Multiquip GAW135H User Manual
OPERATION AND PARTS MANUAL
MODEL GAW-135H
PORTABLE
DC WELDER/AC GENERATOR
(GASOLINE ENGINE)
Revision #1 (06/23/04)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
PAGE 2 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave. 800-421-1244
Carson, CA 90746
Email: mq@multiquip.com
Internet: www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
MAYCO PARTS
800-306-2926
310-537-3700
SERVICE DEPARTMENT
800-478-1244
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-421-1244,
310-537-3700,
ON-HAND
EXT.
279
EXT.
279
WHEN CALLING
FAX:
310-537-3927
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
310-537-4259
FAX:
310-631-5032
FAX:
310-537-1173
© COPYRIGHT 2004, MULTIQUIP INC.
Multiquip Inc, the MQ logo is a registered trademark of Multiquip Inc. and may not be used, reproduced, or altered without written
permission. All other trademarks are the property of thier respective owners and used with permission.
This manual
remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change
specifications, design or the information published in this publication at any time without notice and without incurring any obligations.
MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should
Denyo GAW-135H Portable Welder/Generator.
Illustrations, descriptions, references and technical data contained in
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 3
TABLE OF CONTENTS
MQ GAW-135H — Portable
AC Welder/Generator
Here's How To Get Help ............................................ 3
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Dimensions ............................................................... 6
Specifications ............................................................ 7
Safety Alert Message Symbols ............................. 8-9
Rules for Safe Operation .................................. 10-12
Operation and Safety Decals ............................ 14-15
General Information ................................................ 16
Load Application ..................................................... 17
Controls and Indicators ..................................... 18-19
Welder/Generator Refueling ................................... 20
Installation ......................................................... 21-22
Pre-Inspection (Engine) .......................................... 23
Initial Start-up (Engine) ........................................... 24
Initial Start-up (Generator/Operation) .............. 25-26
Welder Operation .............................................. 27-28
Maintenance ........................................................... 29
Preparation For Long Term Storage ....................... 30
Wiring Diagram ....................................................... 31
Troubleshooting (Engine) .................................. 32-33
Troubleshooting (Generator) ............................ 34-35
Explanation Of Codes In Remarks Column ............ 36
Suggested Spare Parts ........................................... 37
HONDA GX200VEN2 GASOLINE ENGINE
Cylinder Head Assembly .................................... 48-49
Cylinder Barrel Assembly ................................... 50-51
Crankcase Cover Assembly ............................... 52-53
Crankshaft Assembly ......................................... 54-55
Piston Assembly ................................................. 56-57
Camshaft Assembly ........................................... 58-59
Recoil Starter Assembly..................................... 60-61
Fan Cover Assembly .......................................... 62-63
Carburetor Assembly ......................................... 64-65
Air Cleaner Assembly......................................... 66-67
Muffler Assembly ............................................... 68-69
Fuel Cock Assembly .......................................... 70-71
Flywheel Assembly ............................................ 72-73
Ignition Coil Assembly ........................................ 74-75
Rectifer Assembly .............................................. 76-77
Control Assembly ............................................... 78-79
Labels Assembly ................................................ 80-81
Terms and Conditions Of Sale — Parts .................. 82
Component Drawings
Name Plate and Decals .................................... 38-39
Generator Assembly ......................................... 40-41
Control Box Assembly ....................................... 42-43
Pipe Frame and Fuel Tank Assembly ............... 44-45
Muffler Assembly .............................................. 46-47
PAGE 4 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
W
PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒❒
❒ Dealer account number
❒❒
❒❒
❒ Dealer name and address
❒❒
❒❒
❒ Shipping address (if different than billing address)
❒❒
❒❒
❒ Return fax number
❒❒
❒❒
❒ Applicable model number
❒❒
❒❒
❒ Quantity, part number and description of each part
❒❒
❒❒
❒ Specify preferred method of shipment:
❒❒
✓ FedEx or UPS Ground
✓ FedEx or UPS Second Day or Third Day
✓ FedEx or UPS Next Day
✓ Federal Express Priority One
✓ DHL
✓ Tr u c k
Note: Unless otherwise indicated by customer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours. We will make every effort to ship
“Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Here’s how to get help...
Please have the model and serial number
on hand when calling.
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave. 800-421-1244
FAX:
Carson, CA 90746
Email: mq@multiquip.com
Internet: www.multiquip.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
MAYCO PARTS
800-306-2926
310-537-3700
SERVICE DEPARTMENT
800-478-1244
310-537-3700
TECHNICAL ASSISTANCE
800-478-1244
WARRANTY DEPARTMENT
800-421-1244,
310-537-3700,
EXT.
EXT.
279
279
310-537-3927
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
800-672-7877
FAX:
310-637-3284
FAX:
310-537-4259
FAX:
310-631-5032
FAX:
310-537-1173
Place Your Parts Order Via Web or Fax
For Even More Savings!
(Domestic USA Dealers Only)
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered Standard Stock orders
via orders ($750 list and above)
Fax 3% 10%
Web 5% 10%
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE: DISCOUNTS ARE SUBJECT TO CHANGE
at no charge for freight
MULTIQUIP INC.
18910 WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX: 310-537-3927
E-MAIL: mq@multiquip.com
INTERNET: www.multiquip.com
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 5
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
Toll-free FAX — 800-6-PARTS-7
(800/672-7877)
GAW-135H — DIMENSIONS
Figure 1. Dimensions
PAGE 6 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
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GAW-135H — SPECIFICATIONS
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Effects of Altitude and Heat
The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient
conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric
reading of 29.92 inches and a temperature of 60 degrees fahrenheit.
Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10
°°
°
fahrenheit above the standard temperature of 60
°°
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GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 7
GAW-135H — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.
This Owner's Manual has been
developed to provide instructions for
the safe and efficient operation of the
Multiquip Model GAW-135H
NOTE
Portable Generator/Welder.
to the engine manufacturers
instructions for data relative to its safe
operation.
Before using this generator/welder,
ensure that the operating individual
has read and understands all
instructions in this manual.
Refer
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
WARNING, or CAUTION.
Lethal Exhaust Gases
Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
Explosive Fuel
GASOLINE is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
DANGERDANGER
DANGER
DANGERDANGER
You WILL be
if you DO NOT follow these directions.
WARNINGWARNING
WARNING
WARNINGWARNING
You CAN be KILLED or
you DO NOT follow these directions.
CAUTICAUTI
CAUTION
CAUTICAUTI
You CAN be
these directions.
Potential hazards associated with the
Portable
Hazard Symbols which appear throughout this manual, and will
be referenced in conjunction with
Symbols
Generator/Welder
.
KILLED
INJURED
if you DO NOT follow
operation will be referenced with
or
SERIOUSLY INJURED
SERIOUSLY INJURED
Multiquip GAW-135H
Safety Message Alert
if
Burn Hazards
Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. Never operate the engine with heat
shields or heat guards removed.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
PAGE 8 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
ALWAYS place the engine ON/OFF switch
in the OFF position when the generator is
not in use.
Sight and Hearing hazard
ALWAYS wear approved eye and hearing
protection.
Respiratory Hazard
ALWAYS wear approved respiratory
protection.
Equipment Damage Messages
Other important messages are provided throughout this manual
to help prevent damage to your generator, other property, or the
surrounding environment.
This generator, other property, or
the surrounding environment could
NOTE
be damaged if you do not follow
instructions.
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 9
GAW-135H — RULES FOR SAFE OPERATION
■
DANGER:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is for
industrial use only.
The following safety guidelines should always be used when
operating the
GENERAL SAFETY
■
DO NOT operate or service this equipment before
reading this entire manual.
■
This equipment should not be operated by
persons under 18 years of age.
■
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steeltoed boots and other protective devices required
by the job.
■
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking of any
medication.
generator/welder
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to
■
High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact
hot
with
■
The engine of this pump requires an adequate free flow of
cooling air.
■
ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.
components can cause serious burns.
NEVER!
operate the generator in any enclosed or
narrow area where free flow
of the air is restricted. If the
air flow is restricted it will
cause serious damage to
the generator or engine
and may cause injury to
people and property.
Remember the generator's
engine gives off DEADLY
gases.
■
NEVER operate this equipment under the
influence or drugs or alcohol.
■
Whenever necessary, replace nameplate, operation and safety
decals when they become difficult read.
■
ALWAYS check the generator for loosened threads or bolts
before starting.
■
ALWAYS wear proper respiratory (mask) hearing and eye
protection equipment when operating the generator/welder.
■
ALWAYS use extreme caution when working with flammable
liquids. When refueling, stop the engine and allow it to cool.
DO NOT
could result from fuel vapors, or if fuel is spilled on a hot
engine.
■
NEVER operate the generator/welder in an
explosive atmosphere
materials. An explosion or fire could result
causing severe
smoke around or near the machine. Fire or explosion
or near combustible
bodily harm or even
death.
■
Topping-off to filler port is dangerous, as it tends to spill fuel.
■
Refer to the
technical questions or information.
■
NEVER use accessories or attachments, which are not
recommended by
the equipment and/or injury to user may result.
■
Manufacturer does not assume responsibility for any accident
due to equipment modifications.
Honda Engine Owner's Manual
Multiquip
for this equipment. Damage to
for engine
PAGE 10 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — RULES FOR SAFE OPERATION
■
NEVER run engine without air cleaner. Severe engine damage
may occur.
■
ALWAYS read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operation techniques before using generator.
■
NEVER leave the generator unattended, turn off engine when
unattended.
■
Unauthorized equipment modifications will void all
warranties.
■
ALWAYS ensure generator is on level ground before use.
■
Become familiar with the components of the generator before
operating.
■
ALWAYS replace any worn or damaged warning decals.
■
ALWAYS make sure generator is properly grounded to a
suitable earth ground (GROUND ROD).
■
NEVER use gas piping as an electrical ground.
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
NEVER let power cables or cords
■
NEVER
stand in water
while AC power from the generator
lay in wate
r.
is being transfer to a load.
■
NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
■
ALWAYS make certain that proper extension cord has been
selected for the job See Table 3.
■
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
Turn all circuit breakers OFF before
performing maintenance on the generator.
■
High Temperatures – Always stop engine and allow the
engine to cool before adding fuel, oil or performing service
hot
and maintenance functions. Contact with
components can
cause serious burns.
■
NEVER disconnect any
These devices are intended for operator safety. Disconnection
of these devices can cause severe injury, bodily harm or even
death! Disconnection of any of these devices will void all
warranties.
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
"emergency or safety devices"
■
■
■
WELDING SAFETY
■
■
■
■
Maintenance Safety
■
■
■
■
■
■
.
■
■
ALWAYS make sure that electrical circuits are properly
grounded
codes before operating generator. Severe
per the
National Electrical Code
(NEC) and local
injury
or
death!
by
electrocution can result from operating an ungrounded
generator.
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children and un-authorized personnel.
ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
ALWAYS remove any flammable materials in the vacinity of
the generator/welder where flying sparks may come in contact.
The possibility exists of a fire or an explosion which can
damage the equipment and thus cause bodily harm even
death!
High current generated from the welder can affect some
pacemakers. CAUTION, personnel who wear pacemakers
should consult their doctor before operating the welder.
When welding or watching, use a hand shield
or welding helmet fitted with the proper shade
filter.
ALWAYS wear safety glasses with side shields or face shield
Remember flying pieces of metal or dirt can injury eyes.
NEVER lubricate components or attempt
service on a running machine.
ALWAYS allow the machine a proper amount
of time to cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts, or missing decals.
Dispose of hazardous waste properly. Examples of potentially
hazardous waste are used motor oil, fuel and fuel filters.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
Removing the engine oil drain plug while
the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing
severe scalding to any persons in the general
area of the generator.
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 11
GAW-135H — RULES FOR SAFE OPERATION
DANGERDANGER
DANGER
DANGERDANGER
DANGER
DANGERDANGER
Never use damaged or worn cables
when connecting equipment to the
generator. Make sure power connecting
cables are securely connected to the
generator’s output receptacles, incorrect connections
may cause damage to the generator and electrical shock.
DANGERDANGER
DANGER
DANGERDANGER
NEVER grab or touch a live power cord
with wet hands, the possibility exist of
electrical shock, electrocution, and
even
death!
DANGERDANGER
■
Backfeed to a utility system can cause
property damage. NEVER connect the generator to a
building's electrical system without a transfer switch or other
approved device. All installations should be performed by a
licensed electrician
and electrical codes. Failure to do so could result in electrical
shock or burn causing serious injury or even death!
Emergencies
■
ALWAYS know the location of the
nearest
■
ALWAYS know the location of the nearest
first aid kit
:
in accordance with all applicable laws
fire extinguisher
.
.
electrocution
and or
DANGERDANGER
DANGER
DANGERDANGER
NEVER insert any objects into the output receptacles
during operation. This is extremely dangerous. ALWAYS
turn-off the generator and place all circuit breakers in
the “OFF” position when contact with
the output receptacles is required.
There exist the possibility of
electrocution, electrical shock or
burn, which can cause severe
bodily harm or even death
!
■
In emergencies
nearest phone or
Also know the phone numbers of the nearest
ambulance, doctor
information will be invaluable in the case of an
emergency.
always
know the location of the
keep a phone on the job site
and
fire department
.
. This
PAGE 12 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
NOTE PAGE
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 13
GAW-135H — OPERATION AND SAFETY DECALS
Machine Safety Decals
The MQ GAW-135H portable generator/welder is equipped with a number of safety decals (see below and on preceeding page).
These decals are provided for operator safety and maintenance information. The illustration below shows these decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
PAGE 14 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — OPERATION AND SAFETY DECALS
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 15
GAW-135H — GENERAL INFORMATION
GAW-135H Familarization
General Inspection Prior to Operation
This generator/welder has been thoroughly inspected and
accepted prior to shipment from the factory. However, be
sure to check for damaged parts or components, or loose
nuts and bolts, which could have become disloged in transit.
The
MQ Model
designed as a portable lightweight power source for 60 Hz
(single-phase) vibrators, lighting facilities, power tools,
submersible pumps and other industrial and construction
machinery.
This generator/welder is powered by a Honda GX200VEN2,
5.5 HP, air-cooled gasoline engine. The alternator, a
brushless revolving-field type, is permanently aligned to the
engine through rigid coupling.
The generator is mounted on rubber vibration isolators that
have a steel base backplate which is attached to the
protective steel pipe carrying frame. The protective carrying
frame is made of steel tubing and fully wraps around the
generator to protect against damage.
This portable generator is supplied with a electrical
panel
. The control panel includes items as listed below.
Control Panel
The generator control panel has the following componets:
z
(1) NEMA Duplex Receptacle (GFCI) 5-20R (120V,
GAW-135H generator/welder has been
control
Excitation System
The MQ generator/welder uses a magnet attached to a
flywheel to produce AC voltage from a lamp coil beneath
the flywheel. As the magnet passes the coil it produces
approximately 19-22 AC volts.
This voltage (19-22 VAC) is then sent to the control box that
contains three rectifying diodes:
z
Excitation (diode 1)
z
Battery (diode 2)
z
Slow Down (diode 3)
The AC voltage will pass through the excitation diode that
converts the voltage to DC power.
This DC power is then sent to the excitation windings housed
within the main windings commonly called the "stator".
This voltage is then transferred into the rotor through
induction. The rotor contains two diodes within it which rectify
the DC voltage and send it out through the main windings,
as AC voltage.
Engine
The four-cycle air-cooled
to meet every performance requirement of this generator.
Reference Table 1, for engine specifications.
Figure 2 shows the basic controls and indicators for the
MQ GAW-135H generator/welder.
Honda
gasoline engine is designed
20 Amp)
z
One main 2-pole,15 Amp Circuit Breaker.
z
Idle Control Switch
z
Welding Terminal Lugs
z
Ground Terminal
Circuit Breaker
To protect the generator from an overload,
circuit breaker is provided on the control panel. Make sure
to switch this circuit breaker to the "OFF" position prior to
starting the engine.
a 2-pole, 15 amp
NOTE
In keeping with
policy of constantly improving
its products, the specifications
quoted herein are subject to
change without prior notice.
Multiquip's
PAGE 16 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
To determine the running wattage for your load, multiply
the running wattage as indicated by steps 1, 2, and 3 below:
1. INCANDESCENT LOADS
Lights, heaters and similar appliances.
Total the running wattage and multiply by 1.
Example:
29 light bulbs @ 100W each = 2.9 KW
use a 3 KW generator.
2. SMALL MOTORS
Drills and other small power tools.
Total the running wattage and multiply by 2.
Example:
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
A 1 inch drill runs at 1 KW
use a 2 KW generator.
determined by multiplying nameplate
voltage by the nameplate amperage.
3. LARGE MOTORS
Submersible pumps, table saws etc.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 1.0 See Table 2 below
when connecting loads.
Total the running wattage and multiply by 3.
Example:
A conveyor belt runs at 8 KW
use a 24 KW generator.
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CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Motors and motor-driven equipment draw much greater
current for starting than during operation.
adequate size
extension cable
Always
use an
which can carry the
required load.
Extension Cables
When electric power is to be provided to various tools or
loads at some
are normally used.
distance
from the generator, extension cords
Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum
. Use the cable selection chart (Table 2 ) as a
guide for selecting proper cable size.
The idle control device is operated at a
NOTE
minimum load capacity of 100W. If the
load capacity is less than 100W, place
the idle control switch in the OFF position.
When using a combination of dual
NOTE
receptacles, total load
exceed
the rated capacity of the
should not
generator.
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 17
GAW-135H — CONTROLS AND INDICATORS
Figure 2. Generator Controls and Components
PAGE 18 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — CONTROLS AND INDICATORS
1. Engine ON/OFF Switch – Place this switch in the "ON"
position to start the engine. To turn-off the engine place this
switch in the "OFF" position.
2. Current Selector Knob – Place this knob in the desired
setting when welding is required. There are 6 selectable
settings that range from 40 amps to 135 amps.
3. Connect the welder electrodes to these terminals. Please
note the polarity of the electrodes when connecting them
to the welder.
4. Main Circuit Breaker – This 2-pole 15 amp breaker
protects the generator from short circuiting or overloading.
When starting the generator
placed in the "OFF" position.
5. Idle Control Switch – This unit is provided with an
automatic idle control for noise suppression and reduced
fuel consumption. The automatic idle control automatically
engages under a no-load condition. With the automatic
idle control switched “ON”, the engine revolutions will
automatically drop to about 2600 rpm (low-speed
operation) within 3 seconds after the load stops. When the
operation is resumed, the engine speed is automatically
increased to about 3600 rpm (high-speed operation) as
soon as the load is connected.
6. GFCI Receptacle – This receptacle will provide 120V at
all times.
always
have the circuit breaker
11. Fuel Cock Lever – Turn this lever
(down)the flow of fuel to the carburetor. Turn
stop (up)
12. Air Cleaner – Prevents dirt and other debris from entering
the fuel system. Remove wing-nut on top of air filter
cannister to gain access to filter element. NEVER run the
engine without an air cleaner.
13. Choke Lever – Used for starting the engine.
choke lever when starting a cold engine or in cold weather
conditions. The choke enriches the fuel mixture.
choke lever if starting a warm engine or in warm weather
conditions.
14. Fuel Tank Cap – Remove this cap to add unleaded
gasoline to the fuel tank.
gasoline. Make sure cap is tightened securely. DO NOT
over fill. Fuel tank capacity is 1.85 gallons (7 liters).
15. Fuel Gauge – Read this gauge to determine when fuel is
low
16. Spark Plug – Provides spark to the ignition system. Set
spark plug gap to 0.6 - 0.7 mm (0.024 - 0.028 inch). Clean
spark plug once a week.
17. Muffler/Heat Shield – Used to reduce noise and emissions.
NEVER touch this
is in use. Always allow time for the generator to cool down
before performing maintenance.
the flow of fuel.
.
Replenish
heat shield
when the generator/welder
downward
to
upward
Close
Open
with
clean unleaded
start
to
the
the
7. Ground – This ground connection point should be
connect to a good earth ground (ground rod).
8. Engine Oil Filler Cap – Remove this cap/dipstick when
the adding of engine oil is required. See Table 4 for
recommended type engine oil.
9. Engine Oil Drain Plug – Remove this drain plug when
draining of the oil from the engine crankcase is required.
Fill with recommeded type oil as listed in Table 4.
10. Recoil Starter (pull rope) – Manual-starting method. Pull
the starter grip until resistance is felt, then pull briskly and
smoothly.
on level ground. Placing the generator/welder on level ground
will ensure that the low oil sensor will function properly.
NOTE
This
HONDA
with a low oil shutdown capability. A
built in sensor will automatically turn
off the engine should the oil level fall
below a safe operating condition.
Make sure the generator is placed
engine is equipped
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 19
GAW-135H — WELDER/GENERATOR REFUELING
DANGERDANGER
DANGER
DANGERDANGER
Adding fuel to the tank should be done only when
the engine is stopped and has had an opportunity
to cool down. In the event of a fuel spill, DO NOT
attempt to start the engine until the fuel residue
has been completely wiped up, and the area surrounding the
engine is dry. If generator is placed in a truck bed with a plastic
liner, REMOVE generator from truck bed and place on ground
(Figure 3) to refuel. This possibility exist of
to static electricity.
fire
or
explosion
due
Figure 3. Generator/Welder Refueling
PAGE 20 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — INSTALLATION
Outdoor Installation
Install the generator/welder in a area that is free of
bystanders
generator is on secure level ground so that it cannot slide or
shift around. Also install the generator in a manner so that
the exhaust will not be discharged in the direction of nearby
homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.
, and
overhead obstructions
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
. Make sure the
debris
Indoor Installation
,
Exhaust gases from gasoline engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any gasoline engine
are very poisonous if discharged in a closed room, but
harmless if allowed to mix with the outside air. If the generator
is installed indoors, you must make provisions for venting
the engine exhaust to the outside of the building.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground. Always use the ground terminal on the generator to
ground the generator.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
Mounting
The generator should always be mounted on a flat level
surface to isolate vibration of the generator when it is
running. DO NOT place the generator on slopes, the
possibility exists that the generator could slide.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
An electric shock is apt to happen
when vibrators are used. Pay close
attention to handling when operating
vibrators and always use rubber
boots and gloves to insulate the
body from a short circuit.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 3) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 21
GAW-135H — INSTALLATION
Connecting the Ground
The nut and ground terminal on the generator should always be used to connect the generator to a suitable ground. The
ground cable should be #8 size wire minimum.
At the generator, connect the terminal of the ground cable between the lock washer and the nut (Figure 4) and tighten the
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).
Figure 4. Generator Grounding
PAGE 22 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — PRE-INSPECTION (ENGINE)
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CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
NEVER operate the generator in a confined
area or enclosed area structure that does
not provide ample
ALWAYS wear approved eye and hearing
protection before operating the generator.
Before Starting
1. Read safety instructions at the
beginning of manual.
2. Clean the generator, removing dirt
and dust, particularly the engine
cooling air inlet, carburetor and air
cleaner.
3. Check the air filter for dirt and dust. If air filter is dirty, replace
air filter with a new one as required.
4. Check carburetor for external dirt and dust. Clean with dry
compressed air.
5. Check fastening nuts and bolts for tightness.
Engine Oil Check
free flow of air
.
Motor fuels are highly flammable and can
be dangerous if mishandled. DO NOT
smoke while refueling. DO NOT attempt to
refuel the generator if the engine is
running or in the dark
Figure 6. Engine Oil Dipstick (Oil Level)
DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL
DANGER EXPLOSIVE FUEL
DANGER EXPLOSIVE FUELDANGER EXPLOSIVE FUEL
hot!
,
.
1. To check the engine oil level, place the generator on secure
level ground with the engine stopped.
2. Remove the filler dipstick from the engine oil filler hole
(Figure 5) and wipe clean.
Figure 5. Engine Oil Dipstick (Removal)
3. Insert and remove the dipstick without screwing it into the filler
neck. Check the oil level shown on the dipstick.
4. If the oil level is low (Figure 6), fill to the edge of the oil filler
hole with the recommended oil type (Table 4). Maximum oil
capacity is .63 quarts (0.6 liters)
Fuel Check
1. Close the fuel cock before filling the fuel tank.
2. Remove the fuel cap located on top of fuel tank.
3. Read the fuel gauge located on top of the fuel tank (Figure 7) to
determin if the fuel level is low. If fuel is low, replenish with
clean unleaded fuel
4. When refueling, be sure to use a strainer for filtration. DO
NOT top-off fuel.
Wipe up any spilled fuel
.
Figure 7. Fuel Gauge
DO NOT fill the tank beyond capacity.
immediately!
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 23
GAW-135H — INITIAL START-UP (ENGINE)
2. Place the
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
DO NOT attempt to operate this
generator until the Safety, General
Information and Inspection sections of
this manual have been
thoroughly understood
This section is intended to assist the operator with the
start-up
section be read carefully before attempting to use the generator
in the field.
Before Starting the Engine
1. Be sure to
of the trash generator. It is extremely important that this
disconnect all electrical loads
read and
.
initial
from the
generator prior to starting the engine.
2. NEVER
start
the engine with the
main circuit breaker
in the “ON" position. Place the main circuit breaker
if starting a
3. Place the
if starting a
4. Place the
position.
(Figure 8) in the OFF position.
choke lever
cold
Figure 10. Choke Lever
choke lever
warm engine
engine ON/OFF switch
(Figure 10) in the "
engine.
(Figure 10) in the "
or the
temperature is warm.
(Figure 11) in the "
CLOSED
OPEN
" position
" position
ON
"
Figure 8. Main Breaker (OFF Position)
Starting the Engine
1. Place the engine
position.
”
Figure 9. Engine Fuel Valve Lever (ON Position)
fuel valve lever
(Figure 9) to the "ON"
Figure 11. Engine On/Off Switch (ON)
5. Grasp the starter grip (Figure 12) and slowly pull it out. The
resistance becomes the hardest at a certain position, corresponding to the compression point. Pull the starter grip briskly
and smoothly for starting.
Figure 12. Starter Grip
CAUTION
z
DO NOT pull the starter rope all the way to the end.
z
DO NOT release the starter knob after pulling. Allow it
to rewind as soon as
PAGE 24 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
GAW-135H — INITIAL START-UP/GENERATOR OPERATION
6. If the engine has started, slowly return the choke lever
(Figure 13 ) to the
started repeat steps 1 through 6.
7. Before the generator is placed into operation, run the engine
for 3-5 minutes. Check for abnormal smells, fuel leaks, and
noises that would associate with lose components.
8.
Place
the
idle control switch
“OPEN”
position. If the engine has not
(Figure 13) in the "OFF"
9. Place the main circuit breaker (Figure 15) in the ON
position.
(down) position. This will allow the engine speed to run
at speed about 3600 RPM's
10. If desired, verify with a voltmeter (Figure16) that 120
VAC is present at the GFCI duplex receptacle.
Figure 13. Idle Control Switch (Off)
Figure 15. Main Circuit Breaker (ON)
Placing the
the RUN position (Figure 14) allows
NOTE
will run at idle speed (2200 RPM's) until a load is applied, at that
time the engine speed will increase to 3600 RPM's as long as
the load is being applied. When the load is not in use, the engine
speed will drop back to the idle mode after about 3 seconds.
the engine to operate at a maximum
speed of about 3600 RPM's. When
the idle control switch is placed in
the up position (ON), the generator
idle control switch
in
Connecting the Load
1. If small wattage power tools are required, connect them
to the GFCI receptacle.
Figure 14. Idle Control Switch (On)
Figure 16. 120 VAC GFCI Receptacle
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 25
Stopping The Engine
Normal Shutdown
GAW-135H — INITIAL START-UP/GENERATOR OPERATION
1. Place the
position.
2. Remove the load from the generator, and let the engine
run at idle for 3-5 minutes with the idle control switch in
the ON position (Up)
3. Place the
position.
4. Place the engine
position.
main circuit breaker
engine ON/OFF
Figure 24. Operation Switch (Stop)
fuel valve lever
”
(Figure 11) in the OFF
(Figure 24) in the OFF
(Figure 25) to the "OFF"
Figure 25. Engine Fuel Valve Lever (OFF Position)
Emergency Showdown
1. Place the
position.
engine ON/OFF switch
PAGE 26 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)
(Figure 24) in the OFF
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