MULTIQUIP GAW-135H, Operation And Parts Manual

Page 1: ...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: ...PAGE 2 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04...

Page 3: ...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 ThismanualMUSTaccompanythee...

Page 4: ...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 Genera...

Page 5: ...0 537 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...

Page 6: ...PAGE 6 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H DIMENSIONS Figure 1 Dimensions...

Page 7: ...o r t c e l E e l b a c i l p p A 2 3 5 2 3 3 r o t a r e n e G C A t u p t u O d e t a R A V k 5 1 e g a t l o V d e t a R C A V 0 2 1 t n e r r u C d e t a R s p m A 5 2 1 e s a h P e s a h p e l g...

Page 8: ...de 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...

Page 9: ...piratory 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 proper...

Page 10: ...ricted 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 HighTemp...

Page 11: ...n death Disconnection of any of these devices will void all warranties ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using generator ALWAYS ma...

Page 12: ...site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency DANGER DANGER DANGER DANGER DANGER NEVER insert an...

Page 13: ...GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 1 06 23 04 PAGE 13 NOTE PAGE...

Page 14: ...35H portable generator welder is equipped with a number of safety decals see below and on preceeding page These decals are provided for operator safety and maintenance information The illustration bel...

Page 15: ...GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 1 06 23 04 PAGE 15 GAW 135H OPERATION AND SAFETY DECALS...

Page 16: ...FCI 5 20R 120V 20 Amp z One main 2 pole 15 Amp Circuit Breaker z Idle Control Switch z WeldingTerminal Lugs z GroundTerminal Circuit Breaker To protect the generator from an overload a 2 pole 15 amp c...

Page 17: ...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 distanceinlengthandamperagesothatt...

Page 18: ...PAGE 18 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H CONTROLS AND INDICATORS Figure 2 Generator Controls and Components...

Page 19: ...onnected 6 GFCI Receptacle This receptacle will provide 120V at all times 7 Ground This ground connection point should be connect to a good earth ground ground rod 8 Engine Oil Filler Cap Remove this...

Page 20: ...toppedandhashadanopportunity tocooldown Intheeventofafuelspill DONOT attempt to start the engine until the fuel residue has been completely wiped up and the area surrounding the engineisdry Ifgenerato...

Page 21: ...ns for venting the engine exhaust to the outside of the building Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH grou...

Page 22: ...sed to connect the generator to a suitable ground The ground cable should be 8 size wire minimum At the generator connect the terminal of the ground cable between the lock washer and the nut Figure 4...

Page 23: ...7 to determin if the fuel level is low If fuel is low replenish with clean unleaded fuel Engine Oil Check 1 Tochecktheengineoillevel placethegeneratoronsecure level ground with the engine stopped 2 Re...

Page 24: ...0 Choke Lever 3 Place the choke lever Figure 10 in the OPEN position if starting a warm engine or the temperature is warm 4 Place the engine ON OFF switch Figure 11 in the ON position 5 Grasp the star...

Page 25: ...Figure 16 120VAC GFCI Receptacle NOTE Placing the idle control switch in theRUNposition Figure14 allows the enginetooperateatamaximum speed of about 3600 RPM s When the idle control switch is placed i...

Page 26: ...et the engine run at idle for 3 5 minutes with the idle control switch in the ON position Up 3 Place the engine ON OFF Figure 24 in the OFF position 4 Place the engine fuel valve lever Figure 25 to th...

Page 27: ...sed on a maximum voltage drop of 4 volts Figure 23 Welding Cable BareWires Figure 24 Welding Cable Terminal Connector s e i t i r a l o P d n a s e l b a C g n i d l e W 5 e l b a T y t i r a l o P d...

Page 28: ...e of the welding current is listed in Table 8 Select the desired welding current according to the application G N I T A R E L C Y C Y T U D 7 E L B A T A t n e r r u C g n i d l e W 0 4 0 6 0 8 0 0 1...

Page 29: ...cleaner element std or heavy duty types and wash in kerosene or liquid detergent and hot water Wrap foam element in a cloth and squeeze dry Wipe heavy duty paper element dry with toweling Saturate ele...

Page 30: ...ly drain the oil from the crankcase and refill with fresh oil z Remove the spark plug pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil z Slowly rotate the engine a...

Page 31: ...GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 1 06 23 04 PAGE 31 GAW 135H WIRING DIAGRAM...

Page 32: ...k o r b t i n u n o i t i n g i r o t s i n a r T d e l u o f f i g u l p k r a p s e c a l p e R n e k o r b h c t i w s p o t S t r a t S l i o o N d e r i u q e r s a l i o d d A s k n i l b p m a...

Page 33: ...a p s g n o r W g u l p k r a p s e p y t d e t s e g g u s s e r u t c a f u n a m h t i w g u l p k r a p s e c a l p e R y l s u o i n i t n o c s i r o l o c t s u a h x E E T I H W g n o r w s i...

Page 34: ...3 l a m r o n d e e p s e l d i M P R 0 0 5 2 d e d a o l n u g n i r i w l a n r e t n i x o b l o r t n o C n o i t c n u f l a m g n i r i w x o b l o r t n o c k c e h C n o n r u t t o n l l i w...

Page 35: ...p e r r o k c e h C e c i v e d l o r t n o c e l d i e v i t c e f e D e c i v e d l o r t n o c e l d i e c a l p e r r o k c e h C d i o n e l o s e v i t c e f e D e c i v e d l o r t n o c e l d...

Page 36: ...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 N...

Page 37: ...W 135H SUGGESTED SPARE PARTS MQ GAW 135HWELDER GENERATORWITH HONDA GX200VEN2 GASOLINE ENGINE 1 to 3 Units Qty P N Description 1 9924800014 CAP FUELTANK 1 9924800004 FILTER FUEL TANK 3 17211ZB2000 ELEM...

Page 38: ...PAGE 38 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H NAMEPLATE AND DECALS NAMEPLATE AND DECALS...

Page 39: ...S 1238A 6 0820610404 DECAL WARNING TRANSFER SWITCH 1 S 3627 7 8700611804 DECAL WARNING DANGEROUS GAS 1 S 4984 8 9522100204 DECAL PROPOSITION 65 1 REPLACES D92210020 9 7900636004 DECAL CAUTION OPERATE...

Page 40: ...PAGE 40 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H GENERATOR ASSY GENERATOR ASSY...

Page 41: ...2 0110000913 ROTAR ASSY 1 2 0135000002 ARAMATURE ASSY 1 3 0155100003 END BRACKET 1 4 0012808020 HEX HEAD BOLT 4 5 0012308045 HEX HEAD BOLT 1 6 0012108070 HEX HEAD BOLT 1 7 0040008000 WASHER LOCK 1 8 0...

Page 42: ...PAGE 42 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H CONTROL BOX CONTROL BOX ASSY...

Page 43: ...ONDENSER 250V 1 KMH250LGSN 1500MB 21 0028603006 MACHINE SCREW 2 22 0260600104 RUBBER SEAT 1 23 0601826178 GROMMET 2 24 0237200003 BRACKET OUTPUT TERMINAL 1 25 0237100004 COVER OUTPUTTERMINAL 1 26 0237...

Page 44: ...PAGE 44 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H PIPE FRAME AND FUELTANK ASSY PIPE FRAME AND FUEL TANK ASSY...

Page 45: ...0002 PIPE FRAME 1 2 0416400114 GENERATORGUARD 1 3 0016906016 HEX HEAD BOLT 3 4 0454100003 SIDE GUARD 1 5 0016906016 HEX HEAD BOLT 1 6 0019206016 HEX HEAD BOLT 2 7 0040506000 TOOTHEDWASHER 2 8 03630000...

Page 46: ...PAGE 46 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GAW 135H MUFFLER ASSY MUFFLER ASSY...

Page 47: ...ER STAY 1 7 0016906016 HEX HEAD BOLT 2 8 0016908025 HEX HEAD BOLT 1 9 0602302006 MUFFLER COVER OUTER 1 10 0602302007 MUFFLER COVER OUTER 1 11 0330300022 DUCT MUFFLER COVER 1 12 0330300124 DUCT BRACKET...

Page 48: ...PAGE 48 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CYLINDER HEAD ASSY CYLINDER HEAD ASSY...

Page 49: ...HEAD COMP CYLINDER 1 INCLUDES ITEMS W 4 12216ZE5300 CLIP VALVE GUIDE 1 5 12251ZL0003 GASKET 1 6 12310ZE1020 COVER COMP HEAD 1 7 12391ZE1000 PACKING HEAD COVER 1 8 15721883030 TUBE BREATHER 1 9 9001388...

Page 50: ...PAGE 50 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CYLINDER BARREL ASSY CYLINDER BARREL ASSY...

Page 51: ...0 SLIDER GOVERNOR 1 5 16541ZE1000 SHAFT GOVERNOR ARM 1 6 90131ZE1000 BOLT DRAIN PLUG 2 7 90451ZE1000 WASHER THRUST 6MM 1 8 90601ZE1000 WASHER DRAIN PLUG 10 2MM 2 9 90602ZE1000 CLIP GOVERNOR HOLDER 1 1...

Page 52: ...PAGE 52 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CRANKCASE COVER ASSY CRANKCASE COVER ASSY...

Page 53: ...1633 COVER ASSY CRANKCASE 1 INCLUDES ITEMS W 4 11381ZL0000 PACKING CASE COVER 1 5 15600ZE1003 CAP ASSY OIL FILLER 1 INCLUDES ITEMS W 6 15600ZG4003 CAP ASSY OIL FILLER 1 INCLUDES ITEMS W 7 15625ZE1003...

Page 54: ...PAGE 54 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CRANKSHAFT ASSY CRANKSHAFT ASSY...

Page 55: ...GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 1 06 23 04 PAGE 55 GX 200VEN2 CRANKSHAFT ASSY CRANKSHAFT ASSY NO PART NO PART NAME QTY REMARKS 13 13310ZL0A00 CRANKSHAFT COMP 1...

Page 56: ...PAGE 56 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 PISTON ASSY PISTON ASSY...

Page 57: ...TEKOKU 1 1 13011ZL0003 RING SET PISTON 0 25 TEKOKU 1 1 13012ZL0003 RING SET PISTON 0 50 TEKOKU 1 1 13013ZL0003 RING SET PISTON 0 75 TEKOKU 1 2 13101ZL0010 PISTON STD 1 2 13102ZL0010 PISTON 0 25 1 2 1...

Page 58: ...PAGE 58 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CAMSHAFT ASSY CAMSHAFT ASSY...

Page 59: ...ROCKER 2 6 14431ZE1000 ARM VALVE ROCKER 2 7 14451ZE1013 PIVOT ROCKE54 ARM 2 8 14568ZE1000 SPRING WEIGHT RETURN 1 9 14711ZF1000 VALVE IN 1 10 14721ZF1000 VALVE EX 1 11 14731ZL0000 LIFTER VALVE 2 12 147...

Page 60: ...PAGE 60 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 RECOIL STARTER ASSY RECOIL STARTER ASSY...

Page 61: ...ECOIL NH1 BLACK 1 INCLUDES ITEMS W 2 28405ZL0000ZA SPACER MOUNTING NH1 BLACK 1 3 28410ZH8003ZB CASE COMP NH1 BLACK 1 4 28420ZH8013 REEL NATURAL 1 5 28422ZH8013 RATCHET 2 6 28433ZH8003 GUIDE 1 7 28441Z...

Page 62: ...PAGE 62 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 FAN COVER ASSY FAN COVER ASSY...

Page 63: ...20 PLATE COMP SIDE ALERT LAMP 1 5 19620ZL0V30 SHROUD ASSY UPPER 1 INCLUDES ITEMS W 6 196740ZL0V30 SHROUD COMP LOWER 1 8 36100ZH7003 SWITCH ASSY ENGINE STOP 1 9 36101ZE1010 CORD STOP SWITCH 370MM 1 10...

Page 64: ...PAGE 64 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CARBURETOR ASSY CARBURETOR ASSY...

Page 65: ...ITEMS W 8 16044ZE0005 CHOKE SET 1 9 16100ZL0V31 CARBURETOR ASSY BE74A A B 1 INCLUDES ITEMS W 10 16124ZE0005 SCREW THROTTLE STOP 1 11 16166ZL0000 NOZZLE MAIN 1 12 16211ZL0000 INSULATOR 1 13 16212ZH880...

Page 66: ...PAGE 66 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 AIR CLEANER ASSY AIR CLEANER ASSY...

Page 67: ...ASSY AIR CLEANER ASSY NO PART NO PART NAME QTY REMARKS 1 17211ZB2000 ELEMENT 1 2 17212ZB2000 SEPARATOR 1 3 17220ZB2000 CASE COMP 1 4 17222ZL0V30 STAY 1 5 17231ZB2000 COVER 1 6 17252ZB2000 SEAL 1 7 901...

Page 68: ...PAGE 68 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 MUFFLER ASSY MUFFLER ASSY...

Page 69: ...1 18310ZB3C00 MUFFLER COMP 1 3 18355898630 ARRESTER SPARK 1 4 18381ZE1800 GASKET 1 5 92101080200A BOLT HEX 8X20 2 6 94001080000S NUT HEX 8MM 2 7 18310ZB2000 PROTECTOR MUFFLER OUTER 1 8 18325ZH8T90 PR...

Page 70: ...PAGE 70 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 FUEL COCK ASSY FUEL COCK ASSY...

Page 71: ...T NO PART NAME QTY REMARKS 1 16080898631 PACKING SET COCK 1 2 16081471831 CUP FUEL STRAINER 1 4 16950898632 FUEL COCK ASSY 1 5 16952883005 SCREEN SET 1 17 90854ZB3000 RUBBER 9X15X20 1 21 950014514040...

Page 72: ...PAGE 72 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 FLYWHEEL ASSY FLYWHEEL ASSY...

Page 73: ...04 PAGE 73 GX 200VEN2 FLYWHEEL ASSY FLYWHEEL ASSY NO PART NO PART NAME QTY REMARKS 1 13331357000 KEY SPECIAL WOODRUFF 25 X18 1 2 19511ZE1000 FAN COOLING 1 4 28451ZL0000 PULLEY STARTER 1 5 31110ZL0811...

Page 74: ...PAGE 74 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 IGNITION COIL ASSY GX 200VEN2 IGNITION COIL ASSY...

Page 75: ...MARKS 1 30500ZE1033 IGNITION COIL ASSY 1 2 30600ZE1013 TERMINAL ASSY HIGH TENSION 1 NICHIWAY EZ 3 31630ZL0V31 COIL ASSY CHARGE 1 4 31511ZE1000 CLAMAPER CORD 1 5 31512ZE1000 GROMMET CORD 1 7 9001588300...

Page 76: ...PAGE 76 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 CONTROL ASSY CONTROL ASSY...

Page 77: ...PART NO PART NAME QTY REMARKS 1 30500ZE1033 IGNITION COIL ASSY 1 2 16550ZL0V30 ARM COMP GOVERNOR 1 4 16555ZL0V30 ROD GOVERNOR 1 5 16559ZL0V30 RETURN SPRING COVENOR SUB ARM 1 6 16561ZL0V30 SPRING GOVER...

Page 78: ...PAGE 78 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 RECTIFER ASSY RECTIFER ASSY...

Page 79: ...00KAE871 CONDENSER UNIT 1 4 31750ZL0V31 RECTIFIER ASSY REGULATOR 1 5 32110ZL0V30 SUB HARNESS ASSY 1 6 36330ZL0V31 SOLENOID ASSY 1 INCLUDES ITEMS W 7 90683SA0003 CLIP WIRE HARNESS 25MM 2 8 93500050080A...

Page 80: ...PAGE 80 GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 0 06 23 04 GX 200VEN2 LABEL ASSY LABEL ASSY...

Page 81: ...ATOR OPERATION MANUAL REV 1 06 23 04 PAGE 81 GX 200VEN2 LABEL ASSY LABEL ASSY NO PART NO PART NAME QTY REMARKS 3 87521ZL0000 EMBLEM 1 14 87528ZB2630 MARK CHOKE 1 15 87533ZC0630 MARK AIR CLEANER 1 27 8...

Page 82: ...omponents f Paint chemicals andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 Thesenderwillbenotifiedofanymaterial receivedthatisnotacceptable 8 Suchmaterialwillbeheldforfiveworking days...

Page 83: ...GAW 135H DC WELDER AC GENERATOR OPERATION MANUAL REV 1 06 23 04 PAGE 83 NOTE PAGE...

Page 84: ...72 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 TECHNICALASSISTANCE 800 478...