Multiquip GAW135H User Manual

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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

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)

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

SERIOUSLY INJURED

Multiquip GAW-135H

Safety Message Alert

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

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

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:

(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:

Excitation (diode 1)

Battery (diode 2)

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)

One main 2-pole,15 Amp Circuit Breaker.

Idle Control Switch

Welding Terminal Lugs

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

upward

Open

with

clean unleaded

start

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

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

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

DO NOT pull the starter rope all the way to the end.

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.

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

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

GAW-135H — WELDER OPERATION

Connecting the Welding Cables

3. When connecting the cables NEVER allow the cable or welder output terminals to touch each other.

1. Make sure the generator/welder is OFF (not running).

4. The welder's output terminals are marked positive (+)

2. Attach the correct size terminal connector to the free end of each cable. NEVER connect

bare or exposed

and negative (-). Connect the welding cables to the output terminals as referenced in Table 5.

wires (Figure 23) directly to the terminals. Exposed wiring may cause electrical arcing or dilectric breakdown from poor connection.

thgiartS

ytiraloP

esreveR

ytiraloP

Figure 23. Welding Cable (Bare Wires)

NOTE

2. Attach the correct size terminal connector (Figure 24) to the free end of each cable.

suitable welding cable. The calculated values listed in Table 6 are based on a maximum voltage drop of 4 volts.

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tisoP

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gnidnuorG)+(evi

redloHgnidleW)-(evitageN

redloHgnidleW)+(evitisoP

gnidnuorG)-(evitageN

When selecting a welding cable, the welding cable should be larger in size as it becomes longer or its current becomes higher. Use Table 6 as a guideline when selecting a

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yollareppocrofgnidlewcrA

leWpu-dliuB

gnid

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setalpnihtfognidlewcrA

leetssselniatsfognidlewcrA

Figure 24. Welding Cable (Terminal Connector)

TRAHCGNITCELESELBACGNIDLEW.6ELBAT

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A055#5#5#5#5#4#

A0015#5#4#3#2#1#

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tf001

)m03(

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.tf002 )m16(

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:gnideecxEtoNtiucriCdleWnihtgneL)reppoC(elbaClatoT

.tf003 )m19(

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 27

GAW-135H — WELDER OPERATION

Duty Cycle

Because of the different types of job applications for which this equipment is intended, the welding-generator is not designed to withstand continuous welding. To avoid overloads, select an appropriate duty cycle. See Table 7.

GNITARELCYCYTUD.7ELBAT

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)%(elcyCytuD04

NOTE

Duty cycle is based on 10 minute intervals.

Regulating Welding Current

Regulate the welding current with the current selector knob. Never regulate the current by increasing or decreasing the engine operating speed.

The operating range of the welding current is listed in Table 8. Select the desired welding current according to the application.

DO NOT turn the current selector knob while welding. Use only factory selectable settings. The use of any other settings could cause severe damage to the equipment. NEVER place the dial indicator between settings.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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PAGE 28 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — MAINTENANCE

General Inspection

At least daily or prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks.

Engine Side (Refer to the Robin Engine Instruction Manual)

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Make sure the generating set is level. The oil level must be between the two notches on the dipstick.

Changing Oil

Change oil after the first 20 hours of operation. Drain and refill the engine crankcase every 50 operating hours or once a week thereafter. Drain crankcase oil into a suitable container while engine is still warm. Replace the drain plug tightly. Add oil through the filler hole.

Air Cleaner

Every 50 hours: Remove air cleaner element (std. or heavy duty types), and wash in kerosene or liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry. Wipe heavy duty paper element dry with toweling. Saturate element with kerosene; squeeze excess from foam element. Wipe excess from heavy duty paper element.

Service Daily

If engine is operating in very dusty and dry grass conditions. A clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Spark Plug

Remove carbon build-up on the spark plug (Figure 25) with a wire brush. Set the spark plug gap to 0.6—0.7mm (0.024-

0.028 inch). Tighten with a spark plug socket wrench. Clean the spark plug every 50 operating hours or once a week.

Figure 26. Spark Plug Gap

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 29

GAW-135H — PREPARATION FOR LONG -TERM STORAGE

Generator Storage

For storage of the generating set for over 30 days, the following is required:

Drain the fuel tank completely.

Run the engine until the gasoline in the carburetor is completely consumed.

Completely drain the oil from the crankcase and refill with fresh oil.

Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil.

Slowly rotate the engine a few times with the starter Rope and install a new plug.

Pull out the starter rope slowly and stop at the compression point.

Clean all external parts of the generating set with a cloth.

Cover the generating set and store in a clean, dry place.

PAGE 30 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — WIRING DIAGRAM

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 31

GAW-135H — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Engine Troubleshooting (Table 10) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

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"noisserpmoc"

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PAGE 32 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.01ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuorewoptneiciffusnI

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GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 33

GAW-135H — TROUBLESHOOTING (GENERATOR)

Practically all generator breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Generator Troubleshooting (Table 11) information shown below and on the preceding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

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?noitcnuflamgniriwxoblortnoC .stnenopmocevitcefedynaecalper,gniriwxoblortnockcehC

?dionelosevitcefeD .dionelosecalperrokcehC

.gniriwxoblortnockcehC

?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC

PAGE 34 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — TROUBLESHOOTING (GENERATOR)

MOTPMYS MELBORPELBISSOP NOITULOS

?sgnidniwrotorevitcefeD .rotorecalperrokcehC

)DEUNITNOC(GNITOOHSELBUORTROTARENEG.11ELBAT

onetarelecedtonseoD

."TUPTUOEGATLOV"

sahtubetarelecedtonseoD

."TUPTUOEGATLOV"

?dionelosevitcefeD .dionelosecalperrokcehC

?ecivedlortnoceldievitcefeD .ecivedlortnoceldiecalperrokcehC

?dionelosevitcefeD .ecivedlortnoceldiecalperrokcehC

?noitcnuflamgniriwxoblortnoC .stnenopmocevitcefedynaecalper,gniriwxoblortnockcehC

?dionelosevitcefeD .dionelosecalperrokcehC

?noitcnuflamecivedlortnoceldI .ecivedlortnoceldiecalperrokcehC

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 35

GAW-135H — EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

NOTE

If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

Items Found In the “Items Number” Column

All parts with same symbol in the number column,

, belong to the same assembly or kit.

, #, +, %, or

NOTE

The contents of this catalog are subject to change without notice

PAGE 36 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — SUGGESTED SPARE PARTS

MQ GAW-135H WELDER/GENERATOR WITH HONDA GX200VEN2 GASOLINE ENGINE

1 to 3 Units

Qty.... P/N ...................... Description

1 ....... 9924800014 ......... CAP, FUEL TANK

1 ....... 9924800004 ......... FILTER, FUEL TANK

3 ....... 17211ZB2000 ...... ELEMENT, AIR CLEANER

3 ....... 9807956846 ......... SPARK PLUG

1 ....... 28462ZH8003 ...... ROPE, RECOIL STARTER

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 37

NAMEPLATE AND DECALS

GAW-135H— NAMEPLATE AND DECALS

PAGE 38 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H— NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS

1 0561200004 DECAL; MQ MULTIQUIP 135A GAW-135H 1

2 9504200004 DECAL; CAUTION NEVER ATTEMPT ................. 1 ............. REPLACES D90420000

3 0521100003 DECAL; CONTROL PANEL 1

4 8700611904 DECAL; ELECTRICAL SHOCK HAZARD ............. 1.............S-4985

5 0800690804 DECAL; WELDING OUTPUT TERMINAL ............. 1.............S-1238A

6 0820610404 DECAL; WARNING, TRANSFER SWITCH ........... 1.............S-3627

7 8700611804 DECAL; WARNING DANGEROUS GAS ............... 1............. S-4984

8 9522100204 DECAL; PROPOSITION 65 .................................. 1............. REPLACES D92210020

9 7900636004 DECAL; CAUTION OPERATE AT 3600 RPM ....... 1.............S-4461

10 9511100004 DECAL; READ MANUAL ...................................... 1.............A91110000

11 9512100203 DECAL; CAUTION WELDING OPERATION ......... 1.............REPLACES D91210020

12 9521200004 DECAL; OPERATING INSTRUCTIONS ................ 1............. REPLACES A92120000

13 0561000003 DECAL; MQ MULTIQUIP 135A 1 14 0561000104 DECAL; MQ MULTIQUIP 1

15 DECAL; NAMEPLATE .......................................... 1 ............. CONTACT MQ PARTS DEPT.

16 0800628504 DECAL; GROUND TERMINAL ............................. 1.............S-1123

17 1980680004 DECAL; FUEL COCK ........................................... 1............. S-3704

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 39

GENERATOR ASSY.

GAW-135H— GENERATOR ASSY.

PAGE 40 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H— GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0924200004 ENGINE, HONDA GX200VEN2 1 1A 0101000003 GENERATOR ASSY. 1 2 0110000913 ROTAR ASSY. 1 2 0135000002 ARAMATURE ASSY. 1 3 0155100003 END BRACKET 1 4 0012808020 HEX HEAD BOLT 4 5 0012308045 HEX HEAD BOLT 1 6 0012108070 HEX HEAD BOLT 1 7 0040008000 WASHER, LOCK 1 8 0801086004 WASHER, FLAT 1 9 1153300114 GROMMET 2 10 1153400212 COVER 1 11 0416700033 BASE 1 12 7935416004 RUBBER SUSPENSION 2 13 0016908045 HEX HEAD BOLT 2 14 7935419204 RUBBER SUSPENSION 2 15 0207208000 HEX NUT 10

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 41

CONTROL BOX ASSY.

GAW-135H— CONTROL BOX

PAGE 42 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H— CONTROL BOX

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0214000103 CONTROL BOX (FIN SIDE) 1 2 0214000003 CONTROL BOX 1 3 0016906016 HEX HEAD BOLT 3 4 0226900350 TRIM SEAL 1

5 0601807489 CURRENT SELECTROR ............................. 1 ........................ BR-2-5

6 0027004030 MACHINE SCREW 2 7 0601807489 CIRCUIT BREAKER 1 8 3011816004 BRACKET, CIRCUIT BREAKER 1 9 0027004010 MACHINE SCREW 2

10 0601812598 RECEPTACLE ............................................. 1 ........................ GF-530EM

11 0027004010 MACHINE SCREW 2 12 0207004000 HEX NUT 2

13 0601831620 ROCKER SWITCH ...................................... 1 ........................ C1550WABB

14 0923100004 INVERTER UNIT ......................................... 1 ........................ IN-10

15 0207004000 HEX NUT 6

16 0601827350 SLOWDOWN CONTROL UNIT .................... 1 ........................ ND-81

17 0028604010 MACHINE SCREW 2 18 0260600014 BRACKET, CONDENSER 1 19 0028603006 MACHINE SCREW 2

20 0601826178 CONDENSER, 250V .................................... 1 ........................ KMH250LGSN,1500MB

21 0028603006 MACHINE SCREW 2 22 0260600104 RUBBER SEAT 1 23 0601826178 GROMMET 2 24 0237200003 BRACKET, OUTPUT TERMINAL 1 25 0237100004 COVER, OUTPUT TERMINAL 1 26 0237400004 RUBBER SEAT 1 27 0316800160 TRIM SEAL 1 28 0016906020 HEX HEAD BOLT 2 29 0805088304 COLLAR 2 30 0805088004 STAY RUBBER 4 31 0016906016 HEX HEAD BOLT 4 32 1230500004 OUTPUTTERMINAL 2

32A 0266600004 RESISTOR 50K OHMS ............................... 1 ........................ RS-3B

33 0040506000 TOOTHED WEASHER 1 34 0214500003 ROOF, CONTROL BOX 1 35 0016605010 HEX HEAD BOLT 6 36 0213600034 COVER, CONTROL BOX 1 37 0016905010 HEX HEAD BOLT 4

0266000123 FIN ASSY. 1 38 0266300214 FIN 1 39 0016905016 HEX HEAD BOLT 4

40 0601823208 RECTIFER ................................................... 8 ........................ S30VT60

41 0027103012 MACHINE SCREW 16

42 0601821256 TRANSISTOR .............................................. 1 ........................ CM75BU-12H

43 0017105016 MACHINE SCREW 4 44 0601842067 RESISTOR 1/2W 10K OHMS 4 45 0016906016 HEX HEAD BOLT 4 46 0247700004 WIRE HARNESS 1 47 0601826150 CONDENSER 250 VAC 0.1µF1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 43

PIPE FRAME AND FUEL TANK ASSY.

GAW-135H— PIPE FRAME AND FUEL TANK ASSY.

PAGE 44 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H— PIPE FRAME AND FUEL TANK ASSY.

PIPE FRAME AND FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0417000002 PIPE FRAME 1 2 0416400114 GENERATOR GUARD 1 3 0016906016 HEX HEAD BOLT 3 4 0454100003 SIDE GUARD 1 5 0016906016 HEX HEAD BOLT 1 6 0019206016 HEX HEAD BOLT 2 7 0040506000 TOOTHED WASHER 2 8 0363000022 FUEL TANK 1 9 0416400204 OVERFLOW GUARD 1 10 0016998020 HEX HEAD BOLT 4 11 0602125031 FUEL GUAGE 1 12 9924800014 CAP, FUEL TANK 1 13 9924800004 FILTER 1 14 16950898633 FUEL COCK 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 45

MUFFLER ASSY.

GAW-135H— MUFFLER ASSY.

PAGE 46 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 18310ZB3C001 MUFFLER 1 2 0330400314 MUFFLER BRACKET 1 3 0207006000 HEX NUT 2 4 0330400404 MUFFLER ADJUSTER 1 5 0016906016 HEX HEAD BOLT 2 6 0330400033 MUFFLER STAY 1 7 0016906016 HEX HEAD BOLT 2 8 0016908025 HEX HEAD BOLT 1 9 0602302006 MUFFLER COVER, OUTER 1 10 0602302007 MUFFLER COVER, OUTER 1 11 0330300022 DUCT, MUFFLER COVER 1 12 0330300124 DUCT, BRACKET 1 13 0016905010 HEX HEAD BOLT 1 14 0017306010 HEX HEAD BOLT 5 15 0330400124 BRACKET, MUFFLER COVER 1 16 0016906016 HEX HEAD BOLT 1 17 0333000012 EXHAUST PIPE 1 18 18381ZH8800 GASKET 1 19 18381ZE1800 GASKET 1 20 92101980200A HEX HEAD BOLT 2 21 94001080000S HEX NUT 2 22 18355898630 SPARK ARRESTER 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 47

CYLINDER HEAD ASSY.

GX-200VEN2 — CYLINDER HEAD ASSY.

PAGE 48 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 —CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

3 12210ZL00100 HEAD COMP. CYLINDER ................. 1 ................ INCLUDES ITEMS W/

5 12251ZL0003 GASKET 1 6 12310ZE1020 COVER COMP., HEAD 1 7 12391ZE1000 PACKING, HEAD COVER 1 8 15721883030 TUBE, BREATHER 1 9 90013883000 BOLT, FLANGE 6X12 CT200 4 10 90043ZB2003 BOLT, STUD 6X94 2 11 90047ZE1000 BOLT, STUD 8X32 2 12 9430110160 DOWEL PIN, 10X16 2 14 957230806000 BOLT, FLANGE 8X60 4 15 9807956846 SPARK PLUG, BPR6ES NGK 1 15 9807956855 SPARK PLUG, W20EPR-U DENSO 1

12204ZE1306 GUIDE, IN VALVE O.S. 1

122052ZE1315 GUIDE, EX. VALVE O.S. 1

12216ZE5300 CLIP, VALVE GUIDE 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 49

CYLINDER BARREL ASSY.

GX-200VEN2 — CYLINDER BARREL ASSY.

PAGE 50 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CYLINDER BARREL ASSY.

CYLINDER BARREL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 12000ZL0811 CYLINDER BARREL ASSY. .......................... 1 ............ INCLUDES ITEMS W/

2 15510ZE1033 OIL LEVEL SWITCH ASSY. 1 3 16506ZL0000 GOVERNOR ASSY. 1 4 16531ZE1000 SLIDER, GOVERNOR 1 5 16541ZE1000 SHAFT, GOVERNOR ARM 1 6 90131ZE1000 BOLT, DRAIN PLUG 2 7 90451ZE1000 WASHER, THRUST 6MM 1 8 90601ZE1000 WASHER, DRAIN PLUG 10.2MM 2 9 90602ZE1000 CLIP, GOVERNOR HOLDER 1 10 10 11 12 91353671004 O-RING, 14MM NOK 1 13 9405010000 NUT, FLANGE 10MM 1 14 9410106800 WASHER, PLAIN 6MM 2 15 9425108000 PIN, LOCK 8MM 1 16 957010601200 BOL;T, FLANGE 6X12 2

91001ZF1003 BEARING, RADIAL BALL, 6205TMB NTN 1

91001ZF1004 BEARING, RADIAL BALL, 62055 KOYO 1

91202883005 OIL SEAL, 25X41X6 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 51

CRANKCASE COVER ASSY.

GX-200VEN2 — CRANKCASE COVER ASSY.

PAGE 52 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CRANKCASE COVER ASSY.

CRANKCASE COVER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2 11300ZE1633 COVER ASSY., CRANKCASE ...................... 1 ............ INCLUDES ITEMS W/

4 11381ZL0000 PACKING, CASE COVER 1

5 15600ZE1003 CAP ASSY., OIL FILLER .............................. 1 ............ INCLUDES ITEMS W/

6 15600ZG4003 CAP ASSY., OIL FILLER .............................. 1 ............ INCLUDES ITEMS W/%

7 #% 15625ZE1003 PACKING, OIL FILLER CAP 2 9

10 9430108140 DOWEL, PIL 8X14 2 11 957010803200 BOLT, FLANGE 8X32 6 12

91202883005 OIL SEAL, 25X41X6 1

961006205000 BEARING, RADIAL BALL 6205 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 53

CRANKSHAFT ASSY.

GX-200VEN2 — CRANKSHAFT ASSY.

PAGE 54 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

13 13310ZL0A00 CRANKSHAFT COMP. 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 55

PISTON ASSY.

GX-200VEN2 — PISTON ASSY.

PAGE 56 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — PISTON ASSY.

PISTON ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2 11300ZE1633 COVER ASSY., CRANKCASE 1 1 13010ZL0003 RING SET, PISTON STD TEKOKU 1 1 13011ZL0003 RING SET, PISTON 0.25 TEKOKU 1 1 13012ZL0003 RING SET, PISTON 0.50 TEKOKU 1 1 13013ZL0003 RING SET, PISTON 0.75 TEKOKU 1 2 13101ZL0010 PISTON, STD 1 2 13102ZL0010 PISTON, 0.25 1 2 13103ZL0010 PISTON 0.50 1 2 13104ZL0010 PISTON 0.75 1 3 13111ZE1000 PIN, PISTON 1

4 13200ZE1010 ROD ASSY., CONNECTING ROD ................. 2 ............ INCLUDES ITEMS W/

6 90551ZE1000 CLIP, PISTON PIN 18MM 2

90001ZE1000 BOLT, CONNECTING ROD 2

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 57

CAMSHAFT ASSY.

GX-200VEN2 — CAMSHAFT ASSY.

PAGE 58 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CAMSHAFT ASSY.

CAMSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 12209ZH8003 SEAL, VALVE STEM 1

2 14100ZL0000 CAMSHAFT ASSY. ....................................... 1 ............ INCLUDES ITEMS W/

4 14410ZE1000 ARM, VALVE ROCKER 2 6 14431ZE1000 ARM, VALVE ROCKER 2 7 14451ZE1013 PIVOT, ROCKE54 ARM 2 8

9 14711ZF1000 VALVE, IN. 1 10 14721ZF1000 VALVE, EX. 1 11 14731ZL0000 LIFTER, VALVE 2 12 14751ZF1000 SPRING,VALVE 2 13 14771ZE1000 RETAINER, IN. VALVE SPRING 1 14 14773ZE1000 RETAINER, EX. VALVE SPRING 1 15 14781ZE1000 ROTATOR, VAL;VE 1 16 14791ZE1010 PLATEW, PUSH ROD GUIDE 1 17 90012ZE0010 BOLT, PIVOT 8MM 2 18 90206ZE1000 NUT, PIVOT ADJUSTING 2

14568ZE1000 SPRING, WEIGHT RETURN 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 59

RECOIL STARTER ASSY.

GX-200VEN2 — RECOIL STARTER ASSY.

PAGE 60 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — RECOIL STARTER ASSY.

RECOIL STARTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 28400ZH8013ZB STARTER ASSY., RECOIL 2 28405ZL0000ZA SPACER, MOUNTING *NH1* BLACK 1 3 28410ZH8003ZB CASE COMP. 4 28420ZH8013 REEL, NATURAL 1 5 28422ZH8013 RATCHET 2 6 28433ZH8003 GUIDE 1 7 28441ZH8003 SPRING, FRICTION 1 8 28442ZH8003 SPRING 1 9 28443ZH8003 SPRING, RETURN 2 10 28461ZH8003 GRIP 1 11 28462ZH8003 ROPE 1 12 9003ZH8003 SCREW, SETTING 1 13 957010601800 BOLT, FLANGE 6X18 3

NH1* BLACK 1

NH1* BLACK ......... 1 ................ INCLUDES ITEMS W/

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 61

FAN COVER ASSY.

GX-200VEN2 — FAN COVER ASSY.

PAGE 62 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — FAN COVER ASSY.

FAN COVER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2 19610ZL0000ZD COVER COMP., FAN *NH1* BLACK 1 3 19611ZH8820 PLATE COMP., SIDE ALERT & LAMP 1

5 19620ZL0V30 SHROUD ASSY., UPPER ............................. 1 ............ INCLUDES ITEMS W/

6 196740ZL0V30 SHROUD COMP., LOWER 1 8 36100ZH7003 SWITCH ASSY., ENGINE STOP 1 9 36101ZE1010 CORD, STOP SWITCH 370MM 1 10 90013883000 BOLT, FLANGE 6X12 CT200 8 11 90022888010 BOLT, FLANGE 6X20 CT200 1 13 906901ZH7D02 CLIP, HARNESS 1 14 15 957010600800 BOLT, FLANGE 6X8 1 19 34150ZH7003 ALERT UNIT, OIL 1 21 957010600800 BOLT, FLANGE 6X8 1

16584883300 SPRING, CONTROL ADJUSTING 1

93500050350A SCREW, PAN 5X35 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 63

CARBURETOR ASSY.

GX-200VEN2 — CARBURETOR ASSY.

PAGE 64 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CARBURETOR ASSY.

CARBURETOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

#%+ 16010ZB1015 GASKET SET 1

3 16013ZE0005 FLOAT SET 1

4 16015ZE0831 CHAMBER SERT FLOAT .............................. 1 ................INCLUDES ITEMS W/%

% 16024ZE1811 SCREW SETY, DRAIN 1

9 16100ZL0V31 CARBURETOR ASSY. BE74A A/B ............... 1 ................ INCLUDES ITEMS W/

12 16211ZL0000 INSULATOR 1 13 16212ZH8800 PACKING, INSULATOR 1 14 16221ZH8801 PACKING, CARBURETOR 1 15 16269ZE1800 PACKING, AIR CLEANER 1

16 16610ZB2000 LEVER COMP., CHOKE ............................... 1 ................INCLUDES ITEMS W/

16011ZE0005 VALVE SET FLOAT 1

16028ZE0005 SCREW SET ................................................. 1 ................ INCLUDES ITEMS W/#

16044ZE0005 CHOKE SET 1

16124ZE0005 SCREW, THROTTLE STOP 1 16166ZL0000 NOZZLE, MAIN 1

9430520122 PIN, SPRING 2X12 1 99101ZH80720 JET, MAIN #72 1 99101ZH80750 JET, MAIN #75 1 99101ZH80780 JET, MAIN #78 1

99204ZE20400 JET SET, PILOT #40 ..................................... 1 ................ INCLUDES ITEMS W/+

16016ZH7W01 SCREW SET, PILOT 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 65

AIR CLEANER ASSY.

GX-200VEN2 — AIR CLEANER ASSY.

PAGE 66 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — AIR CLEANER ASSY.

AIR CLEANER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 17211ZB2000 ELEMENT 1 2 17212ZB2000 SEPARATOR 1 3 17220ZB2000 CASE COMP. 1 4 17222ZL0V30 STAY 1 5 17231ZB2000 COVER 1 6 17252ZB2000 SEAL 1 7 90115459770 BOLT, WINKER SETTING 4 8 9405006080 NUT, FLANGE 6MM 2 9 957010601000 BOLT, FLANGE 6X10 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 67

MUFFLER ASSY.

GX-200VEN2 — MUFFLER ASSY.

PAGE 68 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 18310ZB3C00 MUFFLER COMP. 1 3 18355898630 ARRESTER, SPARK 1 4 18381ZE1800 GASKET 1 5 92101080200A BOLT, HEX. 8X20 2 6 94001080000S NUT, HEX 8MM 2 7 18310ZB2000 PROTECTOR, MUFFLER OUTER 1 8 18325ZH8T90 PROTECTOR, MUFFLER INNER DENYO 1 9 18329ZB2000 SEAL, MUFFLER PROTECTOR 2 10 18381ZH8800 GASKET 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 69

FUEL COCK ASSY.

GX-200VEN2 — FUEL COCK ASSY.

PAGE 70 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — FUEL COCK ASSY.

FUEL COCK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 16080898631 PACKING SET, COCK 1 2 16081471831 CUP, FUEL STRAINER 1 4 16950898632 FUEL COCK ASSY. 1 5 16952883005 SCREEN SET 1 17 90854ZB3000 RUBBER, 9X15X20 1

21 950014514040 TUBE, 4.5 140 ............................................... 1 ............ REPLACES 950014500160M

22 9500202080 CLIP B8, TUBE 2

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 71

FLYWHEEL ASSY.

GX-200VEN2 — FLYWHEEL ASSY.

PAGE 72 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — FLYWHEEL ASSY.

FLYWHEEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 13331357000 KEY, SPECIAL WOODRUFF, 25 X18 1 2 19511ZE1000 FAN, COOLING 1 4 28451ZL0000 PULLEY, STARTER 1 5 31110ZL0811 FLYWHEEL COMPLETE, (LAMP) 1 7 90201878003 NUT, SPECIAL 14 MM 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 73

IGNITION COIL ASSY.

GX-200VEN2 — IGNITION COIL ASSY.

PAGE 74 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — IGNITION COIL ASSY.

IGNITION COIL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 30500ZE1033 IGNITION COIL ASSY. 1

2 30600ZE1013 TERMINAL ASSY. HIGH TENSION............... 1 ............ NICHIWA Y-EZ

3 31630ZL0V31 COIL ASSY., CHARGE 1 4 31511ZE1000 CLAMAPER, CORD 1 5 31512ZE1000 GROMMET, CORD 1 7 90015883000 BOLT, FLANGE 6X28 2 8 90019883000 BOLT, FLANGE 5X10 1 9 90121952000 BOLT, FLANGEN 6X25 2

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 75

CONTROL ASSY.

GX-200VEN2 — CONTROL ASSY.

PAGE 76 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — CONTROL ASSY.

CONTROL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 30500ZE1033 IGNITION COIL ASSY. 1 2 16550ZL0V30 ARM COMP, GOVERNOR 1 4 16555ZL0V30 ROD, GOVERNOR 1 5 16559ZL0V30 RETURN SPRING, COVENOR SUB. ARM 1 6 16561ZL0V30 SPRING, GOVERNOR 1 7 16562ZL0V30 SPRING, THROTTLE RETURN 1 18 90015ZE5010 BOLT, GOVERNORT ARM 1 24 9405006000 NUT, FLANGE 6MM 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 77

RECTIFER ASSY.

GX-200VEN2 — RECTIFER ASSY.

PAGE 78 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — RECTIFER ASSY.

RECTIFER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

2 16270ZL0V30 AUTO THROTTLE ASSY. .............................. 1 ............ INCLUDES ITEMS W/

5 32110ZL0V30 SUB HARNESS ASSY. 1 6

7 90683SA0003 CLIP, WIRE HARNESS 25MM 2 8

9 9405006000 NUT, FLANGE 6MM 2 10# 9430520062 PIN, SPRING 2X6 1 11 12 957010602500 BOLT, FLANGE 6X25 2 13

1628893000 SPRING, CHOKER RETURN 1

31700KAE871 CONDENSER UNIT 1

31750ZL0V31 RECTIFIER ASSY., REGULATOR 1

36330ZL0V31 SOLENOID ASSY. ......................................... 1 ............ INCLUDES ITEMS W/#

93500050080A SCREW, PAN 5X8 2

957010601600 BOLT, FLANGE 6X16 2

16273ZL0V30 LEVER,SOLENOID THROTTLE 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 79

LABEL ASSY.

GX-200VEN2 — LABEL ASSY.

PAGE 80 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GX-200VEN2 — LABEL ASSY.

LABEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

3 87521ZL0000 EMBLEM 1 14 87528ZB2630 MARK, CHOKE 1 15 87533ZC0630 MARK, AIR CLEANER 1 27 87532ZH8810 MARK, OIL ALERT 1

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 81

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any material

8. Such material will be held for five working

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components. f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

received that is not acceptable.

days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

direct to Government agencies, and to Origi-

nal Equipment Manufacturer accounts who

use our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder for

damages in excess of the purchase price of the

item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental dam-

ages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made

in connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes nor authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 82 — 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 83

OPERATION AND PARTS MANUAL

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

Manufactured for MULTIQUIP INC. by DENYO MANUFACTURING CO., JAPAN

Your Local Dealer is:

Atlanta • Boise • Dallas • Houston • Newark Montreal, Canada • Manchester, UK Rio De Janiero, Brazil • Guadalajara, Mexico

Multiquip GAW135H User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual