OPERATION AND PARTS MANUAL
MODEL GAW180HE/HE1/HEA
PORTABLE WELDER-GENERATOR
(HONDA GX340K1EDE2/GX340RT2EDE2
GASOLINE ENGINES)
Revision #1 (10/01/19)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65/START FIRES WARNING
Operation of this equipment may create
sparks that can start fires around dry
vegetation. A spark arrestor may be
required. The operator should contact
local fire agencies for laws or regulations
relating to fire prevention requirements.
PAGE 2 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
TABLE OF CONTENTS
GAW180HE Series
60 Hz Welder-Generator
Proposition 65/Start Fires Warning .......................... 2
Table of Contents ..................................................... 3
Nameplate/Safety Information ................................. 4
Safety Information ............................................. 6–13
Specifications (Welder-Generator) ........................ 14
Specifications (Engine) .......................................... 15
Dimensions ............................................................ 16
Installation ....................................................... 17–18
General Information ............................................... 19
Welding Polarity and Duty Cycle ........................... 20
Welding Terms ....................................................... 21
Components Generator ......................................... 22
Components Generator (Continued) ..................... 23
Inspection/Setup .............................................. 24–26
Operation ......................................................... 27–29
Preparation for Long Term Storage ....................... 30
Maintenance .................................................... 31–35
Welder/Generator Wiring Diagram ........................ 36
Troubleshooting (Welder/Generator) ............... 37–38
Troubleshooting (Engine) ................................. 40–41
Explanation of Code in Remarks Column.............. 42
Suggested Spare Parts ......................................... 43
Honda GX340K1EDE2/EDE2
Gasoline Engine
Air Cleaner Assembly (GX340K1EDE2) .......... 62–63
Air Cleaner Assembly (GX340RT2EDE2) ....... 64–65
Camshaft Assembly ......................................... 66–67
Carburetor Assembly ....................................... 68–71
Control Assembly ............................................ 72–73
Crankcase Cover Assembly ............................. 74–75
Crankshaft Assembly ....................................... 76–77
Cylinder Barrel Assembly ................................ 78–79
Cylinder Head Assembly ................................. 80–81
Fan Cover Assembly........................................ 82–83
Flywheel Assembly .......................................... 84–85
Ignition Coil Assembly ..................................... 86–87
Piston Assembly .............................................. 88–89
Recoil Starter Assembly .................................. 90–91
Starter Motor Assembly ................................... 92–93
Solenoid Assembly .......................................... 94–95
Engine Decals Assembly ................................. 96–97
NOTICE
Specifications and part numbers are subject to change
without notice.
Component Drawings
Nameplate and Decals Assembly .................... 44–45
Generator Assembly ........................................ 46–47
Control Box Assembly ..................................... 48–51
Pipe Frame Assembly ...................................... 52–55
Battery Assembly............................................. 56–57
Muffler Assembly ............................................. 58–59
UWKB Wheel Kit Assembly (Option) ............... 60–61
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 3
NAMEPLATE/SAFETY INFORMATION
NAMEPLATE AND SAFETY LABELS
Safety labels are attached to the generator as shown in
Figure 1. Keep these safety labels clean at all times. When
the safety labels become worn or damaged, contact your
nearest dealer or the Multiquip Parts Dept.
NOTICE
For safety label part numbers, reference the parts
section of this manual.
Figure 1. Nameplate and Safety Decals
PAGE 4 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
NOTES
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 5
SAFETY INFORMATION
DO NOT operate or service the equipment before reading
the entire manual. 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.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION
SAFETY SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
or NOTICE.
Symbol Safety Hazard
Lethal Exhaust Gas Hazards
Explosive Fuel Hazards
Burn Hazards
Welding Hazards
EMF Hazards
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
Pacemaker Hazards
Implant Hazards
Flying Sparks Hazards
Fire Hazards
Electric Shock Hazards
GENERAL SAFETY
NOTICE
This equipment should only be operated by trained and
Whenever necessary, replace nameplate, operation and
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
keep
Also, know the phone numbers
fi re department.
This information will be invaluable in the case of an
SAFETY INFORMATION
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
qualifi ed personnel 18 years of age and older.
safety decals when they become diffi cult read.
equipment modifi cation will void all warranties.
NEVER
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest phone or
a phone on the job site.
of the nearest ambulance, doctor and
emergency.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 7
SAFETY INFORMATION
WELDER SAFETY
DO NOT touch output terminals during operation.
Contact with output terminals during operation can cause
Remove any combustibles, such as a butane lighter or
After completion of work, inspect area to ensure it is free
Follow requirements in OSHA 1910.252 (a) (2) (iv) and
NFPA 51B for hot work and have a fi re watcher and
Keep your head out of the fumes. Use enough ventilation
or exhaust at the arc, or both, to keep the fumes and
gases from your breathing zone and the general area.
In a large room or outdoors, natural ventilation may be
get too close to the arc. Use corrective lenses
if necessary to stay a reasonable distance away from
Use natural drafts or fans to keep the fumes away from
Have only qualified people remove doors, panels,
covers or guards for maintenance and troubleshooting
Reinstall doors, panels, covers or guards when servicing
emergency or safety devices.
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
DANGER
NEVER install or operate the welder-
generator in an explosive atmosphere or
near combustible materials. An explosion
or fi re could result causing severe bodily
harm or even death.
Flying sparks can cause injury. Wear a face
shield to protect eyes and face.
Remove all fl ammables within 35 ft (10.7 m)
of welding arc. If this is not possible, tightly
cover them with approved covers.
Do not weld where fl ying sparks can strike fl ammable
material.
Hot metal from air arc cutting and gouging
can cause fi re or explosion. DO NOT cut or
gouge near fl ammables.
Welding on closed containers, like tanks, drums or
pipes, can cause them to blow up. DO NOT weld on
closed containers unless they are properly prepared
according to AWS F4.1 (see Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping from American Welding Society
Standards). Check and be sure area is safe before doing
any welding.
Protect yourself and others from fl ying sparks and hot metal.
Wear oil-free protective garments like leather gloves,
heavy shirt, cuffl ess trousers, high shoes and a cap.
electrocution, electrical shock or burn.
matches, from your person before doing any welding.
of sparks, glowing embers and fl ames.
extinguisher nearby.
WARNING
adequate if you keep your head out of the fumes.
DO NOT
the arc.
your face.
Welding wire can cause injury. Do not press
gun trigger until instructed to do so. Do
not point gun toward any part of the body,
other people or any metal when threading
welding wire.
Be alert that welding sparks and hot materials from
welding can go through small cracks and openings to
adjacent areas.
Be aware that welding on a ceiling, fl oor, bulkhead or
partition can cause fi re on hidden side.
Connect welding cable to the work as close to welding
area as practical to prevent welding current from traveling
long, possibly unknown paths and causing electric shock,
sparks and fi re hazards.
DO NOT use welder-generator to thaw frozen pipes.
Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.
PAGE 8 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
if necessary.
is fi nished and before starting engine.
NEVER disconnect any
devices will void all warranties.
SAFETY INFORMATION
To reduce possible interference, keep weld cables as short
as possible, close together and down low, such as on
the fl oor. Locate welding operation 100 meters from any
sensitive electronic equipment. Be sure welder-generator
If interference still occurs, the operator must take extra
measures, like moving the welder-generator, using shielded
lubricate components or attempt service on a
Overheating can damage equipment. Turn off or unplug
equipment before starting or stopping engine. Low
voltage and frequency caused by low engine speed can
damage electric devices. Ensure engine speed is correct
Overloading shortens the life of the welder-generator.
Use the machine with appropriate AC and DC current
ensure welder-generator is on level ground
keep the welder-generator in proper running
Fix damage to welder-generator and replace any broken
store welder-generator properly when it is not
being used. Equipment should be stored in a clean, dry
location out of the reach of children and unauthorized
CAUTION
Electric current flowing through any
conductor causes localized Electro
Magnetic Fields (EMF). Welding current
creates EMF fi elds around welding cables
and welding machines.
Wearers of pacemakers and other
implanted medical devices should keep
away from welding equipment when in use.
Implanted medical device wearers should
consult their doctor and the device
manufacturer before going near arc
welding, spot welding, gouging, plasma
arc cutting or induction heating operations.
Exposure to EMF fi elds in welding may have other health
effects which are now not known.
All welders should use the following procedures in order to
minimize exposure to EMF fi elds from the welding circuit:
• Route the electrode and work cables together. Secure
them with tape when possible.
NOTICE
Electromagnetic energy can interfere
with sensitive electronic equipment such
as microprocessors, computers and
computer-driven equipment such as robots.
Be sure all equipment in the welding area
is electromagnetically compatible.
is installed and grounded according to this manual.
cables, using line fi lters or shielding the work area.
NEVER
running machine.
• NEVER coil the electrode lead around your body.
• DO NOT place your body between the electrode and
work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.
• Connect the work cable to the workpiece as close as
possible to the area being welded.
• DO NOT work next to the welder-generator.
during operation.
and appropriate duty cycle.
ALWAYS
before use.
ALWAYS
condition.
parts immediately.
ALWAYS
personnel.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 9
ENGINE SAFETY
DANGER
STARTSWITCH
OPERATION
SWITCH
0N
OFF
IDLE
CONTROL
120V
GAW-180HEA
120
V
120
AC VOLTMETER
25
TEST
AC CIRCUIT
BREAKER
GFCI
PROTECTED
30
180
60
100
140
MIN.
CURRENT
MAX.
REGULATOR
SOFT
ARC FORCE
HARD
REGULATOR
NORMAL
25A
20A
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
add fuel to equipment if it is placed inside truck
bed with plastic liner. Possibility exists of explosion or
start the engine near spilled fuel or combustible
fl uids. Gasoline fuel is extremely fl ammable and its
refuel in a well-ventilated area, away from
use extreme caution when working with
fi ll the fuel tank while the engine is running
overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
Store fuel in appropriate containers, in well-ventilated
STARTSWITCH
OPERATION
SWITCH
0N
OFF
IDLE
CONTROL
120V
GAW-180HEA
120
V
120
AC VOLTMETER
25
TEST
AC CIRCUIT
BREAKER
GFCI
PROTECTED
30
180
60
100
140
MIN.
CURRENT
MAX.
REGULATOR
SOFT
ARC FORCE
HARD
REGULATOR
NORMAL
25A
20A
ID
L
E
C
O
N
T
R
O
L
O
P
E
R
A
T
IO
N
S
W
IT
C
H
24
0
/1
2
0
V
F
U
L
L
P
O
W
E
R
S
W
IT
C
H
1
2
0
V
A
C
V
O
L
T
M
E
T
E
R
A
C
C
IR
C
U
IT
B
R
E
A
K
E
R
OFF
15A
R
U
N
S
T
O
P
1
2
0
V
2
4
0
V
O
IL
A
L
A
R
M
G
F
C
I
G
N
D
PLASTIC
TRUCK-BED
LINER
HONDA
FUEL
FUEL
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
NEVER operate the engine with heat shields or
guards removed.
SAFETY INFORMATION
local Health and Safety Administrator.
FUEL SAFETY
DANGER
DO NOT
fi re due to static electricity.
DO NOT remove the engine oil drain plug while
the engine is hot. Hot oil will gush out of the engine
crankcase and severely scald any persons in the general
area of the generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
DO NOT
vapors can cause an explosion if ignited.
ALWAYS
sparks and open fl ames.
ALWAYS
fl ammable liquids.
DO NOT
or hot.
DO NOT
the ignition system.
areas and away from sparks and fl ames.
PAGE 10 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
ELECTRICAL SAFETY
Power Cord/Cable Safety
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
These welder-generators are equipped with a grounding
terminal at the base of the pipe frame. Electrical
grounding requirements can differ by State, Province,
For portable and vehicle-mounted welder-generators,
Multiquip recognizes the guidance provided in NEC
Handbook Article 250.34 Parts A and B, and 29 CFR
1926.404 (f) (3) (i). If a more defi nitive earth-to-ground
safeguard is required, please consult a qualified
electrician and reference appropriate National Electrical
Code (NEC) guidelines in establishing an exterior
drop the battery. There is a possibility that the
charge battery if frozen. Battery can explode.
keep the battery charged. If the battery is not
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine
DANGER
Turn welder-generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output receptacles.
NEVER insert any objects into the
output receptacles during operation.
This is extremely dangerous. The
possibility exists of electrical shock,
electrocution or death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the welder-generator
to a building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
SAFETY INFORMATION
NOTICE
ALWAYS
Chart in this manual.
Grounding Safety
DANGER
District, Municipality, and unique application settings.
grounding point
NEVER use gas piping as an electrical ground.
BATTERY SAFETY
DANGER
DO NOT
battery will explode.
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC or DC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the generator.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 11
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
DO NOT
When frozen, warm the battery to at least 61°F (16°C)
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
TRANSPORTING SAFETY
allow any person or animal to stand underneath
Before lifting, make sure that the equipment parts (lifting
bail) is not damaged and screws are not loose or missing.
make sure crane or lifitng device has
been properly secured to the lifting bail (hook) of the
Tighten fuel tank cap securely and close fuel cock to
Use adequate lifting cable (wire or rope) of suffi cient
Use one point suspension hook and lift straight upwards.
tie down equipment during transport by
of combustible gasses..
SAFETY INFORMATION
CAUTION
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
NEVER
the equipment while lifting.
NOTICE
ALWAYS
equipment.
ALWAYS shutdown engine before transporting.
NEVER lift the equipment while the engine is running.
prevent fuel from spilling.
strength.
LI FT
GAW-180H
DO NOT lift machine to unnecessary heights.
ALWAYS
securing the equipment with rope.
PAGE 12 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
SAFETY INFORMATION
ENVIRONMENTAL SAFETY/DECOMMISSIONING
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below.
EMISSIONS INFORMATION
The gasoline engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
This engine has been certifi ed to meet US EPA Evaporative
Attempting to modify or make adjustments to the engine
emmission system by unauthorized personnel without
proper training could damage the equipment or create an
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fi nes or other penalties.
The emission control label is an integral part of the emission
If a replacement emission label is needed, please contact
NOTICE
DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.
Contact your country's Department of
Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.
When the life cycle of this equipment is over, remove
battery (if equipped) and bring to appropriate facility for
lead reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.
When the life cycle of this equipment is over, it is
recommended that the unit frame and all other metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
NOTICE
contained in gasoline exhaust emissions.
emissions requirements in the installed confi guration.
unsafe condition.
Emission Control Label
system and is strictly controlled by regulation(s).
The label must remain with the engine for its entire life.
your authorized Honda Engine Distributor.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 13
SPECIFICATIONS (WELDER-GENERATOR)
Table 1. Specifications (Welder-Generator)
Model GAW180HE GAW180HEA
Rated Output 4.56 kW
Max Current 180 amps
Rated Current 170 amps
DC ARC Welder
60 Hz Generator
Dimensions
(L x W x H)
Dry Net Weight
Weight With Fuel
Battery
Rated Voltage 26.8
Duty Cycle 50%
Current Range 30 ~ 180 amps
Applicable Electrode Size 3/32 ~ 5/32"
Welding Applications SMAW, FCAW, GMAW, GTAW and ACAC
Rated Output 3.0 kW
Rated Voltage 120V
Rated Current 25 amps
Phase Single Phase (3 wire)
Frequency 60 Hz
Power Factor 1
27.6 x 25.6 X 22 in.
(701 X 650 X 559 mm)
236 lbs. (107 kg.)
265 lbs. (120 kg.)
12 volts, 26 Amp hours, 260 amps cold cranking ability :
7-1/2" (L) X 5"(W) X 7-1/4"(H)
28 x 22 X 26 in.
(711 X 559 X 755 mm)
NOTICE
In keeping with Multiquip's policy of constantly
improving its products, the specifications quoted herein
are subject to change without prior notice.
PAGE 14 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
SPECIFICATIONS (ENGINE)
Table 2. Specifications (Engine)
Model HONDA GX340K1EDN2 HONDA GX340RT2EDE2
Engine
Dimensions
(L x W x H)
Dry Net Weight
Type
Bore X Stroke
Displacement 23.70 cu-in (389 cm3)
Max Output 9.5 H.P./3600 R.P.M. 10.7 H.P./3600 R.P.M
Rated Output 7.8 H.P./3600 R.P.M. 8.4 H.P./3600 R.P.M.
Fuel Unleaded Gasoline 86 Octane or Higher
Fuel Capacity 3.7 gal. (14 liters)
Lube Oil Capacity 1.16 quarts (1.1 liters)
Oil Alert System Ye s
Speed Control Method Centrifugal Fly-weight Type
Starting Method Electric Start ~ Recoil Start
Air-cooled 4 stroke, Single Cylinder, OHV, Horizontal Shaft
Gasoline Engine
2.90 in. X 2.30 in.
(73 mm x 58 mm.)
15.0 x 17.7 X 17.4 in.
(380 X 450 X 443 mm)
68.4 lbs. (31 kg.) 69 lbs. (31.5 kg.)
3.46 in. X 2.52 in.
(88 mm x 64 mm.)
16 x 19.1 X 17.7 in.
(407 X 485 X 449 mm)
Effects of Altitude and Heat
The maximum output of the engines listed above are 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° F (15.5° C).
Generally, the engine's output power will decrease 3-1/2% for each 1000 feet (305 meters) of altitude above sea level, and
1% for each 10° F (-12.2° C) above the standard temperature of 60° F (15.5° C).
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 15
NOTICE
C
B
A
D
E
F
UWKB Wheel Kit is optional. Contact MQ inside sales
to order.
GAW-180H
DIMENSIONS
REFERENCE
LETTER
1
Approximate value.
Figure 2. Dimensions
Table 3. Generator Dimensions
DESCRIPTION DIMENSIONS: IN. (MM)
A LENGTH (FRAME) 27.55 (700)
1
B
C HEIGHT (FRAME ONLY)
D HEIGHT (LIFTING BALE)
1
E
LENGTH (W/HANDLE) 30.55 (776)
25.60 (650) HE1/HEA
29.92 (760) HE1/HEA
HEIGHT (FRAME/WHEELS)
30.60 (777) HE1/HEA
23.62 (600) HE
27.95 (710) HE
28.62 (725) HE
F WIDTH (FRAME) 22.0 (560)
1
G
WIDTH (WHEELS) 31.5 (800)
PAGE 16 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
CONNECTING THE GROUND
The ground point on the welder-generator should always
be used to connect the generator to a suitable ground. The
ground cable should be #8 size wire (aluminum) minimum. If
copper wire is used, #10 size wire minimum should be used
At the generator, connect the terminal of the ground cable
between the lock washer and the bolt (Figure 3) and tighten
the bolt fully. Connect the other end of the ground cable to
a suitable earth ground (ground rod).
GAW-180HEA
INSTALLATION
WELDER-GENERATOR
GROUND POINT
GROUND ROD
FOR EARTH GROUND
CONNECT TO
BUILDING GROUND
GROUND CABLE
(#8 MINIMUM)
8 FT.
MINIMUM
REFERENCE
NEC 250-52(C)
IF REQUIRED
Figure 3. Welder-Generator Grounding
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 17
INSTALLATION
OUTDOOR INSTALLATION
If possible install the generator in a area that is free of
debris, bystanders, and overhead obstructions. Make sure
the generator is on secure level ground so that it cannot
slide or shift around.
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.
WARNING
Pay close attention to ventilation when
operating the generator inside tunnels
and caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
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.
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.
INDOOR INSTALLATION
Exhaust gases from gas 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.
PLACEMENT
The generator should always be placed on a flat level
surface when it is running. DO NOT place the generator
on slopes, the possibility exists that the generator could
slide.
DANGER
Electric shock can occur 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.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install an
isolation (transfer) switch.
Serious injury or death may result without this transfer
switch.
PAGE 18 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
GENERAL INFORMATION
GAW180HE/HEA FAMILARIZATION
Your welder-generator 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 dislodged in
transit.
This welder-generator has been 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.
The welder-generator is powered by a Honda GX340
air-cooled gasoline engine. The alternator, a brushless
revolving-field type, is permanently aligned to the engine
through rigid coupling.
The welder-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.
Ground Terminal
This unit is equipped with protection shutdown devices to
protect the welder-generator in the event of an equipment
malfunction. Reference Table 4 for a basic understanding
of the protection devices and their effect on the weldergenerator when activated.
If a malfunction has been detected by a protection device,
simply shutdown the welder-generator and correct the
problem before restarting the unit.
Table 4. Protection Shutdown Devices
Protection
Device
Low Oil Level YES NO NO
AC Power
Overcurrent
Electrical
Ground Fault
Control Unit (AC)
High Temp.
Control Unit (AC)
High Temp.
1
Stop engine for at least 20 seconds before restarting.
2
Output will resume as temperature falls to normal operating level.
1
2
Engine
Shutdown
NO YES YES
NO YES NO
NO NO YES
NO NO YES
AC Circuit Breaker
GFCI Trip
Control Unit
Output Stop
These portable generators are supplied with a electrical
control panel. The control panel includes items as listed
below.
CONTROL PANEL
GFCI, Duplex Receptacle, NEMA 5-20R (120V, 20 Amp)
Twist-Lock Receptacle, NEMA L5-30R (125V, 20 Amp)
Main Circuit Breaker, 2-pole, 25 Amp
ldle Control Switch
Operation Switch
Start Switch
Hourmeter
AC Voltmeter
Current Regulator
ARC Force Regulator
DC Welding Output Terminal Lugs
Canister
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 19
WELDING POLARITY AND DUTY CYCLE
WELDING POLARITY
Polarity indicates the direction of the current flow in that
circuit. Since DC current moves in only one direction,
polarity is important because the flow of current must be
changed depending on the application.
By changing the polarity, the greatest amount of heat can be
concentrated where it is most needed. With straight polarity
(electrode negative) more heat is directed to the workplace.
When using reverse polarity (electrode positive), more of
the heat generated is directed to the electrode. Reference
Figure 4 below.
WELDER OUTPUT
TERMINALS
WELDING OUTPUT TERMINALS
ELECTRODE
STRAIGHT
POLARITY
CLAMP
DUTY CYCLE
NOTICE
The American Welding Society sets all regulations
and procedures for the welding industry. All welders
are subject to the same regulations.
Duty cycle is based on a 10-minute welding period.
Exceeding the duty cycle will have an affect on the welding
process. The amperage will start dropping off and the
welding process will not have the proper amperage required
to proceed. If the duty cycle is exceeded, damage can
occur to the welding machine.
The 10-minute duty cycle period means 100% welding.
If the duty cycle is 60%, then you can only weld for six
minutes and the machine must cool down for four minutes
(Reference Table 5 below).
Table 5. 10-Minute Duty Cycle
Duty
Cycle %
Welding
ON Time (Min)
Cool Down
Time (Min.)
100 Continious N/A 120 or Less
85 8.5 1.5 130
Welding
Current
(Amps)
WELDING OUTPUT TERMINALS
REVERSE
POLARITY
Figure 4. Welding Polarities
WELDER OUTPUT
TERMINALS
ELECTRODE
CLAMP
WORK
WORK
70 7 3 140
60 6 4 150
55 5.5 4.5 160
1
50
5 5 170
40 4 6 180
1
The GAW180HE/HEA welders have a 50% duty cycle @ 170 amps.
PAGE 20 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
WELDING TERMS
DEFINITIONS OF WELDING TERMS
1. Weld – The unification of metallic parts by heating and
allowing the metals to flow together or by hammering
or compressing with or without previous heating.
2. Straight Polarity – A term for direct current electrode
negative.
3. Reverse Polarity – A term for direct current electrode
positive.
4. Manual Welding – A welding operation performed
and controlled completely by hand.
5. AC or Alternating Current – AC is the kind of
electricity, which reverses its direction periodically.
For 60 cycle current, the current goes in one direction
and then in the other direction 60 times in the same
second, so that the current changes its direction 120
times in one second.
6. DC or Direct Current – DC is the kind of electricity,
which only flows in one direction. The flow of electricity
is from the power source to the application. In welding,
an arc welding process wherein the power supply is at
the arc is direct current.
The covering may contain materials providing
such functions as shielding from the atmosphere,
deoxidization, and arc stabilization and can serve as
a source of metallic additions to the weld.
14. Fillet Weld – A weld of triangular cross section joining
two surfaces approximately at right angles to each
other in a lap joint, T-joint or corner joint.
15. Tack Weld – A weld made to hold parts of a weldment
for proper alignment until the final welds are made.
16. Shade Number – This number pertains to the
lightness or darkness of the lens in the welding helmet.
Lens number range from 2 to 14 where 2 would be the
lightest lens and 14 would be the darkest lens.
17. CC or Constant Current – In this mode the
amperage or current stays constant, but the direct
current voltage will change depending on the arc
length. This mode is applied to SMAW, FCAW and
GTAW processes.
18. CV or Constant Voltage – In this mode the direct
current voltage stays constant, but direct current
amperage will change slightly. This mode is applied
to GMAW, FCAW and GTAW.
7. ARC Force – An adjustment that allows the operator
to fine tune the arc characteristics according to job
requirements.
8. ARC Length – The distance from the end of the
electrode to the point where the arc makes contact
with the work surface.
9. ARC Voltage – The voltage across the welding arc.
10. ARC Blow – The deflection of an electric arc from its
normal path because of magnetic forces.
11. Base Metal (Material) – The metal (material) to be
welded, brazed, soldered, or cut.
12. E-Mode – The Improves fuel efficiency by allowing
the operator to weld with engine at idle speed at up to
160 amps. Reduces operating costs and noise levels.
13. Covered Electrode – A composite fill metal electrode
consisting of a core of a bare electrode or metal-cored
electrode to which a covering sufficient to provide a slag
layer on the weld metal has been applied.
19. Parallel Connection – Simply connect the positive
terminals together, then connect the negative terminals
together. Make sure that the machines are located as
close together as possible.
Welding cables should be sized appropriately to handle
the additional amperage. Rheostats must be set at
the same amperage or as close as possible. (Note:
Unlike competitive models, no parallel box is needed
with Multiquip Power machines.)
WELDING PROCESSES
SMAW – Shielded-Metal Arc Welding
FCAW – Flux-Cored Arc Welding
GMAW – Gas-Metal Arc Welding
GTAW – Gas-Tungsten Arc Welding
ACAC – Air Carbon Arc Cutting
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 21
COMPONENTS GENERATOR
1
2
3
4 5
6 7
8
NORMAL
120
V
120
SOFT
HARD
ARC FORCE
REGULATOR
100
AC VOLTMETER
60
CURRENT
25
140
TEST
AC CIRCUIT
30
180
BREAKER
MIN.
MAX.
GFCI
REGULATOR
PROTECTED
GAW-180HEA
20A
25A
0N
OFF
IDLE
OPERATION
CONTROL
SWITCH
120V
START SWITCH
9
10
12
11
Figure 5. Welder-Generator
1. DC Welding Output Terminals – Connect DC welding
cables to these terminals. Note the polarity marked on
the welder-generator. Select the appropriate polarities
according to the application as specified in Table 8.
2. Current Regulator Adjustment Control – Place this
knob in the desired setting when welding is required.
Current range is from 30 to 180 amps. t
3. ARC Force Regulator Adjustment Control – An
adjustment that allows the operator to fine tune the
arc characteristics according to job requirements. This
control allows the user to adjust the arc from a soft
smooth arc to a more aggressive digging arc.
4. AC-Voltmeter – This voltmeter indicates (with a
mark) the rated 60 Hz (single-phase) output voltage.
In addition the voltmeter can also be used as a
diagnostic tool. If the voltmeter indicator (needle) is
below the rated voltage, engine problems may exist
(low/high RPM's). To prevent damage to the generator
or power tools turn the generator OFF and consult your
authorized Multiquip service dealer.
5. Main Breaker – This 2-pole, 25 amp circuit breaker
protects the welder-generator from short circuiting or
overloading. When starting the generator always have
the circuit breaker placed in the "OFF" position.
14
13
8. Idle Control Switch – The welder-generator is
provided with an automatic idle control device 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.
9. Operation Switch – Place switch in the "ON" position
(up) for normal operation. To turn-off the weldergenerator, place the operation switch in the "OFF"
position (down).
10. Start Switch – Press this pushbutton switch to start
the welder-generator.
11. Recoil Starter (pull rope) – Manual-starting method.
Pull the starter grip until resistance is felt, then pull
briskly and smoothly.
12. Charcoal Canister – A container filled with activated
charcoal that traps gasoline vapors emitted by the fuel
system. Installed on GAWHE1/HEA only.
6. 120V Output Receptacle – NEMA L5-30R twist-lock
receptacle will provide 120V, 25 amps, 60 Hz.
7. GFCI Duplex Receptacles – NEMA 5-20R, GFCI
receptacle will provide 120V@ 20 amps.
13. Battery – This unit is equipped with a 12 VDC battery.
Replace with only recommended type battery.
14. Ground – This ground connection point should be
connect to a good earth ground (ground rod).
PAGE 22 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
16
GAW-180H
COMPONENTS GENERATOR (CONTINUED)
26
29
17
18
19
20
25
28
21
15
24
23
22
Figure 6. Welder-Generator Components (Continued)
27
15. Support Stand (Option) – Supports the welder-
generator, part of the UWKB Wheel Kit Assembly.
16. Transport Handles (Option) – Lift up on each handle
when transporting of the welder-generator is required.
Part of the UWKB Wheel Kit Assembly.
17. Choke Lever – Used for starting the engine. Close
the choke lever when starting a cold engine or in
cold weather conditions. The choke enriches the fuel
mixture. Open the choke lever if starting a warm engine
or in warm weather conditions.
18. Spark Plug – Provides spark to the ignition system.
Set spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch).
Clean spark plug once a week.
19. Carburetor Cup – Inspect the fuel cup weekly for
water and dirt. Clean as referenced in the maintenance
section of this manual.
20. Engine – This welder generator uses a HONDA GX340
air-cooled, 4-stroke, single cylinder, overhead camshaft
gasoline engine. Engine uses unleaded gasoline. For
more detailed specifications reference Table 2.
21. Engine Oil Drain Plug – Remove this drain plug
when draining of the oil from the engine crankcase is
required. Fill with recommended type oil as listed in
See Table 7.
22. Engine Oil Filler Cap – Remove this cap/dipstick
when the adding of engine oil is required. See Table 7
for recommended type engine oil.
30
23. Generator Housing – Contains the rotor, rectifier
field coil assembly, armature, bearings and other
components that make up generator assembly.
24. Muffler/Heat Shield – Used to reduce noise and
emissions. NEVER touch this heat shield when the
generator/welder is in use. Always allow time for engine
to cool before servicing.
25. Fuel Cock Lever – Turn this lever downward (ON) to
start the flow of fuel into the carburetor. Turn upward
to stop (OFF) the flow of fuel.
26. Lifting Bail Eye – Attach a rope or chain to this lifting
eye when lifting of the welder-generator is required.
Never stand underneath the welder-generator while it
is being lifted. Place lifting eye in down position when
not in use.
27. 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.
28. Fuel Gauge – This gauge is located on top of the fuel
tank. Read this gauge to determine when fuel is low.
29. Fuel Tank Cap – Remove this cap to add unleaded
gasoline to the fuel tank. Replenish with clean unleaded
gasoline. Make sure cap is tightened securely. DO NOT
over fill. Fuel tank capacity is 3.7 gallons (14 liters).
30. Foam-Filled Tires – Provided for ease of transport.
Replace with only recommended tires.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 23
INSPECTION/SETUP
TWIST-LOCK
ACLES
GENERAL INSPECTION PRIOR TO OPERATION
Ground Power Tools
When using power tools or electrical equipment requiring
AC power from the generator, make sure power tool cord
has a ground pin or is double insulated as shown in Figure 7 .
RECEPT
GROUND
PIN
GROUND
PIN REMOVED
GROUND
PIN
3-PRONGED
AC PLUG
GFCI
RECEPTACLE
NOTICE
Double-insulated power tools and small appliances
have specially insulated housings that eliminate the
need for a ground pin. These types of double-insulated
power cords are designed so that no part of the device
will be electrically live even if the internal insulation fails.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. 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 6) as a guide
for selecting proper cable size.
DANGER
NEVER use power tools or equipment that do not
have a ground capability, the possibility exists of
electrocution, electrical shock or burn, which can cause
severe bodily harm or even DEATH!
DOUBLE
INSULATED
Figure 7. Ground Pin
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Current In
Amperes
Load In Watts Maximum Allowable Cable Length
120 Volts 240 Volts #10 Wire #12 Wire #14 Wire
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
CAUTION: Equipment damage can result from low voltage.
#16 Wire
PAGE 24 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
INSPECTION/SETUP
FULL
EMPTY
BEFORE STARTING
NOTICE
ALWAYS place the AC circuit breaker in the OFF
position prior to starting the engine.
1. Read safety instructions at the beginning of manual.
2. Clean the welder-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
1. To check the engine oil level, place the welder-generator
on secure level ground with the engine stopped.
2. Remove the filler dipstick from the engine oil filler hole
(Figure 8) and wipe clean.
Table 7. Oil Type
Season Temperature Oil Type
Summer 25°C or Higher SAE 10W-30
Spring/Fall 25°C~10°C SAE 10W-30/20
Winter 0°C or Lower SAE 10W-10
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 10) to determine if the fuel level is low. If fuel
is low, replenish with clean unleaded fuel.
Figure 10. Fuel Gauge
4. When refueling, be sure to use a strainer for filtration.
DO NOT top-off fuel. DO NOT fill the tank beyond
capacity. Wipe up any spilled fuel immediately!
DIPSTICK
Figure 8. 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 9), fill to the edge of the
oil filler hole with the recommended oil type (Table 7).
Maximum oil capacity is 1.16 quarts (1.1 liters).
UPPER LIMIT
LOWER LIMIT
BATTERY SETUP
CAUTION
Use all safety precautions specified by the battery
manufacturer when working with the battery. See Safety
Information section of this manual for more details on
battery safety.
1. Place the battery into the battery cradle and secured
with mounting hardware.
2. ALWAYS be sure the battery cables are properly
connected to the battery terminals (Figure 11). The
red cable is connected to the positive terminal of
the battery, and the black cable is connected to the
negative terminal of the battery.
NEGATIVE
POSITIVE
Figure 9. Engine Oil Dipstick(Oil Level)
Figure 11. Battery Connections
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 25
INSPECTION/SETUP
WELDING CABLE AND POLARITIES
1. Lift the output terminal protective cover (Figure 12) on the
welder-generator to gain access to the welding output
terminals.
PROTECTIVE
COVER
WELDING OUTPUT TERMINALS
Figure 12. Protective Cover
2. Next, remove the wings nuts and flat washers that are
attached to the output terminals.
3. Place welder cables onto output terminals (post). Select
apporiate polarity depending on application. Reference
Table 8 and Table 9.
4. Reinstall wing nuts and washers back onto output
terminals. Tighten wing nuts securely to prevent arcing.
NOTICE
NEVER allow the terminal ends of the welding cables
to come in contact with each other or the frame of
the welder-generator. The possibility exits of creating
sparks which could ignite a fire causing damage to the
equipment and bodily harm.
Table 8. Polarities and Applications
Polarity Welding Method Typical Applications
Straight Polarity
Reverse Polarity
(+)...grounding (base metal)
(–)...welding holder
(+)...welding holder
(–)...grounding (base metal)
Arc welding for steel material of general
structures, and for thick plates
Arc welding for copper alloy
Build-up welding
Air gouging
Arc welding of thin plates
Arc welding of stainless steel
WELDING CABLE SELECTION
The welding cable should be larger in size as it becomes
longer or its current becomes higher. Prepare a cable with
suitable size by referring to the table below.
WING NUT
WASHER
OUTPUT
TERMINAL
TERMINAL
RING
WELDING
CABLE
STRANDED
WIRE
Figure 13. Welding Cable Attachment
NOTICE
ALWAYS attach a terminal ring on the end of the
welding cables. NEVER attach stranded or exposed
wires to the output terminals. This condition could cause
arcing which could start a fire.
Calculations for Table 9 are based on a voltage drop of 4
volts maximum.
Table 9. Total Cable (Copper) in Weld Circuit Not Exceeding
Length (ft/m)
Weld Current (A)
50 #5 #5 #5 #5 #5 #4
100 #5 #5 #4 #3 #2 #1
150 #5 #4 #2 #1 #1/0 #2/0
180 #5 #3 #1 #1/0 #2/0 #3/0
50
(15)
100
(30)
150
(46)
200
(61)
250
(76)
300
(91)
Reference Table 10 for applicable electrode size.
Table 10. Applicable Electrode Size
Welding Current (A) 30~180
Applicable Electrode 3/32"~5/32"
PAGE 26 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
OFF
OPERATION
ON
ON
OFF
This section is intended to assist the operator with the initial
start-up of the portable welder-generator. It is extremely
important that this section be read carefully before
attempting to use the generator in the field.
Before Starting the Engine
1. Be sure to disconnect all electrical loads from the
welder-generator prior to starting the engine.
2. NEVER start the engine with the AC circuit breaker
in the ON position. Always place AC circuit breaker
(Figure 14) in the OFF position before starting.
25
TEST
Figure 14. AC Circuit Breaker (OFF)
Starting the Engine (Electric Start)
1. Place the engine fuel valve lever (Figure 15) in the ON
position.
3. Place the choke lever (Figure 16) in the OPEN position
if starting a warm engine or the temperature is warm.
4. Place the generator's operation switch (Figure 17) in
the ON position.
Figure 17. Operation Switch (ON)
5. Next, press the generator's pushbutton start switch
(Figure 18) and listen for the engine to start. If starting
the welder-generator using the recoil start method,
proceed to step 11.
Figure 18. Start Switch
6. If the engine has started, slowly return the choke lever
(Figure 16) to the OPEN position. If the engine has not
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 loose
components.
ON
Figure 15. Engine Fuel Valve Lever (ON)
2. Place the choke lever (Figure 16) in the CLOSED
position if starting a cold engine.
Figure 16. Choke Lever
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 27
8. Place idle control switch (Figure 19) in the OFF
position. This will allow the engine speed to run at
about 3600 RPM's (high speed).
Figure 19. Idle Control Switch (OFF)
OPERATION
NOTICE
OFF
ON
Placing the idle control switch in the OFF position
(Figure 19) allows 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 position (Figure 20), the generator will run at idle
speed (2600 RPM's) until a load is applied, at that time
the engine speed will increase to 3600 RPM's as long
as a 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.
Figure 20. Idle Control Switch (ON)
10. Read voltmeter on front panel of generator (Figure 22)
and verify that 120 VAC is displayed. Using an external
voltmeter as shown in Figure 22, verify that 120 VAC
is present at the 120V twist-lock and GFCI duplex
receptacles.
GFCI
G
120V
120VAC
W
X
L5-30R
120 VAC
OFF
V~
V
300 mV
A~
V
120
A
V
COM
9. Place AC circuit breaker (Figure 21) in the ON position .
25
TEST
Figure 21. AC Circuit Breaker (ON)
ON
Figure 22. 120V Twist-Lock/GFCI Receptacles
11. If starting your welder-generator by the recoil start
method (no battery), grasp the starter grip (Figure 23)
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 23. Starter Grip
NOTICE
DO NOT pull the starter rope all the way to the end.
DO NOT release the starter rope after pulling. Allow it
to rewind as soon as possible..
12. Continue using the welder-generator referencing steps
6 through 10.
PAGE 28 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
OPERATION
140
ARC FORCE
OFF
ON
OFF
OFF
WELDING OPERATION
Adjust the arc force and current regulator control knobs
(Figure 24) to their respective positions depending on the
characteristics of the job requirements.
NORMAL
SOFT
60
30
MIN.
CURRENT
Figure 24. Arc Force And Current
Regulator Control Knob
NOTICE
When high quality welding is required DO NOT use
convience receptacles simultaneously.
HARD
REGULATOR
100
MAX.
REGULATOR
180
Stopping the Engine (Normal Shutdown)
1. Place AC circuit breaker (Figure 25) in the OFF position
25
TEST
Figure 25. AC Circuit Breaker (OFF)
2. Place idle control switch (Figure 26) in the OFF position
Figure 26. Idle Control Switch (OFF)
3. Let engine run at idle with no load for 2-3 minutes.
4. To shut-down the engine, place the generator's
operation switch (Figure 27) in the OFF position).
Both welder-generator models are equipped with a single
phase AC power source in addition to the DC welding
power source.
The AC power source and DC welding power source
can be used simultaneously. Reference Table 11 for the
simultaneous use of AC and DC power.
NOTICE
DO NOT allow welder-generator overloading when AC
and DC power are used simultaneously.
Table 11. AC Power Capacity Allowable
For Simulataneous Use
Electrode Size (Amps) AC Power Capacity
(0) 3.0 kW
3/32" (50A) 2.0 kW
1/8" (80A) 1.4 kW
1/8" (120A) 1.0 kW
5/32" (150A) 0.5 kW
OFF
Figure 27. Operation Switch (OFF)
5. Place engine fuel valve lever (Figure 28) in the OFF
position.
Figure 28. Engine Fuel Valve Lever (OFF)
6. Remove all loads and cables from the welder-generator.
Emergency Shutdown
1. Place operation switch (Figure 27) in the OFF position.
GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19) — PAGE 29
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, or add STA-BIL to the fuel.
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 — GAW180HE/HEA WELDER-GENSET • OPERATION AND PARTS MANUAL — REV. #1 (10/01/19)
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