Multiquip SGW-250SS User Manual

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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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

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

SGW-250SS — TRAILER-SPECIFICATIONS

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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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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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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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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

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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

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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.

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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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daoLfOepyTrotcaFrewoP

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spmalyrucrem,spmaltnecseroulF9.0-4.0

tnempiuqenoitacinummoc,secivedcinortcelE0.1

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)

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