Multiquip SGW-250SS User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

WHISPERWELD

DC WELDER/AC GENERATOR

Model SGW-250SS

Parts No. D2845200004A

Revision #2 (08/08/01)

MULTIQUIP INC. PARTS DEPARTMENT:

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: 310-537-4259

E-mail:mq@multiquip.com • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

ARAR

TS DEPTS DEP

TS DEP

ARAR

TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

SERSER

SER

SERSER 800/835-2551 or 310/537-3700 FAX: 310/638-8046

WW 800/835-2551 or 310/537-3700 FAX: 310/638-8046

MAINMAIN

MAIN

MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

VICE DEPVICE DEP

VICE DEP

VICE DEPVICE DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

ARAR

TMENTTMENT

TMENT

TMENTTMENT

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Rules For Safe Operation ...................................... 6-7

Operation and Safety Decals ................................. 8-9

Specifications .......................................................... 10

General Information ................................................ 11

Dimensions ............................................................. 12

Trailer Safety Guidelines .................................... 13-17

Trailer Wiring Diagram............................................. 18

Towing ..................................................................... 19

Controls and Indicators ...................................... 20-21

Installation ............................................................... 22

Pre-Setup ........................................................... 23-25

Instrumentation ....................................................... 26

Load Application ..................................................... 27

Welder Operating Instructions ........................... 28-30

Engine Operating Instructions ................................ 31

Maintenance ...................................................... 32-33

Preparation For Long Term Storage ....................... 34

Engine/Generator Wiring Diagram .......................... 35

Troubleshooting (Welder) ....................................... 36

Troubleshooting (Engine) ................................... 37-39

Explanation Of Codes In Remarks Column ............ 40

Suggested Spare Parts ........................................... 41

Honda GX610VXD Engine

Cylinder Head Assembly .................................... 60-61

Cylinder Barrel Assembly ................................... 62-63

Crankcase Cover Assembly ...............................64-65

Crankshaft Assembly .........................................66-67

Piston Assembly .................................................68-69

Camshaft Assembly ...........................................70-71

Fan Cover Assembly ..........................................72-73

Carburetor Assembly .........................................74-75

Air Cleaner Assembly......................................... 76-77

Muffler Assembly ............................................... 78-79

Fuel Pump Assembly .........................................80-81

Flywheel Assembly ............................................82-83

Ignition Coil Assembly ........................................ 84-85

Starter Motor Assembly .....................................86-87

Control Assembly ............................................... 88-89

Terms and Conditions Of Sale — Parts .................. 90

MQ Power SGW-250SS— DC Welder/AC Generator

Generator Assembly .......................................... 42-43

Control Panel Assembly ..................................... 44-47

Electric Parts Assembly...................................... 48-49

Battery Assembly ............................................... 50-51

Tail Pipe Assembly ............................................. 52-53

Fuel Tank Assembly ........................................... 54-55

Enclosure Assembly ........................................... 56-57

Specification and part numberSpecification and part number

Specification and part number

Specification and part numberSpecification and part number are subject to change withoutare subject to change without

are subject to change without

are subject to change withoutare subject to change without noticenotice

notice

noticenotice

Name Plate And Decals ..................................... 58-59

PAGE 4 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

NOTE

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.

Now! Direct TOLL-FREE access

Extra Fax Discount

for Domestic USA

Dealers Only

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

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — 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 SGW-250SS Welder/AC Generator :

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed boots and other protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with burns.

■

The engine of this welder/generator requires an adequate free flow of cooling air. Never operate the generator in any

■

Always refuel in a well-ventilated area, away from sparks and open flames.

hot

components can cause serious

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 welder/ generator engine and may cause injury to people. Remember the welder/ generator's engine gives off DEADLY carbon monoxide gas.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts before starting.

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

Topping-off to filler port is dangerous, as it tends to spill fuel.

bodily harm or even death.

smoke around or near

PAGE 6 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

CAUTION:

This generator is a source of providing LETHAL high voltages. Never permit unqualified personnel-especially children to operate the generator.

■

area, away from sparks and open flames.

■

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. hands are wet, or in the rain.

hands are wet, or in the rain. Dangerous electrical shock

hands are wet, or in the rain. hands are wet, or in the rain. could occur causing severe bodily harm or even death.

■

Keep electrical cords in good condition. Worn, bare or frayed wiring can cause electrical shock, thus causing

or 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.

Always refuel in a well-ventilated

ground terminal ground terminal

ground terminal

ground terminal ground terminal

aterater

, while bare f, while bare f

ater

, while bare f

aterater

, while bare f, while bare f

for your

oot, whileoot, while

oot, while

oot, whileoot, while

bodily harm

■

before adding fuel or performing service and maintenance functions. Contact with burns.

CAUTION:

Emergencies

Maintenance Safety

■

RULES FOR SAFE OPERATION

Provide adequate ventilation when operating the generator. DO NOT operate the generator in any enclosed or narrow space. The gasoline engine that provides power to the generator gives off DEADLY monoxide gas.

Always make sure the welder/ generator is secure on level ground so that it cannot slide or shift around, endangering workers. Also keep the immediate area free of bystanders.

High Temperatures – Allow the machine and engine to cool

hot

components can cause serious

Always know the location of the nearest

extinguisherextinguisher

extinguisher

extinguisherextinguisher

location of the nearest telephone. Also know the phone numbers of the nearest

doctordoctor

doctor

doctordoctor

NEVER lubricate components or attempt service on a running machine.

fire departmentfire department

and

fire department

fire departmentfire department

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

. Know the

ambulanceambulance

ambulance

ambulanceambulance

firefire

fire

firefire

■

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, coolant, fuel and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous waste.

■

DO NOT pour waste, oil, coolant, or fuel directly onto the ground, down a drain or into any water source.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 7

OPERATION AND SAFETY DECALS

PAGE 8 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

OPERATION AND SAFETY DECALS

P/N DCL160

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 9

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SGW-250SS — SPECIFICATIONS

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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

°°

PAGE 10 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — GENERAL INFORMATION

SGW-250SS FAMILIARIZATION Generator

The MQ Power Model SGW-250SS welder/generator can provide 200 amps of welding current when in the CV/DC mode and 250 amps of welding current when in the CC/DC mode. When used as a generator it can provide a maximum of 7,200 watts of power.

Control Panel

control panelcontrol panel

The

control panel

control panelcontrol panel

One GFCI 120 volt receptacle, 30 amp (single-phase)

One 120 volt receptacle, 30 amp (single-phase)

One 120/240 volt receptacle, 30 amp (single-phase)

Main Circuit Breaker 265V @25 Amps

Circuit Protector Breaker (GFCI) 120V @20 Amps

Idle Control Switch

Starter Switch

Starter Button

Hour Meter

Ground Terminal

Welder Protection System

In the event of an overload, this welder/generator is equipped with an welder protection system . If an overload is detected while operating the welder/generator, the welder protection system will shut down the engine.

is provided with the following:

Oil Pressure Warning Alarm

In the event of low oil pressure (engine), this welder/generator is equipped with an engine protection fail safe system . If low oil pressure is detected while operating the welder/ generator, the engine protection system will shut down the engine.

If this condition (low oil pressure) should occur, please refer to the engine troubleshooting table in this manual.

Excitation System

The SGW-250SS welder/generator uses a brushless exciter to create rated output electricity. This system will use the mechanical energy generated by the 3600 RPM engine to spin the rotor (or armature) inside the generator (or alternator end).

The motion created by the rotor (which holds copper coils) spins inside a housing of permanent magnets called the "STATOR". A magnetic field is created by the stator and produces an electrical current.

Engine

The SGW-250SS is powered by an air-cooled, 4-cycle HONDA gasoline engine. This engine is designed to meet every performance requirement for generator. Reference Table 1, page 9 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Figures 2 and 3 (pages 14-15) show the basic controls and indicators for the SGW-250SS welder/generator.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 11

SGW-250SS — DIMENSIONS

Figure 1. SGW-250SS Dimensions

PAGE 12 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — TRAILER-SAFETY GUIDELINES

CAUTION:

ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 2.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - This measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to fender.

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 4 and Figure 5 or lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3). Please not that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 13

SGW-250SS — TRAILER-SPECIFICATIONS

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LLEC

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003WLT,052WGS

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51-ACD

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004WLB-RLRT 004-WLBONCIRTCELESBL0072"451TSAM/W

X05-RLRT 52-ACDONONSBL0072"421"55.BL008

FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

LAG541CILUARDYHSBL00001"681"77.BL0002

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METSYS

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LEEHWTLITLLUF

DAPTALF

PAGE 14 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — TRAILER-SPECIFICATIONS

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LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W01-RLRT SSALCLLAB"2

01-RLRT SSALCLLAB"2

FX01-RLRT SSALCLLAB"2

W522-RLRT SSALCLLAB"2

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004

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FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

W07-RLRT SSALCLLAB"2

X07-RLRT SSALCLLAB"2

FX07-RLRT SSALCLLAB"2

FX001-RLRT 6/5-2ELBATSUJDA

521/58-RLRT 6/5-2ELBATSUJDA

FX051-RLRT EYELLAB"3E61-057

FX022-RLRT EYE"3

FX003-RLRT EYE"3

FX004-RLRT EYE"3

FX006-RLRT LEEHWHT5H5.71R57/512TS

RA008-RLRT LEEHWHT5H5.71R57/512TS

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SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 15

SGW-250SS —TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

CAUTION:

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air

pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. Table 3 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Suspension

The leaf suspension springs and associated components (Figure 2) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components as detailed in Table 4.

CAUTION:

Figure 2. Major Suspension Components

NOTE

ALWAYS wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

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SGW-250SS —TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN NUT

BOLT ASSEMBLY

05-XAM03-NIM

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 3. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 5.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

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Figure 3. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 17

SGW-250SS —TRAILER-WIRING DIAGRAM

PAGE 18 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS —TOWING

Towing Safety Precautions

■

ALWAYS attach trailer's safety chain to bumper of towing vehicle.

CAUTION :

■

ALWAYS make sure the vehicle and trailer directional,

Check with your county or state safety towing regulations department before towing your generator. Vehicle towing codes and regulations can vary from state to state.

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 4) and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both the towing vehicle and the trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

backup, brake, and trailer lights are connected and are working properly.

■

The maximum speed (unless otherwise posted) for highway towing is 45 MPH. Recommended off-road towing is not to exceed 10 MPH or less, depending on type of terrain.

■

Place while parked.

■

Place prevent

■

Use the trailer's hand winch to adjust the height of the trailer, then insert locking pin to lock wheel stand in place, while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

tippingtipping

tipping

tippingtipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling rolling

rolling,

rolling rolling

Figure 4. Welder/AC Generator and Towing Trailer

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 19

POWERED

SGW-250SS — CONTROLS AND INDICATORS

Figures 5 and 6 show the location of the controls and indicators. The functions of each control or indicator is described below and on the preceding page.

1. Welding Type (Wire/Stick) Selector Switch (CV/CC) –

Turn this selector switch to either the CV or CC for welding. DO NOT turn this switch under load.

2. Current Range Selector Switch (CV/CC) – Turn this selector switch to either the CV or CC for welding. DO

NOT turn this switch under load.

3. Current Control (CC) Adjustment Knob – Use this

control to adjust welding current. Low scale (50~120 amps), High scale (90~250 amps). This function will not work in the CV mode.

4. Voltage Control (CV) Adjustment Knob – Use this control to adjust the welding voltage. This function will not work in the CC mode.

5. Idle Control Switch – Regulates the engine speed when the generator is under load.

6. Hour Meter – Indicates number of hours the welder has been in use or engine has been running.

7. Oil Filler Port – Use this port when adding oil to the engine.

8. Engine Air Cleaner – Prevents dirt and other debris from entering the fuel system. Lift locking latch on air filter cannister to gain access to filter element.

9. Main Circuit Breaker – This 2-pole circuit breaker provides circuit protection (265V @30 amps) for the electric parts.

10. ON/OFF Switch – This switch is used to start and stop the engine. Must be in th ON position (up) when starting the engine. Place in the OFF position (down) to stop the engine.

11. Start Button – Press and hold this push-button switch until the engine has started. The ON/OFF switch must be in the ‘ON’ position in order for the start push-button switch to start the engine.

12. Oil Filter – Provides oil filtering for the engine.

13. Fuel Cap – Remove this cap to add fuel. Add only clean

unleaded fuel. Always keep an adequate amount of fuel in the tank. DO NOT top off. Wipe up any spilled fuel immediately.

14. Battery Terminals – Connect these terminals to the battery. Always pay close attention to the polarity of the terminals when connecting to the battery, RED (positive), and BLACK (negative).

15. Battery – Provides +12 VDC power for the generator. When replacing battery (12V 35 AH) use only

3 2

7 8

recommended type battery.

WHISPERWELD

-250S S

POWERED

MQ POWER

I R

I T

A K

OFF

Power Source Professionals.

MQ POWER

Figure 5. SGW250SS Components 1

PAGE 20 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

POWERED

WHISPER WELD

MQ POWER

PowerSource Professionals.

SGW-250SS — CONTROLS AND INDICATORS

16. Positive Welding Output Terminal – Connect the

23. Frame Ground Lug – Connect a ground strap between

welding cable to this terminal. Select the appropriate polarities according to the application. See Table 7.

17. Negative Welding Output Terminal – Connect the negative cable of the welding source to this terminal. Select the appropriate polarities according to the

24. Fuel Tank – Holds 10 gallons (38 liters) of unleaded

application. See Table 7.

18. Receptacle G.F.C.I. – This receptacle provides 120 volts

25. Fuel Gauge – Indicates the amount of fuel in the fuel

and output @ 20 amps.

19. Circuit Protector Circuit Breaker – This single pole circuit

26. Choke Knob – Used in the starting of a cold engine, or

breaker provides circuit protection (250V @20 amps) for the G.F.C.I receptacle.

20. Receptacle – Provides 120 volts output @ 25 amps.

21. Receptacle – Provides 120/240 volts output @ 25 amps.

27. Lifting Hook – Use this hook to lift the generator.

28. Engine Oil Dipstick – Indicates engine oil level, add oil

22. G.F.C.I Ground Terminal – Use this terminal to connect

external equipment grounds so the G.F.C.I. receptacle will

29. Oil Drain Plug – Remove this plug to drain oil from the

have a ground path.

30. Fuel drain Plug – Remove this plug to drain fuel from

WHISPERWELD

-2

POWEREDby

IDLECONTROL

AC CIRCUIT

BREAKER

MQ POWER

T Z

A T

T T

MQ POWER

this lug and a ground rod. Make sure the ground rod is inserted deep into the ground to provide a good earth ground. Consult with local Electrical and Safety Codes for proper connection.

fuel.

tank.

in cold weather conditions. The choke enriches the fuel mixture for starting a cold engine.

as required. See Table 3 for correct type of oil.

engine.

the fuel tank.

Power Source Professionals.

MQ POWER

FRONT VIEW

Figure 6. SGW250SS Components 2

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 21

SGW-250SS — INSTALLATION

Outdoor Installation

Install the welder/generator in a location where it will not be exposed to rain or sunshine. Make sure the welder/generator is on secure level ground so that it cannot slide or shift around. Install the generator in a manner so the exhaust fumes 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 will cause excessive wear, to the engine and alternator parts.

Indoor Installation

Exhaust gases from gasoline engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Eliminate the danger of deadly carbon monoxide gas. Remember that exhaust fumes from any gasoline engine are very poisonous if discharged in a closed room, but harmless if allowed to mix with the outside air. If the generator is installed indoors, you must make provisions for venting the engine exhaust to the outside of the building.

CAUTION

CAUTION :

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements.

An electric shock may happen when vibrators are used. Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock.

Selecting Optimum Welding Cable

Use the table below (Table 2) to select the best cable for the total length and current of the application being used.

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0014#4#4#3#3#2#1#

0513#3#3#2#1#0/1#0/2#

0022#2#2#1#0/1#0/2#0/3#

0521#1#1#0/1#0/2#0/3#0/4#

05001521051002052003

Note:

During the operation of Self-Sheld Welding ro MIG Welding, do not allow the cables to bundle, because it will cause a short current drop. This may also happen if the size of the cables are smaller than recommended.

seziSelbaCgnidleW.6elbaT

PAGE 22 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — PRE-SETUP

General Inspection Prior to Operation

The SGW-250SS utilizes a generator that 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 and tighten the nut fully. Connect their end of the wire to a suitable ground.

Circuit Breaker

To protect the generator from an overload, a 2-pole, 30 amp, circuit breaker is provided. Make sure to switch the 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 3 ) as a guide for selecting proper cable size.

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SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 23

SGW-250SS — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the welder/generator is level. With the dipstick inserted all the way, but without being screw into the filler hole, verify that the oil level is maintained between the two notches (Figure 7) on the dipstick. See

Fuel Fill the fuel tank with clean and fresh unleaded gasoline. DO

NOT fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 11, Specification Table 1.

Table 4 for proper selection of engine oil.

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. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards.

Figure 7. Engine Oil Dipstick

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F°32~F°401

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F°5~F°32

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03EAS

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the engine manual.

Battery

This unit is of negative ground. DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level is not properly maintained. Add only distilled water when replenishment is necessary.

The battery is sufficiently charged if the specific gravity of

liOrotoMdednemmoceR.8elbaT

the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions, always keep the terminals firmly tightened. Coating the terminals

03-W01EASro02EAS

with a thin film of grease will help to inhibit corrosion. The battery gradually deteriorates over time. The actual life

span will vary according to operating conditions, but generally a battery two years or older should be replaced.

PAGE 24 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

BLW-400SSW — PRE-SETUP

CAUTION

Day-to-day addition of coolant or antifreeze is done from the reserve tank. See Table 9 for engine, radiator and reserve tank coolant capacities. Make sure the coolant level in the reserve tank is always between the "H" and the "L" markings.

Operation in Freezing Weather

When operating in freezing weather, be certain that the proper amount of antifreeze has been added. See Table 10 for antifreeze operating temperatures.

When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled.

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rotaidaRdnaenignE)L61.4(.laG1.1

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Cleaning the Radiator

The radiator may overheat if the fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect and adjust it in accordance with the

The fan belt tension is proper if the fan belt (Figure 5) bends 7 to 9 mm (0.28- to 0.35 in.) when depressed with the thumb as shown in Figure 13 below.

CAUTION :

Kubota Engine Operator's ManualKubota Engine Operator's Manual

Kubota Engine Operator's Manual

Kubota Engine Operator's ManualKubota Engine Operator's Manual

Figure 13. Fan Belt Tension

Never place hands near the belts or fan

while the welder/AC generator is running.

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Air Cleaner

tnioPgnizeerFtnioPgnilioB

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0442-21-601222

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NOTE

When the antifreeze is mixed withWhen the antifreeze is mixed with

When the antifreeze is mixed with

When the antifreeze is mixed withWhen the antifreeze is mixed with ww

aterater

, the antifreez, the antifreez

ater

, the antifreez

aterater

, the antifreez, the antifreez

be less than 50%.be less than 50%.

be less than 50%.

be less than 50%.be less than 50%.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 25

e mixing re mixing r

e mixing r

e mixing re mixing r

atio matio m

atio m

atio matio m

ustust

ust

ustust

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the

Battery

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions, always keep the terminals firmly tightened. Coating the terminals with a thin film of grease will help to inhibit corrosion.

obota Engine Operobota Engine Oper

obota Engine Oper

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ual.ual.

ual.

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SGW-250SS — INSTRUMENTATION

CAUTION :

When using a combination of dual receptacles, total load should not exceed the rated capacity of the generating set.

Power Outlets

The generator has the following 60 Hz, 120/240 volt singlephase receptacles.

Single Phase

One Duplex NEMA (GFCI) 5-20R (120V, 20 Amp) One Twist Lock NEMA L5-30R (120V, 25 Amp) One Twist Lock NEMA L14-30R (120/240V, 25 Amp)

Main Circuit Breaker (2-Pole)

This 2-pole 25 amp breaker protects the generator from short circuiting or overloading from the 60 Hz single phase load.

Idle Control Switch

The unit is provided with an automatic idle control for noise suppression and fuel cost reduction. 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 2100 rpm (lowspeed operation) within 7 seconds after the welding stops. When welding is resumed, the engine speed is automatically increased to about 3600 rpm (high-speed operation) as soon as the electrode contacts the base metal

This provides for smooth welding operation. With AC loads of more than 100W (such as lighting equipment, motorpowered tools, submersible water pumps, etc.), the engine runs at high speed. When a no load condition is produced, the engine automatically shows down.

Turn the idle control switch to the “ON” (up) position when the welder or AC loads of more than 100W is connected. Turn the idle control switch to the “OFF” (down) position when AC loads of less than 100W or when a magnetic switch is used.

Fuel Gauge

GFCI Protection Breaker (Single-Pole)

This Single-pole 25 amp breaker protects the GFCI receptacle from short circuiting or overloading from the 60 Hz single phase load.

The fuel gauge is located on the fuel tank and allows easy monitoring of the fuel level.

GFCI Receptacle

Before connecting a load to the generator's GFCI receptacle,

push push

push

the "Test Button" on the front of receptacle before

push push

connecting the load, to confirm that the receptacle is functioning correctly.

PAGE 26 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — 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

The power factor of this generator is 1.0. See Table 5. below when connecting loads.

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CAUTION:

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, place the idle control switch to the OFF position.

CAUTION:

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which

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.

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 27

SGW-250SS — WELDER OPERATING INSTRUCTIONS

Welding Cables and Polarities

Connect the welding cables (Figure 8) to the welder's output terminals located on the control panel. The output terminals have positive(+) and negative(-) polarities. Select the appropriate polarities according to the application (See Welding Application, Table 6).

NOTE

Attach terminal connectors at the end of each cable. NEVER connect exposed wires (Figure 9) directly to the terminal. Exposed wiring may cause shocks or di-electric breakdown from poor contact.

Figure 8. Welding Cable Connection

(Correct)

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)+(

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Figure 9. Welding Cable Connection

(Incorrect)

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PAGE 28 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — WELDER OPERATING INSTRUCTIONS

CAUTION :

NEVERNEVER

NEVER

NEVERNEVER SwitchSwitch

Switch

SwitchSwitch

When switching a selector switch, fully rotate it to the right or left position.

1. Turn the CV/CC

(Figure 10) to the

oltage Control oltage Control

the

oltage Control

oltage Control oltage Control

Figure 10. Welding Voltage Adjustment

When the CV/CC

Current Control Current Control

Current Control

the

Current Control Current Control

SwitchSwitch

functions are inoperative.

Switch

SwitchSwitch

switch the CV/CC

during any welding operation.

CVCV

position, and adjust voltage using

CVCV

knob.

NOTE

Selector Switch Selector Switch

Selector Switch

Selector Switch Selector Switch

and

is in the CV position,

Current Range SelectorCurrent Range Selector

Current Range Selector

Current Range SelectorCurrent Range Selector

SelectorSelector

Selector

SelectorSelector

Selector SwitchSelector Switch

Selector Switch

Selector SwitchSelector Switch

NOTE

When the CV/CC

oltage Control oltage Control

oltage Control

the

oltage Control oltage Control

3. Set the

Selector Switch Selector Switch

Selector Switch

Selector Switch Selector Switch

function is inoperative.

CCCC

Current Range Selector Switch Current Range Selector Switch

Current Range Selector Switch

CCCC

Current Range Selector Switch Current Range Selector Switch

is in the CC position,

to the

desired position (Low/High).

4. Adjust current output, by setting

Current Control Current Control

Current Control

Current Control Current Control

knob

to desired current output.

NOTE

When using the output, the outer scale is for the high range, and the inner scale is for the low range.

Current ControlCurrent Control

Current Control

Current ControlCurrent Control

knob to adjust the current

Auxiliary AC Power

The Auxiliary AC power in most cases will not be affected by the CV/CC Selector Switch or any controls (Figure 12) on the front panel, and will supply a stable constant AC voltage except when the welding mode is activated.

2. Turn the CV/CC

Selector SwitchSelector Switch

Selector Switch

Selector SwitchSelector Switch

(Figure 11) to the

CCCC

position.

Figure 12. Auxilliary AC Power

NOTE

When welding, remember that the output of the AC AUXILIARY POWER is affected by the welding operation. See next page for generator output voltage

Figure 11. Welding Current Adjustment

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 29

conditions when welding.

SGW-250SS — WELDER OPERATING INSTRUCTIONS

Welding and Auxiliary Outputs.

The welding and auxiliary outputs can be used simultaneously, subject to all of the following conditions:

CC/CV Selector Switch is in the CC mode.

CC Current Range Selector is in the low mode.

Current Control is in the MAX position.

NOTE

Under the above conditions, the welder can supply welding current of 120 amps, and AC current up to 3 kW at 120V and 240V.

Duty Cycle

The welder is rated at 100% duty cycle at 250 amps. However the duty cycle depends upon the welding current. Select the appropriate duty cycle from Table 7 to prevent overload.

NOTE

The 250 amp, 60% duty cycle referenced in Table 7 is for CV welding ONLY.

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PAGE 30 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — ENGINE OPERATING INSTRUCTIONS

WARNING:

The engine's exhaust contains harmful

ALAL

YS YS

emissions. exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

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 CC or higher (See Table 3 on page 16).

5. Check the coolant level in the radiator and subtank.

Replenish with antifreeze as necessary. Always maintain the coolant level between the FULL and LOW markings on the coolant container. Be sure that the radiator cap is fastened securely.

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ventilate the

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CAUTION:

Check the fuel level on the fuel gauge. When fuel is low, fill the fuel tank with clean fresh unleaded automotive gasoline.

CAUTION:

6. Let the engine idle for five minutes with the Automatic Idle Control switch in the “ON” position.

7. Check the engine for abnormal vibrations, noises and oil leakage.

8. Check the generator's output voltage by connecting an AC voltmeter to the 120/240 volt output receptacles. If the voltmeter indicates 120 volts, then 120 VAC can be obtained from the 120 V and 240V receptacles at the same time.

9. Turn the or “ON” for full engine operation.

Shutdown

1. Remove the load from the generator, then place both the main and GFCI circuit breakers to the OFF position.

2. Listen for the engine speed to drop. Run at low speed for 3-5 minutes.

3. Stop the engine by setting the ON/OFF switch on the generator's front panel to the OFF position.

STST

ARAR

NEVER press the the “ switch while the engine is running.

utomatic Idle Control Switch utomatic Idle Control Switch

utomatic Idle Control Switch

utomatic Idle Control Switch utomatic Idle Control Switch

STST

ARAR

to either “OFF”

” push-button

If gasoline spillage occurs, completely

Starting

1. On the front panel of the generator, set the ON/OFF switch to the ON position (up).

2. Pull the choke knob half way out (half open).

3. Press and hold the start “push-button” switch until the engine starts, then release.

4. After the engine starts gradually push the choke knob inward, all the way back to its closed position.

5. If the engine does not start within 10 seconds after pushing start button, wait about 30 seconds and repeat steps 1 through 4. If the engine fails to start after repeated attempts, refer to Table 8, Engine Troubleshooting.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 31

wipe up the spilled gasoline.

SGW-250SS — MAINTENANCE

General Inspection

At least daily or prior to each use, the welder/AC generator 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:

For a more detail engine maintenance schedule refer to the

HONDHOND

A Engine OperA Engine Oper

HOND

A Engine Oper

HONDHOND

A Engine OperA Engine Oper

Air Cleaner:

Every 50 hours: Remove air cleaner element by removing the wing bolts and screws. Inspect and clean heavy duty paper element by tapping it several times or blow with compressed air (not to exceed 30 psi). If element is too dirty or damaged, replace. Clean foam element with liquid detergent and hot water or with kerosene. Wrap foam element in a cloth and squeeze dry. Wipe any dirt from the inside of the air cleaner body and cover using a moist rag. Be careful to prevent dirt from entering the air chamber that leads to the carburetor.

Place the foam air filter element to the air cleaner body. Be sure the gaskets are in place, then reinstall the paper air filter element and cover. Tighten the air filter wing bolt securely.

ator's Manator's Man

ator's Man

ator's Manator's Man

ualual

ual

ualual

Removing Water from the Fuel ank

After prolonged use, water and other impurities accumulate in the bottom of the fuel tank. Occasionally remove the drain cock and drain the contents. During cold weather, the more empty are inside the tank, the easier it is for water to accumulate inside the tank. This can be reduced by always keeping the fuel tank as full as possible.

Fuel Addition

Always add clean, fresh unleaded fuel. Always pour through mesh lining.

Rectifier Fins

Periodically inspect the rectifier fins for contamination. ALWAYS keep fins free of dirt.

Air Removal

If air enters the fuel system of a gasoline engine, starting becomes impossible. After running out of gasoline, or after disassembling the fuel system, bleed the system by following this procedure: Turn the operation switch to the ‘ON’ position for 15-30 seconds. Try again, if needed.

Cleaning the Fuel Strainer

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

PAGE 32 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SDW-225SS — MAINTENANCE

SGW-250SS — MAINTENANCE

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

ENIGNE

retliFriAnaelC X

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

leveLnoitcetorPtnalooCkcehCdnarotaidaRnaelC X

tnemelEretliFriAecalpeR

spmalCdnasesoHllakcehC

knaTleuFfoedisnInaelC

YLIADsrH01 srH052 srH005

srH0001

ROTARENEG

smhoM3revOecnatsiseRnoitalusnIerusaeM X

.ylnoemittsrif,sruoh001taretlifdnalioenigneecalpeR

.ylnoemittsrif,sruoh052taretlifleufecalpeR

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 33

SGW-250SS — PREPARATION FOR LONG -TERM STORAGE

Welder/Generator Storage

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

Drain the fuel tank completely.

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

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

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

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

Remove the NEGATIVE battery cable from the negative post on the battery.

Stop the engine 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 34 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS —ENGINE/GENERATOR WIRING DIAGRAM

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 35

SGW-250SS — TROUBLESHOOTING (WELDER)

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 Welder Troubleshooting (Table 8) information shown below. If the problem cannot be remedied, please consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?deepswoL .noitces"deepswoltasniamerenignE"otrefeR

?)R(rotsiserevitcefeD .rotsiserecalpeR

s'rotarenegnitneserptonsiegatlovCA

.noitcesgnidlewronoitcesCA

CAniegatlovwoldnagnidlewrooP

.noitcesrewop

?rotorevitcefeD .rotorecalpeR

?3FesufnwolB .esufecalpeR

?rotorevitcefeD .rotorecalpeR

?deepswoL .noitces"deepswoltasniamerenignE"otrefeR

?gnidniw

?rellortnoCdleiFevitcefeD ."rellortnoCdleiF"ecalpeR

?gniriWevitcefeD .gniriwriapeR

?rellortnoCdleiFevitcefeD ."rellortnoCdleiF"ecalpeR

erutamranitiucric-trohsreyaL

GNITOOHSELBUORTREDLEW.41ELBAT

.erutamraecalpeR

?gniriwevitcefeD .gniriwriapeR

?rellortnoCdleiFevitcefeD ."rellortnoCdleiF"ecalpeR

?)eR(reifitcerevitcefeD .reifitcerecalpeR

onsierehttubtublamronsirewopCA

egatlovdnatnerruC.ytilibapacgnidlew

.evitarepo-nierastnemtsujda

,desuebtonnacrowolootsirewopCA

.lamronsignidlewtub

.noosootsegrahcsidyrettaB `?rotalugerenigneevitcefeD .rotalugerecalpeR

.elbacgnidlew

?gnidniw

?gniriwevitcefeD .gniriwriapeR

?sehctiwsrotcelesevitcefeD .2Sro1SecalpeR

rekaerbtiucricevitcefeD .rekaerbtiucricecalpeR

?)edisCA(

?gniriwevitcefeD .gniriwriapeR

?rellortnoCdleiFevitcefeD ."rellortnoCdleiF"ecalpeR

?remrofsnarttnerrucevitcefeD .3TCro2TC,1TC,remrofsnartecalpeR

?)2Lro1LroLCD(rotcaerevitcefeD .rotcaerecalpeR

fossenkcihtdnahtgneletauqedanI

erutamranitiucric-trohsreyaL

gnidniwerutamranitiucric-trohsreyaL

.elbacgnidlewecalpeR

.erutamraecalpeR

?gniriwevitcefeD .gniriwriapeR

?hctiwsnoitingievitcefeD .hctiwsnoitingiecalpeR

PAGE 36 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — 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

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

?erutarepmet

enatecwolhtiwleuF

?rebmun

diagnosis based on the Engine Troubleshooting (Table 9) shown below. If the problem cannot be remedied, please consult our company's business office or service plant.

?metsysleufehtniretaW .knatleufmorfretawevomeR

ytisocsivhgihylevissecxE

woltalioenigneroleuffo

)1TRAP(GNITOOHSELBUORTENIGNE.51ELBAT

.lioenigneroleufdeificepsehtesU

.leufdeificepsehtesU

esooloteudkaelleuF

?tungniniaterepipnoitcejni

.tratstonseodenignE

pmupnoitcejnI

?gninoitcnuflam

?gniraebrorenil

?rednilyc

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

,tfahsknarcfoeruzieS

rednilyc,notsip,tfahsmac

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.tunnethgiT

.ecalperroriapeR

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzondnagulp

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 37

SGW-250SS — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)2TRAP(GNITOOHSELBUORTENIGNE.51ELBAT

esooloteudkaelleuF

?tungniniaterepipnoitcejni

pmupnoitcejnI

?gninoitcnuflam

.htooms

tonsinoituloverenignE

?erusserp

?deggolc

.devresbosisag

tsuahxeeulbroetihwrehtiE

?kcutsro

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

epipwolfrevoleuF

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

nrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.ecalperroriapeR

.tsujdA

.ecalperroriapeR

.naelC

.ecalperroriapeR

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

PAGE 38 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

strapgnivoms'enignE

?gniziesebotmees

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC

.ecalperroriapeR

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzondnagulp

SGW-250SS — TROUBLESHOOTING (ENGINE)

MOTPMYSMELBORPELBISSOPNOITULOS

?tiucrictaeh-erpnekorB.tiucrictaeh-erpkcehC

retratsdnatratsotsliafenignE

.setator

woltasniamerdnastratsenignE

.deeps

.nurtonseodretratS ?degrahcsidyrettaB .yrettabegrahC

?leufoN.leufddA

?gniriwevitcefeD.gniriwkcehC

?reniartsleufdeggolC.ecalperronaelC

?renaelcriadeggolC.ecalperronaelC

?gniriwdetcennocsiD.gniriwriaperdnakcehC

?gninoitcnuflamretratS .ecalperroriapeR

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

?tuodenrub5FesuF.esufecalpeR

)3TRAP(GNITOOHSELBUORTENIGNE.51ELBAT

rewopCAnitneserpegatlovoN

?ecruos

?rotorevitcefeD.rotorecalpeR

egatlovondnasesirdeepsenignE

.ecruosrewopCAnitneserpsi

?gnidniw

rewopCAdnasesirdeepsenignE

ebtonnacrowolootsiegatlov

.desu

yrettabdnasesirdeepsenignE

.noosootsegrahcsid

enignednasesirdeepsenignE

.dedaolrevosmees

lortnoCeldI"dnastratsenignE

enignE.noitisopFFOnisi"hctiwS

egralsahenignednasesirdeeps

.sdaolrevO.snoitarbiv

lortnoCeldI"dnastratsenignE

enignE.noitisopFFOnisi"hctiwS

sahenignednasesirdeeps

.esionlamronba

?retemtlovevitcefeD.retemtlovecalpeR

?gniriwdetcennocsiD.gniriwriaperdnakcehC

erutamranitiucric-trohsreyaL

?)rotcetorp(rekaerbtiucricevitcefeD .)rotcetorp(rekaerbtiucricecalpeR

niseriwnekorb,tiucric-trohsreyaL

?gnidniwerutamra

?rotalugerenigneevitcefeD.rotalugerecalpeR

?gniriwevitcefeD.gniriwecalperroriapeR

?rotanretlaevitcefeD.rotanretlaecalperroriapeR

?gniraebrotanretladegamaD.sgniraebrotanretlaecalpeR

?noitallatsnienignedaB.enignefonoitallatsnitaepeR

?strapenigneesooL .senthgitrofstrapenignellakcehC

?rotanretlaevitcefeD esoolrogniraebdegamadrofrotanretlakcehC

.)1ER(reifitcerecalpeR

.erutamraecalpeR

.erutamraecalperroriapeR

.stlobgnipmalc

?erusolcneevitcefeD .ssenthgitrofstloberusolcnekcehC

lortnoCeldI"dnastratsenignE

enignE.noitisopFFOnisi"hctiwS

hgihtasniamerdnasesirdeeps

sihctiwslortnoCeldInehwdeeps

.noitisopNOehtnidecalp

?dionelosevitcefeD .dionelosecalpeR

?yalerevitcefeD .yalerecalpeR

?ecivedlortnoceldievitcefeD .ecivedlortnoceldiecalperroriapeR

?hctiwslortnoceldievitcefeD .hctiwslortnoceldiecalpeR

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 39

EXPLANATION OF CODE IN REMARKS COLUMN

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

Items Found In the “Remarks” Column

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

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

Items Found In the “Items Number” Column

All parts with same symbol in the number column,

■

, belong to the same assembly or kit.

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

NOTE

The contents of this parts catalog areThe contents of this parts catalog are

The contents of this parts catalog are

The contents of this parts catalog areThe contents of this parts catalog are subject to change without notice.subject to change without notice.

subject to change without notice.

subject to change without notice.subject to change without notice.

, #, +, %,

PAGE 40 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — SUGGESTED SPARE PARTS

SGW SGW

SGW

SGW SGW

Qty. P/N Description

5 ......... 17010ZJ1000 ... AIR FILTER

1 ......... 17218ZJ1000 ... AIR FILTER, OUTER

5 ......... 16910ZE8015 .. FUEL FILTER

5 ......... 15400PR3004 .. OIL FILTER

1 ......... 15427ZJ1000 ... SCREEN, CRANKCASE OIL FILTER

1 ......... 35480ZJ1812 ... SWITCH ASSY., OIL LEVEL

1 ......... 0601200102 ..... STARTER SWITCH

1 ......... 0810105800 ..... FUEL CAP

1 ......... 0601805331 ..... MAIN CIRCUIT BREAKER

1 ......... 0601827399 ..... CONTROL UNIT

1 ......... 1620150404 ..... SOLENOID, ROTARY

4 ......... 9807952876 ..... SPARK PLUG

2 ......... 0601821370 ..... RECTIFIER

1 ......... 0601831841 ..... CV/CC SELECTOR SWITCH

1 ......... 0601803070 ..... CC CURRENT RANGE SELECT. SW

2 ......... D1233000004 .. OUTPUT TERMINAL

2 ......... 0801880004 ..... INSULATOR WASHER

4 ......... 0039510000 ..... HEX NUT

4 ......... 0045110000 ..... LOCK WASHER

4 ......... 0042710000 ..... PLAIN WASHER

2 ......... 0037810000 ..... WING NUT

1 ......... 0601803117 ..... KNOB, SELECTOR SWITCHES

1 ......... A6356400303 .. THROTTLE WIRE

1 ......... 0602125032 ..... FUEL GAUGE

1 ......... 31740ZJ7003 ... DIODE ASSY., ENGINE STOP

W/HONDW/HOND

W/HOND

W/HONDW/HOND

A GX610 AIR-COOLED ENGINE 1 A GX610 AIR-COOLED ENGINE 1

A GX610 AIR-COOLED ENGINE 1

A GX610 AIR-COOLED ENGINE 1 A GX610 AIR-COOLED ENGINE 1

O 3 UNITSO 3 UNITS

O 3 UNITS

O 3 UNITSO 3 UNITS

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 41

GENERATOR ASSY.

SGW-250SS — GENERATOR ASSY.

PAGE 42 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 D2110100003 ROTOR ASSY .......................... 1 .......... INCLUDES ITEMS W/

1-1

1-2

1-3

1-4

2 D2113400004 SET BOLT ROTOR 1 3 0801086104 SET WASHER BEARING 1 4 D2113100004 FAN 1 5 0040010000 LOCK WASHER 1 6 D2155100202 END BRACKET 1 7 D2134000803 ARMATURE ASSY 1 8 D2155000104 END BRACKET 1 9 D2137000203 FIELD ASSY EXCITER 1

10 011606025 HEX HEAD BOLT ..................... 4 .......... REPLACES 0017106025

11 1961324003 GROMMET 1 12 D2133300004 COVER 1 13 D2131500404 SET BOLT 4 14 0040010000 LOCK WASHER 4

15 031110160 PLAIN WASHER....................... 4.......... REPLACES 0041210000

16 D1153500603 COVER 2 17 D11535005031 COVER 2 18 D2155500013 COVER 1

19 011006010 HEX HEAD BOLT ..................... 4 .......... REPLACES 0017106010

20 1961844513 FIN 4

21 0601820012 RECTIFIER .............................. 2 .......... SR30MA- 6S

22 0601820013 RECTIFIER .............................. 2 .......... SR30MA-6R

23 0017105016 HEX HEAD BOLT 16 24 103189004 INSULATOR WASHER 16

25 011208035 HEX HEAD BOLT ..................... 6 .......... REPLACES 0017108035

26 D2185300004 SET BOLT 2 27 0040008000 LOCK WASHER 2

28 031108160 PLAIN WASHER....................... 2.......... REPLACES 0041208000

29 0019008016 HEX HEAD BOLT 4

30 020108060 HEX NUT ..................................4 .......... REPLACES 0207208000

31 1991843504 CONNECTION PLATE 2 32 1001843504 CONNECTION PLATE 12 33 D2155400004 COVER FAN 1 34 02072080000 HEX NUT 2

35 011208025 HEX HEAD BOLT ..................... 4 .......... REPLACES 0012308025

0601820037 RECTIFIER .............................. 1 .......... S10VB60

0601822638 SURGE ABSORBER ................ 1 .......... TNR15G 431K

042006304 BEARING ................................. 1 .......... 6304 DDU; REPLACES 0071206304

3051070003 FAN 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 43

CONTROL PANEL ASSY.

SGW-250SS — CONTROL PANEL ASSY.

PAGE 44 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 D2205000203 CONTROL PANEL ............................................. 1 ........... D25122 00002

2 0021805020 MACHINE SCREW 4

3 0601831841 CV CC SELECTOR SWITCH ............................ 1 ........... SSK- 1831

4 0601803070 CC CURRENT RANGE SELECTOR SWITCH .. 1 ........... SSK-2036C

5 0021304015 MACHINE SCREW ........................................... 6 ........... REPLACES 0021506012

6 8705945004 SEAL 2

7 0601840095 RHEOSTAT CURRENT CONTROL ................... 1 ........... RV24YN20SB2KO

8 0601840026 RHEOSTAT VOLTAGE CONTROL ..................... 1 ........... RA25YN20SB2KOJ

9 0601840103 KNOB ................................................................ 2 ........... K- 2195

10 0023304008 SET SCREW 4

11 0601805331 CIRCUIT BREAKER ......................................... 1 ........... KM52 265V 30A

12 4341817004 BRACKET CIRCUIT BREAKER 1 13 0027104015 MACHINE SCREW 2

14 0601830739 IDLE CONTROL SWITCH ................................. 1 ........... ET210N12

15 0601830796 OPERATION SWITCH ...................................... 1 ........... ET225N12

16 0601200102 STARTER SWITCH ........................................... 1 ........... ST- 403

17 0601800682 HOUR METER .................................................. 1 ........... #820114

18 0027403512 MACHINE SCREW 2

0030003500 HEX NUT 2

19 0801831204A OUTPUT TERMINAL ......................................... 2 ...........REPLACES D1233000004

20 0801880004 INSULATOR WASHER 2

21 020310080 HEX NUT ........................................................... 4 ...........REPLACES 0039510000

22 030212300 LOCK WASHER ................................................. 4 ........... REPLACES 0045110000

23 0042710000 PLAIN WASHER 4 24 0037810000 WING NUT 2

25 0601812529 RECEPTACLE................................................... 1 ........... L14- 30R

26 0601811031 RECEPTACLE................................................... 1 ........... L5- 20R

27 0601812597 RECEPTACLE................................................... 1 ........... 5- 20R

28 0021004012 MACHINE SCREW 6

0030004000 HEX NUT ........................................................... 6........... REPLACES 0207004000

29 0601806420 CIRCUIT PROTECTOR 1 30 0027103006 MACHINE SCREW 2

31 0601815109 GROUND TERMINAL ........................................ 1 ........... T- 381

32 D2238100203 COVER OUTPUT TERMINAL 1

D2238400004 RUBBER SHEET 1 33 0805088004 STAY RUBBER 1 34 0821800014 COLLAR 2

35 011206020 HEX HEAD BOLT .............................................. 2 ........... REPLACES 0016906020

0207006000 HEX NUT 2 36 0016906016 HEX HEAD BOLT 1

37 0601842462 RESISTOR ........................................................ 1 ........... GG40W35O

38 0027104012 MACHINE SCREW 2

39 0601821370 RECTIFIER ....................................................... 3 ........... DE4503

40 0027105040 MACHINE SCREW 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 45

CONTROL PANEL ASSY.

SGW-250SS — CONTROL PANEL ASSY.

PAGE 46 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

41 0601804211 CURRENT TRANSFORMER ............................. 3 ........... MCT-100Y

42 0027104012 MACHINE SCREW 6

43 0601823204 RECTIFIER ....................................................... 2 ........... S5VB60

44 0027103020 MACHINE SCREW 2

45 0601827399 CONTROL UNIT ................................................ 1 ........... FD-80

46 0027105012 MACHINE SCREW 6

47 0601823707 RELAY .............................................................. 1 ........... CA1A-DC12V- N

48 0027105020 MACHINE SCREW 1

49 0601815870 TERMINAL BOARD .......................................... 1 ........... KT-20 2P

D9522001204 SYMBOL SEAL 1

50 0601815758 TERMINAL BOARD .......................................... 1 ........... KT- 30 2P

D9522000804 SYMBOL SEAL 1 51 0027105020 MACHINE SCREW 2

52 8511864601A TERMINAL PLATE ............................................. 1 ...........REPLACES 8511864604

53 0016906016 HEX HEAD BOLT 5

54 0601802137 FUSE ................................................................ 1 ........... 10A AC250V

55 0601803117 KNOB (SELECTOR SWITCHES) 2

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 47

ELECTRIC PARTS ASSY.

SGW-250SS — ELECTRIC PARTS ASSY.

PAGE 48 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — ELECTRIC PARTS ASSY.

ELECTRIC PARTS ASSY.

NO PART NO PART NAME QTY. REMARKS

1 D2263500303 AC REACTOR 2

2 D2263500403 DC REACTOR ..................... 1 ............... INCLUDES ITEMS W/

2-1*0601831054 THERMOSTAT ..................... 1............... REPLACES 0603210120

3 0017106016 HEX HEAD BOLT 12

4 1622636103Z ROTARY SOLENOID ...........1 ............... 7SL25-22; REPLACES 1620150404

5 1992636004 ARM SOLENOID 1 6 0050403020 SPRING PIN 1 7 0010106025 HEX HEAD BOLT 1

0030006000 HEX NUT 1 8 A6356600404 WIRE STOPPER 1 9 0017105010 HEX HEAD BOLT 1 10 D2356200003 BRACKET SOLENOID 1 11 0207006000 HEX NUT 2 12 0010106040 HEX HEAD BOLT 1

0038706000 HEX NUT 1 13 0016906016 HEX HEAD BOLT 4 14 A6356400303B THROTTLE WIRE 1 15 0017105010 HEX HEAD BOLT 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 49

BATTERY ASSY.

SGW-250SS — BATTERY ASSY.

PAGE 50 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0805081004 BATTERY SHEET .................. 1 ............ REPLACES 1702202104

2 D2345200004 BATTERY BAND 1 3 0805082704 BATTERY BOLT 2 4 0037806000 WING NUT 2 5 0040006000 LOCK WASHER 2 6 0041206000 PLAIN WASHER 2 7 0602220600 TERMINAL CAP RED 1

0602220601 TERMINAL CAP BLACK 1 8 D1343200604 TERMINAL CAP 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 51

TAIL PIPE ASSY.

SGW-250SS — TAIL PIPE ASSY.

PAGE 52 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — TAIL PIPE ASSY.

TAIL PIPE ASSY.

NO PART NO PART NAME QTY. REMARKS

1 D2335100013 OUTLET PIPE 1 2 D9102200104 PIPE BAND 1 3 0016908030 HEX HEAD BOLT 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 53

FUEL TANK ASSY.

SGW-250SS — FUEL TANK ASSY.

PAGE 54 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 A6365000402B FUEL TANK ................................ 1 ......... INCLUDES ITEMS W/

1-1

1-2

2 3015530004 DRAIN PLUG 1 3 0150200011 O RING 1 4 0602125032 FUEL GAUGE 1 5 0016908020 HEX HEAD BOLT 4 6 0605513143 FUEL HOSE 1 7 0605515093 HOSE BAND 1 8 0605515240 HOSE BAND 1

0810105900 CAP FUEL TANK ....................... 1 ......... REPLACES 0810105800

0810105900 FUEL FILTER 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 55

ENCLOSURE ASSY.

SGW-250SS — ENCLOSURE ASSY.

PAGE 56 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO PART NO PART NAME QTY. REMARKS

1 D2415000412 BASE 1 1-1 0226900130 EDGE COVER 1 2 D2415400014 BASE COVER 1 3 0016906016 HEX HEAD BOLT 4 4 D2305100004 ENGINE BASE 1 5 D2418500104 GENERATOR BASE 1 6 0016908020 HEX HEAD BOLT 6 7 D2418700103 COMMON BASE 1 7-1 D2498000004 LINING 1 8 3025419304 RUBBER SUSPENSION 2 9 D9312600104 RUBBER SUSPENSION 2 10 0207010000 HEX NUT 8 11 0010110045 HEX HEAD BOLT 2

0207010000 HEX NUT 2 12 0017110030 HEX HEAD BOLT 2 13 D2425000413 FRONT FRAME 1 13-1 D2492200114 LINING 1 14 0016908020 HEX HEAD BOLT 4 15 D2425200104 COVER FRONT FRAME 1 16 0016906016 HEX HEAD BOLT 6 17 D2485100213 PANEL 1 17-1 D2498200013 LINING 1 18 0016908020 HEX HEAD BOLT 2 19 D2445000402 REAR FRAME 1 20 0016908020 HEX HEAD BOLT 8 21 D2445300304 COVER REAR FRAME 1 22 0016906016 HEX HEAD BOLT 5 23 0016906016 HEX HEAD BOLT 1

0040506000 TEETHED WASHER 1 24 D2455400013 COVER 1 25 0016906016 HEX HEAD BOLT 4 26 D2465000303 ROOF PANEL 1

D2498500014 LINING 1 27 0016908020 HEX HEAD BOLT 19 28 D2332300014 COVER EXHAUST PIPE 1 29 0016906016 HEX HEAD BOLT 3

THE PART NUMBER SHOWN IS TEAL. ADD THE FOLLOWING LETTERS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

THE SERIAL NUMBER MAY BE REQUIRED.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 57

NAME PLATE AND DECALS ASSY.

SGW-250SS — NAME PLATE AND DECALS ASSY.

PAGE 58 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — NAME PLATE AND DECALS ASSY.

NAME PLATE AND DECALS ASSY.

NO PART NO PART NAME QTY. REMARKS

1* D2552000404 DECAL: OPERATING INSTRUCTIONS ............ 1.......... REPLACES D25200040B

2* D9512100203 DECAL: CAUTION (MULTIPLE) ........................ 1.......... REPLACES 91210020

3* 0820610404 DECAL: WARNING (TRANSFER SWITCH) 1

4* 0820610304 DECAL: READ OWNER’S MANUAL ................. 1 .......... DCS01

5* 8700611904 DECAL: DANGER ELECT. SHOCK HAZARD ... 1.......... S4985

6* B9504000304 DECAL: CAUTION HOT PARTS ........................ 1.......... REPLACES B90400030

7* A5562100204 DECAL: MQ POWER ........................................ 3 .......... REPLACES D26220010

8* D2562100003 DECAL: STRIPE ............................................... 2 .......... REPLACES D26210000

9* 0600689404 DECAL: BATTERY POSITIVE ..........................1 .......... S2090

10* 0800689504 DECAL: BATTERY NEGATIVE .......................... 1 .......... S2091

11* 0820650604 DECAL: DANGER EXP. GASES (BATTERY) 1

12* D2562100103 DECAL: STRIPE ............................................... 2 .......... REPLACES D26210010

13 PLATE, SERIAL NO. ......................................... 1 .......... CONTACT MQ SERVICE DEPT

WITH MODEL AND S/N

14* D2552000313 DECAL: AC POWER OUTPUT ......................... 1.......... REPLACES D25200031

15* 0800628504 DECAL: GROUND ............................................. 1.......... S1123

16* B9504000404 DECAL: WARNING MOVING PARTS ................2 .......... REPLACES B90400040

17* 0800690804 DECAL: WELDING OUTPUT TERMINAL 1

18* 8700611804 DECAL: WARNING DANGEROUS GAS ............ 1.......... S4984

19* 8700611524 DECAL: CAUTION OIL LEVEL GAUGE 1

20* 7810680104 DECAL: FUEL DRAIN ....................................... 1.......... S3060

21* 1630645004 DECAL: OIL DRAIN .......................................... 1 .......... S1403

22* D2562200004 DECAL: WHISPER WELD ................................. 1.......... REPLACES D26220000

23 DCL160 DECAL;PROPOSITION 65 WARNING .............. 1 .......... REPLACES D9522100204

DCLSGW250SSKIT, DECAL ....................................................... 1 .......... INCLUDES ITEMS W/*

SEE DECAL ILLUSTRATIONS ON PAGE 8 AND 9

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 59

CYLINDER HEAD ASSY.

HONDA GX610VXD ENGINE — CYLINDER HEAD ASSY.

PAGE 60 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

NO PART NO PART NAME QTY. REMARKS

1 12210ZJ1000 CYLINDER HEAD COMP., R. ....... 1 .... INCLUDES ITEMS W/

2 12220ZJ1U80 CYLINDER HEAD COMP., L. ....... 1 .... INCLUDES ITEMS W/

5 12251ZJ1003 GASKET, CYLINDER HEAD 2 6 12311ZJ1000 COVER, HEAD 1 7 12314ZJ1000 COVER, HEAD FILLER 1 8 12391ZJ1000 GASKET, HEAD COVER 2 9 15611921000 CAP, OIL 1 10 17101ZJ1000 MANIFOLD, IN. 1 11 17151ZJ1003 GASKET, IN. MANIFOLD 2 12 90121ZJ1000 BOLT, FLANGE (6X25) (CT200) 8 13 91301805000 O-RING (26X2.7) 1 14 92900080250B BOLT, STUD (8X25) 4 15 9430112200 PIN A, DOWEL (12X20) 4 16 9405008000 NUT FLANGE 8MM 4 17 9430112200 PIN DOWEL 12X20 4 18 957010603200 BOLT, FLANGE (6X32) 4 19 957011007500 BOLT, FLANGE (10X75) 8 20 957011013000 BOLT, FLANGE (10X130) 2 21 9807952876 SPARK PLUG (BPR2ES) 2

12205ZE2305 GUIDE, EX. VALVE (OS) 4 12216ZE2300 CLIP, VALVE GUIDE 4

* *

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 61

HONDA GX610VXD ENGINE — CYLINDER BARREL ASSY.

CYLINDER BARREL ASSY.

PAGE 62 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CYLINDER BARREL ASSY.

CYLINDER BARREL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 12000ZJ1810 CYLINDER BARREL ASSY. .............. 1............... INCLUDES ITEMS W/

2 12356ZJ1000 COVER, BREATHER 1 3 12358ZJ1000 GASKET, BREATHER COVER 1 4 12372ZE2300 VALVE, BREATHER 1 5

7 15400PT7005 FILTER, OIL ....................................... 1 ............... REPLACES 15400PR3004

10 25523VD6010 COLLAR, FILTER SETTING 2 11 31511ZJ1000 CLAMP, WIRE 1 12 35480ZJ1812 SWITCH ASSY., OIL LEVEL 1 15 90014ZE6000 BOLT, FLANGE (6X35) 3 16 90018PN3000 HOLDER, OIL FILTER 1 17 90029888000 BOLT, FLANGE (6X16) 2 18 90031ZE1000 BOLT, FLANGE (6X32) 2 20

22 91353671003 O-RING (14MM) ................................. 1............... REPLACES 91353671004

23 9280014000 BOLT, DRAIN PLUG (14MM) 2 24 9405010000 NUT, FLANGE (10MM) 1 25 9410914000 WASHER, DRAIN PLUG (14MM) 2 26 957010607509 BOLT, FLANGE (6X75) 2 27 961406003010 BEARING, RADIAL BALL (6003) 1

13321ZJ1000 BEARING A, MAIN (BLUE) 1 13322ZJ1000 BEARING B, MAIN (BLACK) 1 13323ZJ1000 BEARING C, MAIN (BROWN) 1

91201ZJ1003 OIL SEAL (38X58X11) 1

1 120A0ZJ1000 CYLINDER ASSY. 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 63

HONDA GX610VXD ENGINE — CRANKCASE COVER ASSY.

CRANKCASE COVER ASSY.

PAGE 64 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CRANKCASE COVER ASSY.

CRANKCASE COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 11300ZJ1000 COVER ASSY., CRANKCASE ..... 1 ......... INCLUDES ITEMS W/*

2 11381ZJ1000 GASKET, CASE COVER 1 3 12105ZAO701 BOLT, SEALING 1 4* 13321ZJ1000 BEARING A, MAIN (BLUE) 1

13322ZJ1000 BEARING B, MAIN (BLACK) 1

13323ZJ1000 BEARING C, MAIN (BROWN) 1 5 15120ZJ1000 COVER ASSY., OIL PUMP 1 6 15124ZJ1003 ROTOR, OIL PUMP (OUTER) 1 7 15232ZJ1000 SPRING, RELIEF VALVE 1 8 15348ZJ1000 COVER, OIL FILTER 1 9 15427ZJ1000 SCREEN, OIL FILTER 1 10 15655ZJ1000 DIPSTICK, OIL 1 11 16541ZJ1000 SHAFT, GOVERNOR ARM 1 12 16542ZJ1000 FORK, GOVERNOR 1 16* 91201ZJ1003 OIL SEAL (38X58X11) 1

17* 91259NM0000 OIL SEAL (10X16X4.5) ................. 1 ......... REPLACES 91206333003

18 91302MB6830 O-RING (13X3.0) 2 19 93500050100A SCREW, PAN (5X10) 2 20 9430108140 PIN A, DOWEL (8X14) 2 21 957010602000 BOLT, FLANGE (6X20) 3 22 957010805000 BOLT, FLANGE (8X50) 9 23 9621112000 BALL, STEEL (#12) (3/8) 1 24 966000601600 BOLT, SOCKET (6X16) 2

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 65

CRANKSHAFT ASSY.

HONDA GX610VXD ENGINE — CRANKSHAFT ASSY.

PAGE 66 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

NO PART NO PART NAME QTY. REMARKS

3 13310ZJ0880 CRANKSHAFT COMP. V-TYPE 1 4 90401ZJ1000 WASHER, CRANKSHAFT THRUST 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 67

PISTON ASSY.

HONDA GX610VXD ENGINE — PISTON ASSY.

PAGE 68 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — PISTON ASSY.

PISTON ASSY.

NO PART NO PART NAME QTY. REMARKS

1 13010ZE8601 RING SET, PISTON (STD) NIPPON 2

13011ZE8601 RING SET, PISTON (0.25) NIPPON 2 13011ZE8602 RING SET, PISTON (0.25) TEIKOKU 2 13012ZE8601 RING SET, PISTON (0.50) NIPPON 2 13013ZE8601 RING SET, PISTON (0.75) NIPPON 2 13101ZJ1000 PISTON (STD) 2 13102ZJ1000 PISTON (0.25) 2 13103ZJ1000 PISTON (0.50) 2

13104ZJ1000 PISTON (0.75) 2 3 13111ZJ1000 PIN, PISTON 2

4 13210ZJ1000 ROD SET, CONNECTING ...................................... 2 .......... INCLUDES ITEM W/

5 13211ZJ1003 BEARING A, CONNECTING ROD (BLUE) 4

13212ZJ1003 BEARING B, CONNECTING ROD (BLACK) 4

13213ZJ1003 BEARING C, CONNECTING ROD (BROWN) 4

13214ZJ1003 BEARING D, CONNECTING ROD (GREEN) 4

13215ZJ1003 BEARING E, CONNECTING ROD 4

13216ZJ1003 BEARING F CONNECTING ROD 4

13217ZJ1003 BEARING G CONNECTING ROD 4 6

8 9460118000 CLIP, PISTON PIN (18MM) 4

13213ML0000 BOLT, CONNECTING ROD 4

13215KM3000 NUT, CONNECTING ROD 4

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 69

CAMSHAFT ASSY.

HONDA GX610VXD ENGINE — CAMSHAFT ASSY.

PAGE 70 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CAMSHAFT ASSY.

CAMSHAFT ASSY.

NO PART NO PART NAME QTY. REMARKS

1 12209ZE8003 SEAL, VALVE STEM 2

2 14100ZJ1801 CAMSHAFT ASSY. ................................................ 1 ......... INCLUDES ITEM W/

4 14410ZJ1000 ROD, PUSH 4 5 14431ZJ1000 ARM, VALVE ROCKER 4 6 14441ZE2000 LIFTER, VALVE 4 7 14461ZJ1000 SHAFT, ROCKER ARM 2 8

11*# 14581ZJ1801 ROD, DECOMPER 1 12 13 14711ZJ1000 VALVE, INLET 2 14 14721ZJ1000 VALVE, EX. 2 15 14751ZE2003 SPRING VALVE 4 16 14771ZE2000 RETAINER, IN. VALVE SPRING 4 17 14775ZE2010 SEAT, VALVE SPRING 2 18 19 20 21 22 23 24 90012415000 SCREW, TAPPET ADJ. 4 25 90206250000 NUT, TAPPET ADJ. 4 26 90446357000 WASHER, THRUST (17.2MM) 1 27 28

14110ZJ1801 CAMSHAFT COMP. ............................................... 1 ......... INCLUDES ITEM W/#

14568ZJ1800 SPRING, WEIGHT RETURN 1 14569ZJ1801 HOLDER, DECOMPER PIN 2 14576ZJ1801 PIN A, DECOMPER (7.85) 2

14577ZJ1801 PIN B, DECOMPER (7.95) ..................................... 2 ......... REPLACES 14577ZJ1800

14578ZJ1800 PIN C, DECOMPER (8.05) ..................................... 2 ......... REPLACES 14578ZJ1800

14579ZJ1800 PIN D, DECOMPER (8.15) 2 14580ZJ1800 PIN E, DECOMPER (8.25) 2 14576ZJ1801 PIN A, DECOMPER (7.85) 2 14577ZJ1801 PIN B, DECOMPER (7.95) 2 14578ZJ1801 PIN C, DECOMPER (8.05 2 14579ZJ1801 PIN D, DECOMPER (8.15) 2 14580ZJ1801 PIN E, DECOMPER (8.25) 2

14586ZJ1800 SPRING, DECOMPER PIN HOLDER 2

16512ZJ1000 HOLDER, GOVERNOR WEIGHT 1

16522ZJ1000 PLATE, GOVERNOR WEIGHT HOLDER 1

16523ZJ1000 PIN, GOVERNOR WEIGHT HOLDER 1

16524ZJ1000 PLATE, GOVERNOR (LOWER) 1

16529ZJ1000 PLATE, GOVERNOR SLIDER 1

16531ZJ1003 SLIDER, GOVERNOR 1

90901ZJ1003 BALL, STEEL (18) 6

9451017000 CIRCLIP (OUTER) (17MM) 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 71

FAN COVER ASSY.

HONDA GX610VXD ENGINE — FAN COVER ASSY.

PAGE 72 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE —FAN COVER ASSY.

FAN COVER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 19611ZJ1800ZB COVER, FAN 1 4 19612ZJ1000 PLATE, R SIDE 1 5 19614ZJ1000 PLATE, L SIDE 1 6 19615ZJ1000 HOOD FAN COVER 1 7 19617ZJ4000 COVER, R, SIDE PLATE 1 9 19631ZJ1000 SHROUD, R 1 10 19632ZJ1000 SHROUD, L 1 12 33713GC2000 COLLAR B, TAILLIGHT 6 13 90013883000 BOLT FLANGE (6X12) 8 14 90018ZE1000 BOLT FLANGE (6X23) 2 15 90042ZJ1000 BOLT, STUD (6X75) 4 16 90055ZE1000 SCREW, TAPPING (4X6) 3 17 90104GF6000 BOLT FLANGE (6X20) 2 18 90113GE4000 BOLT FLANGE (6MM) BLACK 2 19 90320MM5000 NUT, SPRING, 6MM 2 20 9405006000 NUT, FLANGE 6MM 4 21 957010600800 BOLT FLANGE (6X8) 2

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 73

CARBURETOR ASSY.

HONDA GX610VXD ENGINE — CARBURETOR ASSY.

PAGE 74 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CARBURETOR ASSY.

CARBURETOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 12357ZJ1000 TUBE, BREATHER 1 2 15772551000 CLIP, BREATHER TUBE 1 3*# 16010ZG8000 GASKET SET 1 4

7 16016ZJ1010 SCREW SET 1 8*# 16024124760 SCREW SET,DRAIN 1 9

11 16100ZJ0892 CARBURETOR ASSY. (BG21E B) .......... 1 ......... INCLUDES ITEMS W/

12 13 14 15 16 17 16211ZJ1000 INSULATOR, CARBURETOR 1 18 16221ZG8000 GASKET, CARBURETOR 2 19 17228ZG8003 GASKET, AIR CLEANER 1

20 17410ZJ1000 ELBOW COMP., AIR CLEANER ............. 1 ......... INCLUDES ITEMS W/++

21++ 19024ZA0000 COLLAR, DISTANCE 2 22 90682959661 CLIP B, CABLE 1 23 24 9500202080 CLIP, TUBE (B8) 1 25 950054546020 BULK HOSE, VAC (4.5X460) 1 26 958010610508 BOLT, FLANGE (6X105) 2 27

16011382004 VALVE SET, FLOAT ................................ 1 ......... REPLACES 16011GK0891

16013ZV4005 FLOAT SET 1

16015ZJ1000 CHAMBER SET, FLOAT ......................... 1 ......... INCLUDES ITEMS W/#

16028ZG8000 SCREW SET 1 16081ZV4650 SCREW-WASHER 4

16148141881 CAP, CHOKE LEVER DUST 1

16151ZJ0020 JET SET (#60) 1

16166ZJ1010 NOZZLE, MAIN ....................................... 1 ......... REPLACES 16166ZJ0000

16178548004 O-RING (5.8X1.9) 1

16200ZJ1003 VALVE ASSY., SOLENOID 1

938920501218 SCREW-WASHER (5X12) 2

99201ZG80880 JET SET, MAIN (#88) 1

99201ZG80820 JET SET, MAIN (#82 HIGH ALTITUDE) 1 99201ZG80850 JET SET, MAIN (#85 HIGH ALTITUDE) 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 75

AIR CLEANER ASSY.

HONDA GX610VXD ENGINE — AIR CLEANER ASSY.

PAGE 76 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — AIR CLEANER ASSY.

AIR CLEANER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 17010ZJ1000 ELEMENT SET, AIR CLEANER ............. 1 ......... INCLUDES ITEMS W/

4 17218ZJ1000 FILTER (OUTER) 1

5 17220ZJ1000 HOUSING COMP., AIR CLEANER ......... 1 ......... INCLUDES ITEMS W/#

6 17231ZJ1000 COVER, AIR CLEANER 1 7 17232ZJ1000 GROMMET, AIR CLEANER 1 8 17237ZJ1000 HOSE, AIR CLEANER 1 9 17251ZJ1000 TUBE, AIR CLEANER CONN. 1

10 17255758000 BAND, AIR CLEANER CONN. TUBE ...... 1 ......... INCLUDES ITEMS W/&

11 17257HB3000 BAND, AIR CLEANER (B) 1 12 90017ZJ1000 BOLT, AIR CLEANER 1 13 90018ZE1000 BOLT, FLANGE (6X23) 3 14# 90120102000 COLLAR, AIR CLEANER HOUSING 4 15& 93500040200A SCREW, PAN (4X20) 1 16 938910501608 SCREW, WASHER 2

17 957010601800 BOLT, FLANGE (6X18) ........................... 1 ......... REPLACES 957010601800

17216ZJ1000 GASKET A, ELEMENT 1 17217ZJ1000 GASKET B, ELEMENT 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 77

MUFFLER ASSY.

HONDA GX610VXD ENGINE — MUFFLER ASSY.

PAGE 78 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 06183ZJ1820 MUFFLER KIT HIGH B ................. 1 ........ INCLUDES ITEMS W/*

2* 18310ZJ1000 MUFFLER COMP. HIGH ..............1 ........ 18310ZJ1003

3* 18321ZJ1000 PROTECTOR,MUFFLER HIGH ....1 ........ 18321ZJ1003

4* 18330ZJ1601 PIPE COMP., EX. HIGH-L 1

5* 18333ZJ1000 STAY, MUFFLER HIGH ................. 1 ........ 18338ZJ1003

6* 18396ZJ1003 BAND ASSY. 1 7* 957010801400 BOLT, FLANGE (8X14) 4 8* 957010802000 BOLT, FLANGE (8X20) 4 9* 957010600800 BOLT, FLANGE (6X8) 6

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 79

FUEL PUMP ASSY.

HONDA GX610VXD ENGINE — FUEL PUMP ASSY.

PAGE 80 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — FUEL PUMP ASSY.

FUEL PUMP ASSY.

NO PART NO PART NAME QTY. REMARKS 1 16700ZJ1003 PUMP ASSY., FUEL 1 2 16711ZJ1800 STAY, FUEL PUMP 1 4 16910ZE8015 STRAINER COMP., FUEL 1 5 19905ZA8701 GROMMET, WIRE 1 6 35806752630 BASE, CLIP 1 7 90617SA0003 CLIP, WIRE HARNESS 1 8 950014511040 BULK HOSE, FUEL (4.5X110) 1 9 950015519540 BULK HOSE, FUEL (5.5X195) 1 10 950015521540 BULK HOSE, FUEL (5.5X215) 1 11 9500202080 CLIP, TUBE (B8) 2 12 950024105008 CLIP, TUBE (10.5MM) 4 13 950033601620 TUBE, VINYL (11X13X160) 1 14 957010600800 BOLT, FLANGE (6X8) 2 15 957010601400 BOLT, FLANGE (6X14) 2

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 81

FLYWHEEL ASSY.

HONDA GX610VXD ENGINE — FLYWHEEL ASSY.

PAGE 82 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — FLYWHEEL ASSY.

FLYWHEEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 19511ZJ1000 FAN, COOLING 1 2 19513ZJ1000 PLATE, COOLING FAN SETTING 1 7 31110ZJ1811 FLYWHEEL COMP. 1 10 90201ZG3000 NUT, FLANGE (20MM) 1 11 90401ZG3000 WASHER (20MM) 1 12 90741ZE2000 KEY, SPECIAL WOODRUFF (25X18) 1 14 957010801600 BOLT, FLANGE (8X16) 3

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 83

IGNITION COIL ASSY.

HONDA GX610VXD ENGINE — IGNITION COIL ASSY.

PAGE 84 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — IGNITION COIL ASSY.

IGNITION COIL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 30500ZJ1013 COIL ASSY., R. IGNITION 1 2 30518ZJ1000 GROMMET, IGNITION WIRE 2 3 30550ZJ1013 COIL ASSY., L. IGNITION 1 4 30700ZJ1003 CAP ASSY., NOISE SUPPRESSER 2 5 31630ZJ1003 COIL ASSY., CHARGE (12V/3A) 1

31630ZJ0880 COIL ASSY., CHARGE (12V/3A) 1

7 31740ZJ1003 DIODE ASSY., ENGINE STOP ............. 1 ............. INCLUDES ITEM W/*

8* 63312ZA7000 GROMMET, TOOL 1 9 90014ZE6000 BOLT, FLANGE (6X35) 2 11 90121952000 BOLT, FLANGE (6X25) 2 12 90658SA0003 CLIP, WIRE HARNESS 1 13 90673GJ5003 CLIP, CORD 1 14 91504750003 CLIP, WIRE HARNESS 1 15 957010600800 BOLT, FLANGE (6X8) 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 85

STARTER MOTOR ASSY.

HONDA GX610VXD ENGINE — STARTER MOTOR ASSY.

PAGE 86 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — STARTER MOTOR ASSY.

STARTER MOTOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 31200ZJ1004 MOTOR ASSY., STARTER 1 2 31243ZJ1800 BRACKET, STARTER MAGNETIC SET. 1

3 32402ZJ1810 CABLE, MAGNET SWITCH ....................... 1 ........ INCLUDES ITEMS W/

6 35850ZJ1811 SWITCH ASSY., STARTER MAGNETIC 1 7 9405006000 NUT, FLANGE (6MM) 2 8 9407006080 NUT, WASHER (6MM) 2 9 9430110120 PIN, DOWEL (10X12) 2 10 957010811000 BOLT, FLANGE (8X10) 2

32411KB9930 COVER A, MAGNETIC SWITCH 1 32411402000 COVER, STARTER. MOTOR TERMINAL 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 87

CONTROL ASSY.

HONDA GX610VXD ENGINE — CONTROL ASSY.

PAGE 88 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

HONDA GX610VXD ENGINE — CONTROL ASSY.

CONTROL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 16263ZE3790 JOINT, ROD .................................. 1 .......... INCLUDES ITEMS W/*

2 165500ZJ1U80 CONTROL ASSY. 1 3 16534ZJ1U80 SPRING, RETURN 1 5 16555ZJ1000 ROD, GOVERNOR 1 6* 16561ZG1000 SPRING, GOVERNOR 1 7 16561ZJ1000 SPRING, GOVERNOR 1 8 16562ZJ1000 SPRING, THROTTLE RETURN 1 9* 16574ZE1000 SPRING, LEVER 1 10* 16575ZH8000 WASHER, CONTROL LEVER 1 11* 16576891000 HOLDER, CABLE 1 12* 16578ZE1000 SPACER, CONTROL LEVER 1 13* 16584883300 SPRING, CONTROL ADJ. 2 16* 16628ZJ1000 ROD, CHOKE KNOB 1 17* 16649ZJ1000 HOLDER, CHOKE KNOB 1 18* 17951ZG1000 KNOB, CHOKE 1 19 90013883000 BOLT, FLANGE (6X12) 2 20 90015ZE3790 BOLT, GOVERNOR ARM 1 22* 90114SA0000 NUT, SELFLOCK (6MM) 1 25* 9350005012OH SCREW, PAN (5X12) 2 26* 93500050160A SCREW, PAN (5X16) 1 27* 9350005025OH SCREW, PAN (5X25) 1 28* 94001050000s NUT, HEX 5MM 1 29 9455006000 NUT,FLANGE 6MM 1

31 16265ZJ1U80 STAY ASSY., AUTO THROTTLE... 1 .......... INCLUDES ITEMS W/#

32% 16534ZJU80 SPRING, RETURN 1

33 16550ZJ1U80 ARM COMP., GOVERNOR ........... 1 ......... INCLUDES ITEMS W/%

34# 16576891000 HOLDER, CABLE 1 35 16584883300 SPRING, CONTROL ADJ. 1 36# 16592ZJ1000 SPRING, CABLE RETURN 1 37# 16594883010 HOLDER, WIRE 1 38# 90605230000 CIRCLIP (5MM) 1 39# 9350004006OH SCREW, PAN (4X6) 1 40 9350005012OH SCREW, PAN (5X12) 1 41#% 9350005030OH SCREW, PAN (5X30) 2 42 9350005016OA SCREW, PAN (5X16) 1 43% 9405006000 NUT, HEX 5MM 1

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 89

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PART S

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

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

MINIMUM ORDER

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

RETURNED GOODS POLICY

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

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

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

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

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

the return.

d. The list must reference the sales

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

e. The list must include the name and

phone number of the person requesting the RMA.

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

4. Freight is at the sender’s expense. All

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any material

8. Such material will be held for 5 working

9. Credit on returned parts will be issued at

10. In cases where an item is accepted for

11. Credit issued will be applied to future

PRICING AND REBATES

parts must be returned freight prepaid to Multiquip’s designated receiving point.

condition, in the original Multiquip package (if any), and with Muiltiquip part numbers clearly marked.

a. Obsolete parts. (If an item is listed

in the parts price book as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

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

c. Any line item with an extended dealer

net price of less than $5.00. d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products. h. Items purchased in kits.

received that is not acceptable.

days from notification, pending instructions. If a reply is not received within 5 days, the material will be returned to the sender at his expense.

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

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

purchases only.

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

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. A part from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

PAGE 90 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

NOTE PAGE

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 91

PARTS AND OPERATION MANUAL PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

ARAR

TS DEPTS DEP

TS DEP

ARAR

TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

SERSER

VICE DEPVICE DEP

SER

VICE DEP

SERSER

VICE DEPVICE DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046

MAINMAIN

MAIN

MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

Manufactured for Multiquip Inc.

DENYO MANUFACTURING, CO., USA

MULTIQUIP INC.

18910 WILMINGTON AVE. CARSON, CALIFORNIA 90746 310-537-3700 800-421-1244 FAX: 310-537-3927

E-mail:mq@multiquip.com • www:multiquip.com

Multiquip SGW-250SS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual