Honda EW170 User's Manual

HONDA
GENERATOR/WELDER
OWNER’S
P1HONDA
MOTOR
3lZAlOOO
00X3
1 -ZAI-0001
MANUAL
CO., LTD. 1983
@I5009012
Thank you for purchasing a Honda generator/welder.
This manual covers operation and maintenance of the EW170 Generator/
welder. All information in this publication is based on the latest product
information available at the time of approval for 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 welder and should
remain with the welder if it is sold.
Pay special attention to statements preceded by the following words:
B
Indicates a strong possibility
life if instructions are not followed.
CAUTION:
instructions
NOTE:
Indicates a possibility
are not followed.
of severe personal
of personal injury
injury
or loss of
or equipment
damage if
Gives helpful information.
If a problem should arise, or if you have any questions about this product,
consult an authorized Honda dealer.
B
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.
This Honda product is designed to give safe and dependable service if operated
according to instructions.
Read and understand the owner’s Manual before
operating this product. Failure to do,so could result in personal injury or
equipment damage.
,
CONTENTS
CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
2
GENERATOR/WELDER SAFETY ...........................
............................
COMPONENT IDENTIFICATION
PRE-OPERATION CHECK .................................
.STARTING THE ENGINE .................................
OPERATION ............................................
STOPPING THE ENGINE ..................................
MAINTENANCE.,
.......................................
TRANSPORTING/STORAGE
..............................
TROUBLESHOOTING .....................................
SPECIFICATIONS .......................................
WIRINGDIAGRAM
......................................
............................
HANGER KIT INSTALLATION
WARRANTY SERVICE ...................................
3
5
7
11
14
21
23
30
32
35
36
37
38
1. GENERATOR/WELDER
(CAUTION
SAFETY
LABEL LOCATION>
ELECTRICAL
SHOCK
WARNING
LABEL
OBJECTS
INTOTHEWELDER
TERMINALS.
CARBON
MONOXIDE
CAUTION
LABEL
DO NOT USE INOOOAS OUE TO DANGER Of CARBON
;;
~“,,“,“,‘,,‘rs’UyC:NREENSOS
POROUE EL MONOXIOE
EXHAUST
CAUTION
HOT.
’
LABEL
EXHAUST]
~CHECK fOR SPILLED fW OR fML
STOP fNGlNt BffORE MfULLING.
IINSPECCIONAR
LEAKS.
PARA COMBUSTIBLI OIRRAMAOO
TO ENSURE
SAFE OPERATION
-
0 The Generator/welder
is a potential source of deadly electrical shocks when
misused; do not operate in rain or snow or any other wet conditions.
l Place the generator/welder
at least lm (3 ft.) away from buildings or other
equipment when operating.
l Operate the generator/welder
on a level surface.
If it is tilted, fuel spillage may result.
l Exhaust
gas contains poisonous carbon monoxide.
Welding vapor is also
harmful to your health. Be sure to provide adequate ventilation.
Never
operate the generator or perform welding in an enclosed area.
l Know how to stop the-welder
quickly and understand operation of-all the
controls. Never permit anyone to operate the welder without
proper instructions.
Keep children and pets away from the welder when it is in ‘operation.
Keep away from rotating parts while the engine is running.
l 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.
l Looking
at a welding arc with unprotected
eyes may produce severe pain
and even temporary blindness.
9 Eye hazards include stray flashes, reflected glare, sparks, and flying bits of
molten metal.
0 Be sure to 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 as well as reduce the glare from the arc light.
l 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.
l
l
FACE
4
SHIELD
GLOVES
SAFETY
SHOES
APRON
2. COMPONENT
IDENTIFICATION
FUEL H
VALVE
SEDIMEI;
CUP
RECOIL,
STARTEI
ENGINE
OIL
DRAIN
PLUG
AC RECiPTACLE
I
ENGINE
OIL
I
FILLER
CAP
5
HANGER
/
MU
AIR
/
EXHAUST
6
PIPE
CLEANER
3. PRE-OPERATION
CHECK
1. OIL LEVEL
CAUTION:
l Engine oil is a major factor affecting
engine performance and service life.
Non-detergent or vegetable oils are not recommended.
l Be sure to check the oil on a level surface with the engine stopped.
Use Honda 4-stroke oil, or an equivalent high detergent, premium quality
motor oil certified to meet or exceed
U.S. automobile manufacturer’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. If single
viscosity oil is used, select the appropriate viscosity for the average temperature in your area.
1. Remove the oil filler cap and wipe the dipstick clean.
2. Insert the dipstick into the oil filler neck, but do not screw it in.
3. If the level is low, fill to the top of the oil filler neck with the recommended oil.
’
UPPER
LOWER‘/
OIL
I
FILLER
NECK
OIL
\
FILLER
CAP
NOTE: The engine is protected by an Oil Alert System which automatically
turns the engine switch to the OFF position before the oil level falls below
a safe limit.
If this occurs, add oil to the top of the oil filler’neck then turn the switch on
and restart the engine according to the instructions on page 1 1.
ENGINE SWITCH
8
2. Check the fuel level.
Use any regular grade automotive gasoline (unleaded gasoline is preferred)
with a pump octane rating of 86 or higher.
Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust
or water in the fuel tank.
CAUTION:
Gasoline substitutes
ful to fuel system components.
are not recommended;
they may be harm-
0 Gasoline is extremely flammable.and
explosive under certain conditions.
Refuel in a well ventilated area with the engine stopped.
l Do not smoke or allow flames or sparks in the area where the welder is
refueled or where gasoline is stored.
l Do not overfill
the tank and make sure the filler cap is securely closed
after refueling.
l 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
CAP
9
3. Check the air cleaner element for dirt or obstruction.
cleaning instructions.
AIR
\
%
Refer to page25 for
CLEANER
ELEMENT
CLIP
4. Make sure that the AC circuit breaker are OFF. Not only will this make
starting the engine easier, but failure to do so could cause injury or equipment damage.
CIRCUIT
10
BREAKER
4. STARTING
THE ENGINE
1. Turn the fuel valve on.
FUEL
VALVE
2. Pull the choke rod to CLOSE.
CHOKE
ROD
11
3. Turn the engine switch on.
ENGINE
SWITCH
4. Turn the auto-throttle
AUTO
NOTE:
12
More
THROTTLE
warm-up
switch off.
SWITCH
time
will
be required
if the auto-throttle
is left
on.
5. Pull the starter grip until compression is felt, then pull briskly.
NOTE:
hand.
Do not allow the starter grip to snap back. Return it slowly by
STARTER
GRIP
6. Push the choke rod to OPEN as the engine warms up.
CHOKE
ROD-
13
5. OPERATION
Auto-throttle system
With the switch in the AUTO position, engine speed is automatically reduced
to an idle when all loads are turned off or disconnected. When appliances are
turned on or reconnected, the engine resumes the rated speed. At OFF, the
auto-throttle system does not operate.
NOTE:
AUTO is recommended to minimize fuel consumption.
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 appliance that require only momentary power. To avoid extended warm-up periods, keep the switch OFF
until the engine reaches operating temperature.
l
AC applications
l
m
To prevent electrical shock from faulty appliances, the generator should be grounded.
Connect a length of heavy wire between the
ground terminal and the ground source.
CAUTION:
Limit operation requiring maximum power (4.0 kVA) to 30 minutes.
The total wattage of all appliances connected must be considered.
l Do not exceed the current limit specified for any one receptacle.
l Connections
for emergency power to household circuits must be made
by a qualified electrician and must comply with all applicable laws and
electrical codes. Improper installation
may result in personal injury or
damage to equipment or property.
l
NOTE: Single phase electric motors whose capacities are up to 750W can
be operated. Motors which require heavy starting current may not be used.
1.4
1. Turn the AC/DC (Weld) selector to the AC position.
CAUTION:
AC voltage is present at the AC receptacles at all times regardiessof the position of the AC/DC (WELD) selector. However, when this
selector is in the DC (WELD) position, the AC voltage fluctuates consider.
ably.
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.
2. Plug the appliance into the proper receptacle.
3. Turn on the appropriate AC circuit breaker.
The appliance may now be turned on.
15
l
Welding
m
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 and 4 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.
16
2. Connect the welding cables to the welder’s DC terminals.
CAUTION:
Failure to use the proper gauge cable may lead to painful
burns and/or damage to equipment. See table on page 20.
TERMINALS
3. Start the engine, and when it has warmed up fully, turn the Auto-Throttle
Switch to the AUTO position.
17
4. Turn the AC/DC (WELD) selector to the DC (WELD) position.
CAUTION:
0 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.
0 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.
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.
18
5. Set the current adjuster knob to the proper current level for the job being
done.
19
WELDING
CABLE
SELECTION
When choosing welding cable, it is best to allow a comfortable safety margin.
The cable’s length, gauge (diameter), and material all combine to determine
how much current it can safely carry. The table below gives the current carrying capacity of various lengths and gauges of standard copper welding cable.
I
I
I
CABLE
GAUGE
CAB L,E
DIA.
LENGTH IN FEET*
O-50 FT.
50-100 FT.
I
loo-250 FT.
CURRENT CAPACITY AMPERES
1
.644
250
200
170
2
.604
200
195
150
* Lengths given are for the combined length of the positive and negative
cables.
CAUTION:
An undersize cable will offer unacceptably
high resistance to
current flow from the welder. This will lead to poor quality welds and will
shorten the life of the generator/welder.
OPERATING
RATE
The welder should not be operated continuously at high current settings. Th,e
proportion of welding time to “rest” time is called the Operating Rate. For
example: The welder’s Operating Rate at 1.10 Amps is 70%. This means that
in a given 10 minutes period actual welding can be performed for a total of
7 minutes. Use the table below to determine the Operating Rate for other
current settings.
Current
170A
150A
130A
IlOA
Below 90A
Rate
20%
30%
50%
70%
100%
20
6. STOPPING
1. <AC APPLICATION>
Turn the appliance switch off and the
ClRCUli
AC
THE ENGINE
circuit breaker off.
BREAKER
2. <WELDING>
Stop welding or cutting.
Turn the engine switch off.
21
3. Turn the fuel valve off.
22
7. MAINTENANCE
The purpose of the maintenance
and adjustment
schedule
is to keep the generator/welder
in the best operating
condition.
Inspect or service as scheduled
in the table on the next page.
m
Shut off the engine before performing
any maintenance.
If the
engine must be run, make sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas.
CAUTION:
Use only genuine HONDA parts or their equivalent. The use of
replacement parts which are not of equivalent quality may damage the generator/welder.
Maintenance
REGULAR
Schedule
SERVICE
Perform at every indicated month or operating hour interval,
Engine oil
Daily
First
month
Every
3 months
Every
6 months
Every
year
20°i rs.
6O’Ars.
1OCZlrs.
3OCZlrs.
Check Level
Change
Air cleaner
element
Check
Spark plug
Clean-Adjust
0
Clean
Spark arrester Clean
Fuel filter
Clean every 100 operating hours
Clean
Valve clearance
Check-Adjust
Combustion
Fuel tank
chamber
Clean-Lap valves
Clean
Fuel line
Check
(Replace, if necessary)
._.^.
dote (I ): Service more trequently 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.
23
Tool kit
The tools supplied are necessary for performing some periodic maintenance,
simple adjustments and repairs.
Always keep the tool kit with the generator/welder.
Changing oil
Drain the oil while the engine is still warm to assure rapid and complete draining.
1. Remove the drain plug and filler cap, and drain the oil. Retighten the drain
plug securely.
2. Refill with the recommended oil (see page 7) and check the level.
DRAIN
I L FILLER
24
CAP
Air cleaner service
A dirty air cleaner will restrict air flow to the carburetor. To prevent carbure,
tor malfunction, service the air cleaner regularly. Service more frequently
when operating the generator/welder in extremely dusty areas.
-N
ever use gasoline or low flash point
cleaner element. A fire or explosion could result.
CAUTION:
will result.
Never run the engine without
solvents for cleaning
the air
the air cleaner. Rapid engine wear
1. Unsnap the clips, remove the air cleaner cover and remove the element.
1 EMENT
2. Wash the element in a non-flammable or high flash point solvent and allow
it to dry.
3. Soak the element in clean engine oil and squeeze out the excess oil.
4. Reinstall the air cleaner element and the cover.
t
ELEMENT
25
Sediment
cup service
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
cup should be cleaned.
1. Turn the fuel valve OFF. Remove the sediment cup.
2. Clean the cup thoroughly.
3. Reassemble. Do not’ damage the rubber gasket.
B
After installing the sediment cup, check for fuel leaks and make
sure the area is dry before starting the engine.
UEL VALVE
SEDli’lENT
26
CUP
Spark plug service
Recommended spark plug: BR-4HS(NGK)
W14FR-U(ND)
To ensure proper engine operation, the spark plug must be properly gapped
and free of deposits.
~
1. Remove the spark plug cover.
2. Clean any dirt from around the spark plug base.
3. Remove the spark plug cap.
SPARK
PLUG
COVER
PLUG’CAP
27
4. Use the wrench supplied in the tool kit to remove the spark plug.
5. Visually inspect the spark plug. Discard it if the insulator is cracked or
chipped.
6. Measure the plug gap with a feeler gauge.
The gap should be 0.6-0.7 mm (0.024-0.028 in):Correct as necessary by
carefully bending the side electrode.
7. Attach the plug washer. Thread the plug in by hand to prevent crossthreading.
8. Tighten a new spark plug l/2 turn with the wrench to compress the washer.
If you are reusing a plug, it should only take l/8-1/4
turn after the plug
seats.
CAUTION:
The spark plug must be securely tightened. An improperly
can become very hot and possibly damage the engine.
l Never use a spark plug with an improper heat range.
l
tightened
PLUG,GAP
0.6-0.7
mm
(0.024-0.028
PLUG
28
~VRENCH
plug
in)
Spark arrester maintenance
w
If the engine has been running,
it to cool before proceeding.
the muffler
will be very hot. Allow
CAUTION:
The spark arrester must be serviced every 100 operating
maintain its efficiency.
hours to
1. Loosen the bolts and nuts and remove the muffler.
2. Loosen two 8 mm bolts to remove the exhaust pipe.
3. Check the muffler exhaust port for carbon deposits; clean if necessary.
4. Remove the spark arrester from the muffler.
Clean the screen with a wire brush, and inspect it for damage. Replace if
necessary .
5. Install the spark arrester in the muffler.
Install the muffler and gasket and tighten the bolts and nuts securely.
NUTS
EXHAUST
PIPE
I
MUFFLER
PROTiCiOR
\/
6mm BOLTS
8 mm BOLTS
29
8. TRANSPORTING/STORAGE
m
When transporting
the generator/welder,
turn the engine switch
OFF and ‘keep the unit level to prevent fuel spillage. Fuel vapor or spilled fuel
may ignite.
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Drain the fuel a. With the fuel valve OFF, remove and empty the sediment cup.
b. Turn the fuel valve ON and drain the gasoline in the fuel tank into a
suitable container.
c. Replace the sediment cup and tighten securely.
FUEL
\
30
/
VALVE
d. Drain the carburetor by loosening the drain screw. Drain the gasoline
into a suitable container.
I-----KDRAiNSC
e. Pull the starter grip until resistance is felt; the piston is coming up on its
compression stroke. At this position, the exhaust and intake valves are
closed, and this will help protect the engine from corrosion.
STARTER
GRIP
f. Change the engine oil if the unit is to be stored for more than 1 year.
.31
,,..‘.
.’
9. TROUBLESHOOTING
The chart that follows relates various generator/welder troubles to their possible ,causes and corrections. Many of the troubles listed are closely related,
and elimination of one may eliminate others. Before taking the unit to your
Honda Dealer, perform the following steps.
----------------__--------w When the engine will not start:
Is the correct starting procedure being used?
Check the following :
l Fuel valve position
0 Engine switch position
0 Choke rod position
0 Starter grip operation
I
I
Is there enough’fuel in the fuel tank?
Is gasoline reaching the carburetor?
To check, loosen the drain screw with the fuel valve on.
m
If any fuel is spilled, make sure the area is dry before testing the spark plug or starting the engine. Fuel vapor or spilled fuel
may ignite.
J
32
Is there enough bil in the crankcase?
The oil alert system prevents the engine from being started if the
level of oil in the crankcase falls below prescribed level:
l
Is the spark plug wet or fouled?
0 Clean the spark plug.
0 Check the plug gap and adjust.
Is there spark at the spark plug?
1) Remove the spark plug cap. Clean any dirt from around the spark
plug base, and remove the spark plug.
2) Install the spark plug in the plug cap.
3) Turn the engine switch on. Grounding the side electrode to the
stay, pull the recoil starter to see ,if sparks jump across the gap.
STARTER
GRIP
,’
-A
ENGINE
GROUNDING
STAY
0 If there are no sparks, replace the plug.
l If a new plug produces no sparks or if there are sparks and the
engine still does not start, take the generator to the dealer.
33
When the welding arc is weak :
n
Is the cable size correct? (Page20)
Length
l
Gauge/Diameter
l
Is the proper electrode being used?
n
When there appears to be no electricity at the AC receptacles:
Are the circuit breakers tripped?
Is the generator over-loaded?
l
Is the appliance in good operating condition?
Disconnect the appliance from the generator and carefully inspect it and
its power cord for defects.
l
l
34
10. SPECIFICATIONS
TYPE AND DIMENSIONS
Honda generator/welder
695 mm (27.4 in.)
465 mm (18.3 in.)
695 mm (27.4 in.)
104 kg (229 lb.)
Type
Overall length
Overall width
Overall height
Dry weight
EWl70
ENGINE
Model
Type
Displacement
Bore x stroke
Rated output
Cooling system
Ignition system
Fuel tank capacity
Oil capacity
DC (WELDING)
G E400
4-stroke, side valve, 1 cylinder
406 cm3 (24.8 cu.in.1
86 x 70 mm (3.4 x 2.8 in.)
8.0 PS/3,600 rpm
Forced air cooling
Flywheel magneto
16.5 liters (4.3 US gal.)
1.2 liters (1.27 US qt.)
OUTPUTS
Generator
Phase
Rated current
Rated voltage
Welding current
Operating rate
Rated rpm
Electrode diameter
2-pole rotating field magnet
6-phase, semi-wave rectification
130A
26.5V
55-l 70A
50% / 130A
3,600 rpm
2.6-4.0 mm (0.1 O-O.1 6 in.)
AC OUTPUTS
Maximum output
Rated output
Rated voltage
Power factor
Phase
Frequency
4 kVA (4,OOOW)
4.0 kVA (4,000W)
12ov
1.0
Single
60 Hz
35
?k
ENGINE BLOCK
AUTO-THROTTLE
SWITCH
=
AC RECEPTACLES
-I=
1R/w
9I
RESI
12. HANGER
8 x 16 mm FLANGED,BOLT
KIT. INSTALLATION
HAYGER
(4)
BRACKET
CAUTION:
0 Position the hanger at the generator’s balance point, midway between the
spark plug cover and the fuel tank cap.
l Fit the end tabs of the hanger through
the bracket slots, and bolt the
brackets to the hanger.
SPARK
COVER
PLUG
\
FUEL TANK
CAP
I
\
HANGER
37
13. WARRANTY
I
Owner
SERVICE
Satisfaction
Your satisfaction
and goodwill
are important
to your,dealer
and to us.
Normally,
any problems with the product will be handled by your dealer’s service department.
Sometimes,
however,
despite the best intentionsof
all concerned,
misunderstandings
can occur. If your problem
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 Motorcycle
and Power Products Customer
Relations Department at the regional office of American
Honda Motor Co., Inc. in your
area. Regional office locations are shown on the following
page. We
will need the following
information
in order to assist you:
-Your
-Product
-Date
name,
address,
model
and telephone
and serial
number
number
of purchase
-Dealer
name and address
-Nature
of the prob’lem
After reviewing
all the facts involved, you will
can be taken. Please bear in mind that your
solved at the dealership,.using
the dealer’s
personnel,
so it is very important
that your
dealer.
be advised of what action
problem will likely be refacilities,
equipment,
and
initial contact be with the
Your purchase
of a Honda product is greatly appreciated
by both the
dealer and American
Honda Motor Co., Inc. We want to assist you in ev;
ery way possible
to assure your complete
satisfaction
with your
purchase.
,.
38
Regional
Office
Locations
NORTHWEST
REGIONAL
OFFICE
(includes
Alaska)
American
Honda Motor Co., Inc.
Customer
Relations
Department
P.O. Box 30295
Portland.
Oregon 97220
Telephone:
(6031255-1186
MIDWEST
REGIONAL
OFFICE
American
Honda Motor Co.. Inc.
Customer
Relations
Department
P.O. Box 22
Greendale.
Wisconsin
53129
Telephone:
(414) 421-9300
\
NORTHEAST
REGIONAL
OFFICE
American
Honda Motor CO.. 1°C.
Customer
Relations
Department
P.O. Box 749
Moorertown.
New Jersey 06057
Telephone:
1609) 776-l 100
\
J-
.
WESTERN
REGIONAL
OFFICE
(includes
Hawaii)
American
Honda Motor Co.. Inc.
Customer
Relations
Department
P.O. Box 420
Gardena.
California
90247
Telephone:
(213) 6042524
SOUTHWEST
REGIONAL
OFFICE
American
Honda Motor Co.. Inc.
Customer
Relations
Department
P.O. Box 5406
.
Irving. Texas 75062
Telephone:
(2141 256.6663
SOUTHEAST
REGIONAL OFFICE
Iincludes Puerto Rico1
n---:--.^
%nda Motor Co., Inc.
;;;::;;:;
. Relations Department
1600 Morrison Parkway
Alpharetta.
Georgia 30201
Telephone:
14041 442.2000
39
MEMO