MULTIQUIP GAW-135H Leitfaden

OPERATION AND PARTS MANUAL

Revision #1 (06/23/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALLTIMES.

MODEL GAW-135H

PORTABLE

DC WELDER/AC GENERATOR

(GASOLINE ENGINE)

PAGE 2 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 3

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

ON-HAND

WHEN CALLING

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

Carson, CA 90746

FAX:

310-537-3927

Email: [email protected]

Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244

FAX:

800-672-7877

310-537-3700

FAX:

310-637-3284

MAYCO PARTS

800-306-2926

FAX:

800-672-7877

310-537-3700

FAX:

310-637-3284

SERVICE DEPARTMENT

800-478-1244

FAX:

310-537-4259

310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

FAX:

310-631-5032

WARRANTY DEPARTMENT

800-421-1244,

EXT.

279

FAX:

310-537-1173

310-537-3700,

EXT.

279

Multiquip Inc, the MQ logo is a registered trademark of Multiquip Inc. and may not be used, reproduced, or altered without written

permission. All other trademarks are the property of thier respective owners and used with permission.

This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should

remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are

based on the

Denyo GAW-135H Portable Welder/Generator.

Illustrations, descriptions, references and technical data contained in

this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change

specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of this

publication, visit our website at:

www.multiquip.com

PAGE 4 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

TABLE OF CONTENTS

MQ GAW-135H — Portable

AC Welder/Generator

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

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

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

Dimensions ............................................................... 6

Specifications ............................................................ 7

Safety Alert Message Symbols ............................. 8-9

Rules for Safe Operation .................................. 10-12

Operation and Safety Decals ............................ 14-15

General Information ................................................ 16

Load Application ..................................................... 17

Controls and Indicators ..................................... 18-19

Welder/Generator Refueling ................................... 20

Installation ......................................................... 21-22

Pre-Inspection (Engine) .......................................... 23

Initial Start-up (Engine) ........................................... 24

Initial Start-up (Generator/Operation) .............. 25-26

Welder Operation .............................................. 27-28

Maintenance ........................................................... 29

Preparation For Long Term Storage ....................... 30

Wiring Diagram ....................................................... 31

Troubleshooting (Engine) .................................. 32-33

Troubleshooting (Generator) ............................ 34-35

Explanation Of Codes In Remarks Column ............ 36

Suggested Spare Parts ........................................... 37

Component Drawings

Name Plate and Decals .................................... 38-39

Generator Assembly ......................................... 40-41

Control Box Assembly ....................................... 42-43

Pipe Frame and Fuel Tank Assembly ............... 44-45

Muffler Assembly .............................................. 46-47

HONDA GX200VEN2 GASOLINE ENGINE

Cylinder Head Assembly .................................... 48-49

Cylinder Barrel Assembly ................................... 50-51

Crankcase Cover Assembly ............................... 52-53

Crankshaft Assembly ......................................... 54-55

Piston Assembly ................................................. 56-57

Camshaft Assembly ........................................... 58-59

Recoil Starter Assembly..................................... 60-61

Fan Cover Assembly .......................................... 62-63

Carburetor Assembly ......................................... 64-65

Air Cleaner Assembly......................................... 66-67

Muffler Assembly ............................................... 68-69

Fuel Cock Assembly .......................................... 70-71

Flywheel Assembly ............................................ 72-73

Ignition Coil Assembly ........................................ 74-75

Rectifer Assembly .............................................. 76-77

Control Assembly ............................................... 78-79

Labels Assembly ................................................ 80-81

Terms and Conditions Of Sale — Parts .................. 82

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 5

When ordering parts,

please supply the following information:

❒❒

❒Dealer account number

❒❒

❒Dealer name and address

❒❒

❒Shipping address (if different than billing address)

❒❒

❒Return fax number

❒❒

❒Applicable model number

❒❒

❒Quantity, part number and description of each part

❒❒

❒Specify preferred method of shipment:

✓FedEx or UPS Ground

✓FedEx or UPS Second Day or Third Day

✓FedEx or UPS Next Day

✓Federal Express Priority One

✓DHL

✓Tr u c k

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7 (800/672-7877)

MULTIQUIP INC.

18910 WILMINGTON AVENUE

POST OFFICE BOX 6254

CARSON, CALIFORNIA 90749

310-537-3700 • 800-421-1244

FAX: 310-537-3927

E-MAIL: [email protected]

INTERNET:www.multiquip.com

Here’s how to get help...

Please have the model and serial number

on hand when calling.

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

Carson, CA 90746

FAX:

310-537-3927

Email: [email protected]

Internet: www.multiquip.com

PARTS DEPARTMENT

800-427-1244

FAX:

800-672-7877

310-537-3700

FAX:

310-637-3284

MAYCO PARTS

800-306-2926

FAX:

800-672-7877

310-537-3700

FAX:

310-637-3284

SERVICE DEPARTMENT

800-478-1244

FAX:

310-537-4259

310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

FAX:

310-631-5032

WARRANTY DEPARTMENT

800-421-1244,

EXT.

279

FAX:

310-537-1173

310-537-3700,

EXT.

279

PARTS ORDERING PROCEDURES

Note:Unless otherwise indicated by customer, all

orders are treated as “Standard Orders”, and will

ship within 24 hours.We will make every effort to ship

“Air Shipments” the same day that the order is

received, if prior to 2PM west coast time. “Stock

Orders” must be so noted on fax or web forms.

Extra Discounts!

All parts orders which include complete part numbers and

are received by our automated web parts order system, or

by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances

when you order 10 or more

line items via Web or Fax!**

FedEx Ground Service

at no charge for freight

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.

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

NOTE:DISCOUNTS ARE SUBJECT TO CHANGE

PAGE 6 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — DIMENSIONS

Figure 1. Dimensions

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 7

GAW-135H — SPECIFICATIONS

Effects of Altitude and Heat

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient

conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric

reading of 29.92 inches and a temperature of 60 degrees fahrenheit.

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10

°°

fahrenheit above the standard temperature of 60

°°

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PAGE 8 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — SAFETY MESSAGE ALERT SYMBOLS

Safety precautions should be followed at all times when operating

this equipment. Failure to read and understand the Safety

Messages and Operating Instructions could result in injury to

yourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

This Owner's Manual has been

developed to provide instructions for

the safe and efficient operation of the

Multiquip

Model GAW-135H

Portable Generator/Welder.

Refer

to the engine manufacturers

instructions for data relative to its safe

operation.

Before using this generator/welder,

ensure that the operating individual

has read and understands all

instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you

about potential hazards that could injure you or others. The

Safety Messages specifically address the level of exposure to

the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

HAZARD SYMBOLS

Engine exhaust gases contain poisonous

carbon monoxide. This gas is colorless and

odorless, and can cause death if inhaled.

NEVER operate this equipment in a confined

area or enclosed structure that does not

provide ample free flow air.

Potential hazards associated with the

Multiquip GAW-135H

Portable

Generator/Welder

operation will be referenced with

Hazard Symbols which appear throughout this manual, and will

be referenced in conjunction with

Safety Message Alert

Symbols

GASOLINE is extremely flammable, and its

vapors can cause an explosion if ignited. DO

NOT start the engine near spilled fuel or

combustible fluids. DO NOT fill the fuel tank

while the engine is running or hot. DO NOT

overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or

sparks from the ignition system. Store fuel in

approved containers, in well-ventilated areas

and away from sparks and flames. NEVER

Explosive Fuel

Lethal Exhaust Gases

Burn Hazards

Engine components can generate extreme heat.

To prevent burns, DO NOT touch these areas

while the engine is running or immediately after

operations. Never operate the engine with heat

shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep fingers, hands, hair

and clothing away from all moving parts to

prevent injury.

NOTE

You WILL be

KILLED

SERIOUSLY INJURED

if you DO NOT follow these directions.

You CAN be KILLED or

SERIOUSLY INJURED

you DO NOT follow these directions.

You CAN be

INJURED

if you DO NOT follow

these directions.

CAUTICAUTI

CAUTION

DANGERDANGER

DANGER

WARNINGWARNING

WARNING

GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 9

GAW-135H — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF switch

in the OFF position when the generator is

not in use.

Respiratory Hazard

ALWAYS wear approved respiratory

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual

to help prevent damage to your generator, other property, or the

surrounding environment.

ALWAYS wear approved eye and hearing

protection.

Sight and Hearing hazard

This generator, other property, or

the surrounding environment could

be damaged if you do not follow

instructions.

NOTE

PAGE 10 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)

GAW-135H — RULES FOR SAFE OPERATION

■

ALWAYS refuel in a well-ventilated area, away from sparks

and open flames.

■

ALWAYS use extreme caution when working with flammable

liquids. When refueling, stop the engine and allow it to cool.

DO NOT smoke around or near the machine. Fire or explosion

could result from fuel vapors, or if fuel is spilled on a hot

engine.

■

NEVER operate the generator/welder in an

explosive

atmosphere

or near combustible

materials. An explosion or fire could result

causing severe

bodily harm or even

death.

■

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

■

Refer to the

Honda Engine Owner's Manual

for engine

technical questions or information.

■

NEVER use accessories or attachments, which are not

recommended by

Multiquip

for this equipment. Damage to

the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident

due to equipment modifications.

■

NEVER touch the hot exhaust manifold,

muffler or cylinder. Allow these parts to

■

The engine of this pump 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 or engine

and may cause injury to

people and property.

Remember the generator's

engine gives off DEADLY

gases.

■

HighTemperatures – Allow the engine to cool before adding

fuel or performing service and maintenance functions. Contact

with

hot

components can cause serious burns.

GENERAL SAFETY

■

DO NOT operate or service this equipment before

reading this entire manual.

■

This equipment should not be operated by

persons under 18 years of age.

■

NEVER operate this equipment without proper

protective clothing, shatterproof glasses, steel-

toed boots and other protective devices required

by the job.

■

NEVER operate this equipment when not feeling

well due to fatigue, illness or taking of any

medication.

■

NEVER operate this equipment under the

influence or drugs or alcohol.

■

Whenever necessary, replace nameplate, operation and safety

decals when they become difficult read.

■

ALWAYS check the generator for loosened threads or bolts

before starting.

■

ALWAYS wear proper respiratory (mask) hearing and eye

protection equipment when operating the generator/welder.

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.

DANGER:

The following safety guidelines should always be used when

operating the

generator/welder

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