Multiquip Portable Generator GAW 135H User Manual
OPERATION AND PARTS MANUAL  
MODEL GAW-135H  
PORTABLE  
DC WELDER/AC GENERATOR  
(GASOLINE ENGINE)  
Revision #1 (06/23/04)  
THIS MANUAL MUST ACCOMPANY  
THE EQUIPMENT AT ALLTIMES.  
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HERE'S HOW TO GET HELP  
PLEASE HAVETHE MODEL AND SERIAL  
NUMBER ON-HANDWHEN CALLING  
MULTIQUIP CORPORATE OFFICE  
18910 Wilmington Ave.  
Carson, CA 90746  
800-421-1244  
FAX:310-537-3927  
Email: mq@multiquip.com  
Internet:www.multiquip.com  
PARTS DEPARTMENT  
800-427-1244  
310-537-3700  
FAX:800-672-7877  
FAX:310-637-3284  
MAYCO PARTS  
800-306-2926  
310-537-3700  
FAX:800-672-7877  
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  
FAX:310-537-1173  
WARRANTYDEPARTMENT  
800-421-1244,EXT.279  
310-537-3700,EXT.279  
© COPYRIGHT 2004, MULTIQUIP INC.  
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 PortableWelder/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  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 3  
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TABLE OF CONTENTS  
HONDA GX200VEN2 GASOLINE ENGINE  
MQ GAW-135H — Portable  
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  
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  
Terms and Conditions Of Sale — Parts .................. 82  
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  
W
PAGE 4 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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PARTS ORDERING PROCEDURES  
When ordering parts,  
please supply the following information:  
❒
❒
❒
❒
❒
❒
❒
Dealeraccountnumber  
Dealernameandaddress  
Shipping address (if different than billing address)  
Returnfaxnumber  
Applicable model number  
Quantity,part number and description of each part  
Specifypreferredmethodofshipment:  
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground  
FedEx or UPS Second Day or Third Day  
FedEx or UPS Next Day  
Federal Express Priority One  
DHL  
Note:Unlessotherwiseindicatedbycustomer, 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.  
Truck  
Place Your Parts Order Via Web or Fax  
For Even More Savings!  
Here’s how to get help...  
Please have the model and serial number  
on hand when calling.  
(Domestic USA Dealers Only)  
MULTIQUIP CORPORATE OFFICE  
18910 Wilmington Ave.  
Carson, CA 90746  
Email: mq@multiquip.com  
Internet: www.multiquip.com  
800-421-1244  
FAX: 310-537-3927  
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  
via  
Standard  
orders  
Stock orders  
PARTS DEPARTMENT  
800-427-1244  
310-537-3700  
MAYCO PARTS  
800-306-2926  
310-537-3700  
SERVICE DEPARTMENT  
800-478-1244  
310-537-3700  
TECHNICAL ASSISTANCE  
800-478-1244  
WARRANTY DEPARTMENT  
800-421-1244, EXT. 279  
310-537-3700, EXT. 279  
($750 list and above)  
FAX: 800-672-7877  
FAX: 310-637-3284  
Fax  
3%  
5%  
10%  
10%  
Web  
FAX: 800-672-7877  
FAX: 310-637-3284  
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.  
FAX: 310-537-4259  
FAX: 310-631-5032  
FAX: 310-537-1173  
**Common nuts, bolts and washers (all items under $1.00  
list price) do not count towards the 10+ line items.  
NOTE:DISCOUNTSARESUBJECTTOCHANGE  
MULTIQUIP INC.  
Direct TOLL-FREE access  
to our Parts Department:  
18910WILMINGTON AVENUE  
POST OFFICE BOX 6254  
CARSON, CALIFORNIA 90749  
310-537-3700 • 800-421-1244  
FAX:310-537-3927  
Toll-free nationwide — 800-427-1244  
E-MAIL:mq@multiquip.com  
INTERNET:www.multiquip.com  
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 5  
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GAW-135H — DIMENSIONS  
Figure 1. Dimensions  
PAGE 6 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — SPECIFICATIONS  
Table 1. Specifications (Generator/Welder)  
Model  
GAW-135H  
Rated Output  
Max. Current  
Rated Current  
Rated Voltage  
Duty Cycle  
3.28 kW  
135 Amps  
130 Amps  
25.2 VAC  
DC ARC  
WELDER  
40%  
Rated Speed  
Current Range (Selectable)  
Applicable Electrode Size  
Rated Output  
Rated Voltage  
Rated Current  
Phase  
3600 RPM  
40, 60, 80, 115 and 135 Amps  
3/32" ~ 5/32"  
1.5 kVA  
120 VAC  
12.5 Amps  
Single-phase  
60 Hz  
AC Generator  
Frequency  
Power Factor  
1
Dimensions  
(L x W x H)  
21.9 x 17.7 X 18.9 in.  
(555 X 450 X 480 mm)  
Dry Net Weight  
114.6 lbs (52 Kg.)  
Table 2. Specifications (Engine)  
Model  
HONDA GX200VEN2  
Air-cooled 4 stroke, Single  
Cylinder, OHV, Horizontal Shaft  
Gasoline Engine  
Type  
2.68 in. X 2.13in.  
(68 mm x 54 mm)  
Bore X Stroke  
Displacement  
Max Output  
12.0 cu. in. (196 cc)  
5.5 H.P./3600 rpm  
Engine  
Fuel Tank Capacity  
Fuel  
1.85 U.S. Gallons (7.0 Liters)  
Unleaded Automobile Gasoline  
0.63 qt. (0.6 liter)  
Lube Oil Capacity  
Speed Control  
Method  
Centrifugal Fly-weight Type  
Recoil Start  
Starting Method  
Dimensions  
(L x W x H)  
12.3 x 14.8 X 13.2 in.  
(313 X 376 X 335 mm)  
Dry Net Weight  
35.3 lbs (16 Kg.)  
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° F  
fahrenheit above the standard temperature of 60° F  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 7  
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GAW-135H — SAFETY MESSAGE ALERT SYMBOLS  
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!  
HAZARD 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.  
Lethal Exhaust Gases  
Engine exhaust gases contain poisonous  
This Owner's Manual has been  
developed to provide instructions for  
the safe and efficient operation of the  
Multiquip Model GAW-135H  
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.  
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.  
Explosive Fuel  
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  
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.  
DANGER  
Burn Hazards  
You WILL be KILLED or SERIOUSLY INJURED  
if you DO NOT follow these directions.  
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.  
WARNING  
You CAN be KILLED or SERIOUSLY INJURED if  
you DO NOT follow these directions.  
Rotating Parts  
CAUTION  
You CAN be INJURED if you DO NOT follow  
NEVER operate equipment with covers, or  
guards removed. Keep fingers, hands, hair  
and clothing away from all moving parts to  
prevent injury.  
these directions.  
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.  
PAGE 8 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — SAFETY MESSAGE ALERT SYMBOLS  
Accidental Starting  
Respiratory Hazard  
ALWAYS place the engine ON/OFF switch  
in the OFF position when the generator is  
not in use.  
ALWAYS wear approved respiratory  
protection.  
Equipment Damage Messages  
Sight and Hearing hazard  
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.  
This generator, other property, or  
the surrounding environment could  
be damaged if you do not follow  
instructions.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 9  
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GAW-135H — RULES FOR SAFE OPERATION  
■
NEVER touch the hot exhaust manifold,  
muffler or cylinder.Allow these parts to  
DANGER:  
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 generator/welder  
■
■
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  
readingthisentiremanual.  
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  
■
■
This equipment should not be operated by  
persons under 18 years of age.  
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.  
NEVER operate this equipment without proper  
protective clothing, shatterproof glasses, steel-  
toed boots and other protective devices required  
by the job.  
Remember the generator's  
engine gives off DEADLY  
gases.  
■
■
NEVER operate this equipment when not feeling  
well due to fatigue, illness or taking of any  
medication.  
■
■
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 this equipment under the  
influence or drugs or alcohol.  
■
NEVER operate the generator/welder in an  
explosiveatmosphere ornear combustible  
materials. An explosion or fire could result  
causing severe bodily harm or even  
death.  
■
■
■
Whenever necessary, replace nameplate, operation and safety  
decals when they become difficult read.  
ALWAYS check the generator for loosened threads or bolts  
before starting.  
■
■
Topping-off to filler port is dangerous, as it tends to spill fuel.  
ALWAYS wear proper respiratory (mask) hearing and eye  
protection equipment when operating the generator/welder.  
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.  
PAGE 10 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — RULES FOR SAFE OPERATION  
■
■
■
■
■
NEVER run engine without air cleaner.Severe engine damage  
■
ALWAYS make sure that electrical circuits are properly  
grounded per the National Electrical Code (NEC) and local  
codes before operating generator.Severe injury or death! by  
electrocution can result from operating an ungrounded  
generator.  
may occur.  
ALWAYS read, understand, and follow procedures in  
Operator’s Manual before attempting to operate equipment.  
ALWAYS be sure the operator is familiar with proper safety  
precautions and operation techniques before using generator.  
■
■
ALWAYS store equipment properly when it is not being used.  
Equipment should be stored in a clean, dry location out of the  
reach of children and un-authorized personnel.  
NEVER leave the generator unattended, turn off engine when  
unattended.  
ALWAYS read, understand, and follow  
procedures in Operator’s Manual before  
attempting to operate equipment.  
Unauthorized equipment modifications will void all  
warranties.  
■
■
ALWAYS ensure generator is on level ground before use.  
WELDING SAFETY  
Become familiar with the components of the generator before  
operating.  
■
ALWAYS remove any flammable materials in the vacinity of  
the generator/welder where flying sparks may come in contact.  
The possibility exists of a fire or an explosion which can  
damage the equipment and thus cause bodily harm even  
death!  
■
■
ALWAYS replace any worn or damaged warning decals.  
ALWAYS make sure generator is properly grounded to a  
suitable earth ground (GROUND ROD).  
■
■
NEVER use gas piping as an electrical ground.  
■
■
■
High current generated from the welder can affect some  
pacemakers. CAUTION, personnel who wear pacemakers  
should consult their doctor before operating the welder.  
DO NOT place hands or fingers inside generator engine  
compartment when engine is running.  
■
■
NEVER let power cables or cords lay in water.  
When welding or watching, use a hand shield  
or welding helmet fitted with the proper shade  
filter.  
NEVER stand in water while AC power from the generator  
is being transfer to a load.  
ALWAYS wear safety glasses with side shields or face shield  
■
■
■
■
NEVER use a defective or frayed power cable. Check the  
cable for cuts in the insulation.  
Remember flying pieces of metal or dirt can injury eyes.  
Maintenance Safety  
NEVER use a extension cord that is frayed or damaged where  
the insulation has been cut.  
■
NEVER lubricate components or attempt  
service on a running machine.  
ALWAYS make certain that proper extension cord has been  
selected for the job See Table 3.  
■
ALWAYS allow the machine a proper amount  
of time to cool before servicing.  
The electrical voltage required to operate the generator can  
cause severe injury or even death through physical contact  
with live circuits. Turn all circuit breakers OFF before  
performing maintenance on the generator.  
■
■
Keep the machinery in proper running condition.  
Fix damage to the machine immediately and always replace  
broken parts, or missing decals.  
■
■
High Temperatures – Always stop engine and allow the  
engine to cool before adding fuel, oil or performing service  
and maintenance functions. Contact with hot components can  
cause serious burns.  
■
■
■
■
Dispose of hazardous waste properly.Examples of potentially  
hazardous waste are used motor oil, fuel and fuel filters.  
DO NOT use food or plastic containers to dispose of  
hazardous waste.  
NEVER disconnect any "emergency or safety devices".  
These devices are intended for operator safety. Disconnection  
of these devices can cause severe injury, bodily harm or even  
death! Disconnection of any of these devices will void all  
warranties.  
DO NOT pour waste, oil or fuel directly onto the ground,  
down a drain or into any water source.  
Removing the engine oil drain plug while  
the engine is hot will result in hot oil to gush  
out of the oil drain plug, therefore causing  
severescaldingtoanypersonsinthegeneral  
area of the generator.  
■
ALWAYS be sure the operator is familiar with proper safety  
precautions and operations techniques before using generator.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 11  
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GAW-135H — RULES FOR SAFE OPERATION  
DANGER  
:
DANGER  
Never use damaged or worn cables  
when connecting equipment to the  
generator.Make sure power connecting  
cables are securely connected to the  
generator’s output receptacles, incorrect connections  
may cause damage to the generator and electrical shock.  
■
Backfeed to a utility system can cause electrocution and or  
property damage. NEVER connect the generator to a  
building's electrical system without a transfer switch or other  
approved device. All installations should be performed by a  
licensed electrician in accordance with all applicable laws  
and electrical codes.Failure to do so could result in electrical  
shock or burn causing serious injury or even death!  
DANGER  
NEVER grab or touch a live power cord  
with wet hands, the possibility exist of  
electrical shock, electrocution, and  
even death!  
Emergencies  
■
ALWAYS know the location of the  
nearest fire extinguisher.  
■
■
ALWAYS know the location of the nearest  
first aid kit.  
DANGER  
In emergencies always know the location of the  
nearest phone or keep a phone on the job 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.  
NEVER insert any objects into the output receptacles  
during operation. This is extremely dangerous. ALWAYS  
turn-off the generator and place all circuit breakers in  
the “OFF” position when contact with  
the output receptacles is required.  
There exist the possibility of  
electrocution, electrical shock or  
burn, which can cause severe  
bodily harm or even death!  
PAGE 12 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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NOTE PAGE  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 13  
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GAW-135H — OPERATION AND SAFETY DECALS  
Machine Safety Decals  
The MQ GAW-135H 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 below shows these decals as they  
appear on the machine.Should any of these decals become unreadable, replacements can be obtained from your dealer.  
PAGE 14 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — OPERATION AND SAFETY DECALS  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 15  
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GAW-135H — GENERAL INFORMATION  
Excitation System  
GAW-135H Familarization  
The MQ generator/welder uses a magnet attached to a  
flywheel to produce AC voltage from a lamp coil beneath  
the flywheel. As the magnet passes the coil it produces  
approximately 19-22 AC volts.  
General Inspection Prior to Operation  
This generator/welder 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 become disloged in transit.  
This voltage (19-22 VAC) is then sent to the control box that  
contains three rectifying diodes:  
The MQ Model GAW-135H generator/welder has been  
designed as a portable lightweight power source for 60 Hz  
(single-phase) vibrators, lighting facilities, power tools,  
submersible pumps and other industrial and construction  
machinery.  
z
z
z
Excitation (diode 1)  
Battery (diode 2)  
Slow Down (diode 3)  
The AC voltage will pass through the excitation diode that  
converts the voltage to DC power.  
This generator/welder is powered by a Honda GX200VEN2,  
5.5 HP, air-cooled gasoline engine. The alternator, a  
brushless revolving-field type, is permanently aligned to the  
engine through rigid coupling.  
This DC power is then sent to the excitation windings housed  
within the main windings commonly called the "stator".  
This voltage is then transferred into the rotor through  
induction.The rotor contains two diodes within it which rectify  
the DC voltage and send it out through the main windings,  
as AC voltage.  
The generator is mounted on rubber vibration isolators that  
have a steel base backplate which is attached to the  
protective steel pipe carrying frame.The protective carrying  
frame is made of steel tubing and fully wraps around the  
generator to protect against damage.  
Engine  
This portable generator is supplied with a electrical control  
The four-cycle air-cooled Honda gasoline engine is designed  
to meet every performance requirement of this generator.  
Reference Table 1, for engine specifications.  
panel. The control panel includes items as listed below.  
Control Panel  
Figure 2 shows the basic controls and indicators for the  
MQ GAW-135H generator/welder.  
The generator control panel has the following componets:  
z
(1) NEMA Duplex Receptacle (GFCI) 5-20R (120V,  
20 Amp)  
z
z
z
z
One main 2-pole,15 Amp Circuit Breaker.  
Idle Control Switch  
In keeping with Multiquip's  
policy of constantly improving  
its products, the specifications  
quoted herein are subject to  
change without prior notice.  
WeldingTerminal Lugs  
GroundTerminal  
Circuit Breaker  
To protect the generator from an overload, a 2-pole, 15 amp  
circuit breaker is provided on the control panel. Make sure  
to switch this circuit breaker to the "OFF" position prior to  
starting the engine.  
PAGE 16 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — LOAD APPLICATION  
To determine the running wattage for your load, multiply  
the running wattage as indicated by steps 1, 2, and 3 below:  
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.  
1. INCANDESCENT LOADS  
Lights, heaters and similar appliances.  
Total the running wattage and multiply by 1.  
Example:  
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.  
29 light bulbs @ 100W each = 2.9 KW  
use a 3 KW generator.  
2. SMALL MOTORS  
Drills and other small power tools.  
Total the running wattage and multiply by 2.  
Example:  
A 1 inch drill runs at 1 KW  
use a 2 KW generator.  
If wattage is not given on the equipment's  
name plate, approximate wattage may be  
determined by multiplying nameplate  
voltage by the nameplate amperage.  
3. LARGE MOTORS  
Submersible pumps, table saws etc.  
Total the running wattage and multiply by 3.  
Example:  
A conveyor belt runs at 8 KW  
use a 24 KW generator.  
WATTS = VOLTAGE x AMPERAGE  
The power factor of this generator is 1.0 See Table 2 below  
when connecting loads.  
Table 2. Power Factor By Load  
Type Of Load  
Power Factor  
CAUTION  
Single-phase induction motors  
0.4 - 0.75  
Motors and motor-driven equipment draw much greater  
current for starting than during operation.Always use an  
adequate size extension cable which can carry the  
required load.  
Electric heaters, incandescent  
lamps  
1.0  
Fluorescent lamps, mecury  
lamps  
0.4 - 0.9  
Extension Cables  
Electronic devices,  
communication equipment  
1.0  
0.8  
When electric power is to be provided to various tools or  
loads at some distance from the generator, extension cords  
are normally used. Cables should be sized to allow for  
distance in length and amperage so that the voltage drop  
between the generator and point of use (load) is held to  
a minimum. Use the cable selection chart (Table 2 ) as a  
guide for selecting proper cable size.  
Common power tools  
Table 3. Cable Selection (60 Hz, Single Phase Operation)  
Load In Watts  
At 120 Volts  
300  
Maximum Allowable Cable Length  
Current in  
Amperes  
#10 Wire  
1000 ft.  
500 ft.  
350 ft.  
250 ft.  
150 ft.  
125 ft.  
#12 Wire  
600 ft.  
300 ft.  
200 ft.  
150 ft.  
100 ft.  
75 ft.  
#14 Wire  
375 ft.  
200 ft.  
125 ft.  
100 ft.  
65 ft.  
#16 Wire  
250 ft.  
2.5  
5
The idle control device is operated at a  
600  
125 ft.  
minimum load capacity of 100W. If the  
load capacity is less than 100W, place  
the idle control switch in the OFF position.  
7.5  
10  
15  
20  
900  
100 ft.  
1200  
1800  
When using a combination of dual  
receptacles, total load should not  
exceed the rated capacity of the  
generator.  
2400  
50 ft.  
CAUTION: Equipment damage can result from low voltage.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 17  
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GAW-135H — CONTROLS AND INDICATORS  
Figure 2. Generator Controls and Components  
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GAW-135H — CONTROLS AND INDICATORS  
11. Fuel Cock Lever – Turn this lever downward to start  
(down)the flow of fuel to the carburetor. Turn upward to  
stop (up) the flow of fuel.  
1. Engine ON/OFF Switch – Place this switch in the "ON"  
position to start the engine.To turn-off the engine place this  
switch in the "OFF" position.  
12. Air Cleaner – Prevents dirt and other debris from entering  
the fuel system. Remove wing-nut on top of air filter  
cannister to gain access to filter element. NEVER run the  
engine without an air cleaner.  
2. Current Selector Knob – Place this knob in the desired  
setting when welding is required. There are 6 selectable  
settings that range from 40 amps to 135 amps.  
3.  
Connect the welder electrodes to these terminals. Please  
note the polarity of the electrodes when connecting them  
to the welder.  
13. Choke Lever – Used for starting the engine. Close the  
choke lever when starting a cold engine or in cold weather  
conditions.The choke enriches the fuel mixture.Open the  
choke lever if starting a warm engine or in warm weather  
conditions.  
4. Main Circuit Breaker – This 2-pole 15 amp breaker  
protects the generator from short circuiting or overloading.  
When starting the generator always have the circuit breaker  
placed in the "OFF" position.  
14. Fuel Tank Cap – Remove this cap to add unleaded  
gasoline to the fuel tank. Replenish with clean unleaded  
gasoline. Make sure cap is tightened securely. DO NOT  
over fill. Fuel tank capacity is 1.85 gallons (7 liters).  
5. Idle Control Switch – This unit is provided with an  
automatic idle control for noise suppression and reduced  
fuel consumption.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 2600 rpm (low-speed  
operation) within 3 seconds after the load stops. When the  
operation is resumed, the engine speed is automatically  
increased to about 3600 rpm (high-speed operation) as  
soon as the load is connected.  
15. Fuel Gauge – Read this gauge to determine when fuel is  
low.  
16. Spark Plug – Provides spark to the ignition system. Set  
spark plug gap to 0.6 - 0.7 mm (0.024 - 0.028 inch). Clean  
spark plug once a week.  
17. Muffler/Heat Shield – Used to reduce noise and emissions.  
NEVER touch this heat shield when the generator/welder  
is in use. Always allow time for the generator to cool down  
before performing maintenance.  
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.  
9.  
Engine Oil Filler Cap – Remove this cap/dipstick when  
the adding of engine oil is required. See Table 4 for  
recommended type engine oil.  
This HONDA engine is equipped  
with a low oil shutdown capability.A  
Engine Oil Drain Plug – Remove this drain plug when  
draining of the oil from the engine crankcase is required.  
Fill with recommeded type oil as listed in Table 4.  
built in sensor will automatically turn  
off the engine should the oil level fall  
below a safe operating condition.  
Make sure the generator is placed  
on level ground. Placing the generator/welder on level ground  
will ensure that the low oil sensor will function properly.  
10. Recoil Starter (pull rope) – Manual-starting method. Pull  
the starter grip until resistance is felt, then pull briskly and  
smoothly.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 19  
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GAW-135H —WELDER/GENERATOR REFUELING  
DANGER  
Adding fuel to the tank should be done only when  
the engine is stopped and has had an opportunity  
to cool down. In the event of a fuel spill, DO NOT  
attempt to start the engine until the fuel residue  
has been completely wiped up, and the area surrounding the  
engine is dry. If generator is placed in a truck bed with a plastic  
liner, REMOVE generator from truck bed and place on ground  
(Figure 3) to refuel.This possibility exist of fire or explosion due  
to static electricity.  
Figure 3. Generator/Welder Refueling  
PAGE 20 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — INSTALLATION  
Outdoor Installation  
Indoor Installation  
Install the generator/welder in a area that is free of debris,  
bystanders, and overhead obstructions. Make sure the  
generator is on secure level ground so that it cannot slide or  
shift around. Also install the generator in a manner so that  
the exhaust will not be discharged in the direction of nearby  
homes.  
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.  
The installation site must be relatively free from moisture  
and dust. All electrical equipment should be protected from  
excessive moisture. Failure to do will result in deterioration  
of the insulation and will result in short circuits and grounding.  
Foreign materials such as dust, sand, lint and abrasive  
materials have a tendency to cause excessive wear to  
engine and alternator parts.  
Generator Grounding  
To guard against electrical shock and possible damage to  
the equipment, it is important to provide a good EARTH  
ground. Always use the ground terminal on the generator to  
ground the generator.  
CAUTION  
Article 250 (Grounding) of the National Electrical Code (NEC)  
provides guide lines for proper grounding and specifies that  
the cable ground shall be connected to the grounding system  
of the building as close to the point of cable entry as  
practical.  
Pay close attention to ventilation when  
operating the generator inside tunnels and  
caves. The engine exhaust contains  
noxious elements.  
NEC articles 250-64(b) and 250-66 set the following  
grounding requirements:  
Mounting  
The generator should always be mounted on a flat level  
surface to isolate vibration of the generator when it is  
running. DO NOT place the generator on slopes, the  
possibility exists that the generator could slide.  
1. Use one of the following wire types to connect the  
generator to earth ground.  
a. Copper - 10 AWG (5.3 mm2) or larger.  
b. Aluminum - 8 AWG (8.4 mm2) or larger.  
2. When grounding the generator (Figure 3) connect the  
ground cable between the lock washer and the nut on  
the generator and tighten the nut fully.Connect the other  
end of the ground cable to earth ground.  
CAUTION  
An electric shock is apt to 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 a short circuit.  
3. NEC article 250-52(c) specifies that the earth ground  
rod should be buried a minimum of 8 ft. into the ground.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 21  
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GAW-135H — INSTALLATION  
Connecting the Ground  
The nut and ground terminal on the generator should always be used 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) and tighten the  
nut fully. Connect the other end of the ground cable to a suitable earth ground (ground rod).  
Figure 4. Generator Grounding  
PAGE 22 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — PRE-INSPECTION (ENGINE)  
CAUTION  
NEVER operate the generator in a confined  
area or enclosed area structure that does  
not provide ample free flow of air.  
Figure 6. Engine Oil Dipstick (Oil Level)  
Table 4. Oil Type  
ALWAYS wear approved eye and hearing  
protection before operating the generator.  
Season  
Summer  
Spring/Fall  
Winter  
Temperature  
25°C or Higher  
25°C~10°C  
Oil Type  
SAE 10W-30  
SAE 10W-30/20  
SAE 10W-10  
Before Starting  
1.  
Read safety instructions at the  
beginning of manual.  
0°C or Lower  
2.  
Clean the generator, removing dirt  
and dust, particularly the engine  
cooling air inlet, carburetor and air  
cleaner.  
DANGER EXPLOSIVE FUEL  
3.  
4.  
5.  
Check the air filter for dirt and dust. If air filter is dirty, replace  
air filter with a new one as required.  
Motor fuels are highly flammable and can  
be dangerous if mishandled. DO NOT  
smoke while refueling. DO NOT attempt to  
refuel the generator if the engine is hot! ,  
running or in the dark.  
Check carburetor for external dirt and dust. Clean with dry  
compressed air.  
Check fastening nuts and bolts for tightness.  
Engine Oil Check  
1.  
To check the engine oil level, place the generator on secure  
level ground with the engine stopped.  
Fuel Check  
1. Close the fuel cock before filling the fuel tank.  
2. Remove the fuel cap located on top of fuel tank.  
2.  
Remove the filler dipstick from the engine oil filler hole  
(Figure 5) and wipe clean.  
3. Readthefuelgaugelocatedontopofthefueltank(Figure7)to  
determin if the fuel level is low. If fuel is low, replenish with  
clean unleaded fuel.  
Figure 7. Fuel Gauge  
Figure 5. Engine Oil Dipstick (Removal)  
3. Insertandremovethedipstickwithoutscrewingitintothefiller  
neck. Check the oil level shown on the dipstick.  
4. When refueling, be sure to use a strainer for filtration. DO  
NOT top-off fuel. DO NOT fill the tank beyond capacity.  
Wipe up any spilled fuel immediately!  
4. If the oil level is low (Figure 6), fill to the edge of the oil filler  
holewiththerecommendedoiltype(Table4).Maximum oil  
capacity is .63 quarts (0.6 liters)  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 23  
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GAW-135H — INITIAL START-UP (ENGINE)  
2. Placethechokelever (Figure10)inthe"CLOSED"position  
if starting a cold engine.  
CAUTION  
DO NOT attempt to operate this  
generator until the Safety, General  
Information and Inspection sections of  
this manual have been read and  
thoroughly understood.  
This section is intended to assist the operator with the initial  
start-up of the trash generator. It is extremely important that this  
section be read carefully before attempting to use the generator  
in the field.  
Figure 10. Choke Lever  
Before Starting the Engine  
3. Place the choke lever (Figure 10) in the "OPEN " position  
1. Be sure to disconnect all electrical loads from the  
if starting a warm engine or the temperature is warm.  
generator prior to starting the engine.  
4. Place the engine ON/OFF switch (Figure 11) in the "ON "  
2. NEVER start the engine with the main circuit breaker  
in the “ON" position. Place the main circuit breaker  
(Figure 8) in the OFF position.  
position.  
Figure 8. Main Breaker (OFF Position)  
Figure 11. Engine On/Off Switch (ON)  
Starting the Engine  
5. Grasp the starter grip (Figure 12) and slowly pull it out.The  
resistancebecomesthehardestatacertainposition,corre-  
spondingtothecompressionpoint.Pullthestartergripbriskly  
andsmoothlyforstarting.  
1. Place the engine fuel valve lever (Figure 9) to the "ON"  
position.  
”
Figure 9. Engine FuelValve Lever (ON Position)  
Figure 12. Starter Grip  
CAUTION  
z
z
DO NOT pull the starter rope all the way to the end.  
DO NOT release the starter knob after pulling. Allow it  
to rewind as soon as  
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GAW-135H — INITIAL START-UP/GENERATOR OPERATION  
6. If the engine has started, slowly return the choke lever  
9. Place the main circuit breaker (Figure 15) in the ON  
(Figure 13 ) to the “OPEN” position. If the engine has not  
started repeat steps 1 through 6.  
position.  
7. Beforethegeneratorisplacedintooperation,runtheengine  
for3-5minutes. Checkfor abnormalsmells,fuelleaks, and  
noises that would associate with lose components.  
8. Place the idle control switch (Figure 13) in the "OFF"  
(down) position.This will allow the engine speed to run  
at speed about 3600 RPM's  
Figure 15. Main Circuit Breaker (ON)  
10. If desired, verify with a voltmeter (Figure16) that 120  
VAC is present at the GFCI duplex receptacle.  
Figure 13. Idle Control Switch (Off)  
Placing the idle control switch in  
the RUN position (Figure 14) allows  
the engine to operate at a maximum  
speed of about 3600 RPM's. When  
the idle control switch is placed in  
the up position (ON), the generator  
will run at idle speed (2200 RPM's) until a load is applied, at that  
time the engine speed will increase to 3600 RPM's as long as  
the load is being applied. When the load is not in use, the engine  
speed will drop back to the idle mode after about 3 seconds.  
Figure 16. 120 VAC GFCI Receptacle  
Connecting the Load  
1. If small wattage power tools are required, connect them  
to the GFCI receptacle.  
Figure 14. Idle Control Switch (On)  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 25  
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GAW-135H — INITIAL START-UP/GENERATOR OPERATION  
Stopping The Engine  
Normal Shutdown  
1. Place the main circuit breaker (Figure 11) in the OFF  
position.  
2. Remove the load from the generator, and let 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.  
Figure 24. Operation Switch (Stop)  
4. Place the engine fuel valve lever (Figure 25) to the "OFF"  
position.  
”
Figure 25. Engine Fuel Valve Lever (OFF Position)  
Emergency Showdown  
1. PlacetheengineON/OFFswitch(Figure24)intheOFF  
position.  
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GAW-135H —WELDER OPERATION  
3. When connecting the cables NEVER allow the cable or  
Connecting the Welding Cables  
welder output terminals to touch each other.  
1. Make sure the generator/welder is OFF (not running).  
4. The welder's output terminals are marked positive (+)  
and negative (-). Connect the welding cables to the  
output terminals as referenced in Table 5.  
2. Attach the correct size terminal connector to the free  
end of each cable. NEVER connect bare or exposed  
wires (Figure 23) directly to the terminals. Exposed wiring  
may cause electrical arcing or dilectric breakdown from  
poor connection.  
Table 5. Welding Cables and Polarities  
Polarity  
Welding Method  
Typical Application  
Straight  
Polarity  
Positive (+) Grounding  
(Base Metal)  
Arc welding for steel material  
of general structures, and for  
thick plates.  
Negative (-) Welding Holder Arc welding for copper alloy  
Reverse  
Polarity  
Positive (+) Welding Holder Build-up Welding  
Air gouging  
Negative (-) Grounding  
(Base Metal)  
Arc welding of thin plates  
Arc welding of stainless steel  
Figure 23.Welding Cable (Bare Wires)  
When selecting a welding cable, the  
welding cable should be larger in  
size as it becomes longer or its  
current becomes higher.UseTable 6  
as a guideline when selecting a  
NOTE  
2. Attach the correct size terminal connector (Figure 24)  
to the free end of each cable.  
suitable welding cable. The calculated values listed in Table 6  
are based on a maximum voltage drop of 4 volts.  
TABLE 6. WELDING CABLE SELECTING CHART  
Total Cable (Copper) Length in Weld Circuit Not Exceeding:  
Welding  
Current  
50ft.  
(15m)  
100ft  
(30m)  
150ft.  
(46m)  
200ft.  
(61m)  
250ft.  
(61m)  
300ft.  
(91m)  
50A  
#5  
#5  
#5  
#5  
#5  
#4  
#5  
#4  
#2  
#5  
#3  
#1  
#5  
#2  
#4  
#1  
100A  
135A  
#1/0  
#1/0  
Figure 24.Welding Cable (Terminal Connector)  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 27  
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GAW-135H —WELDER OPERATION  
Duty Cycle  
Regulating Welding Current  
Because of the different types of job applications for which  
this equipment is intended, the welding-generator is not  
designed to withstand continuous welding. To avoid  
overloads, select an appropriate duty cycle. See Table 7.  
Regulate the welding current with the current selector knob.  
Never regulate the current by increasing or decreasing the  
engine operating speed.  
The operating range of the welding current is listed in Table 8.  
Select the desired welding current according to the  
application.  
TABLE 7. DUTY CYCLE RATING  
Welding Current (A)  
Duty Cycle (%)  
40 60 80 100 115 135  
40  
CAUTION  
DO NOT turn the current selector knob while welding.  
Use only factory selectable settings.The use of any other  
settings could cause severe damage to the equipment.  
NEVER place the dial indicator between settings.  
Duty cycle is based on 10 minute  
intervals.  
NOTE  
TABLE 8. APPLICABLE ELECTRODE  
Welding Current (A)  
40  
60  
80  
100  
115  
135  
Fleetweld 5P+  
Excalibur 7018  
E6010  
3/32 in. 3/32 in.  
1/8 in. 1/8 in. 1/8 in. 5/32 in.  
3/32 in. 1/8 in. 1/8 in. 5/32 in.  
E7018 H4R  
N/A  
N/A  
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GAW-135H — MAINTENANCE  
General Inspection  
Service Daily  
At least daily or prior to each use, the generating set should  
be cleaned and inspected for deficiencies. Check for loose,  
missing or damaged nuts, bolts or other fasteners. Also check  
for fuel or oil leaks.  
If engine is operating in very dusty and dry grass conditions.  
A clogged air cleaner will result in high fuel consumption,  
loss of power and excessive carbon buildup in the  
combustion chamber.  
Engine Side (Refer to the Robin Engine Instruction Manual)  
Cleaning the Fuel Strainer  
Check Oil Level  
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.  
Check the crankcase oil level prior to each use, or when the  
fuel tank is filled. Make sure the generating set is level.The  
oil level must be between the two notches on the dipstick.  
Changing Oil  
Spark Plug  
Change oil after the first 20 hours of operation. Drain and  
refill the engine crankcase every 50 operating hours or once  
a week thereafter.Drain crankcase oil into a suitable container  
while engine is still warm.Replace the drain plug tightly.Add  
oil through the filler hole.  
Remove carbon build-up on the spark plug (Figure 25) with a  
wire brush. Set the spark plug gap to 0.6—0.7mm (0.024-  
0.028 inch).Tighten with a spark plug socket wrench. Clean  
the spark plug every 50 operating hours or once a week.  
Air Cleaner  
Every 50 hours: Remove air cleaner element (std. or heavy  
duty types), and wash in kerosene or liquid detergent and  
hot water. Wrap foam element in a cloth and squeeze dry.  
Wipe heavy duty paper element dry with toweling. Saturate  
element with kerosene; squeeze excess from foam element.  
Wipe excess from heavy duty paper element.  
Figure 26. Spark Plug Gap  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 29  
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GAW-135H — PREPARATION FOR LONG -TERM STORAGE  
Generator Storage  
For storage of the generating set for over 30 days, the  
following is required:  
z
z
Drain the fuel tank completely.  
Run the engine until the gasoline in the carburetor is  
completely consumed.  
z
z
z
z
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 starter  
Rope and install a new plug.  
Pull out the starter rope slowly and stop at the  
compression point.  
z
z
Clean all external parts of the generating set with a cloth.  
Cover the generating set and store in a clean, dry place.  
PAGE 30 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H —WIRING DIAGRAM  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 31  
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GAW-135H —TROUBLESHOOTING (ENGINE)  
diagnosis based on the Engine Troubleshooting (Table 10)  
information shown below and on the proceeding page. If the  
problem cannot be remedied, please leave the unit just as it  
is and consult our company's business office or service  
plant.  
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  
TABLE 10. ENGINE TROUBLESHOOTING  
SYMPTOM  
POSSIBLE PROBLEM  
SOLUTION  
Inspect carburetor to see if fuel  
is reaching it?  
Check fuel line  
No Fuel?  
Add Fuel  
Water in fuel tank?  
Fuel filter clogged?  
Stuck carburetor?  
Spark plug is red?  
Flush or replace fuel tank.  
Replace fuel filter  
Check float mechanism.  
Poor starting  
Spark plug is fouled. Check tranistor ignition unit.  
Insufficient compression, injected air leaking. Carburetor jets are  
clogged (overflow).  
Spark plug is blue-white?  
No spark present at tip of spark  
plug?  
Tranistor ignition unit broken, high voltage cord cracked or broken.  
Start/Stop switch broken. Replace spark plug if fouled.  
No oil?  
Add oil as required.  
Oil pressure alarm lamp blinks  
upon starting?  
Check Automatic shutdown circuit "oil sensor".  
Replace cylinder and piston and if necessary axel joint.  
Tighten cylinder head connecting bolts.  
Engine will not turn over?  
Cylinder head connecting bolts  
loose?  
Cylinder head gasket damaged? Replace cylinder head gasket.  
Insufficient power output "no  
compression"  
Malfunction of valve seat?  
Spark plug is loose?  
Worn piston rings?  
Re-seat valves.  
Replace spark plug.  
Replace piston rings.  
Malfunction in air-cleaner  
system, air filter clogged?  
Clean or replace air filter.  
Air leaking in from interface  
between carburetor and cylinder  
head?  
Tighten bolts between carburetor and cylinder head. Replace  
cylinder head gasket.  
Insufficient power output  
"compression"  
Clean or replace fuel filter.  
Clean or replace carburetor.  
Check carburetor float.  
Malfunction in fuel system?  
PAGE 32 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H —TROUBLESHOOTING (ENGINE)  
TABLE 10. ENGINE TROUBLESHOOTING (CONTINUED)  
SYMPTOM  
POSSIBLE PROBLEM  
Malfunction in blower?  
SOLUTION  
Check or replace blower.  
Insufficient power output  
"compression" and overheats  
Air in-take filter clogged?  
Clean or replace air in-take filter.  
Over accumulation of exhaust  
products?  
Clean and check valves.  
Check muffler, replace if necessary.  
Burns to much fuel  
Wrong spark plug?  
Replace spark plug with manufactures suggested type spark plug.  
Replace lubricating oil with correct viscosity.  
Replace rings  
Lubricating oil is wrong  
viscosity?  
Exhaust color is continiously  
"WHITE"  
Worn rings?  
Air cleanner clogged?  
Clean or replace air cleaner.  
Choke valve has not been set  
to the correct position?  
Adjust choke valve to the correct position.  
Exhaust color is continiously  
"BLACK"  
Carburetor defective, seal on  
carburetor broken?  
Replace carburetor or seal.  
Adjust carburetor.  
Poor carburetor adjustment  
"engine runs too rich?  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 33  
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GAW-135H —TROUBLESHOOTING (GENERATOR)  
diagnosis based on the GeneratorTroubleshooting (Table 11)  
information shown below and on the preceding page. If the  
problem cannot be remedied, please leave the unit just as it  
is and consult our company's business office or service  
plant.  
Practically all generator breakdowns can be prevented by  
proper handling and maintenance inspections, but in the event  
of a breakdown, please take a remedial action following the  
TABLE 11. GENERATOR TROUBLESHOOTING  
SYMPTOM  
Low voltage  
POSSIBLE PROBLEM  
SOLUTION  
Raise engine speed to rated RPM.  
Engine speed too low?  
Control box internal wiring  
malfunction?  
Check control box wiring.  
Defective ignition coil?  
Check red and green ignition wires. Replace ignition wires if  
necessary.  
Low voltage. Engine speed  
normal 3650 RPM (unloaded),  
2500 RPM (idle)  
Rotor winding malfunction?  
Stator winding malfunction?  
Breaker malfunction?  
Check or replace rotor.  
Check or replace stator.  
Check or replace CB1.  
Voltage output too high.  
Engine speed too high?  
Lower engine speed to rated RPM.  
Check control box wiring.  
Voltage output too high. Engine  
speed normal 3650 RPM  
(unloaded), 2500 RPM (idle)  
Control box internal wiring  
malfunction  
Circuit breaker will not turn on  
"NO LOAD"  
Defective circuit breaker?  
Replace circuit breaker.  
Overload?  
Reduce load or replace breaker.  
Check load circuit for short.  
Check solenoid.  
Circuit breaker will turn on  
"LOADED" but trips immediately.  
Load circuit is shorted?  
Stuck solenoid?  
Does not accelerate from low to  
high "NO LOAD"  
Does not accelerate from low to  
high "LOAD ACTIVE  
Control box interal wiring  
defective?  
Check control box wiring.  
Defective rotor windings?  
Defective solenoid?  
Check or replace rotor.  
Check or replace solenoid.  
Does not decelerate no  
"VOLTAGE OUTPUT".  
Defective idle control device?  
Defective solenoid?  
Check or replace idle control device.  
Check or replace idle control device.  
Check control box wiring, replace any defective components.  
Check or replace solenoid.  
Control box wiring malfunction?  
Defective solenoid?  
Does not decelerate but has  
"VOLTAGE OUTPUT".  
Idle control device malfunction?  
Check or replace idle control device.  
PAGE 34 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H —TROUBLESHOOTING (GENERATOR)  
TABLE 11. GENERATOR TROUBLESHOOTING (CONTINUED)  
SYMPTOM  
POSSIBLE PROBLEM  
Defective rotor windings?  
Defective solenoid?  
SOLUTION  
Check or replace rotor.  
Check or replace solenoid.  
Does not decelerate no  
"VOLTAGE OUTPUT".  
Defective idle control device?  
Defective solenoid?  
Check or replace idle control device.  
Check or replace idle control device.  
Check control box wiring, replace any defective components.  
Check or replace solenoid.  
Control box wiring malfunction?  
Defective solenoid?  
Does not decelerate but has  
"VOLTAGE OUTPUT".  
Idle control device malfunction?  
Check or replace idle control device.  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 35  
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GAW-135H — EXPLANATION OF CODE IN REMARKS COLUMN  
How to read the marks and remarks used in this parts book.  
If more than one of the same  
reference number is listed, the last  
one listed indicates newest (or latest)  
part available.  
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.  
The contents of this catalog are  
subject to change without notice.  
Items Found In the “Items Number” Column  
All parts with same symbol in the number column, , #,  
+
, %, or  
*
>
, belong to the same assembly or kit.  
PAGE 36 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H — SUGGESTED SPARE PARTS  
MQ GAW-135HWELDER/GENERATORWITH HONDA  
GX200VEN2 GASOLINE ENGINE  
1 to 3 Units  
Qty.... P/N ...................... Description  
1 ....... 9924800014......... CAP, FUEL TANK  
1 ....... 9924800004......... FILTER, FUEL TANK  
3 ....... 17211ZB2000 ...... ELEMENT, AIR CLEANER  
3 ....... 9807956846......... SPARK PLUG  
1 ....... 28462ZH8003...... ROPE, RECOIL STARTER  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 37  
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GAW-135H— NAMEPLATE AND DECALS  
NAMEPLATE AND DECALS  
PAGE 38 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H— NAMEPLATE AND DECALS  
NAMEPLATE AND DECALS  
NO.  
1
PART NO.  
PART NAME  
QTY.  
REMARKS  
0561200004  
9504200004  
0521100003  
8700611904  
0800690804  
0820610404  
8700611804  
9522100204  
7900636004  
9511100004  
9512100203  
9521200004  
0561000003  
0561000104  
DECAL; MQ MULTIQUIP 135A GAW-135H  
1
2
DECAL; CAUTION NEVER ATTEMPT ................. 1.............REPLACES D90420000  
DECAL; CONTROL PANEL  
3
1
4
DECAL; ELECTRICAL SHOCK HAZARD............. 1.............S-4985  
DECAL; WELDING OUTPUT TERMINAL ............. 1.............S-1238A  
DECAL; WARNING, TRANSFER SWITCH ........... 1.............S-3627  
DECAL; WARNING DANGEROUS GAS ............... 1.............S-4984  
DECAL; PROPOSITION 65 .................................. 1.............REPLACES D92210020  
DECAL; CAUTION OPERATE AT 3600 RPM ....... 1.............S-4461  
DECAL; READ MANUAL ...................................... 1.............A91110000  
DECAL; CAUTION WELDING OPERATION ......... 1.............REPLACES D91210020  
DECAL; OPERATING INSTRUCTIONS ................ 1.............REPLACES A92120000  
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
DECAL; MQ MULTIQUIP 135A  
DECAL; MQ MULTIQUIP  
1
1
DECAL; NAMEPLATE .......................................... 1.............CONTACT MQ PARTS DEPT.  
DECAL; GROUND TERMINAL ............................. 1.............S-1123  
0800628504  
1980680004  
DECAL; FUEL COCK ........................................... 1.............S-3704  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 39  
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GAW-135H— GENERATOR ASSY.  
GENERATOR ASSY.  
PAGE 40 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H— GENERATOR ASSY.  
GENERATOR ASSY.  
NO.  
1
PART NO.  
PART NAME  
QTY.  
1
REMARKS  
0924200004  
0101000003  
0110000913  
0135000002  
0155100003  
0012808020  
0012308045  
0012108070  
0040008000  
0801086004  
1153300114  
1153400212  
0416700033  
7935416004  
0016908045  
7935419204  
0207208000  
ENGINE, HONDA GX200VEN2  
GENERATOR ASSY.  
ROTAR ASSY.  
1A  
2
1
1
2
ARAMATURE ASSY.  
END BRACKET  
HEX HEAD BOLT  
HEX HEAD BOLT  
HEX HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
GROMMET  
COVER  
BASE  
RUBBER SUSPENSION  
HEX HEAD BOLT  
RUBBER SUSPENSION  
HEX NUT  
1
3
1
4
4
5
1
6
1
7
1
8
1
9
2
10  
11  
12  
13  
14  
15  
1
1
2
2
2
10  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 41  
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GAW-135H— CONTROL BOX  
CONTROL BOX ASSY.  
PAGE 42 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H— CONTROL BOX  
CONTROL BOX ASSY.  
NO.  
1
PART NO.  
PART NAME  
QTY.  
REMARKS  
0214000103  
0214000003  
0016906016  
0226900350  
0601807489  
0027004030  
0601807489  
3011816004  
0027004010  
0601812598  
0027004010  
0207004000  
0601831620  
0923100004  
0207004000  
0601827350  
0028604010  
0260600014  
0028603006  
0601826178  
0028603006  
0260600104  
0601826178  
0237200003  
0237100004  
0237400004  
0316800160  
0016906020  
0805088304  
0805088004  
0016906016  
1230500004  
0266600004  
0040506000  
0214500003  
0016605010  
0213600034  
0016905010  
0266000123  
0266300214  
0016905016  
0601823208  
0027103012  
0601821256  
0017105016  
0601842067  
0016906016  
0247700004  
0601826150  
CONTROL BOX (FIN SIDE)  
CONTROL BOX  
HEX HEAD BOLT  
TRIM SEAL  
1
1
3
1
2
3
4
5
CURRENT SELECTROR ............................. 1 ........................ BR-2-5  
6
MACHINE SCREW  
CIRCUIT BREAKER  
2
1
1
2
7
8
BRACKET, CIRCUIT BREAKER  
MACHINE SCREW  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
32A  
33  
34  
35  
36  
37  
RECEPTACLE ............................................. 1 ........................ GF-530EM  
MACHINE SCREW  
HEX NUT  
2
2
ROCKER SWITCH ...................................... 1 ........................ C1550WABB  
INVERTER UNIT ......................................... 1 ........................ IN-10  
HEX NUT  
6
SLOWDOWN CONTROL UNIT .................... 1 ........................ ND-81  
MACHINE SCREW  
2
1
2
BRACKET, CONDENSER  
MACHINE SCREW  
CONDENSER, 250V.................................... 1 ........................ KMH250LGSN,1500MB  
MACHINE SCREW  
RUBBER SEAT  
GROMMET  
2
1
2
1
1
1
1
2
2
4
4
2
BRACKET, OUTPUT TERMINAL  
COVER, OUTPUT TERMINAL  
RUBBER SEAT  
TRIM SEAL  
HEX HEAD BOLT  
COLLAR  
STAY RUBBER  
HEX HEAD BOLT  
OUTPUTTERMINAL  
RESISTOR 50K OHMS ............................... 1 ........................ RS-3B  
TOOTHEDWEASHER  
ROOF, CONTROL BOX  
HEX HEAD BOLT  
COVER, CONTROL BOX  
HEX HEAD BOLT  
FIN ASSY.  
1
1
6
1
4
1
1
4
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
FIN  
HEX HEAD BOLT  
RECTIFER................................................... 8 ........................ S30VT60  
MACHINE SCREW  
16  
TRANSISTOR.............................................. 1 ........................ CM75BU-12H  
MACHINE SCREW  
RESISTOR 1/2W 10K OHMS  
HEX HEAD BOLT  
4
4
4
1
1
WIRE HARNESS  
CONDENSER 250 VAC 0.1  
µ
F
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 43  
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GAW-135H— PIPE FRAME AND FUELTANK ASSY.  
PIPE FRAME AND FUEL TANK ASSY.  
PAGE 44 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H— PIPE FRAME AND FUELTANK ASSY.  
PIPE FRAME AND FUEL TANK ASSY.  
NO.  
1
PART NO.  
PART NAME  
QTY.  
1
REMARKS  
0417000002  
0416400114  
0016906016  
0454100003  
0016906016  
0019206016  
0040506000  
0363000022  
0416400204  
0016998020  
0602125031  
9924800014  
9924800004  
16950898633  
PIPE FRAME  
2
GENERATOR GUARD  
HEX HEAD BOLT  
SIDE GUARD  
HEX HEAD BOLT  
HEX HEAD BOLT  
TOOTHEDWASHER  
FUELTANK  
OVERFLOW GUARD  
HEX HEAD BOLT  
FUEL GUAGE  
1
3
3
4
1
5
1
6
2
7
2
8
1
9
1
10  
11  
12  
13  
14  
4
1
CAP, FUEL TANK  
FILTER  
FUEL COCK  
1
1
1
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 45  
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GAW-135H— MUFFLER ASSY.  
MUFFLER ASSY.  
PAGE 46 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GAW-135H— MUFFLER ASSY.  
MUFFLER ASSY.  
NO.  
1
PART NO.  
PART NAME  
QTY.  
1
REMARKS  
18310ZB3C001  
0330400314  
0207006000  
0330400404  
0016906016  
0330400033  
0016906016  
0016908025  
0602302006  
0602302007  
0330300022  
0330300124  
0016905010  
0017306010  
0330400124  
0016906016  
0333000012  
18381ZH8800  
18381ZE1800  
92101980200A  
94001080000S  
18355898630  
MUFFLER  
2
MUFFLER BRACKET  
HEX NUT  
1
3
2
4
MUFFLER ADJUSTER  
HEX HEAD BOLT  
MUFFLER STAY  
HEX HEAD BOLT  
HEX HEAD BOLT  
MUFFLER COVER, OUTER  
MUFFLER COVER, OUTER  
DUCT, MUFFLER COVER  
DUCT, BRACKET  
HEX HEAD BOLT  
HEX HEAD BOLT  
BRACKET, MUFFLER COVER  
HEX HEAD BOLT  
EXHAUST PIPE  
GASKET  
1
5
2
6
1
7
2
8
1
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
1
1
1
1
5
1
1
1
1
GASKET  
1
HEX HEAD BOLT  
HEX NUT  
2
2
SPARK ARRESTER  
1
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 47  
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GX-200VEN2 — CYLINDER HEAD ASSY.  
CYLINDER HEAD ASSY.  
PAGE 48 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 —CYLINDER HEAD ASSY.  
CYLINDER HEAD ASSY.  
NO.  
PART NO.  
PART NAME  
GUIDE, IN VALVE O.S.  
GUIDE, EX. VALVE O.S.  
HEAD COMP. CYLINDER................. 1 ................INCLUDES ITEMS W/  
CLIP, VALVE GUIDE  
GASKET  
COVER COMP., HEAD  
PACKING, HEAD COVER  
TUBE, BREATHER  
BOLT, FLANGE 6X12 CT200  
BOLT, STUD 6X94  
QTY.  
1
1
REMARKS  
1
*
2
*
3
4
*
5
6
7
8
9
10  
11  
12  
14  
15  
15  
12204ZE1306  
122052ZE1315  
12210ZL00100  
12216ZE5300  
12251ZL0003  
12310ZE1020  
12391ZE1000  
15721883030  
90013883000  
90043ZB2003  
90047ZE1000  
9430110160  
*
1
1
1
1
1
4
2
2
2
4
1
BOLT, STUD 8X32  
DOWEL PIN, 10X16  
BOLT, FLANGE 8X60  
SPARK PLUG, BPR6ES NGK  
957230806000  
9807956846  
9807956855  
SPARK PLUG, W20EPR-U DENSO 1  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 49  
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GX-200VEN2 — CYLINDER BARREL ASSY.  
CYLINDER BARREL ASSY.  
PAGE 50 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CYLINDER BARREL ASSY.  
CYLINDER BARREL ASSY.  
NO.  
1
2
3
4
5
6
7
8
PART NO.  
PART NAME  
QTY.  
REMARKS  
12000ZL0811  
15510ZE1033  
16506ZL0000  
16531ZE1000  
16541ZE1000  
90131ZE1000  
90451ZE1000  
90601ZE1000  
90602ZE1000  
91001ZF1003  
91001ZF1004  
91202883005  
91353671004  
9405010000  
9410106800  
9425108000  
957010601200  
CYLINDER BARREL ASSY. .......................... 1 ............ INCLUDES ITEMS W/  
*
OIL LEVEL SWITCH ASSY.  
GOVERNOR ASSY.  
SLIDER, GOVERNOR  
SHAFT, GOVERNOR ARM  
BOLT, DRAIN PLUG  
WASHER, THRUST 6MM  
WASHER, DRAIN PLUG 10.2MM  
CLIP, GOVERNOR HOLDER  
BEARING, RADIAL BALL, 6205TMB NTN  
BEARING, RADIAL BALL, 62055 KOYO  
OIL SEAL, 25X41X6  
1
1
1
1
2
1
2
1
1
1
1
1
1
2
1
2
9
10  
*
10  
*
11  
*
12  
O-RING, 14MM NOK  
NUT, FLANGE 10MM  
WASHER, PLAIN 6MM  
PIN, LOCK 8MM  
13  
14  
15  
16  
BOL;T, FLANGE 6X12  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 51  
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GX-200VEN2 — CRANKCASE COVER ASSY.  
CRANKCASE COVER ASSY.  
PAGE 52 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CRANKCASE COVER ASSY.  
CRANKCASE COVER ASSY.  
NO.  
2
4
5
6
PART NO.  
PART NAME  
QTY.  
REMARKS  
11300ZE1633  
11381ZL0000  
15600ZE1003  
15600ZG4003  
15625ZE1003  
91202883005  
9430108140  
COVER ASSY., CRANKCASE ...................... 1 ............ INCLUDES ITEMS W/  
*
PACKING, CASE COVER  
CAP ASSY., OIL FILLER .............................. 1 ............ INCLUDES ITEMS W/#  
CAP ASSY., OIL FILLER .............................. 1 ............ INCLUDES ITEMS W/%  
PACKING, OIL FILLER CAP  
OIL SEAL, 25X41X6  
DOWEL, PIL 8X14  
1
7#%  
2
1
2
6
1
9
10  
11  
*
957010803200  
961006205000  
BOLT, FLANGE 8X32  
BEARING, RADIAL BALL 6205  
12  
*
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 53  
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GX-200VEN2 — CRANKSHAFT ASSY.  
CRANKSHAFT ASSY.  
PAGE 54 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CRANKSHAFT ASSY.  
CRANKSHAFT ASSY.  
NO.  
13  
PART NO.  
13310ZL0A00  
PART NAME  
CRANKSHAFT COMP.  
QTY.  
1
REMARKS  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 55  
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GX-200VEN2 — PISTON ASSY.  
PISTON ASSY.  
PAGE 56 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — PISTON ASSY.  
PISTON ASSY.  
NO.  
2
1
1
1
1
2
2
2
2
3
4
5
*
6
PART NO.  
PART NAME  
QTY.  
REMARKS  
11300ZE1633  
13010ZL0003  
13011ZL0003  
13012ZL0003  
13013ZL0003  
13101ZL0010  
13102ZL0010  
13103ZL0010  
13104ZL0010  
13111ZE1000  
13200ZE1010  
90001ZE1000  
90551ZE1000  
COVER ASSY., CRANKCASE  
RING SET, PISTON STD TEKOKU  
RING SET, PISTON 0.25 TEKOKU  
RING SET, PISTON 0.50 TEKOKU  
RING SET, PISTON 0.75 TEKOKU  
PISTON, STD  
1
1
1
1
1
1
1
1
1
1
PISTON, 0.25  
PISTON 0.50  
PISTON 0.75  
PIN, PISTON  
ROD ASSY., CONNECTING ROD ................. 2 ............ INCLUDES ITEMS W/  
BOLT, CONNECTING ROD  
CLIP, PISTON PIN 18MM  
*
2
2
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 57  
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GX-200VEN2 — CAMSHAFT ASSY.  
CAMSHAFT ASSY.  
PAGE 58 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CAMSHAFT ASSY.  
CAMSHAFT ASSY.  
NO.  
1
2
4
6
7
8
*
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
PART NO.  
PART NAME  
QTY.  
REMARKS  
12209ZH8003  
14100ZL0000  
14410ZE1000  
14431ZE1000  
14451ZE1013  
14568ZE1000  
14711ZF1000  
14721ZF1000  
14731ZL0000  
14751ZF1000  
14771ZE1000  
14773ZE1000  
14781ZE1000  
14791ZE1010  
90012ZE0010  
90206ZE1000  
SEAL, VALVE STEM  
1
CAMSHAFT ASSY. ....................................... 1 ............ INCLUDES ITEMS W/  
*
ARM, VALVE ROCKER  
ARM, VALVE ROCKER  
PIVOT, ROCKE54 ARM  
SPRING, WEIGHT RETURN  
VALVE, IN.  
VALVE, EX.  
LIFTER, VALVE  
2
2
2
1
1
1
2
2
1
1
1
1
2
2
SPRING,VALVE  
RETAINER, IN. VALVE SPRING  
RETAINER, EX. VALVE SPRING  
ROTATOR, VAL;VE  
PLATEW, PUSH ROD GUIDE  
BOLT, PIVOT 8MM  
NUT, PIVOT ADJUSTING  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 59  
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GX-200VEN2 — RECOIL STARTER ASSY.  
RECOIL STARTER ASSY.  
PAGE 60 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — RECOIL STARTER ASSY.  
RECOIL STARTER ASSY.  
NO.  
1
2
3
4
5
6
7
8
PART NO.  
PART NAME  
QTY.  
REMARKS  
28400ZH8013ZB  
28405ZL0000ZA  
28410ZH8003ZB  
28420ZH8013  
28422ZH8013  
28433ZH8003  
28441ZH8003  
28442ZH8003  
28443ZH8003  
28461ZH8003  
28462ZH8003  
9003ZH8003  
STARTER ASSY., RECOIL *NH1* BLACK .........1 ................ INCLUDES ITEMS W/  
*
SPACER, MOUNTING *NH1*BLACK  
1
CASE COMP. NH1 BLACK  
1
1
2
1
1
1
2
1
1
1
3
* *  
REEL, NATURAL  
RATCHET  
GUIDE  
SPRING, FRICTION  
SPRING  
SPRING, RETURN  
GRIP  
ROPE  
SCREW, SETTING  
BOLT, FLANGE 6X18  
9
10  
11  
12  
13  
957010601800  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 61  
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GX-200VEN2 — FAN COVER ASSY.  
FAN COVER ASSY.  
PAGE 62 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — FAN COVER ASSY.  
FAN COVER ASSY.  
NO.  
PART NO.  
PART NAME  
QTY.  
REMARKS  
1
*
2
3
5
6
8
9
10  
11  
13  
16584883300  
19610ZL0000ZD  
19611ZH8820  
19620ZL0V30  
196740ZL0V30  
36100ZH7003  
36101ZE1010  
90013883000  
90022888010  
906901ZH7D02  
93500050350A  
957010600800  
34150ZH7003  
957010600800  
SPRING, CONTROL ADJUSTING  
1
1
1
COVER COMP., FAN NH1 BLACK  
PLATE COMP., SIDE ALERT & LAMP  
SHROUD ASSY., UPPER ............................. 1 ............ INCLUDES ITEMS W/  
SHROUD COMP., LOWER  
SWITCH ASSY., ENGINE STOP  
CORD, STOP SWITCH 370MM  
BOLT, FLANGE 6X12 CT200  
BOLT, FLANGE 6X20 CT200  
CLIP, HARNESS  
SCREW, PAN 5X35  
BOLT, FLANGE 6X8  
ALERT UNIT, OIL  
BOLT, FLANGE 6X8  
* *  
*
1
1
1
8
1
1
1
1
1
1
14  
15  
19  
21  
*
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 63  
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GX-200VEN2 — CARBURETOR ASSY.  
CARBURETOR ASSY.  
PAGE 64 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CARBURETOR ASSY.  
CARBURETOR ASSY.  
NO.  
PART NO.  
PART NAME  
QTY.  
REMARKS  
1 #%+  
16010ZB1015  
16011ZE0005  
16013ZE0005  
16015ZE0831  
16024ZE1811  
16028ZE0005  
16044ZE0005  
16100ZL0V31  
16124ZE0005  
16166ZL0000  
16211ZL0000  
16212ZH8800  
16221ZH8801  
16269ZE1800  
16610ZB2000  
9430520122  
GASKET SET  
VALVE SET FLOAT  
FLOAT SET  
1
1
1
*
2
3
*
4
CHAMBER SERT FLOAT .............................. 1 ................INCLUDES ITEMS W/%  
SCREW SETY, DRAIN  
SCREW SET ................................................. 1 ................INCLUDES ITEMS W/#  
CHOKE SET  
CARBURETOR ASSY. BE74A A/B ............... 1 ................INCLUDES ITEMS W/  
SCREW, THROTTLE STOP  
NOZZLE, MAIN  
6 %  
1
*
7
8
*
1
*
9
*
10  
1
1
1
1
1
1
*
11  
*
12  
INSULATOR  
13  
14  
15  
16  
PACKING, INSULATOR  
PACKING, CARBURETOR  
PACKING, AIR CLEANER  
LEVER COMP., CHOKE ............................... 1 ................INCLUDES ITEMS W/  
>
17>  
PIN, SPRING 2X12  
JET, MAIN #72  
JET, MAIN #75  
JET, MAIN #78  
1
1
1
1
18  
18  
18  
19  
20  
99101ZH80720  
99101ZH80750  
99101ZH80780  
99204ZE20400  
16016ZH7W01  
*
*
*
*
*
JET SET, PILOT #40 ..................................... 1 ................INCLUDES ITEMS W/+  
SCREW SET, PILOT  
1
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 65  
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GX-200VEN2 — AIR CLEANER ASSY.  
AIR CLEANER ASSY.  
PAGE 66 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — AIR CLEANER ASSY.  
AIR CLEANER ASSY.  
NO.  
1
2
3
4
5
6
7
8
PART NO.  
PART NAME  
ELEMENT  
SEPARATOR  
CASE COMP.  
STAY  
COVER  
SEAL  
BOLT, WINKER SETTING  
NUT, FLANGE 6MM  
BOLT, FLANGE 6X10  
QTY.  
REMARKS  
17211ZB2000  
17212ZB2000  
17220ZB2000  
17222ZL0V30  
17231ZB2000  
17252ZB2000  
90115459770  
9405006080  
1
1
1
1
1
1
4
2
1
9
957010601000  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 67  
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GX-200VEN2 — MUFFLER ASSY.  
MUFFLER ASSY.  
PAGE 68 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — MUFFLER ASSY.  
MUFFLER ASSY.  
NO.  
1
3
4
5
6
7
8
9
PART NO.  
PART NAME  
QTY.  
REMARKS  
18310ZB3C00  
18355898630  
18381ZE1800  
92101080200A  
94001080000S  
18310ZB2000  
18325ZH8T90  
18329ZB2000  
18381ZH8800  
MUFFLER COMP.  
1
1
1
2
2
1
1
2
1
ARRESTER, SPARK  
GASKET  
BOLT, HEX. 8X20  
NUT, HEX 8MM  
PROTECTOR, MUFFLER OUTER  
PROTECTOR, MUFFLER INNER DENYO  
SEAL, MUFFLER PROTECTOR  
GASKET  
10  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 69  
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GX-200VEN2 — FUEL COCK ASSY.  
FUEL COCK ASSY.  
PAGE 70 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — FUEL COCK ASSY.  
FUEL COCK ASSY.  
NO.  
1
2
4
5
17  
21  
22  
PART NO.  
PART NAME  
QTY.  
REMARKS  
16080898631  
16081471831  
16950898632  
16952883005  
90854ZB3000  
950014514040  
9500202080  
PACKING SET, COCK  
CUP, FUEL STRAINER  
FUEL COCK ASSY.  
SCREEN SET  
1
1
1
1
1
RUBBER, 9X15X20  
TUBE, 4.5 140 ............................................... 1 ............ REPLACES 950014500160M  
CLIP B8, TUBE  
2
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 71  
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GX-200VEN2 — FLYWHEEL ASSY.  
FLYWHEEL ASSY.  
PAGE 72 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — FLYWHEEL ASSY.  
FLYWHEEL ASSY.  
NO.  
1
2
4
5
PART NO.  
PART NAME  
KEY, SPECIAL WOODRUFF, 25 X18  
FAN, COOLING  
PULLEY, STARTER  
FLYWHEEL COMPLETE, (LAMP)  
NUT, SPECIAL 14 MM  
QTY.  
REMARKS  
13331357000  
19511ZE1000  
28451ZL0000  
31110ZL0811  
90201878003  
1
1
1
1
1
7
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 73  
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GX-200VEN2 — IGNITION COIL ASSY.  
IGNITION COIL ASSY.  
PAGE 74 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — IGNITION COIL ASSY.  
IGNITION COIL ASSY.  
NO.  
1
2
3
4
5
7
8
9
PART NO.  
PART NAME  
QTY.  
REMARKS  
30500ZE1033  
30600ZE1013  
31630ZL0V31  
31511ZE1000  
31512ZE1000  
90015883000  
90019883000  
90121952000  
IGNITION COIL ASSY.  
1
TERMINAL ASSY. HIGH TENSION............... 1 ............ NICHIWA Y-EZ  
COIL ASSY., CHARGE  
CLAMAPER, CORD  
GROMMET, CORD  
BOLT, FLANGE 6X28  
BOLT, FLANGE 5X10  
BOLT, FLANGEN 6X25  
1
1
1
2
1
2
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 75  
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GX-200VEN2 — CONTROL ASSY.  
CONTROL ASSY.  
PAGE 76 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — CONTROL ASSY.  
CONTROL ASSY.  
NO.  
1
2
4
5
6
7
18  
24  
PART NO.  
PART NAME  
QTY.  
REMARKS  
30500ZE1033  
16550ZL0V30  
16555ZL0V30  
16559ZL0V30  
16561ZL0V30  
16562ZL0V30  
90015ZE5010  
9405006000  
IGNITION COIL ASSY.  
ARM COMP, GOVERNOR  
ROD, GOVERNOR  
1
1
1
1
1
1
1
1
RETURN SPRING, COVENOR SUB. ARM  
SPRING, GOVERNOR  
SPRING,THROTTLE RETURN  
BOLT, GOVERNORT ARM  
NUT, FLANGE 6MM  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 77  
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GX-200VEN2 — RECTIFER ASSY.  
RECTIFER ASSY.  
PAGE 78 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — RECTIFER ASSY.  
RECTIFER ASSY.  
NO.  
1
*
2
PART NO.  
PART NAME  
QTY.  
REMARKS  
1628893000  
SPRING, CHOKER RETURN  
1
16270ZL0V30  
31700KAE871  
31750ZL0V31  
32110ZL0V30  
36330ZL0V31  
90683SA0003  
93500050080A  
9405006000  
AUTO THROTTLE ASSY. .............................. 1 ............ INCLUDES ITEMS W/  
CONDENSER UNIT  
RECTIFIER ASSY., REGULATOR  
SUB HARNESS ASSY.  
SOLENOID ASSY.......................................... 1 ............ INCLUDES ITEMS W/#  
CLIP, WIRE HARNESS 25MM  
SCREW, PAN 5X8  
NUT, FLANGE 6MM  
*
3
*
4
*
5
1
1
1
6
*
7
2
2
2
1
2
2
1
8
*
9
10#  
9430520062  
PIN, SPRING 2X6  
11  
12  
957010601600  
957010602500  
16273ZL0V30  
BOLT, FLANGE 6X16  
BOLT, FLANGE 6X25  
LEVER,SOLENOIDTHROTTLE  
*
13  
*
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 79  
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GX-200VEN2 — LABEL ASSY.  
LABEL ASSY.  
PAGE 80 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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GX-200VEN2 — LABEL ASSY.  
LABEL ASSY.  
NO.  
3
14  
15  
27  
PART NO.  
PART NAME  
QTY.  
REMARKS  
87521ZL0000  
87528ZB2630  
87533ZC0630  
87532ZH8810  
EMBLEM  
1
1
1
1
MARK, CHOKE  
MARK, AIR CLEANER  
MARK, OIL ALERT  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 81  
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Effective: October 1, 2002  
TERMS AND CONDITIONS OF SALE — PARTS  
PAYMENT TERMS  
5. Partsmustbeinnewandresalablecon-  
dition,intheoriginalMultiquippackage(if  
any), and with Multiquip part numbers  
clearlymarked.  
Multiquipreservestherighttoquoteandsell  
directtoGovernmentagencies,andtoOrigi-  
nal Equipment Manufacturer accounts who  
useourproductsasintegralpartsoftheirown  
products.  
Terms of payment for parts are net 10 days.  
FREIGHTPOLICY  
All parts orders will be shipped collect or  
prepaidwiththechargesaddedtotheinvoice.  
All shipments are F.O.B. point of origin.  
Multiquip’sresponsibilityceaseswhenasigned  
manifesthasbeenobtainedfromthecarrier,  
andanyclaimforshortageordamagemustbe  
settledbetweentheconsigneeandthecarrier.  
6. Thefollowingitemsarenotreturnable:  
SPECIALEXPEDITINGSERVICE  
a. Obsolete parts. (If an item is in the  
price book and shows as being re-  
placedbyanotheritem,itisobsolete.)  
A$35.00surchargewillbeaddedtotheinvoice  
forspecialhandlingincludingbusshipments,  
insuredparcelpostorincaseswhereMultiquip  
mustpersonallydeliverthepartstothecarrier.  
b. Any parts with a limited shelf life  
(such as gaskets, seals, “O” rings,  
andotherrubberparts)thatwerepur-  
chasedmorethansixmonthspriorto  
thereturndate.  
LIMITATIONSOFSELLER’SLIABILITY  
MINIMUMORDER  
Multiquip shall not be liable hereunder for  
damagesinexcessofthepurchasepriceofthe  
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  
otherspecial,consequentialorincidentaldam-  
ages.  
The minimum charge for orders from Mul-  
tiquipis$15.00net.Customerswillbeasked  
for instructions regarding handling of orders  
notmeetingthisrequirement.  
c. Anylineitemwithanextendeddealer  
netpriceoflessthan$5.00.  
d. Special order items.  
RETURNEDGOODSPOLICY  
e. Electricalcomponents.  
f. Paint,chemicals,andlubricants.  
g. Decalsandpaperproducts.  
h. Itemspurchasedinkits.  
Returnshipmentswillbeacceptedandcredit  
willbeallowed,subjecttothefollowingprovi-  
sions:  
LIMITATIONOFWARRANTIES  
Nowarranties,expressorimplied,aremade  
in connection with the sale of parts or trade  
accessoriesnorastoanyenginenotmanufac-  
turedbyMultiquip.Suchwarrantiesmadein  
connectionwiththesaleofnew,completeunits  
aremadeexclusivelybyastatementofwar-  
rantypackagedwithsuchunits,andMultiquip  
neitherassumesnorauthorizesanypersonto  
assume for it any other obligation or liability  
whatever in connection with the sale of its  
products.Apartfromsuchwrittenstatementof  
warranty, there are no warranties, express,  
impliedorstatutory,whichextendbeyondthe  
descriptionoftheproductsonthefacehereof.  
1. AReturnedMaterialAuthorizationmust  
be approved by Multiquip prior to ship-  
ment.  
7. Thesenderwillbenotifiedofanymaterial  
receivedthatisnotacceptable.  
2. ToobtainaReturnMaterialAuthorization,  
alistmustbeprovidedtoMultiquipParts  
Salesthatdefinesitemnumbers,quanti-  
ties, and descriptions of the items to be  
returned.  
8. Suchmaterialwillbeheldforfiveworking  
days from notification, pending instruc-  
tions.Ifareplyisnotreceivedwithinfive  
days,thematerialwillbereturnedtothe  
senderathisexpense.  
a. Thepartsnumbersanddescriptions  
must match the current parts price  
list.  
9. Creditonreturnedpartswillbeissuedat  
dealer net price at time of the original  
purchase,lessa15%restockingcharge.  
b. The list must be typed or computer  
generated.  
10. In cases where an item is accepted, for  
which the original purchase document  
can not be determined, the price will be  
basedonthelistpricethatwaseffective  
twelvemonthspriortotheRMAdate.  
c. The list must state the reason(s) for  
thereturn.  
d. The list must reference the sales  
order(s)orinvoice(s)underwhichthe  
itemswereoriginallypurchased.  
11. Credit issued will be applied to future  
purchasesonly.  
e. The list must include the name and  
phonenumberofthepersonrequest-  
ingtheRMA.  
PRICINGANDREBATES  
Prices are subject to change without prior  
notice.Pricechangesareeffectiveonaspe-  
cificdateandallordersreceivedonorafterthat  
datewillbebilledattherevisedprice.Rebates  
3. AcopyoftheReturnMaterialAuthoriza-  
tionmustaccompanythereturnshipment.  
4. Freight is at the sender’s expense. All forpricedeclinesandaddedchargesforprice  
partsmustbereturnedfreightprepaidto increaseswillnotbemadeforstockonhand  
Multiquip’sdesignatedreceivingpoint.  
atthetimeofanypricechange.  
PAGE 82 — GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #0 (06/23/04)  
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NOTE PAGE  
GAW-135H DC WELDER/AC GENERATOR — OPERATION MANUAL — REV. #1 (06/23/04) — PAGE 83  
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OPERATION AND PARTS MANUAL  
HERE'S HOW TO GET HELP  
PLEASE HAVETHE MODEL AND SERIAL  
NUMBER ON-HANDWHEN CALLING  
MULTIQUIP CORPORATE OFFICE  
18910 Wilmington Ave.  
Carson, CA 90746  
800-421-1244  
FAX:310-537-3927  
Email: mq@multiquip.com  
Internet:www.multiquip.com  
PARTS DEPARTMENT  
800-427-1244  
310-537-3700  
FAX:800-672-7877  
FAX:310-637-3284  
MAYCO PARTS  
800-306-2926  
310-537-3700  
FAX:800-672-7877  
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  
FAX:310-537-1173  
WARRANTYDEPARTMENT  
800-421-1244,EXT.279  
310-537-3700,EXT.279  
Manufactured for MULTIQUIP INC.  
by  
DENYO MANUFACTURING CO., JAPAN  
Your Local Dealer is:  
Atlanta • Boise • Dallas • Houston • Newark  
Montreal, Canada • Manchester, UK  
Rio De Janiero, Brazil • Guadalajara, Mexico  
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