Honda GXE2.0S Manual
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A Few Words About Safety
How to use this manual
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the product up in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the motor is off and the battery pack is removed before you begin any servicing procedures, unless the instruction tells
you to do otherwise. This will help eliminate several potential hazards:
• Injury from moving parts. If the instruction tells you to run the motor, be sure your hands, fingers, and clothing are out of the way.
• Do not tilt this product when starting the motor. Start the motor and run it on a flat surface that is free of obstacles.
Moisture and electricity are not compatible.
• Always handle and connect battery pack in dry conditions.
• Never allow battery pack to contact wet areas.
Keep all cigarettes, sparks, and flames away from the battery pack and its related equipment.
How to use this manual
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Summary of Contents for Honda GXE2.0S

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2 dummyhead dummyhead How to use this manual REVISION HISTORY Date of revision Contents of revision February, 2021 Newly published...
  • Page 3: Table Of Contents

    dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER CONTROL UNIT POWER UNIT WIRING DIAGRAMS INDEX...
  • Page 4 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE 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 WHATSOEVER.
  • Page 5 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 6 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator Air Fuel Ratio Analog Front End American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center...
  • Page 7 dummyhead dummyhead How to use this manual Abbreviated Full term term State of Charge Standard Switch Throttle By Wire Top Dead Center Throttle Position Variable Speed Transmission VTEC Variable Valve Timing & Valve Lift Electronic Control...
  • Page 8 dummyhead dummyhead MEMO...
  • Page 9: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ················· 1-2 DIMENSIONAL DRAWINGS ···················· 1-4 SPECIFICATIONS·································· 1-2 P.T.O. DIMENSIONAL DRAWINGS··········· 1-5...
  • Page 10: Serial Number Location

    The serial number [1] is located on the bottom of the frame. Refer to it when ordering parts or making technical inquiries. SPECIFICATIONS DIMENSIONS AND WEIGHTS DC POWER UNIT Model GXE2.0S Type Overall length Motor 233 mm (9.2 in) 216 mm (8.5 in) Control unit 351 mm (13.8 in)
  • Page 11 SPECIFICATIONS DC POWER UNIT Model GXE2.0S Description code GMACK Type P.T.O. M type V type Motor Type Permanent magnet 3-phase DC brushless Continuous rated power 1.6 kW (2.1 HP)/3,600 min (rpm) Continuous rated torque 4.3 N·m (0.44 kgf·m, 3.2 lbf·ft)/3,600 min...
  • Page 12: Dimensional Drawings

    dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS *: P. T. O. type (page 1-3) Unit: mm (in) 105.5 (4.15) 125.5 (4.94) 10.5 (0.41) 10.5 (0.41) M5 (2 places) M8 x 1.25 (2 places) 105.5 (4.15) 125.5 (4.94) 299 (11.8) 10.5 (0.41) 10.5 (0.41) M5 (2 places) M8 x 1.25 (2 places) 80 (3.1)
  • Page 13: Dimensional Drawings

    dummyhead dummyhead SPECIFICATIONS P.T.O. DIMENSIONAL DRAWINGS *: P. T. O. type (page 1-3) M TYPE* Unit: mm (in) 8 (0.3) 160 (6.3) 80 (3.1) 41.5 (1.63) 23.6 (0.93) 4.000 - 4.018 (0.1575 - 0.1582) Φ8.5 (0.33) (4 places) 96 (3.8) Φ8.4 (0.33) V TYPE* Unit: mm (in)
  • Page 14 dummyhead dummyhead MEMO...
  • Page 15: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ················· 2-2 TOOLS ················································ 2-3 TORQUE VALUES ································· 2-2 HARNESS ROUTING ····························· 2-4 LUBRICATION & SEAL POINTS ·············· 2-2...
  • Page 16 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Part Item Standard Service Limit Motor Stator coil resistance (at 20 °C/68 °F) 66.5 – 73.5 mΩ – TORQUE VALUES Torque values Item Thread Dia. and pitch Remarks N·m kgf·m lbf·ft Rotor fan bolt M5 x 0.8 Stator bolt M6 x 1.0...
  • Page 17 SERVICE INFORMATION TOOLS Special tools used in this manual can be ordered using normal Honda parts ordering procedures. Cooling fan holder Rotor guide 070PB-8A00100 070PG-8A00100...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION HARNESS ROUTING CONTROL UNIT JOINT CONNECTOR Install the connector in the direction as shown so the cover is not turned over. CONNECTOR JOINT HARNESS CLIP COVER CONNECTOR Clamp at the white tape position. ROTOR SENSOR WIRE HARNESS ROTOR SENSOR 8P (Black) CONNECTOR MAIN WIRE...
  • Page 19 dummyhead dummyhead SERVICE INFORMATION POWER SWITCH 2P (Black) ALERT INDICATOR 2P (Black) CONNECTOR CONNECTOR SPEED CHANGE SWITCH 2P (Blue) CONNECTOR MAIN WIRE HARNESS HARNESS CLIP HARNESS CLIP START/STOP SWITCH 10P (Black) CONNECTOR Route the branch wire for Insert the switch cover until it is seated. the error indicator over CONTROL the main wire harness as...
  • Page 20 dummyhead dummyhead SERVICE INFORMATION MOTOR GROMMET Assemble by aligning the grommet 3-PHASE center with the harness marking. WIRE HARNESS 3-PHASE WIRE HARNESS Center ROTOR SENSOR WIRE HARNESS HARNESS BAND ROTOR SENSOR Make sure to tighten the harness band securely in position. WIRE HARNESS Cut the band end.
  • Page 21: Maintenance

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE ··················· 3-2 DRAIN HOLE CLEANING························ 3-3 BEFORE OPERATION CHECK ················ 3-3 MOTOR SET SPEED CHECK ·················· 3-3 WIRE HARNESS CHECK ························ 3-3...
  • Page 22 (1) Perform at every indicated time or operating hours interval, whichever comes first. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Consult an authorized Honda dealer. (3) Set speed is set to 3,600 min...
  • Page 23 dummyhead dummyhead MAINTENANCE BEFORE OPERATION CHECK NOTE: Before beginning the checks, be sure the power pack is on a level surface and stopped. Also, perform a test run during the checks. BEFORE ATTACHING THE BATTERY PACK Check the following: – Exterior covers [1] for damage –...
  • Page 24 dummyhead dummyhead MEMO...
  • Page 25: Troubleshooting

    dummytext 4. TROUBLESHOOTING TROUBLESHOOTING INFORMATION ······ 4-2 DTC TROUBLESHOOTING ····················· 4-6...
  • Page 26 dummyhead dummyhead TROUBLESHOOTING TROUBLESHOOTING INFORMATION TROUBLESHOOTING SYSTEM DESCRIPTION SELF-DIAGNOSIS AND FAIL-SAFE FUNCTION The power drive unit (PDU) in the DC power unit is equipped with a self-diagnostic function. When an abnormality occurs, the PDU turns on the appropriate indicators related to the failure (page 4-3) and stores a diagnostic trouble code (DTC) in its memory, and the fail-safe function stops the system (except for "Warning"...
  • Page 27 dummyhead dummyhead TROUBLESHOOTING INDICATOR DESCRIPTION Each component of the battery pack, power unit and battery charger is equipped with several indicators that identify the operation and failure status. The indication patterns are described below, and if the indicator(s) related the failure lights or flashes, perform the DTC troubleshooting (page 4-6).
  • Page 28 dummyhead dummyhead TROUBLESHOOTING POWER UNIT INDICATOR The power unit has the indicators for ALERT (Orange) [1] and ERROR (Red) [2] along with the POWER indicator (Green) [3]. Indicator Classifica- Unit Indication Lighting-off Protection Function ERROR ALERT POWER tion Operation Condition Requirement (Red) (Orange)
  • Page 29 dummyhead dummyhead TROUBLESHOOTING CHARGER INDICATOR The battery charger has the ERROR (Red) [1] and POWER (Green) [2] indicators. If it detects an abnormality, the ERROR indicator lights and the charging stops. Indicator Indication Lighting-off Classification Status POWER ERROR Condition Requirement (Green) (Red) Normal...
  • Page 30 dummyhead dummyhead TROUBLESHOOTING DTC TROUBLESHOOTING BATTERY PACK Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A400 Overcharging Power unit is unable to 1. Battery connectors (at Any foreign material, (permanent power on battery pack and power short-circuit failure, or...
  • Page 31 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A407 Discharging Battery cannot be 1. Battery connectors (at Any foreign material, discharged due to D-FET battery pack and power short-circuit failure, or abnormality damaged...
  • Page 32 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A414 FET thermistor Line short-circuit failure 1. Battery connectors (at Any foreign material, shorted due to thermistor battery pack and power short-circuit failure, or (permanent damaged, resulting in...
  • Page 33 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A422 Charge Excessive current flows in 1. Battery indicator (single ERROR (Red) indicator overcurrent battery, so that does not part) of battery pack stays on, protection...
  • Page 34 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A425 Short-circuit Excessive current flows in 1. Battery current (connected Battery current is 80 A or protection battery, so that does not with Dr.
  • Page 35 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A430 Short circuit between DLC 1. DLC (4P) Short circuit communication terminals error Open circuit in CAN 2. CAN wires between PDU Open circuit communication line and battery pack (CAN L/...
  • Page 36 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A442 Battery cell low Battery cell overcools 1. Battery cell temperature Cell temperature is 0°C temperature resulting in battery not (connected with Dr.
  • Page 37 dummyhead dummyhead TROUBLESHOOTING POWER UNIT Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A102 CAN received Short circuit between DLC 1. DLC (4P) Short circuit message terminals Open circuit in CAN 2.
  • Page 38 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A120 Lock error Overload operation 1. PDU (connected with Dr. Current value is 35 A or more in motor running status (abnormal) Lock or overload by driven 2.
  • Page 39 dummyhead dummyhead TROUBLESHOOTING Verification Item (Check in numerical order) Failure Condition/ Detecting Item Check for Possible Cause Applicable Part (abnormal symptom) 3A141 Overload operation 1. PDU (connected with Dr. Current value is 35 A or overheating more in motor running (OT1) status (abnormal) High ambient temperature...
  • Page 40 dummyhead dummyhead MEMO...
  • Page 41: Cover

    dummytext 5. COVER BATTERY TRAY COVER/BATTERY TRAY BATTERY FASTENING COMPONENT REMOVAL/INSTALLATION ····················· 5-2 CHECK ················································ 5-3...
  • Page 42 dummyhead dummyhead COVER BATTERY TRAY COVER/BATTERY TRAY REMOVAL/INSTALLATION COVER Remove the battery pack (page 7-2). [16] [15] [14] [13] [12] 10 N·m [11] (1.0 kgf·m, 7 lbf·ft) [10] 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)
  • Page 43 dummyhead dummyhead COVER Parts Remarks [1] BATTERY TRAY COVER [2] SPECIAL BOLT (6 x 12 mm) (2) [3] HOLE CAP (2) [4] BATTERY MOUNT RUBBER (4) INSPECTION: page 5-3 [5] BATTERY TRAY [6] BOLT (8 x 20 mm) (2) [7] BATTERY HOOK INSPECTION: page 5-3 [8] BOLT (8 x 16 mm) (2) [9] CONNECTOR STAY...
  • Page 44 dummyhead dummyhead MEMO...
  • Page 45: Control Unit

    dummytext 6. CONTROL UNIT CONTROL COVER SWITCH INSPECTION···························· 6-3 REMOVAL/INSTALLATION ····················· 6-2 PDU REMOVAL/INSTALLATION·············· 6-4...
  • Page 46 dummyhead dummyhead CONTROL UNIT CONTROL COVER REMOVAL/INSTALLATION CONTROL UNIT Remove the battery tray (page 5-2). NOTE: Route the wire harness properly (page 2-4). [14] [13] [12] [11] [10] [15]...
  • Page 47 dummyhead dummyhead CONTROL UNIT Parts Remarks [1] CONTROL COVER [2] START/STOP SWITCH INSPECTION: page 6-3 [3] BOLT (6 x 20 mm) [4] SPECIAL BOLT (6 x 12 mm) (2) [5] POWER CABLE INSTALLATION: Pass through the frame before installing the control base [6] and assemble securely.
  • Page 48 dummyhead dummyhead CONTROL UNIT PDU REMOVAL/INSTALLATION Remove the control base (page 6-2). NOTE: Route the wire harness properly (page 2-4). [10] [11] [12]...
  • Page 49 dummyhead dummyhead CONTROL UNIT Parts Remarks [1] PDU [2] BOLT (6 x 16 mm) (4) [3] POWER CABLE [4] BATTERY CONNECTOR CAP [5] MOTOR WIRE HARNESS [6] MAIN WIRE HARNESS [7] FRONT FRAME [8] BOLT (6 x 10 mm) (3) [9] FRAME [10] HARNESS CLIP [11] UNDER FRAME...
  • Page 50 dummyhead dummyhead MEMO...
  • Page 51: Power Unit

    dummytext 7. POWER UNIT BATTERY PACK MOTOR DISASSEMBLY/ASSEMBLY········ 7-4 REMOVAL/INSTALLATION ····················· 7-2 STATOR INSPECTION ··························· 7-6 P.T.O. FLANGE REMOVAL/INSTALLATION ····················· 7-3...
  • Page 52 dummyhead dummyhead POWER UNIT BATTERY PACK REMOVAL/ POWER UNIT INSTALLATION NOTICE : Do not handle the battery with wet hands or in wet or rainy conditions. NOTE: Always clean the battery attaching area and battery connector, and be sure that there is no foreign material on the contacts or in the connector. REMOVAL Disconnect the battery connector [1] of the power cable from the battery pack [2].
  • Page 53 dummyhead dummyhead POWER UNIT P.T.O. FLANGE REMOVAL/INSTALLATION NOTE: Route the wire harness properly (page 2-4). [10] [11] [13] [12] Parts Remarks [1] BOLT (8 x 40 mm) (4) (Applicable type) [2] P.T.O. FLANGE (Applicable type) [3] DOWEL PIN (6 x 10 mm) (2) (Applicable type) [4] NUT (8 mm) (2) [5] MOTOR BRACKET STAY...
  • Page 54 dummyhead dummyhead POWER UNIT MOTOR DISASSEMBLY/ASSEMBLY Remove the following: – Motor wire harness connectors (page 6-4) – P.T.O. flange (page 7-3) 59 N·m (6.0 kgf·m, 44 lbf·ft) [19] [17] [16] [18] [13] [12] 10 N·m (1.0 kgf·m, 7 lbf·ft) [15] [14] 10 N·m GREASE...
  • Page 55 dummyhead dummyhead POWER UNIT Parts Remarks [1] BOLT (6 x 20 mm) (4) [2] TOP COVER INSTALLATION: Install the cover in the direction as shown. [3] FAN COVER [4] NUT (12 mm) TOOL: [19] COOLING FAN HOLDER (070PB-8A00100) Tighten the four 6 mm bolts of the tool to 12 N·m (1.2 kgf·m, 9 lbf·ft) [5] COOLING FAN [6] MOTOR HOUSING (FAN SIDE) INSPECTION: Check the dust seal and bearing in the housing for wear or damage.
  • Page 56 dummyhead dummyhead POWER UNIT STATOR INSPECTION Remove the battery tray cover (page 5-2). Disconnect the PDU 3P (Gray) connector [1]. Check for connector for loose contacts or corroded terminals. Measure the coil resistance between the terminals of the stator side 3P (Gray) connector.
  • Page 57: Wiring Diagrams

    dummytext 8. WIRING DIAGRAMS WIRING DIAGRAM ································ 8-2...
  • Page 58 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAM WIRING DIAGRAMS...
  • Page 59: Index

    INDEX dummytext INDEX BATTERY FASTENING COMPONENT CHECK ··········5-3 MOTOR SET SPEED CHECK ·································3-3 BATTERY PACK REMOVAL/INSTALLATION ·············7-2 P.T.O. DIMENSIONAL DRAWINGS ··························1-5 BATTERY TRAY COVER/BATTERY TRAY P.T.O. FLANGE REMOVAL/INSTALLATION ··············7-3 REMOVAL/INSTALLATION ·····································5-2 PDU REMOVAL/INSTALLATION······························6-4 BEFORE OPERATION CHECK ·······························3-3 SERIAL NUMBER LOCATION ·································1-2 CONTROL COVER REMOVAL/INSTALLATION··········6-2 SPECIFICATIONS·················································1-2 DIMENSIONAL DRAWINGS····································1-4...

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