 24 MAINTENANCE Periodic maintenance and adjustment is necessary to keep the generator welder in good operating condition Perform the service and inspection at the intervals shown in the Maintenance schedule below Exhaust gas contains poisonous carbon monoxide Shut off the engine before performing any maintenance If the engine must be run make sure the area is well ventilated NOTICE Use only genuine HONDA parts or their equivalent for maintenance or repair Replacement parts which are not of equivalent quality may damage the generator MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD Performed at every indic
9. 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 Satisfaction with your purchase 41 INDEX COMPONENT IDENTIFICA HON ia 8 CONTROLES erence ome a er ts ene oan encore ee 10 AC DC Weld Selector Switch Nb 13 A to throtle System oa 13 Choke ROQ aza 11 Circuit ehe ko etta sie Ute tope PU Peel ees 12 ENGINE SWIICh mi ehe e a atto ond 10 EU 11 Oll Alert SVSIOITI Wa 12 SIAN TO o UU Sl 10 Welding Cable Terminal ziii iocos eode side hendre muni endings 14 Welding Current Adjust System pp 14 GENERATOR RE 15 AC Ope aliODi ee UI DN ate 16 Autothrotle System canes od tud dera Bonis As cuota lide 20 Connections to a Building s Electrical System 15 High Altitude uoi rare eee reel sanete eU E ARM has 19 meli eli M tice a eects 19 Selecting the Correct Welding Current 17 Welding C 17 Welding Cable SOON iia 18 Welding Duty Cycle eb Und dox tap eias 18 INSTALLATION OF OPTIONAL PARTS 38 MAINTENANCE aa 25 Air Cleaner Servite ood oa Fidi ecd reo e ENE Dn aap ink Sas uuu dns OU 28 Oll GARGS a d retenta e ska esti alea 27 Fuel Sediment Cu
10. problems Gasoline containing ethanol may be marketed under the name Gasohol Methanol methyl or wood alcohol Gasoline containing methanol must contain cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems and may damage metal rubber and plastic parts of your fuel system MTBE methyl tertiary butyl ether You may use gasoline containing up to 15 MTBE by volume Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces in Canada require this information to be posted on the pump If you notice any undesirable operating symptoms switch to a conventional unleaded gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel are not the responsibility of Honda and are not covered under warranty NOTICE Oxygenated fuels can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty 23 STARTING THE ENGINE STOPPING THE ENGINE Starting the Engine 1 Make sure that the AC circuit breaker is in the OFF position and that there are no welding cables attached to the DC terminals The generator may be hard to start if a load is connected 2 Turn the fuel valve to the ON position 3 Pull the choke rod to the CLOSE position 4 Make sure the auto throttle switch is
11. spillage Fuel vapor or spilled fuel may ignite Contact with a hot engine or exhaust system can cause serious burns or fires Let the engine cool before transporting or storing the generator welder Take care not to drop strike the generator welder when transporting Do not place heavy objects on the generator welders Before storing the unit for an extended period 1 Be sure the storage area is free of excessive humidity and dust 2 Service according to the table below STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING Less than 1 month No preparation required Fill with fresh gasoline and add gasoline Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl Drain the fuel sediment cup 2 months to 1 year Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl Drain the fuel sediment cup Remove the spark plug Put a tablespoon of engine oil into the cylinder Turn the engine slowly with the pull rope to distribute the oil Reinstall the spark plug Change the engine oil After removal from storage drain the stored gasoline into a Suitable container and fill with fresh gasoline 1 year or more before starting Use gasoline conditioners that are formulated to extend storage life Contact your authorized Honda generator dealer for conditioner recommendations 32 1 Drain the carburetor by lo
12. CONTROLS Engine Switch To start and stop the engine Switch position OFF To stop the engine Torun the engine ENGINE SWITCH Recoil Starter To start the engine pull the starter grip lightly until resistance is felt then pull briskly NOTICE Do not allow the starter to snap back against the engine Return it gently to prevent damage to the starter 10 Fuel Valve Thefuelvalve islocatedbetweenthefueltank and carburetor Whenthevalve 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 SET 2 4 4 M t SN ANH S 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 WI The Oil Alert system is designed to prevent engine damage caused by an insuf
13. NTION RISQUE D EMPOISONNEMENT DU GAZ NO LO USE EN LUGARES CERRADOS PORQUE EL MONOXIDE ATENCION DE CARBONO ES VENENOSO 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 Know how to stop the generator welder quickly in case of emergency Understand the use of all generator welder controls output receptacles and connections 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 Breathing exhaust can cause loss of consciousness and may lead to death 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 s
14. afety 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 A and one of three words DANGER WARNING or CAUTION These mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions 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 NOTICE Your generatorwelders or other property could be damaged if you don t follow instructions The purpose of these messages is to help prevent damage to your generator welder other property or the environment 1 CONTENTS Auto throttle system eese mmm mnm m nmm tnm menm 13 AC DC Weld Selector Switch 13 Welding Cable Terminal 14 CE 16 BGB MMM 17 electing the Correct Welding Current 17 18 Welding D 18 E 19
15. asis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it ina sealed container to your local service Station or recycling center for reclamation Do not throw it in the trash or pour it on the ground 27 Air cleaner service A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the generator welder in extremely dusty areas Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion Use only soapy water or nonflammable solvent engine wear will result 1 Unsnap the air cleaner cover clips remove the air cleaner cover and remove the 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 element to dry thoroughly Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during initial start up it too much oil is left in the element Reinstall the air cleaner element and the cover ELEMENT 28 Never run the generator welder without the air cleaner Rapid AIR CLEANER COVER CLIP Fuel Sediment Cup Cleaning
16. ated month or operating hour interval whichever comes first Engine oil Check level Change Air cleaner Check Clean Fuel line Replace if Every 2 years 2 necessary Service more frequently when used in dusty areas These items should be serviced by an authorized Honda generator dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 3 For professional commercial use log hours of operation to determine proper maintenance intervals 25 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 y essent 90 10 x 12 mm WRENCH SCREW DRIVER bie PLUG WRENCH DRIVER HANDLE HANDLE TOOL BAG 26 Engine oil change Drain the oil while the engine is warm to assure complete and rapid draining 1 Remove the drain plug and sealing washer oil filler cap and drain the oil 2 Install the drain plug and sealing washer Tighten the plug securely 3 Refill with the recommended oil see page 21 and check the level Oil capacity 1 1 1 16 US qt 0 97 Imp gt OIL DRAIN PLUG UPPER LEVEL 6 mei Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily b
17. city 17 0 2 4 50 US gal 3 74 Imp gal FUEL TANK CAP FUEL STRAINER Z ss Use gasoline with a pump octane rating of 86 or higher 4 FUEL LEVEL GAUGE We recommend unleaded gasoline because it produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda generator dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse Oxygenated Fuels Some gasolines are being blended with alcohol or an ether compound to increase the octane These gasolines are collectively referred to as oxygenated fuels Some areas of the United States use oxygenated fuels to help meet clean air standards If you use an oxygenated fuel be sure its pump octane rating is 86 or higher Ethanol ethyl or grain alcohol Gasoline containing more than 10 ethanol by volume may cause starting and or performance
18. e 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 YES Is the fuel reaching NO Clean the fuel sedi YES To check DRAIN SCREW 1 Turn off the engine switch and loosen the drain screw 2 Fuel should flow from the drain when the engine switch is tumed on If the engine still does not start take the gen erator welder to an authorized Honda generator dealer 34 No electricity at the AC receptacles Is the AC circuit break Turn the AC circuit breaker er ON ON YES Check the electrical ap NO DEFECTS Take the generator welder to pliance or equipment for an authorized Honda gene any defects rator dealer Replace the electrical ap pliance or equipment e Take the electrical appliance or equipmentto an electrical shop for repair DEFECTS When the welding arc is weak Is the cable size cor rect Check the welding cable se lection See page 18 e Length e Gauge Diameter Check the electrode diameter see page 18 Is the proper electrode being used Take the generator welders to an authorized Honda generator dealer 35 WIRING DIAGRAM 36 SPECIFICATIONS Dimensions Engine Engine type 4 stroke overhead valve single cylinder Displac
19. ement Bore x Stroke 337 cc 20 6 cu in 82 x 64 mm 3 2 x 2 5 in BPRSES W16EPR U NIPPONDENSO Rated current 130A Generator WELDING Welding current 50 170 output Duty cycle 50 130A Electrode diameter 3 32 1 8 9 32 2 6 4 0 mm Rated Voltage 120 V Hated Frequency 60 Hz AC output Rated Ampere 33 3 A Rated Output 4 0 KVA NOTE Specifications are subject to change without notice 37 INSTALLATION OF OPTIONAL PARTS Hanger Kit Installation 8 x 16 mm FLANGE BOLT 4 HANGER BRACKET e Position the hanger at the generator s balance point in the middle of the fuel tank e Fit the end tabs of the hanger through the bracket slots and bolt the brackets to the hanger HANGER FUEL TANK CAP 38 4 Wheel Kit Installation 1 Install the four wheels on the axle shaft 2 Install the axle assembly on the generator using four bolts and nuts Inside Shorter end WHEEL STOPPER NOTE Install the shaft with wheel stopper facing engine side 39 ee 2 Wheel kit Installation Install the two wheels on the axle shaft Install the axle assembly on the generator using four bolts and nuts Install the two stands using four bolts and nuts Install right and left handles on the generator upper frame using brackets and six bolts Inside mp Outside 40 WARRANTY SERVICE Owner satisfact
20. ent at the welding terminals whenever the engine is running regardless of the position of the AC DC WELD selector 2 Connectthe welding cables to the welder s DC terminals See page 18 and 19 NOTICE Failure to use the proper gauge cable may lead to painful burns and or damage to equipment See table on page 18 3 Start the engine and when it has warmed up fully turn the Auto Throttle owitch to the AUTO position 4 Turn the AC DC WELD selector to the DC WELD position 9 Setthe current adjustment knob to the proper current level for the job being done See page 18 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 CURRENT SETTING PLATE THICKNESS ELECTRODE DIAMETER IN INCHES IN INCHES UP TO 3 16 90 100 UP TO 1 4 100 150 ABOVE 1 8 125 175 1 4 150 200 NOTICE Always make a sample weld on a piece of scrap material to be sure you have chosen the correct electrode and current setting 17 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 manufacturers 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
21. ficient 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 OIL ALERT e oe AC CIRCUIT BREAKER 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 Miu 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 U AUTO THROTTLE SWITCH SS bod AC DC Weld Selector Switch A AC DC Weld selector switch is located on the contro panel e Toavoid 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 e Undernocircumstances should any type of electrical appliance be plugged into any of the AC receptacle
22. ician CAUTION Improper connections to a building s electrical system can allow electrical current from the utility company to backfeed into the generator When utility power is restored the generator may explode burn or cause fires in the building s electrical system In some areas generators are required by law to be registered with local utility companies Check local regulations for proper registration and use procedures 15 AC operation 1 Start the engine 2 Turn the AC DC Weld selector switch to AC position 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 which could damage AC appliances 3 Switch on the AC circuit breaker 4 Plug in the appliance e Do not connect the generator welder to a household circuit This could cause damage to the generator or to electrical wiring and appliances in the house e Forcontinuous operation do not exceed the rated load capacity EW171 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
23. ion 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 e 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 e fyour problem still has not been resolved to your satisfaction contact the Power Equipment Customer Service Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipment Customer Service 4475 River Green Parkway Duluth Georgia 30136 9420 Telephone 404 497 6400 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 itis very important your initial contact be with dealer Your purchase of a Honda product
24. lassification SG SF CC AMBIENT TEMPERATURE CD Motor oils classified SG SF CC CD will show this designation on the container SAE 10W 30 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 into 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 OIL FILLER HOLE UPPER S JN LEVEL yi OIL FILLER CAP Fuel Recommendation 1 Check the fuel ievel gauge 2 Refill the tank if the fuel level is low Do not fill above the shoulder of the fuel strainer e Gasoline is extremely flammable and is explosive under certain conditions e Refuel in a well ventilated area with the engine stopped Do smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored e Donotoverfill the fuel tank there should be no fuel in the filler neck After refueling make sure the tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine e Avoid repeated or prolonged contact with skin or breathing of vapor e KEEP OUT OF REACH OF CHILDREN Fuel tank capa
25. or best results For straight polarity attach the electrode cable to the negative terminal and attach the ground cable to the positive terminal To change to reverse polarity reverse the cables STRAIGHT POLARITY REVERSE POLARITY ELECTRODE T ELECTRODE High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the engine at altitudes higher than 6 000 feet above sea level have an authorized Honda generator dealer perform this carburetor modification Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 1 000 foot increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE Ifa generator welder jetted for high altitude is used at a lower altitude the air fuel mixture will reduce performance and may overheat or seriously damage the engine 19 Auto throttle system With the switch in the AUTO position engine speed is automatically reduced when ALL loads are turned OFF or disconnected When appliances are turned ON or reconnected the engine returns to rated speed In the OFF position the auto throttle system does not operate The a
26. osening the drain screw Drain the gasoline into a Suitable container Gasoline is extremely flammable and is explosive under certain conditions Perform this task in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area during this procedure DRAIN SCREW 2 Change the engine oil 3 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to 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 up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in this position will help to protect it from internal corrosion Align the notch on the starter pulley with the hole at the top of recoil starter 33 TROUBLESHOOTING When the engine will not start 15 there fuel in the NO tank YES Is there enough oilin NO the engine The oil alert lamp flashes when cranking the engine Refill the fuel tank Add the recommend ed oil Still Take the generator Replace the spark welder to an autho spark plug rized Honda gene YES To check rator dealer Is there a spark from NO the spark plug 1 Remove the spark plug Be sure cap and clean any dirt there is no spilled fuel from around the spark around the spark plug plug Spilled fuel may ignit
27. p Cleaning RN 29 Maintenance Schedule ii aa 25 Spark Arrester Maintenance pp 31 Spark Plug SEVE AA 30 0 26 PREOPERATION CHECK wi wai 21 ED NE 21 Fuel Recommendation pp 22 SAFETY a ev ue i a a eatin 4 SS SLY TON ANON ost E 6 Safely Label Locations ii aa 4 SPECIFICATIONS Ede nus oust ANAS MWA MORI emanate ID ZANA NE UM 37 STARTING THE ENGINE STOPPING THE ENGINE ses 24 42 INDEX TRANSPORTING SIORAGE 32 TROUBLESHOOTING stares a Fach 34 WARRANTY SERVICE aco rti tiep d ecu 41 WIRING DIAGRAM eso ER ee tein 36 43 44 MEMO
28. s 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 WELD AC DC WELD SELECTOR SWITCH ee C 13 Welding Cable Terminal A separate terminal is provided for connection to the welding cable Failure to use the proper gauge cable may lead to painful burns and or damage to equipment See table on page 18 WELDER S A gt DC TERMINALS lt MAE B 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 method of welding See page 17 l CURRENT ADJUSTMENT KNOB 14 GENERATOR WELDER USE Connections to a Building s Electrical System Connections for standby power to a building s electrical system must be made by a qualified electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes Improper connections to a building s electrical system 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 Consult the utility company or a qualified electr
29. uto throttle system will not respond to electrical loads of less than 1 ampere Turn the auto throttle to the OFF position to operate loads of less than 1 amp Appliances with large start up power demands may not 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 normal operating 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 operating temperature The auto throttle system is not effective for use with appliances that require only momentary power If the tool or appliance will be turned ON and OFF quickly the auto throttle switch should be in the OFF position AUTO THROTTLE SWITCH U AUTO N SS 20 PRE OPERATION CHECK Engine oil NOTICE Engine oil is a major factor affecting engine performance and service life Non detergent and 2 stroke engine oils will damage the engine and are not recommended Check the oil level BEFORE EACH gag USE with the generator on a level surface with the engine stopped Use Honda 4 stroke oil or an equivalent high detergent premi um quality motor oil certified to meet or exceed U S automobile TEMP 20 0 20 40 60 80 100 F manufacturers requirements for 30 20 10 0 10 20 30 40 C Service C
30. ystem 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 Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials Keep the generator welder atleast 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
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