Multiquip GLW-180H User Manual
PARTS AND OPERATION MANUAL
MULTIQUIP
Model GLW-180H
D.C. WELDER
A.C. GENERATOR
© COPYRIGHT 2004, MULTIQUIP INC.
Revision #5 (03/14/05)
MULTIQUIP INC
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244 800-478-1244
FAX: 310-537-3927 FAX: 310-631-5032
E-mail:mq@multiquip.com • www:multiquip.com
Atlanta • Boise • Dallas • Houston • Newark
Montreal, Canada • Manchester, UK
Rio De Janiero, Brazil • Guadalajara, Mexico
..
. PARTS DEPARTMENT:
..
SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:
WARNING
CALIFORNIA
Proposition 65 Warning
This product contains or produces chemicals known to
the State of California to cause cancer and birth defects
(or other reproductive harm).
PAGE 2 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
DCL160
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800-427-1244 or 310-537-3700
FAX: 800-672-7877 or 310-637-3284
SERVICE DEPARTMENT/TECHNICAL ASSISTANCE
800-478-1244 or 310-537-3700
FAX: 310- 537-4259
WARRANTY DEPARTMENT
888-661-4279, or 310-661-4279
FAX: 310- 537-1173
MAIN
800-421-1244 or 310-537-3700
FAX: 310-537-3927
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ............................................ 3
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Rules For Safe Operation ......................................... 6
Operation and Safety Decals .................................... 7
Specifications ............................................................ 8
General Information .................................................. 9
Multiquip GLW-180H — AC
Generator And Welder
Controls and Indicators ........................................... 10
Instrumentation ....................................................... 11
Installation .......................................................... 12-13
Pre-Setup ........................................................... 14-15
Load Application ..................................................... 16
Operating Instructions (Generator) ........................ 17
Operating Instructions (Welder)......................... 18-19
Maintenance ........................................................... 20
Preparation For Long Term Storage ....................... 21
Wiring Diagram ....................................................... 22
Troubleshooting (Engine) ................................... 23-24
Troubleshooting (Generator/Welder) ................. 25-26
Explanation Of Codes In Remarks Column ............ 28
Suggested Spare Parts ........................................... 29
Generator Assembly .......................................... 30-31
Control Box Assembly ........................................ 32-33
Control Box Assembly ........................................ 34-35
Pipe Frame Assembly ........................................ 36-37
Muffler Assembly ............................................... 38-39
Nameplate and Decals....................................... 40-41
Honda GX340K1 Engine
Cylinder Head Assembly ....................................42-43
Recoil Starter Assembly.....................................44-45
Fan Cover Assembly .......................................... 46-47
Camshaft/Valves Assembly ................................ 48-49
Piston/Rings Assembly.......................................50-51
Air Cleaner Assembly.........................................52-53
Cylinder Barrel (Recoil) Assembly ..................... 54-55
Cylinder Barrel (Electric) Assembly ................... 56-57
Crankcase Cover/Governor Assembly ..............58-59
Flywheel/Fan Assembly .....................................60-61
Coil Assembly..................................................... 62-63
Crankshaft Assembly .........................................64-65
Electric Start Assembly ......................................66-67
Governor Controls Assembly ............................. 68-69
Carburetor Assembly .........................................70-71
Solenoid Assembly ............................................. 72-73
Fuel Cock Assembly ..........................................74-75
Terms and Conditions Of Sale — Parts .................. 76
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
PARTS ORDERING PROCEDURES
■■
■ 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:
■■
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
•
Express account number)*
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■
UPS Ground Service at no charge for freight
■■
■■
■
PS Third Day Service at one-half of actual freight cost
■■
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.
Extra Fax DiscountExtra Fax Discount
Extra Fax Discount
Extra Fax DiscountExtra Fax Discount
for Domestic USAfor Domestic USA
for Domestic USA
for Domestic USAfor Domestic USA
Dealers OnlyDealers Only
Dealers Only
Dealers OnlyDealers Only
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 5
800/6-PARTS-7 • 800-672-7877
RULES FOR SAFE OPERATION
■
CAUTION:
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 GLW-180H Generator/Welder:
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, steel-toed boots and other
protective devices required by the job.
■
This generator is a source of potentially LETHAL high voltage.
Never permit unqualified personnel-especially children to
operate the generator.
■
Always refuel in a well-ventilated area, away from sparks and
open flames.
■
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.
■
This generator is equipped with a
protection. Always complete the grounding path from the
generator to an external grounding source.
■
NEVER operate this generator, or handle any electrical
equipment while standing in
hands are wet, or in the rain. Electrical shock could occur
causing severe bodily harm or even death.
■
Keep electrical cords in good condition. Worn, bare or frayed
wiring can cause electrical shock, leading to
even death.
■
This generator requires an adequate free flow of cooling air.
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 and may cause
injury to people.
■
NEVER touch the hot exhaust manifold, muffler or cylinder.
Allow these parts to cool before servicing generator.
smoke around or near the machine. Fire or explosion
ground terminal
for your
water, while bare foot, while
bodily harm or
Provide adequate ventilation when operating the generator.
DO NOT operate the generator in any enclosed or narrow
space. The generator's GLWsoline engine gives off DEADLY
carbon monoxide GLWs
■
NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe
■
Always make sure that the generator is secure on level ground
so that it cannot slide or shift around, endangering workers.
Also keep the immediate area free of bystanders.
■
When using a concrete vibrator or a similar device that is
immersed in a water based solution, make sure the device is
equipped with short circuit protection.
■
Always use rubber boots and gloves when operating a
concrete vibrator or similar device.
■
Use adequate size connecting cable for extension.
■
Maintain electrical cords in good condition and frequently
replace the entire cable of the concrete vibrator with a new
one.
■
High Temperatures – Allow the machine and engine to cool
before adding fuel or performing service and maintenance
functions. Contact with
burns.
Emergencies
■
Always know the location of the nearest
and
first aid kit
Also know the phone numbers of the nearest
doctor
invaluable in the case of an emergency.
Maintenance Safety
■
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.
■
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
bodily harm or even death.
. Know the location of the nearest telephone.
and
fire department
.
hot
components can cause serious
fire extinguisher
ambulance
. This information will be
,
PAGE 6 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
OPERATION AND SAFETY DECALS
Machine Safety Decals
The GLW-180H portable generator is equipped with a number of safety decals. 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.
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 7
GLW-180H — SPECIFICATIONS
H081-WLGsnoitacificepS.1elbaT
tnerruC.xaMspmA081
egatloVdetaRstloV4.62
redleW
rotareneGelcyC06
elcyCytuD%05
egnaRtnerruCelbatsujdAspmA081-05
tnerruCdetaRspmA0
eziSedortcelEelbacilppA"23/5-"46/5
rotanretlAepyT dleiFgnivloveRepyTsselhsurB,elop-2
ptuO.xaMsttaW0054
tu
)suounitnoc(tuptuOdetaRsttaW0004
egatloVdetaRCAV021
tnerruCdetaRspmA3.33
esahP )eriw-3(esahP
ycneuqerFzH06
deepSdetaRMPR0063
rotcaFrewoP%001
ledoMDV1K043XGadnoH
epyT rednilycdednilcni°52HVOek
ekortSXeroB
orts4delooc-riA
61
elgniS
.ni25.2X.ni32.3
)mm46Xmm28(
tnemecalpsiDcc36.02
enignE
)HXWXL(noisnemiD
gieWteNyrD
th
tuptuOxaM.M.P.R0063/.P.H0.8
paCknaTleuF snollaG.S.U4/3-3.xorppA
ytica
leuF enilosaGelibomotuAdedaelnU
yticapaCliOebuLstnip4/3-1
deepS epyTthgiew-ylFlagufirtneC
dohteMlortnoC
dohteMgnitratStratSlioceR
.ni22x22x5.13
).mm065x065x008(
).gK531(.sbl792
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
°°
F .
F
PAGE 8 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — GENERAL INFORMATION
WARNING:
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.
GLW-180H FAMILIARIZATION
Generator/Welder
The Multiquip Model GLW-180H generator has been designed
as a portable lightweight power source for 60 Hz (singlephase) vibrators, lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
This generator is powered by a HONDA GLWsoline 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 aGLWinst damage.
This portable generator is supplied with a electrical
box
. To reduce vibration caused by the engine, the control
box is also placed on rubber isolators.
control
Excitation System
All GLW-series generators use a magnet attached to a
flywheel to produce AC voltage from a lamp coil beneath
the flywheel. As the magnet passes the coil it produces
approximately 19-22 AC volts.
This voltage (19-22 VAC) is then sent to the control box that
contains three rectifying diodes:
z
Excitation (diode 1)
z
Battery (diode 2)
z
Slow Down (diode 3)
The AC voltage will pass through the excitation diode that
converts the voltage to DC power.
This DC power is then sent to the excitation windings housed
within the main windings commonly called the "stator".
This voltage is then transferred into the rotor through
induction. The rotor contains two diodes within it which rectify
the DC voltage and send it out through the main windings,
as AC voltage.
Engine
The four-cycle air-cooled HONDA GLWsoline engine is
designed to meet every performance requirement of this
generator. Reference Table 1, page 8 for engine
specifications.
Figure 1 (page 10) shows the basic controls and indicators
for the GLW-180H generator.
Control Box
The control box has the following: (all outputs are 60 Hz,
single phase)
z
One 120V output receptacle.
z
One 120V output receptacle (GFCI protected).
z
One main 40 amp circuit breaker.
z
AC Voltmeter
z
Idle Control Switch
z
Operation Switch
z
Output Terminals (Welding)
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 9
Idle Control Switch
DO NOT use the idle control switch in conjunction with AC
electro-magnetic switches relays etc. Using the idle control switch
with these devices will cause the idle control device not to actuate.
If any of these devices are being used, leave the idle control
switch in the
When running capacitor start motors such as submersible
pumps, the idle control switch should
Disconnect the pump or tool from the power source by
switching OFF the main circuit breaker.
OFF
position.
NOT BE USED.
NOTE
In keeping with Multiquip's policy of
constantly improving its products, the
specifications quoted herein are subject
to change without prior notice.
GLW-180H — CONTROLS AND INDICATORS
Figure 1. Controls and Indicators
PAGE 10 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — INSTRUMENTATION
CAUTION :
When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the generating.
The definitions below describe the controls and functions of the
of the GLW-180 H Generator/Welder.
1. Ground Terminal Equipment – If required ground
equipment (power tools etc,) to this ground terminal. This
ground is not
2. 120 VAC Twist Lock Receptacle – This unit is supplied
with one
EARTH
Twist Lock
output receptacle.
3. 120 VAC GFCI Receptacle – This unit is supplied with
one
Duplex
NEMA (GFCI) 5-20R (120V, 20 Amp) output
receptacle.
4. AC Voltmeter – This voltmeter indicates (with a mark) the
rated 60 Hz, 120 VAC
addition the voltmeter can also be used as a diagnostic
tool.
ground.
NEMA L5-30R (120V, 30 Amp)
single phase output voltage
7. Current Regulator – Use this dial to adjust the welder's
output to the desired setting.
8. Idle Control Switch – This unit is provided with an
automatic idle control for noise suppression and reduced
fuel consumption. The automatic idle control automatically
enGLWges under a no-load condition.
With the automatic idle control switched “ON”, the engine
revolutions will automatically drop to about 2500 rpm (lowspeed 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. Current Regulator Selector Switch – Two position switch,
left
amps),
(max.-180).
10. DC Output Terminals – Connect the welder's (+) and (-)
welding cables to these terminals.
11. Fuel Tank – The fuel GLWuge is located on the fuel tank
. In
and allows easy monitoring of the fuel level.
12. Chassis Ground – Connect earth ground (
to this lug. See Figure 3.
position selects minimum current output (min.-130
right
position selects maximum current output
ground rod
)
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. Circuit Breaker – This single-pole, 40 amp breaker is
provided to protect both 120 VAC output receptacles from
overload.
6. Operation Switch – Must be in the up position (
normal operation. To turn-off generator place this switch in
OFF
the down position (
).
ON
) for
CAUTION :
NEVER turn the load ON or OFF by
connecting and disconnecting the load
power cord from the generator's AC output
receptacle. ALWAYS turn the circuit
breaker OFF to remove power from the
120 AC recepracles (load).
CAUTION :
When AC power is required, ALWAYS
place the current regulator dial in the
power using range
Figure 2. Current Regulator Switch
AC Power Range
.
AC
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 11
GLW-180H — INSTALLATION
Outdoor Installation
Install the generator in a location where it will not be exposed to
rain or sunshine. Make sure that the 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, not only to the engine
parts, but also to the alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside confined
areas. The engine exhaust contains
noxious elements.
Indoor Installation
Exhaust GLWses from GLWsoline 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
CAUTION :
Generator Grounding
To guard aGLWnist electrical shock and possible damage to
the equipment, it is important to provide a good
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 (Figure 3) as close to the point of cable entry
as practical.
NEC articles 250-91a and 250-95 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 250-83c specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
An
electric shock
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.
is apt to happen when
EARTH
Eliminate the danger of deadly carbon monoxide GLWs.
Remember that exhaust fumes from any GLWsoline 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.
PAGE 12 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
NOTE
Grounding
GLW-180H — INSTALLATION
Figure 3. Generator Ground Rod Application
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 13
GLW-180H — PRE-SETUP
General Inspection Prior to Operation
This 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 occurred in transit.
Ground
The nut and ground terminal on the generator should always
be used to connect the generator to a suitable ground. The
ground path should be of #8 size wire.
Connect the terminal of the ground wire between the
lock washer and the nut at the base of the generator
and tighten the nut fully. Connect the other end of the
ground wire to a
grounding rod
as shown in Figure 3.
Circuit Breaker
To protect the generator from an overload,
amp circuit breaker is provided on the control box. Make
sure to switch this circuit breaker to the "OFF" position prior
to starting the engine.
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 2 ) as a guide for selecting the proper extension
cable size.
a single-pole 40
)noitarepOesahPelgniS,zH06(noitceleSelbaCnoisnetxE.2elbaT
nIdaoL
nitnerruC
serepmA
sttaW
021tA
stloV
eriW01#eriW21#eriW41#eriW61#
htgneLelbaCelbawollAmumixaM
5.2003.tf0001.tf006.tf573.tf052
5006.tf005.tf003.tf002.tf521
5.7009.tf
053.tf002.tf521.tf001
010021.tf052.tf051.tf001
510081.tf051.tf001.tf56
020042.tf521.tf57.tf05
amadtnempiuqE:NOITUAC
.egatlovwolmorftlusernaceg
PAGE 14 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — PRE-SETUP
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
Fuel
Close the fuel cock before filling the tank. Fill the fuel tank
with clean and fresh unleaded GLWsoline. DO NOT fill the
tank beyond capacity.
into the filler hole, verify that the oil level is maintained
between the two notches on the dipstick.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 8
The oil listed in Table 3 is recommended to ensure better
Specification Table 1.
engine performance. Use class SC or higher grade motor
oil.
egnaRerutarepmeTliOepyT
F°32~F°401
)C°5-~C°04(
F°5~F°32
)C°51-~C°5-(
woleB)°51-(C°503-W0
liOrotoMdednemmoceR.3elbaT
03EAS
03-W01easro02EAS
1EASroW01EAS
The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not have
a spout, use a funnel.
CAUTION :
Never fill the
fuel tank
while the engine is
running or in the dark. GLWsoline spillage
on a hot engine can cause a fire or
explosion. If GLWsoline spillage occurs,
wipe up the spilled GLWsoline completely
to prevent fire hazards.
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 15
GLW-180H — 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.
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
To determine the running wattage for your load, multiply the
running wattage as indicated by steps 1, 2, and 3 below:
CAUTION:
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.
The idle control is operated at minimum load capacity of
100W. If the load capacity is less than 100W, throw the idle
control switch to the OFF position.
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
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:
A 1 inch drill runs at 1 KW
use a 2 KW generator.
3. LARGE MOTORS
Submersible pumps, table saws etc.
Total the running wattage and multiply by 3.
Example:
A conveyor belt runs at 8 KW
use a 24 KW generator.
PAGE 16 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — GENERATOR OPERATING INSTRUCTIONS
Before Starting
1. Be sure to disconnect the electrical load and switch the
main circuit breaker to the “OFF” position prior to starting
the engine.
2. Never start the engine with the main circuit breaker “ON”.
3. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
4. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified SC, SD or SE. (See Table 3 on page 15)
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
z
NEVER start the engine when the oil level
is below the lower mark on the dipstick.
z
Check the fuel level on the fuel GLWuge.
When fuel is low, fill the fuel tank with
clean fresh unleaded automotive
GLWsoline.
z
If GLWsoline spillage occurs, completely
Starting
1. Place the idle control switch in the “ON” (up) position.
2. Close the choke. Adjust the opening of the choke valve
according to operating conditions. When the engine is
warm or the air temperature is high, close the choke
valve halfway or open it all the way.
3. Confirm that the main circuit breaker on the generator
control box is “OFF”.
wipe up the spilled GLWsoline.
Warm up
1. When the engine starts, open the choke slowly.
2. Run the engine at low speed for 3 minutes without load
until the engine warms up.
3. Turn the idle control switch to the "OFF" (down) position
and check the voltage by referring to the voltmeter on
the control box.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
1. Check the generator for abnormal noise and smells. Then
connect the load to the receptacles of the generator.
2. Switch the main circuit breaker to the “ON” position and
turn the idle control switch to the “ON” (down) position
for normal (load) engine operation.
Operation
Check the voltage by referring to the voltmeter on the control
box. When the voltmeter indicates 120 volts, 120 volts from
the 120V receptacles and 240 volts from the 240V receptacle
can be obtained at the same time. Refer to Figure 1, Controls
and Indicators, item 4 on page 10.
Stopping the Engine
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
DO NOT change the engine speed control
lever which has been set at the factory prior
to shipping.
4. Set the operation switch to the “ON” position and grasp
the starting rope and slowly pull it out. The resistance
becomes hardest at a certain position, corresponding
to the compression point. Rewind the rope a little from
that point and pull out sharply.
5. If the engine fails to start, repeat the procedure.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
z
DO NOT pull the starter rope all the way
to the end.
z
DO NOT release the starter rope after
pulling. Allow it to rewind as soon as
possible.
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 17
1. Remove the load from the generator. Place the circuit
breaker in the “OFF” position. Refer to Figure 1, item 5
on page 10. Run the engine (no-load) with the idle control
switch set to the ON position for three to five minutes,
then stop the engine.
2. Turn the START/STOP switch to the “STOP” position.
3. Never stop the engine suddenly while running at high
speed.
4. Close the fuel cock.
NEVER stop the engine suddenly while
running at high speeds.
GLW-180H — WELDER OPERATING INSTRUCTIONS
Welding Cables and Polarities
Connect the welding cables (Figure 4) to the welder's output
terminals located on the control panel. The output terminals
have (+) and (-) polarities. Select the appropriate polarities
according to the application (See Welding Application, Table 5).
NOTE
Attach terminal connectors at the end
of each cable. NEVER connect
exposed wires (Figure 5) directly to the
terminal. Exposed wiring may cause
shocks or di-electric breakdown from
poor contact.
Figure 4. Welding Cable Connection
(Correct)
YTIRALOPDOHTEMGNIDLEWSNOITACILPPALACIPYT
...
)+(
ytiraloPthgiartS
ytiraloPesreveR
...
)+(
nidraugeR:etoN
.rekameriwehtmorfsnoitcurtsni
Figure 5. Welding Cable Connection
(Incorrect)
snoitacilppAgnidleW.4elbaT
)lateMesaB(gnidnuorG
redloHredleW...)-(yol
redloHredleW...)+(
setalpniht
)lateMesaB(gnidnuorGleetssselniatsfognidlewcrA
larenegrofslairetamleetsgnidleW
.setalpssenkcihtdna,serutcurts
lareppocrofgnidlewcrA
fognidlewCRA,gnidlewpu-dliuB
ehtwollof,scitretcarahcVCehtniytiralopehtfonoitcelesehtg
PAGE 18 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — WELDER OPERATING INSTRUCTIONS
Welding Cables
The required cable welding size is governed by this simple
rule: The longer the welding cable, or the greater the welding
Duty Cycle
The duty cycle for the generator/welder is based on 10 minute
intervals. See Table 6 below.
current, the thicker (copper strands) the calbe must be.
Select a welding cable with adequate thickness according
to the cable length and welding amperage (current) as listed
in Table 5.
seziSelbaCredleW.5elbaT
tuptuOredleW
tnerruC
001
htgneLelbaCeziSelbaC
053.oN
0013.oN
5213.oN
0513.oN
0023.oN
0523.oN
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
1. Connect the welding cables (electrodes) to the
0033.oN
053.oN
0013.oN
5213.o
051
0513.oN
0022.oN
0521.oN
N
generator's output terminals (Figure 4). For
welding current (min-130 amps), use an eyelet terminal
connector with a 5/64" to 1/8" diameter, for
welding current (110 - max amps), use an eyelet terminal
connector with a 3/32" to 5/32" diameter
2. Set the current
panel (Figure X) to the desired setting. The
is for
gnidleW
tnerruC
ytuD
%elcyC
NEVER
switch
low
current, the
elcyCytuD.6elbaT
ro011
sseL
00108060504
switch the
521541061081
current range selector
during any welding operation.
minimum
maximum
regulator control switch
on the control
inner
outer
scale is
high
current output.
scale
0031.oN
053.oN
0013.oN
5213.oN
002
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
0512.oN
0021.oN
0520/1.oN
0030/1.oN
Figure 6. Current Regulator/Range Switches
To prevent serious accidents, ALWAYS turn
off the generator/welder ( operation switch)
and set the main circuit breaker to the OFF
position.
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 19
3. Set the current
low
or
high
range control switch
. DO NOT change the position of this switch
while welding.
(Figure 7) to either
GLW-180H — 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 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 GLWsoline.
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 5) with a
wire brush. Set the spark plug GLWp 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 5. Spark Plug GLWp
PAGE 20 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — PREPARATION FOR LONG -TERM STORAGE
Generator Storage
For storage of the generating set for over 30 days, the
following is required:
z
Drain the fuel tank completely.
z
Run the engine until the GLWsoline in the carburetor is
completely consumed.
z
Completely drain the oil from the crankcase and refill
with fresh oil.
z
Remove the spark plug, pour 2 or 3 cc of SAE 30 oil
into the cylinder and crank slowly to distribute the oil.
z
Slowly rotate the engine a few times with the starter
Rope and install a new plug.
z
Pull out the starter rope slowly and stop at the
compression point.
z
Clean all external parts of the generating set with a cloth.
z
Cover the generating set and store in a clean, dry place.
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 21
GLW-180H — WIRING DIAGRAM GENERATOR/ ENGINE
GENERATOR
ENGINE
PAGE 22 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
GLW-180H — 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 7)
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
?tignihcaersi
?leuFoN leuFddA
?knatleufniretaW .knatleufecalperrohsulF
?deggolcretlifleuF retlifleufecalpeR
?roterubrackcutS .msinahcemtaolfkcehC
gnitratsrooP
?dersigulpkrapS .tinunoitingirotsinartkcehC.deluofsigulpkrapS
leuffieesotroterubractcepsnI
?etihw-eulbsigulpkrapS
GNITOOHSELBUORTENIGNE.7ELBAT
enilleufkcehC
erastejroterubraC.gnikaelriadetcejni,noisserpmoctneiciffusnI
.)wolfrevo(deggolc
?gulp
?liooN .deriuqersalioddA
?gnitratsnopu
?esool
"noisserpmoc
"noisserpmoc"
on"tuptuorewoptneiciffusnI
?esoolsigulpkrapS .gulpkrapsecalpeR
?sgnirnotsipnroW .sgnirnotsipecalpeR
tuptuorewoptneiciffusnI
?daeh
krapsfopittatneserpkrapsoN
sknilbpmalmralaerusserpliO
?revonruttonlliwenignE .tniojlexayrassecenfidnanotsipdnarednilycecalpeR
stlobgnitcennocdaehrednilyC
?degamadteksagdaehrednilyC .teksagdaehrednilycecalpeR
?taesevlavfonoitcnuflaM .sevlavtaes-eR
renaelc-rianinoitcnuflaM
?deggolcretlifria,metsys
ecafretnimorfnignikaelriA
rednilycdnaroterubracneewteb
/tratS
.stlobgnitcennocdaehrednilycnethgiT
.retlifriaecalperronaelC
.teksagdaehrednilyc
.deluoffigulpkrapsecalpeR.nekorbhctiwspotS
."rosneslio"tiucricnwodtuhscitamotuAkcehC
.nekorbrodekcarcdrocegatlovhgih,nekorbtinunoitingirotsinarT
ecalpeR.daehrednilycdnaroterubracneewtebstlobnethgiT
?metsysleufninoitcnuflaM
.retlifleufecalperronaelC
.roterubracecalperronaelC
.taolfroterubrackcehC
GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05) — PAGE 23
GLW-180H — TROUBLESHOOTING (ENGINE)
)DEUNITNOC(GNITOOHSELBUORTENIGNE.7ELBAT
MOTPMYS MELBORPELBISSOP NOITULOS
tuptuorewoptneiciffusnI
staehrevodna"noisserpmoc"
leufhcumotsnruB
ylsuoinitnocsiroloctsuahxE
"ETIHW"
ylsuoinitnocsiroloctsuahxE
"KCALB"
?stcudorp
?ytisocsiv
?sgnirnroW sgnirecalpeR
?nafgniloocninoitcnuflaM .nafgniloocecalperrokcehC
?deggolcretlifekat-niriA .retlifekat-niriaecalperronaelC
tsuahxefonoitalumuccarevO
?gulpkrapsgnorW .gulpkrapsepytdetseggusserutcafunamhtiwgulpkrapsecalpeR
gnorwsiliognitacirbuL
?deggolcrennaelcriA .renaelcriaecalperronaelC
tesneebtonsahevlavekohC
?noitisoptcerrocehtot
nolaes,evitcefedroterubraC
?nekorbroterubrac
tnemtsujdaroterubracrooP
?hcirootsnurenigne"
.sevlavkcehcdnanaelC
.yrassecenfiecalper,relffumkcehC
.ytisocsivtcerrochtiwliognitacirbulecalpeR
.noitisoptcerrocehtotevlavekohctsujdA
.laesroroterubracecalpeR
.roterubractsujdA
PAGE 24 — GLW-180H A.C. GENERATOR/WELDER — PARTS & OPERATION MANUAL — REV. #5 (03/14/05)
Loading...