MULTIQUIP SGW-250SS Specifications

MULTIQUIP SGW-250SS Specifications
PARTS AND OPERATION MANUAL
MQ POWER
WHISPERWELDTM
DC WELDER/AC GENERATOR
© COPYRIGHT 2001, MULTIQUIP INC.
Model SGW-250SS
Parts No. D2845200004A
Revision #2 (08/08/01)
MULTIQUIP INC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
SERVICE DEPARTMENT:
800-421-1244
800-478-1244
FAX: 310-537-3927
FAX: 310-537-4259
E-mail:[email protected] • www:multiquip.com
PAGE 2 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SER
VICE DEP
AR
TMENT
DEPAR
ARTMENT
SERVICE
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ............................................ 3
Table Of Contents ..................................................... 4
Parts Ordering Procedures ....................................... 5
Rules For Safe Operation ...................................... 6-7
Operation and Safety Decals ................................. 8-9
Specifications .......................................................... 10
General Information ................................................ 11
Dimensions ............................................................. 12
Trailer Safety Guidelines .................................... 13-17
Trailer Wiring Diagram............................................. 18
Towing ..................................................................... 19
Controls and Indicators ...................................... 20-21
Installation ............................................................... 22
Pre-Setup ........................................................... 23-25
Instrumentation ....................................................... 26
Load Application ..................................................... 27
Welder Operating Instructions ........................... 28-30
Engine Operating Instructions ................................ 31
Maintenance ...................................................... 32-33
Preparation For Long Term Storage ....................... 34
Engine/Generator Wiring Diagram .......................... 35
Troubleshooting (Welder) ....................................... 36
Troubleshooting (Engine) ................................... 37-39
Explanation Of Codes In Remarks Column ............ 40
Suggested Spare Parts ........................................... 41
Honda GX610VXD Engine
Cylinder Head Assembly ....................................60-61
Cylinder Barrel Assembly ...................................62-63
Crankcase Cover Assembly ...............................64-65
Crankshaft Assembly .........................................66-67
Piston Assembly .................................................68-69
Camshaft Assembly ...........................................70-71
Fan Cover Assembly ..........................................72-73
Carburetor Assembly .........................................74-75
Air Cleaner Assembly.........................................76-77
Muffler Assembly ...............................................78-79
Fuel Pump Assembly .........................................80-81
Flywheel Assembly ............................................82-83
Ignition Coil Assembly ........................................84-85
Starter Motor Assembly .....................................86-87
Control Assembly ...............................................88-89
Terms and Conditions Of Sale — Parts .................. 90
MQ Power SGW-250SS—
DC Welder/AC Generator
Generator Assembly .......................................... 42-43
Control Panel Assembly ..................................... 44-47
Electric Parts Assembly...................................... 48-49
Battery Assembly ............................................... 50-51
Tail Pipe Assembly ............................................. 52-53
Fuel Tank Assembly ........................................... 54-55
Enclosure Assembly ........................................... 56-57
Name Plate And Decals ..................................... 58-59
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
PARTS ORDERING PROCEDURES
■
■
■
■
■
■
■
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
•
•
•
•
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
•
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
1-9 items
Additional Discount
3%
10+ items**
5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■ UPS Ground Service at no charge for freight
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
ount
c
s
i
D
Fax
Extra
c USA
i
t
s
e
m
for Do
Only
s
r
e
l
a
De
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 5
RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is for
industrial use only.
The following safety guidelines should always be used when
operating the SGW-250SS Welder/AC Generator :
GENERAL SAFETY
■ DO NOT operate or service this equipment before
reading this entire manual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steeltoed boots and other protective devices required
by the job.
■ NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
■ Manufacture does not assume responsibility for any accident
due to equipment modifications.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
■ The engine of this welder/generator requires an adequate
free flow of cooling air. Never operate the generator in any
enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause serious
damage to the welder/
generator engine and may
cause injury to people.
Remember the welder/
generator's engine gives off
DEADLY carbon monoxide
gas.
■ Always refuel in a well-ventilated area, away from sparks and
open flames.
■ Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is
spilled on a hot engine.
■ NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
■ Always check the machine for loosened threads or bolts
before starting.
PAGE 6 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
RULES FOR SAFE OPERATION
CAUTION:
This generator is a source of providing
LETHAL high voltages. Never permit
unqualified personnel-especially children to
operate the generator.
■
Always refuel in a well-ventilated
area, away from sparks and open flames.
■ This generator is equipped with a ground terminal for your
protection. Always complete the grounding path from the
generator to an external grounding source.
■ NEVER operate this generator, or handle any electrical
oot, while
ater,, while bare ffoot,
equipment while standing in w ater
hands are wet, or in the rain. Dangerous electrical shock
could occur causing severe bodily harm or even death.
■ Keep electrical cords in good condition. Worn, bare or frayed
wiring can cause electrical shock, thus causing bodily harm
or even death.
■ Provide adequate ventilation when operating the generator.
DO NOT operate the generator in any enclosed or narrow
space. The gasoline engine that provides power to the
generator gives off DEADLY monoxide gas.
■ Always make sure the welder/ generator is secure on level
ground so that it cannot slide or shift around, endangering
workers. Also keep the immediate area free of bystanders.
■ High Temperatures – Allow the machine and engine to cool
before adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
CAUTION:
Emergencies
Always know the location of the nearest fire
extinguisher and first aid kit . Know the
location of the nearest telephone. Also know
the phone numbers of the nearest ambulance,
doctor and fire department.
■ This generator requires an adequate free flow of cooling
air. Never operate the generator in any enclosed or narrow
area where free flow of the air is restricted. If the air flow is
restricted it will cause serious damage to the generator and
may cause injury to people.
Maintenance Safety
■ NEVER touch the hot exhaust manifold, muffler or cylinder.
Allow these parts to cool before servicing generator.
■ NEVER lubricate components or attempt service on a running
machine.
■ Always allow the machine a proper amount of time to cool
before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always replace
broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant, fuel
and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant, or fuel directly onto the
ground, down a drain or into any water source.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 7
OPERATION AND SAFETY DECALS
PAGE 8 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
OPERATION AND SAFETY DECALS
P/N DCL160
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 9
SGW-250SS — SPECIFICATIONS
Table 1. Specifications
Welder Specifications
Rated Output (CV/CC)
4.0/5.6 kW
Rated Current (CC)
200 Amps
Rated Voltage (CV/CC)
20/28 Volts
Duty Cycle
100%
Rated Speed
3600/rpm
Voltage Range
15-28 Volts
Current Range
50 - 225 Amps
Generator Specifications
Phase
Single Phase
Wires
3-Wires (Neutral Grounded)
Rated Output
7.2 kW
Rated Voltage
120/240 Volts
Frequency
60 Hz
Power Factor
1.0
Rating
Continuous
Engine Specifications
Model
HONDA GX610VXD
Type
4-STROKE, OHV
Rated Output
10.7 kW/14.4 HP
@ 3600 rpm
Displacement
37.5 cu. in (614 cc)
Cooling System
Forced air
Starting System
Electric Start
Fuel Tank Capacity
10 gal/38 liters
Lube Oil Capacity
0.40 gal/1.5 liters
Fuel Consumption:
CV Welding
0.93 gal (3.51 liters)/hr.
CC Welding
1.11 gal (4.22 liters)/hr.
AC Power
1.16 gal (4.38 liters)/hr.
Battery
12V-35Ah
Fuel
Unleaded Gasoline
Dimensions (LxWxH)
1070 x 590 x 815 mm
(42.1 x 23.2 x 32.1 in)
Dry Weight
553 lbs. (251 kg)
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
PAGE 10 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — GENERAL INFORMATION
SGW-250SS FAMILIARIZATION
Generator
The MQ Power Model SGW-250SS welder/generator can
provide 200 amps of welding current when in the CV/DC
mode and 250 amps of welding current when in the CC/DC
mode. When used as a generator it can provide a maximum
of 7,200 watts of power.
Control Panel
The control panel is provided with the following:
z One GFCI 120 volt receptacle, 30 amp (single-phase)
z One 120 volt receptacle, 30 amp (single-phase)
z One 120/240 volt receptacle, 30 amp (single-phase)
z Main Circuit Breaker 265V @25 Amps
z Circuit Protector Breaker (GFCI) 120V @20 Amps
z Idle Control Switch
z Starter Switch
z Starter Button
z Hour Meter
z Ground Terminal
Welder Protection System
In the event of an overload, this welder/generator is equipped
with an welder protection system . If an overload is detected
while operating the welder/generator, the welder protection
system will shut down the engine.
Oil Pressure Warning Alarm
In the event of low oil pressure (engine), this welder/generator
is equipped with an engine protection fail safe system . If
low oil pressure is detected while operating the welder/
generator, the engine protection system will shut down the
engine.
If this condition (low oil pressure) should occur, please refer
to the engine troubleshooting table in this manual.
Excitation System
The SGW-250SS welder/generator uses a brushless
exciter to create rated output electricity. This system will
use the mechanical energy generated by the 3600 RPM
engine to spin the rotor (or armature) inside the generator
(or alternator end).
The motion created by the rotor (which holds copper coils)
spins inside a housing of permanent magnets called the
"STATOR". A magnetic field is created by the stator and
produces an electrical current.
Engine
The SGW-250SS is powered by an air-cooled, 4-cycle
HONDA gasoline engine. This engine is designed to meet
every performance requirement for generator. Reference
Table 1, page 9 for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Figures 2 and 3 (pages 14-15) show the basic controls and
indicators for the SGW-250SS welder/generator.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 11
SGW-250SS — DIMENSIONS
Figure 1. SGW-250SS Dimensions
PAGE 12 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — TRAILER-SAFETY GUIDELINES
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
ALWAYS make sure the trailer is in good 5. Frame Width - This measurement is from fender to
operating condition. Check the tires for
fender.
proper inflation and wear. Also check the 6.
Jack Stand - Trailer support device with maximum
wheel lug nuts for proper tightness.
pound requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
Explanation of Chart:
8. Tire Size - Indicates the diameter of the tire in inches
This section is intended to provide the user with trailer ser(10,12,14, etc.), and the width in millimeters
vice and maintenance information. The service and main(175,185,205, etc.). The tire diameter must match the
tenance guidelines referenced in this section apply a wide
diameter of the tire rim.
range of trailers. Remember periodic inspection of the trailer 9. Tire Ply - The tire ply (layers) number is rated in letters;
will ensure safe towing of the equipment and will prevent
2-ply,4-ply,6-ply, etc.
damage to the equipment and personal injury.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
It is the purpose of this section to cover the major mainte- 11. Tire Rim - Tires mounted on a tire rim. The tire rim must
nance components of the trailer. The following trailer commatch the size of the tire.
ponents will be discussed in this section:
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
„ Brakes
nuts. See Table 4 and Figure 5 or lug nut tightening and
„ Tires
sequence.
„ Lug Nut Torquing
13. Axle - Indicates the maximum weight the axle can sup„ Suspension
port in pounds, and the diameter of the axle expressed
„ Electrical
in inches (see Table 3). Please not that some trailers
„ Brake Troubleshooting Tables
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
Use the following definitions with reading Table 2.
pounds.
1. Fuel Cell - Provides an adequate amount of fuel for 14. Suspension - Protects the trailer chassis from shocks
the equipment in use. Fuel cells must be empty when
transmitted through the wheels. Types of suspension
transporting equipment.
used are leaf, Q-flex, and air ride.
2. Braking System - System employed in stopping the 15. Electrical - Electrical connectors (looms) are provided
trailer. Typical braking systems are electric, surge, hywith the trailer so the brake lights and turn signals can
draulic, hydraulic-surge and air.
be connected to the towing vehicle.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the 16. Application - Indicates which units can be employed
maximum number of pounds the trailer can carry, inon a particular trailer.
cluding the fuel cell (empty).
CAUTION:
4.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 13
SGW-250SS — TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FU E L
C E LL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
SDW225,
SGW250,TLW300
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10
DCA10, TLG12,
DCA-15
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10XF
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-225W
WELDERS,
D A 7000S S
NO
NO
2200LB S
85"
42"
800LB .
FULL TILT WHEEL
TRLR-BLW400
BLW-400
NO
ELECTRIC
2700LB S
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB .
FULL TILT WHEEL
TRLR-50X
DCA-25
NO
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-50XF
DCA-25
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-70W
DCA-45, -60, 70
NO
SURGE
7000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-70X
DCA-45, -60, 70
OPT
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-70XF
DCA-45, -60, 70
53 GAL
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-100XF
DCA-100, 125
150 GAL
HYDRAULIC SURGE
7000LB S
190"
76"
2000LB .
FLAT PAD
TRLR-85/125
DCA-85, 100,
125
145 GAL
HYDRAULIC
10000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-150XF
DCA-150, 180
200 GAL
HYDRAULIC SURGE
11160LBS
204"
84"
5000 LB .
FLAT PAD
TRLR-220XF
DCA-220
250 GAL
HYDRAULIC SURGE
14000LB S
222"
83"
5000 LB .
FLAT PAD
TRLR-300XF
DCA-300
250 GAL
HYDRAULIC SURGE
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-400XF
DCA-400
350 GAL
ELECTRIC
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-600XF
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
TRLR-800SX
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
PAGE 14 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS
SUSPENSION
ELECTRICAL
TRLR-10W
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X 2
5 LUG
3 LE A F
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-10XF
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
2" B A LL C LA S S
2 ADJUSTABLE
175-13B
13X4.5"
2200#2X 2
5 LUG
Q F LE X
4 POLE FLAT
TRLR-BLW
400
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13 X 4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-50X
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-50XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-70W
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70X
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70XF
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-100XF
ADJUSTABLE 2-5/6
OPT 3" EYE
205-15C
BIAS (4)
14"X5.5"
3500lbs
3"
5 LUG
5 LE A F
4 WIRE LOOM
TRLR-85/125
ADJUSTABLE 2-5/6
OPT 3" EYE
ST225/75R15D
RADIAL (4)
14"x6"
(2)-6000lbs
6 LUG
7 LE A F
4 WIRE LOOM
TRLR-150XF
3" BALL EYE
750-16 E
BIAS (4)
16" X 7"
(2)-6000lbs
8 LUG
7 LE A F
4 WIRE LOOM
TRLR-220XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16" X 7"
(2)-7000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-300XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(2)-6000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-400XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(3)-7000lbs.
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-600XF
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
7 LE A F
6 WIRE LOOM
TRLR-800AR
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
AIR-RIDE
6 WIRE LOOM
TRLR-225W
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 15
SGW-250SS —TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked,
the
air
pressure in
the inner tube may cause pieces
of the rim to explode (break off)
with great force and cause serious
eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 3 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components
(Figure 2) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 4.
CAUTION:
Figure 2. Major Suspension Components
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
PAGE 16 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS —TRAILER SAFETY GUIDELINES
Table 4. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
MIN-30 MAX-35
7/16" U-BOLT
MIN-45 MAX-60
1/2" U-BOLT
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
SPRING EYE BOLT
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
MIN-30 MAX-50
SHOULDER TYPE
SHACKLE BOLT
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 3. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 5.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 5. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
Figure 3. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 17
SGW-250SS —TRAILER-WIRING DIAGRAM
PAGE 18 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS —TOWING
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
Towing Safety Precautions
CAUTION :
Check with your county or state safety
towing regulations department before
towing your generator. Vehicle towing
codes and regulations can vary from state
to state.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 4) and the towing vehicle are in good operating
condition and both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
■ Check the tire air pressure on both the towing vehicle and
the trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and are
working properly.
■ The maximum speed (unless otherwise posted) for highway
towing is 45 MPH. Recommended off-road towing is not to
exceed 10 MPH or less, depending on type of terrain.
■ Place chocked blocks underneath wheel to prevent rolling
rolling,
while parked.
■ Place support blocks underneath the trailer's bumper to
prevent tipping, while parked.
■ Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.
■ Avoid sudden stops and starts. This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 4. Welder/AC Generator and Towing Trailer
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 19
SGW-250SS — CONTROLS AND INDICATORS
Figures 5 and 6 show the location of the controls and indicators.
The functions of each control or indicator is described below
and on the preceding page.
8.
Engine Air Cleaner – Prevents dirt and other debris
from entering the fuel system. Lift locking latch on air
filter cannister to gain access to filter element.
1.
Welding Type (Wire/Stick) Selector Switch (CV/CC) –
Turn this selector switch to either the CV or CC for
welding. DO NOT turn this switch under load.
9.
Main Circuit Breaker – This 2-pole circuit breaker provides
circuit protection (265V @30 amps) for the electric parts.
2.
Current Range Selector Switch (CV/CC) – Turn this
selector switch to either the CV or CC for welding. DO
NOT turn this switch under load.
3.
Current Control (CC) Adjustment Knob – Use this
control to adjust welding current. Low scale (50~120 amps),
High scale (90~250 amps). This function will not work in
the CV mode.
4.
Voltage Control (CV) Adjustment Knob – Use this
control to adjust the welding voltage. This function will not
work in the CC mode.
5.
Idle Control Switch – Regulates the engine speed when
the generator is under load.
6.
Hour Meter – Indicates number of hours the welder has
been in use or engine has been running.
7.
Oil Filler Port – Use this port when adding oil to the
engine.
3
5
2
ON
6
7
WHISPERWELD
1
4
AC CIRCUIT
BREAKER
QUARTZ
11. Start Button – Press and hold this push-button switch
until the engine has started. The ON/OFF switch must be
in the ‘ON’ position in order for the start push-button switch
to start the engine.
12. Oil Filter – Provides oil filtering for the engine.
13. Fuel Cap – Remove this cap to add fuel. Add only clean
unleaded fuel. Always keep an adequate amount of fuel
in the tank. DO NOT top off. Wipe up any spilled fuel
immediately.
14. Battery Terminals – Connect these terminals to the
battery. Always pay close attention to the polarity of the
terminals when connecting to the battery, RED (positive),
and BLACK (negative).
15. Battery – Provides +12 VDC power for the generator.
When replacing battery (12V 35 AH) use only
recommended type battery.
MQ POWER
10
SGW-250S
S
OFF
POWERE
IDLE CONTROL HONDAD by
8
10. ON/OFF Switch – This switch is used to start and stop the
engine. Must be in th ON position (up) when starting the
engine. Place in the OFF position (down) to stop the engine.
HOUR MET
ER
ON
OFF
OPERATION
SWITCH
9
MQ POWER
START
BUTTON
Po
MQ PO
WER
urce
wer So
Profess
12
ionals.
14
11
13
15
Figure 5. SGW250SS Components 1
PAGE 20 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — CONTROLS AND INDICATORS
16. Positive Welding Output Terminal – Connect the
welding cable to this terminal. Select the appropriate
polarities according to the application. See Table 7.
23. Frame Ground Lug – Connect a ground strap between
this lug and a ground rod. Make sure the ground rod is
inserted deep into the ground to provide a good earth
ground. Consult with local Electrical and Safety Codes
for proper connection.
17. Negative Welding Output Terminal – Connect the
negative cable of the welding source to this terminal.
Select the appropriate polarities according to the
application. See Table 7.
24. Fuel Tank – Holds 10 gallons (38 liters) of unleaded
fuel.
18. Receptacle G.F.C.I. – This receptacle provides 120 volts
and output @ 20 amps.
25. Fuel Gauge – Indicates the amount of fuel in the fuel
tank.
19. Circuit Protector Circuit Breaker – This single pole circuit
breaker provides circuit protection (250V @20 amps) for
the G.F.C.I receptacle.
26. Choke Knob – Used in the starting of a cold engine, or
in cold weather conditions. The choke enriches the fuel
mixture for starting a cold engine.
20. Receptacle – Provides 120 volts output @ 25 amps.
27. Lifting Hook – Use this hook to lift the generator.
21. Receptacle – Provides 120/240 volts output @ 25 amps.
28. Engine Oil Dipstick – Indicates engine oil level, add oil
as required. See Table 3 for correct type of oil.
22. G.F.C.I Ground Terminal – Use this terminal to connect
external equipment grounds so the G.F.C.I. receptacle will
have a ground path.
30. Fuel drain Plug – Remove this plug to drain fuel from
the fuel tank.
27
ON
MQ POWER
WHISPERWELD
SGW-250SS
POWERED
by
OFF
POWERED
IDLE CONTROL HONDA by
AC CIRCUIT
BREAKER
QUARTZ
HOUR MET
ER
ON
26
OFF
OPERATION
SWITCH
MQ POWER
START
BUTTON
Power
16
17
18
Source
MQ PO
Profess
ionals.
28
23
24
MQ POWER
WHISPER WELD
22
WER
19 20
21
29. Oil Drain Plug – Remove this plug to drain oil from the
engine.
Power
Source
HC
25
30
FRONT VIEW
29
Figure 6. SGW250SS Components 2
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 21
Profes
sionals.
SGW-250SS — INSTALLATION
Outdoor Installation
Indoor Installation
Install the welder/generator in a location where it will not be
exposed to rain or sunshine. Make sure the welder/generator
is on secure level ground so that it cannot slide or shift
around. Install the generator in a manner so the exhaust
fumes will not be discharged in the direction of nearby homes.
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.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials will cause excessive wear, to the engine and
alternator parts.
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any gasoline engine
are very poisonous if discharged in a closed room, but
harmless if allowed to mix with the outside air. If the generator
is installed indoors, you must make provisions for venting
the engine exhaust to the outside of the building.
CAUTION :
CAUTION :
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.
Note:
Selecting Optimum Welding Cable
Use the table below (Table 2) to select the best cable for the
total length and current of the application being used.
During the operation of Self-Sheld Welding ro MIG
Welding, do not allow the cables to bundle, because it
will cause a short current drop. This may also happen
if the size of the cables are smaller than recommended.
Table 6. Welding Cable Sizes
Total Cable Length (ft)/
Current (A)
50
100
125
150
200
250
300
100
#4
#4
#4
#3
#3
#2
#1
150
#3
#3
#3
#2
#1
#1/0
#2/0
200
#2
#2
#2
#1
#1/0
#2/0
#3/0
250
#1
#1
#1
#1/0
#2/0
#3/0
#4/0
PAGE 22 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — PRE-SETUP
General Inspection Prior to Operation
The SGW-250SS utilizes a generator that has been thoroughly
inspected and accepted prior to shipment from the factory.
However, be sure to check for damaged parts or components,
or loose nuts and bolts, which could have occurred in transit.
Ground
The nut and ground terminal on the generator should always
be used to connect the generator to a suitable ground. The
ground path should be of #8 size wire.
Connect the terminal of the ground wire between the lock
washer and the nut and tighten the nut fully. Connect their
end of the wire to a suitable ground.
Circuit Breaker
To protect the generator from an overload, a 2-pole, 30 amp,
circuit breaker is provided. Make sure to switch the circuit
breaker to the "OFF" position prior to starting the engine.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 3 ) as a guide
for selecting proper cable size.
Table 7. Generator Cable
Load In Watts
Current in
Amperes At 120 At 240
Volts
Volts
Maximum Allowable Cable Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
CAUTION: Equipment damage can result from low voltage.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 23
SGW-250SS — PRE-SETUP
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the welder/generator is
level. With the dipstick inserted all the way, but without being
screw into the filler hole, verify that the oil level is maintained
between the two notches (Figure 7) on the dipstick. See
Table 4 for proper selection of engine oil.
Fuel
Fill the fuel tank with clean and fresh unleaded gasoline. DO
NOT fill the tank beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 11,
Specification Table 1.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel.
CAUTION :
Never fill the fuel tank while the engine is
running or in the dark. Gasoline spillage
on a hot engine can cause a fire or
explosion. If gasoline spillage occurs, wipe
up the spilled gasoline completely to
prevent fire hazards.
Figure 7. Engine Oil Dipstick
Table 8. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
Below 5° C (-15°)
SAE 10W or SAE 10W-30
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the engine manual.
Battery
This unit is of negative ground. DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions, always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.
The battery gradually deteriorates over time. The actual life
span will vary according to operating conditions, but
generally a battery two years or older should be replaced.
PAGE 24 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
BLW-400SSW — PRE-SETUP
CAUTION :
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant or antifreeze is done from the
reserve tank. See Table 9 for engine, radiator and reserve
tank coolant capacities. Make sure the coolant level in the
reserve tank is always between the "H" and the "L" markings.
Cleaning the Radiator
The radiator may overheat if the fins become overloaded
with dust or debris. Periodically clean the radiator fins with
compressed air.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect and adjust it in
accordance with the Kubota Engine Operator's Manual.
The fan belt tension is proper if the fan belt (Figure 5) bends
7 to 9 mm (0.28- to 0.35 in.) when depressed with the thumb
as shown in Figure 13 below.
Table 9. Coolant Capacity
Engine and Radiator
1.1 Gal. (4.16L)
Reserve Tank
0.2 Gal. (0.75L)
Operation in Freezing Weather
When operating in freezing weather, be certain that the proper
amount of antifreeze has been added. See Table 10 for
antifreeze operating temperatures.
Figure 13. Fan Belt Tension
CAUTION :
Never place hands near the belts or fan
while the welder/AC generator is running.
Table 10. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
°C
°F
°C
°F
40
-24
-12
106
222
50
-37
-34
108
226
Vol %
Anti-Freeze
NOTE
When the antifreeze is mixed with
w ater
atio m
ust
ater,, the antifreez
antifreezee mixing rratio
must
be less than 50%.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
ator's Man
ual.
Operator's
Manual.
accordance with the Kobota Engine Oper
Battery
This unit is of negative ground. DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions, always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 25
SGW-250SS — INSTRUMENTATION
CAUTION :
Idle Control Switch
When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the generating set.
Power Outlets
The generator has the following 60 Hz, 120/240 volt singlephase receptacles.
z Single Phase
One Duplex NEMA (GFCI) 5-20R (120V, 20 Amp)
One Twist Lock NEMA L5-30R (120V, 25 Amp)
One Twist Lock NEMA L14-30R (120/240V, 25 Amp)
Main Circuit Breaker (2-Pole)
This 2-pole 25 amp breaker protects the generator from short
circuiting or overloading from the 60 Hz single phase load.
The unit is provided with an automatic idle control for noise
suppression and fuel cost reduction. The automatic idle
control automatically engages under a no-load condition.
With the automatic idle control switched “ON”, the engine
revolutions will automatically drop to about 2100 rpm (lowspeed operation) within 7 seconds after the welding stops.
When welding is resumed, the engine speed is automatically
increased to about 3600 rpm (high-speed operation) as soon
as the electrode contacts the base metal
This provides for smooth welding operation. With AC loads
of more than 100W (such as lighting equipment, motorpowered tools, submersible water pumps, etc.), the engine
runs at high speed. When a no load condition is produced,
the engine automatically shows down.
Turn the idle control switch to the “ON” (up) position when
the welder or AC loads of more than 100W is connected.
Turn the idle control switch to the “OFF” (down) position
when AC loads of less than 100W or when a magnetic switch
is used.
Fuel Gauge
GFCI Protection Breaker (Single-Pole)
This Single-pole 25 amp breaker protects the GFCI
receptacle from short circuiting or overloading from the 60
Hz single phase load.
The fuel gauge is located on the fuel tank and allows easy
monitoring of the fuel level.
GFCI Receptacle
Before connecting a load to the generator's GFCI receptacle,
push the "Test Button" on the front of receptacle before
connecting the load, to confirm that the receptacle is
functioning correctly.
PAGE 26 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — LOAD APPLICATION
CAUTION:
Single Phase Load
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
NOTE
If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which
cannot carry the required load can cause a voltage drop
which can burn out the appliance or tool and overheat the
cable.
The idle control is operated at minimum load capacity of
100W. If the load capacity is less than 100W, place the idle
control switch to the OFF position.
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
The power factor of this generator is 1.0. See Table 5. below
when connecting loads.
Table 11. Power Factor By Load
Type Of Load
Single-phase induction motors
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
Electronic devices, communication equipment
Power Factor
0.4 - 0.75
1.0
0.4 - 0.9
1.0
z When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
z When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
z When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 27
SGW-250SS — WELDER OPERATING INSTRUCTIONS
Welding Cables and Polarities
Connect the welding cables (Figure 8) to the welder's output
terminals located on the control panel. The output terminals
have positive(+) and negative(-) polarities. Select the
appropriate polarities according to the application (SeeWelding
Application, Table 6).
NOTE
Attach terminal connectors at the end
of each cable. NEVER connect
exposed wires (Figure 9) directly to the
terminal. Exposed wiring may cause
shocks or di-electric breakdown from
poor contact.
Figure 8. Welding Cable Connection
(Correct)
Figure 9. Welding Cable Connection
(Incorrect)
Table 12. Welding Applications
POLARITY
Straight Polarity
Reverse Polarity
WELDING METHOD
TYPICAL APPLICATIONS
(+) ... Ground Clamp
Welding steel materials for general
structures, and thickness plates.
(-) ... Electrode Holder
Arc welding for copper alloy
(+) ... Ground Clamp
Build-up welding, ARC welding of
thin plates
(+) ... Electrode Holder
Arc welding of stainless steel
Note: Reguarding the selection of the polarity in the CV charactertics, follow the
instructions from the wire manufacturer.
PAGE 28 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — WELDER OPERATING INSTRUCTIONS
CAUTION :
NEVER switch the CV/CC Selector
Switch during any welding operation.
When switching a selector switch, fully
rotate it to the right or left position.
1.
Turn the CV/CC Selector Switch
(Figure 10) to the CV position, and adjust voltage using
the Voltage Control knob.
NOTE
When the CV/CC Selector Switch is in the CC position,
the Voltage Control function is inoperative.
3. Set the CC Current Range Selector Switch to the
desired position (Low/High).
4. Adjust current output, by setting Current Control knob
to desired current output.
NOTE
When using the Current Control knob to adjust the current
output, the outer scale is for the high range, and the inner
scale is for the low range.
Auxiliary AC Power
Figure 10. Welding Voltage Adjustment
NOTE
When the CV/CC Selector Switch is in the CV position,
the Current Control , and Current Range Selector
Switch functions are inoperative.
The Auxiliary AC power in most cases will not be affected
by the CV/CC Selector Switch or any controls (Figure 12)
on the front panel, and will supply a stable constant AC
voltage except when the welding mode is activated.
2. Turn the CV/CC Selector Switch (Figure 11) to the CC
position.
Figure 12. Auxilliary AC Power
NOTE
Figure 11. Welding Current Adjustment
When welding, remember that the output of the AC
AUXILIARY POWER is affected by the welding
operation. See next page for generator output voltage
conditions when welding.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 29
SGW-250SS — WELDER OPERATING INSTRUCTIONS
Welding and Auxiliary Outputs.
Duty Cycle
The welding and auxiliary outputs can be used simultaneously,
subject to all of the following conditions:
The welder is rated at 100% duty cycle at 250 amps.
However the duty cycle depends upon the welding
current. Select the appropriate duty cycle from Table 7
to prevent overload.
z CC/CV Selector Switch is in the CC mode.
z CC Current Range Selector is in the low mode.
z Current Control is in the MAX position.
NOTE
NOTE
The 250 amp, 60% duty cycle referenced in
Table 7 is for CV welding ONLY.
Under the above conditions, the welder can
supply welding current of 120 amps, and
AC current up to 3 kW at 120V and 240V.
Table 13. Duty Cycle
Duty Cycle (%)
100
80
60
Current (Amps)
200 or less
225
250
PAGE 30 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — ENGINE OPERATING INSTRUCTIONS
WARNING:
CAUTION:
The engine's exhaust contains harmful
W AY S ventilate the
emissions. A LLW
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.
AR
T ” push-button
STAR
ART
NEVER press the the “ST
switch while the engine is running.
Before Starting
1. Be sure to disconnect the electrical load and switch the
main circuit breaker to the “OFF” position prior to starting
the engine.
6. Let the engine idle for five minutes with the Automatic
Idle Control switch in the “ON” position.
2. Never start the engine with the main circuit breaker “ON”.
7. Check the engine for abnormal vibrations, noises and
oil leakage.
3. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
4. When there is not enough lubricating oil, fill the
crankcase with high grade motor oil. Use a high quality
detergent oil classified CC or higher (See Table 3 on
page 16).
8. Check the generator's output voltage by connecting an
AC voltmeter to the 120/240 volt output receptacles. If
the voltmeter indicates 120 volts, then 120 VAC can be
obtained from the 120 V and 240V receptacles at the
same time.
9. Turn the Automatic Idle Control Switch to either “OFF”
or “ON” for full engine operation.
5. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure that the radiator cap
is fastened securely.
Shutdown
CAUTION:
z Check the fuel level on the fuel gauge.
When fuel is low, fill the fuel tank with
clean fresh unleaded automotive
gasoline.
Starting
1. Remove the load from the generator, then place both
the main and GFCI circuit breakers to the OFF position.
2. Listen for the engine speed to drop. Run at low speed
for 3-5 minutes.
3. Stop the engine by setting the ON/OFF switch on the
generator's front panel to the OFF position.
z If gasoline spillage occurs, completely
wipe up the spilled gasoline.
1. On the front panel of the generator, set the ON/OFF
switch to the ON position (up).
2. Pull the choke knob half way out (half open).
3. Press and hold the start “push-button” switch until the
engine starts, then release.
4. After the engine starts gradually push the choke knob
inward, all the way back to its closed position.
5. If the engine does not start within 10 seconds after
pushing start button, wait about 30 seconds and repeat
steps 1 through 4. If the engine fails to start after repeated
attempts, refer to Table 8, Engine Troubleshooting.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 31
SGW-250SS — MAINTENANCE
General Inspection
At least daily or prior to each use, the welder/AC generator
should be cleaned and inspected for deficiencies. Check for
loose, missing or damaged nuts, bolts or other fasteners.
Also check for fuel or oil leaks.
Engine Side:
For a more detail engine maintenance schedule refer to the
HOND
A Engine Oper
ator's Man
ual.
HONDA
Operator's
Manual
Air Cleaner:
Every 50 hours: Remove air cleaner element by removing
the wing bolts and screws. Inspect and clean heavy duty
paper element by tapping it several times or blow with
compressed air (not to exceed 30 psi). If element is too
dirty or damaged, replace. Clean foam element with liquid
detergent and hot water or with kerosene. Wrap foam element
in a cloth and squeeze dry. Wipe any dirt from the inside of
the air cleaner body and cover using a moist rag. Be careful
to prevent dirt from entering the air chamber that leads to
the carburetor.
Place the foam air filter element to the air cleaner body. Be
sure the gaskets are in place, then reinstall the paper air
filter element and cover. Tighten the air filter wing bolt
securely.
Removing Water from the Fuel ank
After prolonged use, water and other impurities accumulate in the bottom of the fuel tank. Occasionally remove
the drain cock and drain the contents. During cold
weather, the more empty are inside the tank, the easier it
is for water to accumulate inside the tank. This can be
reduced by always keeping the fuel tank as full as possible.
Fuel Addition
Always add clean, fresh unleaded fuel. Always pour
through mesh lining.
Rectifier Fins
Periodically inspect the rectifier fins for contamination.
ALWAYS keep fins free of dirt.
Air Removal
If air enters the fuel system of a gasoline engine, starting
becomes impossible. After running out of gasoline, or
after disassembling the fuel system, bleed the system by
following this procedure:
Turn the operation switch to the ‘ON’ position for 15-30
seconds. Try again, if needed.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
PAGE 32 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SDW-225SS — MAINTENANCE
SGW-250SS — MAINTENANCE
INSPECTION / MAINTENANCE
ENGINE
GENERATOR
10 Hrs DAILY
Check Engine Fluid Levels
X
Check Air Cleaner
X
Check Battery Acid Level
X
Check Fan Belt Condition
X
Check for Leaks
X
Check for Loosening of Parts
X
250 Hrs
Replace Engine Oil and Filter *1
X
Clean Air Filter
X
Drain Bottom of Fuel Tank
X
Clean Unit, Inside and Outside
X
500 Hrs
Change Fuel Filter *2
X
Clean Radiator and Check Coolant Protection Level
X
1000 Hrs
Replace Air Filter Element
X
Check all Hoses and Clamps
X
Clean Inside of Fuel Tank
X
Measure Insulation Resistance Over 3M ohms
X
*1 Replace engine oil and filter at 100 hours, first time only.
*2 Replace fuel filter at 250 hours, first time only.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 33
SGW-250SS — PREPARATION FOR LONG -TERM STORAGE
Welder/Generator Storage
For storage of the generating set for over 30 days, the
following is required:
z Drain the fuel tank completely.
z Run the engine until the gasoline in the carburetor is
completely consumed.
z Completely 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 few times with the and install
a new plug.
z Remove the NEGATIVE battery cable from the negative
post on the battery.
z Stop the engine at the compression point.
z Clean all external parts of the generating set with a cloth.
z Cover the generating set and store in a clean, dry place.
PAGE 34 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS —ENGINE/GENERATOR WIRING DIAGRAM
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 35
SGW-250SS — TROUBLESHOOTING (WELDER)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of
a breakdown, please take a remedial action following the
diagnosis based on the Welder Troubleshooting (Table 8)
information shown below. If the problem cannot be remedied,
please consult our company's business office or service
plant.
TABLE 14. WELDER TROUBLESHOOTING
SYMPTOM
AC voltage is not present in generator's
AC section or welding section.
Poor welding and low voltage in AC
power section.
AC power is normal but but there is no
welding capability. Current and voltage
adjustments are in-operative.
AC power is too low or can not be used,
but welding is normal.
Battery discharges too soon.
POSSIBLE PROBLEM
SOLUTION
Low speed ?
Refer to "Engine remains at low speed" section.
Defective resistor (R)?
Replace resistor.
Defective Field Controller?
Replace "Field Controller".
Defective rotor?
Replace rotor.
Defective Wiring?
Repair wiring.
Blown fuse F3?
Replace fuse.
Defective Field Controller?
Replace "Field Controller".
Defective rotor?
Replace rotor.
Low speed ?
Refer to "Engine remains at low speed" section.
Layer short-circuit in armature
winding?
Replace armature.
Defective wiring?
Repair wiring.
Defective current transformer?
Replace transformer, CT1, CT2 or CT3.
Defective Field Controller?
Replace "Field Controller".
Defective rectifier (Re)?
Replace rectifier.
Defective reactor (DCL or L1 or L2)?
Replace reactor.
Inadequate length and thickness of
welding cable.
Replace welding cable.
Layer short-circuit in armature
winding?
Replace armature.
Defective wiring?
Repair wiring.
Defective selector switches?
Replace S1 or S2.
Defective circuit breaker
Replace circuit breaker.
Layer short-circuit in armature winding
(AC side)?
Replace armature.
Defective wiring?
Repair wiring.
Defective Field Controller?
Replace "Field Controller".
Defective engine regulator?`
Replace regulator.
Defective wiring?
Repair wiring.
Defective ignition switch?
Replace ignition switch.
PAGE 36 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of
a breakdown, please take a remedial action following the
diagnosis based on the Engine Troubleshooting (Table 9)
shown below. If the problem cannot be remedied, please
consult our company's business office or service plant.
TABLE 15. ENGINE TROUBLESHOOTING (PART 1)
SYMPTOM
Engine does not start.
POSSIBLE PROBLEM
SOLUTION
No fuel?
Replenish fuel.
Air in the fuel system?
Bleed system.
Water in the fuel system?
Remove water from fuel tank.
Fuel pipe clogged?
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity
of fuel or engine oil at low
temperature?
Use the specified fuel or engine oil.
Fuel with low cetane
number?
Use the specified fuel.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Incorrect injection timing?
Adjust.
Fuel cam shaft worn?
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump
malfunctioning?
Repair or replace.
Seizure of crankshaft,
camshaft, piston, cylinder
liner or bearing?
Repair or replace.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Piston ring and liner worn?
Replace.
Excessive valve clearance?
Adjust.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 37
SGW-250SS — TROUBLESHOOTING (ENGINE)
TABLE 15. ENGINE TROUBLESHOOTING (PART 2)
SYMPTOM
Engine revolution is not
smooth.
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Clean or change.
Air cleaner clogged?
Clean or change.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Injection pump
malfunctioning?
Repair or replace.
Incorrect nozzle opening
pressure?
Adjust.
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe
clogged?
Clean.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn
Either white or blue exhaust or stuck?
gas is observed.
Incorrect injection timing?
Either black or dark gray
exhaust gas is observed.
Deficient output.
SOLUTION
Repair or replace.
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving parts
seem to be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
PAGE 38 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — TROUBLESHOOTING (ENGINE)
TABLE 15. ENGINE TROUBLESHOOTING (PART 3)
SYMPTOM
Engine fails to start and starter
rotates.
Engine starts and remains at low
speed.
Starter does not run.
POSSIBLE PROBLEM
SOLUTION
Broken pre-heat circuit?
Check pre-heat circuit.
No fuel?
Add fuel.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Clean or replace.
Clogged air cleaner?
Clean or replace.
Disconnected wiring?
Check and repair wiring.
Battery discharged?
Charge battery.
Starter malfunctioning?
Repair or replace.
Key switch malfunctioning?
Repair or replace.
Wiring disconnected?
Connect wiring.
Fuse F5 burned out?
Replace fuse.
No voltage present in AC power
source?
Replace rectifier (RE1).
Defective rotor?
Engine speed rises and no voltage
Defective voltmeter?
is present in AC power source.
Disconnected wiring?
Layer short-circuit in armature
winding?
Engine speed rises and AC power Defective circuit breaker (protector)?
voltage is too low or cannot be
Layer short-circuit, broken wires in
used.
armature winding?
Replace rotor.
Replace voltmeter.
Check and repair wiring.
Replace armature.
Replace circuit breaker (protector).
Repair or replace armature.
Engine speed rises and battery
discharges too soon.
Defective engine regulator?
Replace regulator.
Defective wiring?
Repair or replace wiring.
Engine speed rises and engine
seems overloaded.
Defective alternator?
Repair or replace alternator.
Damaged alternator bearing?
Replace alternator bearings.
Engine starts and "Idle Control
Switch" is in OFF position. Engine Bad engine installation?
speed rises and engine has large
vibrations. Overloads.
Engine starts and "Idle Control
Switch" is in OFF position. Engine
speed rises and engine has
abnormal noise.
Engine starts and "Idle Control
Switch" is in OFF position. Engine
speed rises and remains at high
speed when Idle Control switch is
placed in the ON position.
Repeat installation of engine.
Loose engine parts?
Check all engine parts for tightnes.
Defective alternator?
Check alternator for damaged bearing or loose
clamping bolts.
Defective enclosure?
Check enclosure bolts for tightness.
Defective idle control device?
Repair or replace idle control device.
Defective idle control switch?
Replace idle control switch.
Defective solenoid?
Replace solenoid.
Defective relay?
Replace relay.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 39
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #, +, %,
or ■, belong to the same assembly or kit.
*
Note: If more than one of the same reference number is listed,
the last one listed indicates newest (or latest) part available.
NOTE
The contents of this parts catalog are
subject to change without notice.
PAGE 40 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — SUGGESTED SPARE PARTS
SGW W/HOND
A GX610 AIR-COOLED ENGINE 1 TO 3 UNITS
W/HONDA
Qty.
P/N
Description
5 ......... 17010ZJ1000 ... AIR FILTER
1 ......... 17218ZJ1000 ... AIR FILTER, OUTER
5 ......... 16910ZE8015 .. FUEL FILTER
5 ......... 15400PR3004 .. OIL FILTER
1 ......... 15427ZJ1000 ... SCREEN, CRANKCASE OIL FILTER
1 ......... 35480ZJ1812 ... SWITCH ASSY., OIL LEVEL
1 ......... 0601200102 ..... STARTER SWITCH
1 ......... 0810105800 ..... FUEL CAP
1 ......... 0601805331 ..... MAIN CIRCUIT BREAKER
1 ......... 0601827399 ..... CONTROL UNIT
1 ......... 1620150404 ..... SOLENOID, ROTARY
4 ......... 9807952876 ..... SPARK PLUG
2 ......... 0601821370 ..... RECTIFIER
1 ......... 0601831841 ..... CV/CC SELECTOR SWITCH
1 ......... 0601803070 ..... CC CURRENT RANGE SELECT. SW
2 ......... D1233000004 .. OUTPUT TERMINAL
2 ......... 0801880004 ..... INSULATOR WASHER
4 ......... 0039510000 ..... HEX NUT
4 ......... 0045110000 ..... LOCK WASHER
4 ......... 0042710000 ..... PLAIN WASHER
2 ......... 0037810000 ..... WING NUT
1 ......... 0601803117 ..... KNOB, SELECTOR SWITCHES
1 ......... A6356400303 .. THROTTLE WIRE
1 ......... 0602125032 ..... FUEL GAUGE
1 ......... 31740ZJ7003 ... DIODE ASSY., ENGINE STOP
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 41
SGW-250SS — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 42 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — GENERATOR ASSY.
GENERATOR ASSY.
NO
1
1-1
*
1-2
*
1-3
*
1-4
*
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
PART NO
D2110100003
0601820037
0601822638
042006304
3051070003
D2113400004
0801086104
D2113100004
0040010000
D2155100202
D2134000803
D2155000104
D2137000203
011606025
1961324003
D2133300004
D2131500404
0040010000
031110160
D1153500603
D11535005031
D2155500013
011006010
1961844513
0601820012
0601820013
0017105016
103189004
011208035
D2185300004
0040008000
031108160
0019008016
020108060
1991843504
1001843504
D2155400004
02072080000
011208025
PART NAME
QTY.
REMARKS
ROTOR ASSY .......................... 1 .......... INCLUDES ITEMS W/
*
RECTIFIER .............................. 1 .......... S10VB60
SURGE ABSORBER ................ 1 .......... TNR15G 431K
BEARING ................................. 1 .......... 6304 DDU; REPLACES 0071206304
FAN
1
SET BOLT ROTOR
1
SET WASHER BEARING
1
FAN
1
LOCK WASHER
1
END BRACKET
1
ARMATURE ASSY
1
END BRACKET
1
FIELD ASSY EXCITER
1
HEX HEAD BOLT ..................... 4 .......... REPLACES 0017106025
GROMMET
1
COVER
1
SET BOLT
4
LOCK WASHER
4
PLAIN WASHER ....................... 4 .......... REPLACES 0041210000
COVER
2
COVER
2
COVER
1
HEX HEAD BOLT ..................... 4 .......... REPLACES 0017106010
FIN
4
RECTIFIER .............................. 2 .......... SR30MA- 6S
RECTIFIER .............................. 2 .......... SR30MA-6R
HEX HEAD BOLT
16
INSULATOR WASHER
16
HEX HEAD BOLT ..................... 6 .......... REPLACES 0017108035
SET BOLT
2
LOCK WASHER
2
PLAIN WASHER ....................... 2 .......... REPLACES 0041208000
HEX HEAD BOLT
4
HEX NUT .................................. 4 .......... REPLACES 0207208000
CONNECTION PLATE
2
CONNECTION PLATE
12
COVER FAN
1
HEX NUT
2
HEX HEAD BOLT ..................... 4 .......... REPLACES 0012308025
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 43
SGW-250SS — CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
PAGE 44 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
PART NO
D2205000203
0021805020
0601831841
0601803070
0021304015
8705945004
0601840095
0601840026
0601840103
0023304008
0601805331
4341817004
0027104015
0601830739
0601830796
0601200102
0601800682
0027403512
0030003500
0801831204A
0801880004
020310080
030212300
0042710000
0037810000
0601812529
0601811031
0601812597
0021004012
0030004000
0601806420
0027103006
0601815109
D2238100203
D2238400004
0805088004
0821800014
011206020
0207006000
0016906016
0601842462
0027104012
0601821370
0027105040
PART NAME
QTY.
REMARKS
CONTROL PANEL ............................................. 1 ........... D25122 00002
MACHINE SCREW
4
CV CC SELECTOR SWITCH ............................ 1 ........... SSK- 1831
CC CURRENT RANGE SELECTOR SWITCH .. 1 ........... SSK-2036C
MACHINE SCREW ........................................... 6 ........... REPLACES 0021506012
SEAL
2
RHEOSTAT CURRENT CONTROL ................... 1 ........... RV24YN20SB2KO
RHEOSTAT VOLTAGE CONTROL ..................... 1 ........... RA25YN20SB2KOJ
KNOB ................................................................ 2 ........... K- 2195
SET SCREW
4
CIRCUIT BREAKER ......................................... 1 ........... KM52 265V 30A
BRACKET CIRCUIT BREAKER
1
MACHINE SCREW
2
IDLE CONTROL SWITCH ................................. 1 ........... ET210N12
OPERATION SWITCH ...................................... 1 ........... ET225N12
STARTER SWITCH ........................................... 1 ........... ST- 403
HOUR METER .................................................. 1 ........... #820114
MACHINE SCREW
2
HEX NUT
2
OUTPUT TERMINAL .........................................2 ...........REPLACES D1233000004
INSULATOR WASHER
2
HEX NUT ........................................................... 4 ...........REPLACES 0039510000
LOCK WASHER ................................................. 4 ...........REPLACES 0045110000
PLAIN WASHER
4
WING NUT
2
RECEPTACLE ................................................... 1 ........... L14- 30R
RECEPTACLE ................................................... 1 ........... L5- 20R
RECEPTACLE ................................................... 1 ........... 5- 20R
MACHINE SCREW
6
HEX NUT ........................................................... 6 ...........REPLACES 0207004000
CIRCUIT PROTECTOR
1
MACHINE SCREW
2
GROUND TERMINAL ........................................ 1 ........... T- 381
COVER OUTPUT TERMINAL
1
RUBBER SHEET
1
STAY RUBBER
1
COLLAR
2
HEX HEAD BOLT .............................................. 2 ...........REPLACES 0016906020
HEX NUT
2
HEX HEAD BOLT
1
RESISTOR ........................................................ 1 ........... GG40W35O
MACHINE SCREW
2
RECTIFIER ....................................................... 3 ........... DE4503
MACHINE SCREW
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 45
SGW-250SS — CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
PAGE 46 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
NO
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
PART NO
0601804211
0027104012
0601823204
0027103020
0601827399
0027105012
0601823707
0027105020
0601815870
D9522001204
0601815758
D9522000804
0027105020
8511864601A
0016906016
0601802137
0601803117
PART NAME
QTY.
REMARKS
CURRENT TRANSFORMER ............................. 3 ........... MCT-100Y
MACHINE SCREW
6
RECTIFIER ....................................................... 2 ........... S5VB60
MACHINE SCREW
2
CONTROL UNIT ................................................ 1 ........... FD-80
MACHINE SCREW
6
RELAY .............................................................. 1 ........... CA1A-DC12V- N
MACHINE SCREW
1
TERMINAL BOARD .......................................... 1 ........... KT-20 2P
SYMBOL SEAL
1
TERMINAL BOARD .......................................... 1 ........... KT- 30 2P
SYMBOL SEAL
1
MACHINE SCREW
2
TERMINAL PLATE ............................................. 1 ...........REPLACES 8511864604
HEX HEAD BOLT
5
FUSE ................................................................ 1 ........... 10A AC250V
KNOB (SELECTOR SWITCHES)
2
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 47
SGW-250SS — ELECTRIC PARTS ASSY.
ELECTRIC PARTS ASSY.
PAGE 48 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — ELECTRIC PARTS ASSY.
ELECTRIC PARTS ASSY.
NO
1
2
2-1
*
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO
D2263500303
D2263500403
0601831054
0017106016
1622636103Z
1992636004
0050403020
0010106025
0030006000
A6356600404
0017105010
D2356200003
0207006000
0010106040
0038706000
0016906016
A6356400303B
0017105010
PART NAME
QTY.
REMARKS
AC REACTOR
2
DC REACTOR ..................... 1 ............... INCLUDES ITEMS W/
*
THERMOSTAT ..................... 1 ............... REPLACES 0603210120
HEX HEAD BOLT
12
ROTARY SOLENOID ........... 1 ............... 7SL25-22; REPLACES 1620150404
ARM SOLENOID
1
SPRING PIN
1
HEX HEAD BOLT
1
HEX NUT
1
WIRE STOPPER
1
HEX HEAD BOLT
1
BRACKET SOLENOID
1
HEX NUT
2
HEX HEAD BOLT
1
HEX NUT
1
HEX HEAD BOLT
4
THROTTLE WIRE
1
HEX HEAD BOLT
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 49
SGW-250SS — BATTERY ASSY.
BATTERY ASSY.
PAGE 50 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
0805081004
D2345200004
0805082704
0037806000
0040006000
0041206000
0602220600
0602220601
D1343200604
PART NAME
QTY.
REMARKS
BATTERY SHEET.................. 1 ............ REPLACES 1702202104
BATTERY BAND
1
BATTERY BOLT
2
WING NUT
2
LOCK WASHER
2
PLAIN WASHER
2
TERMINAL CAP RED
1
TERMINAL CAP BLACK
1
TERMINAL CAP
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 51
SGW-250SS — TAIL PIPE ASSY.
TAIL PIPE ASSY.
PAGE 52 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — TAIL PIPE ASSY.
TAIL PIPE ASSY.
NO
1
2
3
PART NO
D2335100013
D9102200104
0016908030
PART NAME
OUTLET PIPE
PIPE BAND
HEX HEAD BOLT
QTY.
1
1
1
REMARKS
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 53
SGW-250SS — FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 54 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — FUEL TANK ASSY.
FUEL TANK ASSY.
NO
1
1-1
*
1-2
*
2
3
4
5
6
7
8
PART NO
A6365000402B
0810105900
0810105900
3015530004
0150200011
0602125032
0016908020
0605513143
0605515093
0605515240
PART NAME
QTY.
REMARKS
FUEL TANK ................................ 1 ......... INCLUDES ITEMS W/
*
CAP FUEL TANK ....................... 1 ......... REPLACES 0810105800
FUEL FILTER
1
DRAIN PLUG
1
O RING
1
FUEL GAUGE
1
HEX HEAD BOLT
4
FUEL HOSE
1
HOSE BAND
1
HOSE BAND
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 55
SGW-250SS — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 56 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO
1
1-1
2
3
4
5
6
7
7-1
8
9
10
11
12
13
13-1
14
15
16
17
17-1
18
19
20
21
22
23
24
25
26
27
28
29
PART NO
D2415000412
0226900130
D2415400014
0016906016
D2305100004
D2418500104
0016908020
D2418700103
D2498000004
3025419304
D9312600104
0207010000
0010110045
0207010000
0017110030
D2425000413
D2492200114
0016908020
D2425200104
0016906016
D2485100213
D2498200013
0016908020
D2445000402
0016908020
D2445300304
0016906016
0016906016
0040506000
D2455400013
0016906016
D2465000303
D2498500014
0016908020
D2332300014
0016906016
PART NAME
BASE
EDGE COVER
BASE COVER
HEX HEAD BOLT
ENGINE BASE
GENERATOR BASE
HEX HEAD BOLT
COMMON BASE
LINING
RUBBER SUSPENSION
RUBBER SUSPENSION
HEX NUT
HEX HEAD BOLT
HEX NUT
HEX HEAD BOLT
FRONT FRAME
LINING
HEX HEAD BOLT
COVER FRONT FRAME
HEX HEAD BOLT
PANEL
LINING
HEX HEAD BOLT
REAR FRAME
HEX HEAD BOLT
COVER REAR FRAME
HEX HEAD BOLT
HEX HEAD BOLT
TEETHED WASHER
COVER
HEX HEAD BOLT
ROOF PANEL
LINING
HEX HEAD BOLT
COVER EXHAUST PIPE
HEX HEAD BOLT
QTY.
1
1
1
4
1
1
6
1
1
2
2
8
2
2
2
1
1
4
1
6
1
1
2
1
8
1
5
1
1
1
4
1
1
19
1
3
REMARKS
THE PART NUMBER SHOWN IS TEAL. ADD THE
FOLLOWING LETTERS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
MQW - WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 57
SGW-250SS — NAME PLATE AND DECALS ASSY.
NAME PLATE AND DECALS ASSY.
PAGE 58 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
SGW-250SS — NAME PLATE AND DECALS ASSY.
NAME PLATE AND DECALS ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1*
D2552000404 DECAL: OPERATING INSTRUCTIONS ............ 1 .......... REPLACES D25200040B
2*
D9512100203 DECAL: CAUTION (MULTIPLE) ........................ 1 .......... REPLACES 91210020
3*
0820610404
DECAL: WARNING (TRANSFER SWITCH)
1
4*
0820610304
DECAL: READ OWNER’S MANUAL ................. 1 .......... DCS01
5*
8700611904
DECAL: DANGER ELECT. SHOCK HAZARD ... 1 .......... S4985
6*
B9504000304 DECAL: CAUTION HOT PARTS ........................ 1 .......... REPLACES B90400030
7*
A5562100204 DECAL: MQ POWER ........................................ 3 .......... REPLACES D26220010
8*
D2562100003 DECAL: STRIPE ............................................... 2 .......... REPLACES D26210000
9*
0600689404
DECAL: BATTERY POSITIVE .......................... 1 .......... S2090
10*
0800689504
DECAL: BATTERY NEGATIVE .......................... 1 .......... S2091
11*
0820650604
DECAL: DANGER EXP. GASES (BATTERY) 1
12*
D2562100103 DECAL: STRIPE ............................................... 2 .......... REPLACES D26210010
13
PLATE, SERIAL NO. ......................................... 1 .......... CONTACT MQ SERVICE DEPT
WITH MODEL AND S/N
14*
D2552000313 DECAL: AC POWER OUTPUT ......................... 1 .......... REPLACES D25200031
15*
0800628504
DECAL: GROUND ............................................. 1 .......... S1123
16*
B9504000404 DECAL: WARNING MOVING PARTS ................ 2 .......... REPLACES B90400040
17*
0800690804
DECAL: WELDING OUTPUT TERMINAL
1
18*
8700611804
DECAL: WARNING DANGEROUS GAS ............ 1 .......... S4984
19*
8700611524
DECAL: CAUTION OIL LEVEL GAUGE
1
20*
7810680104
DECAL: FUEL DRAIN ....................................... 1 .......... S3060
21*
1630645004
DECAL: OIL DRAIN .......................................... 1 .......... S1403
22*
D2562200004 DECAL: WHISPER WELD ................................. 1 .......... REPLACES D26220000
23
DCL160
DECAL;PROPOSITION 65 WARNING .............. 1 .......... REPLACES D9522100204
DCLSGW250SSKIT, DECAL ....................................................... 1 .......... INCLUDES ITEMS W/*
SEE DECAL ILLUSTRATIONS ON PAGE 8 AND 9
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 59
HONDA GX610VXD ENGINE — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
PAGE 60 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CYLINDER HEAD ASSY.
CYLINDER HEAD ASSY.
NO
1
2
3
*
4
*
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
PART NO
12210ZJ1000
12220ZJ1U80
12205ZE2305
12216ZE2300
12251ZJ1003
12311ZJ1000
12314ZJ1000
12391ZJ1000
15611921000
17101ZJ1000
17151ZJ1003
90121ZJ1000
91301805000
92900080250B
9430112200
9405008000
9430112200
957010603200
957011007500
957011013000
9807952876
PART NAME
QTY. REMARKS
CYLINDER HEAD COMP., R. ....... 1 .... INCLUDES ITEMS W/
*
CYLINDER HEAD COMP., L. ....... 1 .... INCLUDES ITEMS W/
*
GUIDE, EX. VALVE (OS)
4
CLIP, VALVE GUIDE
4
GASKET, CYLINDER HEAD
2
COVER, HEAD
1
COVER, HEAD FILLER
1
GASKET, HEAD COVER
2
CAP, OIL
1
MANIFOLD, IN.
1
GASKET, IN. MANIFOLD
2
BOLT, FLANGE (6X25) (CT200) 8
O-RING (26X2.7)
1
BOLT, STUD (8X25)
4
PIN A, DOWEL (12X20)
4
NUT FLANGE 8MM
4
PIN DOWEL 12X20
4
BOLT, FLANGE (6X32)
4
BOLT, FLANGE (10X75)
8
BOLT, FLANGE (10X130)
2
SPARK PLUG (BPR2ES)
2
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 61
HONDA GX610VXD ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
PAGE 62 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CYLINDER BARREL ASSY.
CYLINDER BARREL ASSY.
NO
1
2
3
4
5
*
7
10
11
12
15
16
17
18
20
*
22
23
24
25
26
27
1
PART NO
12000ZJ1810
12356ZJ1000
12358ZJ1000
12372ZE2300
13321ZJ1000
13322ZJ1000
13323ZJ1000
15400PT7005
25523VD6010
31511ZJ1000
35480ZJ1812
90014ZE6000
90018PN3000
90029888000
90031ZE1000
91201ZJ1003
91353671003
9280014000
9405010000
9410914000
957010607509
961406003010
120A0ZJ1000
PART NAME
QTY.
REMARKS
CYLINDER BARREL ASSY. .............. 1............... INCLUDES ITEMS W/
*
COVER, BREATHER
1
GASKET, BREATHER COVER
1
VALVE, BREATHER
1
BEARING A, MAIN (BLUE)
1
BEARING B, MAIN (BLACK)
1
BEARING C, MAIN (BROWN)
1
FILTER, OIL ....................................... 1............... REPLACES 15400PR3004
COLLAR, FILTER SETTING
2
CLAMP, WIRE
1
SWITCH ASSY., OIL LEVEL
1
BOLT, FLANGE (6X35)
3
HOLDER, OIL FILTER
1
BOLT, FLANGE (6X16)
2
BOLT, FLANGE (6X32)
2
OIL SEAL (38X58X11)
1
O-RING (14MM) ................................. 1............... REPLACES 91353671004
BOLT, DRAIN PLUG (14MM)
2
NUT, FLANGE (10MM)
1
WASHER, DRAIN PLUG (14MM)
2
BOLT, FLANGE (6X75)
2
BEARING, RADIAL BALL (6003)
1
CYLINDER ASSY.
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 63
HONDA GX610VXD ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
PAGE 64 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CRANKCASE COVER ASSY.
CRANKCASE COVER ASSY.
NO
1
2
3
4*
5
6
7
8
9
10
11
12
16*
17*
18
19
20
21
22
23
24
PART NO
11300ZJ1000
11381ZJ1000
12105ZAO701
13321ZJ1000
13322ZJ1000
13323ZJ1000
15120ZJ1000
15124ZJ1003
15232ZJ1000
15348ZJ1000
15427ZJ1000
15655ZJ1000
16541ZJ1000
16542ZJ1000
91201ZJ1003
91259NM0000
91302MB6830
93500050100A
9430108140
957010602000
957010805000
9621112000
966000601600
PART NAME
QTY.
REMARKS
COVER ASSY., CRANKCASE ..... 1 ......... INCLUDES ITEMS W/*
GASKET, CASE COVER
1
BOLT, SEALING
1
BEARING A, MAIN (BLUE)
1
BEARING B, MAIN (BLACK)
1
BEARING C, MAIN (BROWN)
1
COVER ASSY., OIL PUMP
1
ROTOR, OIL PUMP (OUTER)
1
SPRING, RELIEF VALVE
1
COVER, OIL FILTER
1
SCREEN, OIL FILTER
1
DIPSTICK, OIL
1
SHAFT, GOVERNOR ARM
1
FORK, GOVERNOR
1
OIL SEAL (38X58X11)
1
OIL SEAL (10X16X4.5) ................. 1 ......... REPLACES 91206333003
O-RING (13X3.0)
2
SCREW, PAN (5X10)
2
PIN A, DOWEL (8X14)
2
BOLT, FLANGE (6X20)
3
BOLT, FLANGE (8X50)
9
BALL, STEEL (#12) (3/8)
1
BOLT, SOCKET (6X16)
2
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 65
HONDA GX610VXD ENGINE — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
PAGE 66 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO
3
4
PART NO
13310ZJ0880
90401ZJ1000
PART NAME
QTY.
CRANKSHAFT COMP. V-TYPE
1
WASHER, CRANKSHAFT THRUST
1
REMARKS
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 67
HONDA GX610VXD ENGINE — PISTON ASSY.
PISTON ASSY.
PAGE 68 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — PISTON ASSY.
PISTON ASSY.
NO
1
3
4
5
6
*
7
*
8
PART NO
13010ZE8601
13011ZE8601
13011ZE8602
13012ZE8601
13013ZE8601
13101ZJ1000
13102ZJ1000
13103ZJ1000
13104ZJ1000
13111ZJ1000
13210ZJ1000
13211ZJ1003
13212ZJ1003
13213ZJ1003
13214ZJ1003
13215ZJ1003
13216ZJ1003
13217ZJ1003
13213ML0000
13215KM3000
9460118000
PART NAME
QTY. REMARKS
RING SET, PISTON (STD) NIPPON
2
RING SET, PISTON (0.25) NIPPON
2
RING SET, PISTON (0.25) TEIKOKU
2
RING SET, PISTON (0.50) NIPPON
2
RING SET, PISTON (0.75) NIPPON
2
PISTON (STD)
2
PISTON (0.25)
2
PISTON (0.50)
2
PISTON (0.75)
2
PIN, PISTON
2
ROD SET, CONNECTING ...................................... 2 .......... INCLUDES ITEM W/
*
BEARING A, CONNECTING ROD (BLUE)
4
BEARING B, CONNECTING ROD (BLACK)
4
BEARING C, CONNECTING ROD (BROWN)
4
BEARING D, CONNECTING ROD (GREEN)
4
BEARING E, CONNECTING ROD
4
BEARING F CONNECTING ROD
4
BEARING G CONNECTING ROD
4
BOLT, CONNECTING ROD
4
NUT, CONNECTING ROD
4
CLIP, PISTON PIN (18MM)
4
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 69
HONDA GX610VXD ENGINE — CAMSHAFT ASSY.
CAMSHAFT ASSY.
PAGE 70 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CAMSHAFT ASSY.
CAMSHAFT ASSY.
NO
1
2
3
*
4
5
6
7
8
*
9
*
10
*
11 #
*
12
*
13
14
15
16
17
18
*
19
*
20
*
21
*
22
*
23
*
24
25
26
27
*
28
*
PART NO
12209ZE8003
14100ZJ1801
14110ZJ1801
14410ZJ1000
14431ZJ1000
14441ZE2000
14461ZJ1000
14568ZJ1800
14569ZJ1801
14576ZJ1801
14577ZJ1801
14578ZJ1800
14579ZJ1800
14580ZJ1800
14576ZJ1801
14577ZJ1801
14578ZJ1801
14579ZJ1801
14580ZJ1801
14581ZJ1801
14586ZJ1800
14711ZJ1000
14721ZJ1000
14751ZE2003
14771ZE2000
14775ZE2010
16512ZJ1000
16522ZJ1000
16523ZJ1000
16524ZJ1000
16529ZJ1000
16531ZJ1003
90012415000
90206250000
90446357000
90901ZJ1003
9451017000
PART NAME
QTY.
REMARKS
SEAL, VALVE STEM
2
CAMSHAFT ASSY. ................................................ 1 ......... INCLUDES ITEM W/
*
CAMSHAFT COMP. ............................................... 1 ......... INCLUDES ITEM W/#
ROD, PUSH
4
ARM, VALVE ROCKER
4
LIFTER, VALVE
4
SHAFT, ROCKER ARM
2
SPRING, WEIGHT RETURN
1
HOLDER, DECOMPER PIN
2
PIN A, DECOMPER (7.85)
2
PIN B, DECOMPER (7.95) ..................................... 2 ......... REPLACES 14577ZJ1800
PIN C, DECOMPER (8.05) ..................................... 2 ......... REPLACES 14578ZJ1800
PIN D, DECOMPER (8.15)
2
PIN E, DECOMPER (8.25)
2
PIN A, DECOMPER (7.85)
2
PIN B, DECOMPER (7.95)
2
PIN C, DECOMPER (8.05
2
PIN D, DECOMPER (8.15)
2
PIN E, DECOMPER (8.25)
2
ROD, DECOMPER
1
SPRING, DECOMPER PIN HOLDER
2
VALVE, INLET
2
VALVE, EX.
2
SPRING VALVE
4
RETAINER, IN. VALVE SPRING
4
SEAT, VALVE SPRING
2
HOLDER, GOVERNOR WEIGHT
1
PLATE, GOVERNOR WEIGHT HOLDER
1
PIN, GOVERNOR WEIGHT HOLDER
1
PLATE, GOVERNOR (LOWER)
1
PLATE, GOVERNOR SLIDER
1
SLIDER, GOVERNOR
1
SCREW, TAPPET ADJ.
4
NUT, TAPPET ADJ.
4
WASHER, THRUST (17.2MM)
1
BALL, STEEL (18)
6
CIRCLIP (OUTER) (17MM)
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 71
HONDA GX610VXD ENGINE — FAN COVER ASSY.
FAN COVER ASSY.
PAGE 72 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE —FAN COVER ASSY.
FAN COVER ASSY.
NO
1
4
5
6
7
9
10
12
13
14
15
16
17
18
19
20
21
PART NO
19611ZJ1800ZB
19612ZJ1000
19614ZJ1000
19615ZJ1000
19617ZJ4000
19631ZJ1000
19632ZJ1000
33713GC2000
90013883000
90018ZE1000
90042ZJ1000
90055ZE1000
90104GF6000
90113GE4000
90320MM5000
9405006000
957010600800
PART NAME
COVER, FAN
PLATE, R SIDE
PLATE, L SIDE
HOOD FAN COVER
COVER, R, SIDE PLATE
SHROUD, R
SHROUD, L
COLLAR B, TAILLIGHT
BOLT FLANGE (6X12)
BOLT FLANGE (6X23)
BOLT, STUD (6X75)
SCREW, TAPPING (4X6)
BOLT FLANGE (6X20)
BOLT FLANGE (6MM) BLACK
NUT, SPRING, 6MM
NUT, FLANGE 6MM
BOLT FLANGE (6X8)
QTY.
1
1
1
1
1
1
1
6
8
2
4
3
2
2
2
4
2
REMARKS
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 73
HONDA GX610VXD ENGINE — CARBURETOR ASSY.
CARBURETOR ASSY.
PAGE 74 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CARBURETOR ASSY.
CARBURETOR ASSY.
NO
1
2
3#
*
4
*
5
*
6
*
7
8#
*
9
*
10
*
11
12
*
13
*
14
*
15
*
16
*
17
18
19
20
21++
22
23
*
24
25
26
27
*
PART NO
12357ZJ1000
15772551000
16010ZG8000
16011382004
16013ZV4005
16015ZJ1000
16016ZJ1010
16024124760
16028ZG8000
16081ZV4650
16100ZJ0892
16148141881
16151ZJ0020
16166ZJ1010
16178548004
16200ZJ1003
16211ZJ1000
16221ZG8000
17228ZG8003
17410ZJ1000
19024ZA0000
90682959661
938920501218
9500202080
950054546020
958010610508
99201ZG80880
99201ZG80820
99201ZG80850
PART NAME
QTY. REMARKS
TUBE, BREATHER
1
CLIP, BREATHER TUBE
1
GASKET SET
1
VALVE SET, FLOAT ................................ 1 ......... REPLACES 16011GK0891
FLOAT SET
1
CHAMBER SET, FLOAT ......................... 1 ......... INCLUDES ITEMS W/#
SCREW SET
1
SCREW SET,DRAIN
1
SCREW SET
1
SCREW-WASHER
4
CARBURETOR ASSY. (BG21E B) .......... 1 ......... INCLUDES ITEMS W/
*
CAP, CHOKE LEVER DUST
1
JET SET (#60)
1
NOZZLE, MAIN ....................................... 1 ......... REPLACES 16166ZJ0000
O-RING (5.8X1.9)
1
VALVE ASSY., SOLENOID
1
INSULATOR, CARBURETOR
1
GASKET, CARBURETOR
2
GASKET, AIR CLEANER
1
ELBOW COMP., AIR CLEANER ............. 1 ......... INCLUDES ITEMS W/++
COLLAR, DISTANCE
2
CLIP B, CABLE
1
SCREW-WASHER (5X12)
2
CLIP, TUBE (B8)
1
BULK HOSE, VAC (4.5X460)
1
BOLT, FLANGE (6X105)
2
JET SET, MAIN (#88)
1
JET SET, MAIN (#82 HIGH ALTITUDE) 1
JET SET, MAIN (#85 HIGH ALTITUDE) 1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 75
HONDA GX610VXD ENGINE — AIR CLEANER ASSY.
AIR CLEANER ASSY.
PAGE 76 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — AIR CLEANER ASSY.
AIR CLEANER ASSY.
NO
1
2
*
3
*
4
5
6
7
8
9
10
11
12
13
14#
15&
16
17
PART NO
17010ZJ1000
17216ZJ1000
17217ZJ1000
17218ZJ1000
17220ZJ1000
17231ZJ1000
17232ZJ1000
17237ZJ1000
17251ZJ1000
17255758000
17257HB3000
90017ZJ1000
90018ZE1000
90120102000
93500040200A
938910501608
957010601800
PART NAME
QTY.
REMARKS
ELEMENT SET, AIR CLEANER ............. 1 ......... INCLUDES ITEMS W/
*
GASKET A, ELEMENT
1
GASKET B, ELEMENT
1
FILTER (OUTER)
1
HOUSING COMP., AIR CLEANER ......... 1 ......... INCLUDES ITEMS W/#
COVER, AIR CLEANER
1
GROMMET, AIR CLEANER
1
HOSE, AIR CLEANER
1
TUBE, AIR CLEANER CONN.
1
BAND, AIR CLEANER CONN. TUBE ...... 1 ......... INCLUDES ITEMS W/&
BAND, AIR CLEANER (B)
1
BOLT, AIR CLEANER
1
BOLT, FLANGE (6X23)
3
COLLAR, AIR CLEANER HOUSING
4
SCREW, PAN (4X20)
1
SCREW, WASHER
2
BOLT, FLANGE (6X18) ........................... 1 ......... REPLACES 957010601800
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 77
HONDA GX610VXD ENGINE — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 78 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2*
3*
4*
5*
6*
7*
8*
9*
PART NO
06183ZJ1820
18310ZJ1000
18321ZJ1000
18330ZJ1601
18333ZJ1000
18396ZJ1003
957010801400
957010802000
957010600800
PART NAME
QTY. REMARKS
MUFFLER KIT HIGH B ................. 1 ........ INCLUDES ITEMS W/*
MUFFLER COMP. HIGH .............. 1 ........ 18310ZJ1003
PROTECTOR,MUFFLER HIGH .... 1 ........ 18321ZJ1003
PIPE COMP., EX. HIGH-L
1
STAY, MUFFLER HIGH ................. 1 ........ 18338ZJ1003
BAND ASSY.
1
BOLT, FLANGE (8X14)
4
BOLT, FLANGE (8X20)
4
BOLT, FLANGE (6X8)
6
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 79
HONDA GX610VXD ENGINE — FUEL PUMP ASSY.
FUEL PUMP ASSY.
PAGE 80 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — FUEL PUMP ASSY.
FUEL PUMP ASSY.
NO
1
2
4
5
6
7
8
9
10
11
12
13
14
15
PART NO
16700ZJ1003
16711ZJ1800
16910ZE8015
19905ZA8701
35806752630
90617SA0003
950014511040
950015519540
950015521540
9500202080
950024105008
950033601620
957010600800
957010601400
PART NAME
QTY.
PUMP ASSY., FUEL
1
STAY, FUEL PUMP
1
STRAINER COMP., FUEL
1
GROMMET, WIRE
1
BASE, CLIP
1
CLIP, WIRE HARNESS
1
BULK HOSE, FUEL (4.5X110) 1
BULK HOSE, FUEL (5.5X195) 1
BULK HOSE, FUEL (5.5X215) 1
CLIP, TUBE (B8)
2
CLIP, TUBE (10.5MM)
4
TUBE, VINYL (11X13X160)
1
BOLT, FLANGE (6X8)
2
BOLT, FLANGE (6X14)
2
REMARKS
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 81
HONDA GX610VXD ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
PAGE 82 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — FLYWHEEL ASSY.
FLYWHEEL ASSY.
NO
1
2
7
10
11
12
14
PART NO
19511ZJ1000
19513ZJ1000
31110ZJ1811
90201ZG3000
90401ZG3000
90741ZE2000
957010801600
PART NAME
QTY. REMARKS
FAN, COOLING
1
PLATE, COOLING FAN SETTING
1
FLYWHEEL COMP.
1
NUT, FLANGE (20MM)
1
WASHER (20MM)
1
KEY, SPECIAL WOODRUFF (25X18)
1
BOLT, FLANGE (8X16)
3
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 83
HONDA GX610VXD ENGINE — IGNITION COIL ASSY.
IGNITION COIL ASSY.
PAGE 84 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — IGNITION COIL ASSY.
IGNITION COIL ASSY.
NO
1
2
3
4
5
7
8*
9
11
12
13
14
15
PART NO
30500ZJ1013
30518ZJ1000
30550ZJ1013
30700ZJ1003
31630ZJ1003
31630ZJ0880
31740ZJ1003
63312ZA7000
90014ZE6000
90121952000
90658SA0003
90673GJ5003
91504750003
957010600800
PART NAME
QTY.
REMARKS
COIL ASSY., R. IGNITION
1
GROMMET, IGNITION WIRE
2
COIL ASSY., L. IGNITION
1
CAP ASSY., NOISE SUPPRESSER 2
COIL ASSY., CHARGE (12V/3A)
1
COIL ASSY., CHARGE (12V/3A)
1
DIODE ASSY., ENGINE STOP ............. 1 ............. INCLUDES ITEM W/*
GROMMET, TOOL
1
BOLT, FLANGE (6X35)
2
BOLT, FLANGE (6X25)
2
CLIP, WIRE HARNESS
1
CLIP, CORD
1
CLIP, WIRE HARNESS
1
BOLT, FLANGE (6X8)
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 85
HONDA GX610VXD ENGINE — STARTER MOTOR ASSY.
STARTER MOTOR ASSY.
PAGE 86 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — STARTER MOTOR ASSY.
STARTER MOTOR ASSY.
NO
1
2
3
4
*
5
*
6
7
8
9
10
PART NO
31200ZJ1004
31243ZJ1800
32402ZJ1810
32411KB9930
32411402000
35850ZJ1811
9405006000
9407006080
9430110120
957010811000
PART NAME
QTY. REMARKS
MOTOR ASSY., STARTER
1
BRACKET, STARTER MAGNETIC SET. 1
CABLE, MAGNET SWITCH ....................... 1 ........ INCLUDES ITEMS W/
*
COVER A, MAGNETIC SWITCH
1
COVER, STARTER. MOTOR TERMINAL 1
SWITCH ASSY., STARTER MAGNETIC 1
NUT, FLANGE (6MM)
2
NUT, WASHER (6MM)
2
PIN, DOWEL (10X12)
2
BOLT, FLANGE (8X10)
2
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 87
HONDA GX610VXD ENGINE — CONTROL ASSY.
CONTROL ASSY.
PAGE 88 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
HONDA GX610VXD ENGINE — CONTROL ASSY.
CONTROL ASSY.
NO
1
2
3
5
6*
7
8
9*
10*
11*
12*
13*
16*
17*
18*
19
20
22*
25*
26*
27*
28*
29
31
32%
33
34#
35
36#
37#
38#
39#
40
41#%
42
43%
PART NO
16263ZE3790
165500ZJ1U80
16534ZJ1U80
16555ZJ1000
16561ZG1000
16561ZJ1000
16562ZJ1000
16574ZE1000
16575ZH8000
16576891000
16578ZE1000
16584883300
16628ZJ1000
16649ZJ1000
17951ZG1000
90013883000
90015ZE3790
90114SA0000
9350005012OH
93500050160A
9350005025OH
94001050000s
9455006000
16265ZJ1U80
16534ZJU80
16550ZJ1U80
16576891000
16584883300
16592ZJ1000
16594883010
90605230000
9350004006OH
9350005012OH
9350005030OH
9350005016OA
9405006000
PART NAME
QTY.
REMARKS
JOINT, ROD .................................. 1 .......... INCLUDES ITEMS W/*
CONTROL ASSY.
1
SPRING, RETURN
1
ROD, GOVERNOR
1
SPRING, GOVERNOR
1
SPRING, GOVERNOR
1
SPRING, THROTTLE RETURN 1
SPRING, LEVER
1
WASHER, CONTROL LEVER
1
HOLDER, CABLE
1
SPACER, CONTROL LEVER
1
SPRING, CONTROL ADJ.
2
ROD, CHOKE KNOB
1
HOLDER, CHOKE KNOB
1
KNOB, CHOKE
1
BOLT, FLANGE (6X12)
2
BOLT, GOVERNOR ARM
1
NUT, SELFLOCK (6MM)
1
SCREW, PAN (5X12)
2
SCREW, PAN (5X16)
1
SCREW, PAN (5X25)
1
NUT, HEX 5MM
1
NUT,FLANGE 6MM
1
STAY ASSY., AUTO THROTTLE ... 1 .......... INCLUDES ITEMS W/#
SPRING, RETURN
1
ARM COMP., GOVERNOR ........... 1 ......... INCLUDES ITEMS W/%
HOLDER, CABLE
1
SPRING, CONTROL ADJ.
1
SPRING, CABLE RETURN
1
HOLDER, WIRE
1
CIRCLIP (5MM)
1
SCREW, PAN (4X6)
1
SCREW, PAN (5X12)
1
SCREW, PAN (5X30)
2
SCREW, PAN (5X16)
1
NUT, HEX 5MM
1
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 89
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4.
Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and the
carrier.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5.
Parts must be in new and resalable
condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.
6.
The following items are not returnable:
a.
Obsolete parts. (If an item is listed
in the parts price book as being
replaced by another item, it is
obsolete.)
b.
Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific
date and all orders received on or after that date
will be billed at the revised price. Rebates for
price declines and added charges for price
increases will not be made for stock on hand
at the time of any price change.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
A $20.00 to $50.00 surcharge will be added to
the invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
c.
Any line item with an extended dealer
net price of less than $5.00.
d.
Special order items.
RETURNED GOODS POLICY
e.
Electrical components.
Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:
f.
Paint, chemicals, and lubricants.
LIMITATIONS OF SELLER’S LIABILITY
g.
Decals and paper products.
1.
h.
Items purchased in kits.
Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
2.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
a.
b.
The list must be typed or computer
generated.
c.
The list must state the reason(s) for
the return.
d.
The list must reference the sales
order(s) or invoice(s) under which
the items were originally purchased.
e.
3.
The parts numbers and descriptions
must match the current parts price
list.
The list must include the name and
phone number of the person
requesting the RMA.
A copy of the Return Material
Authorization must accompany the return
shipment.
7.
The sender will be notified of any material
received that is not acceptable.
8.
Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made
in connection with the sale of parts or trade
accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.
PAGE 90 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)
NOTE PAGE
SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 91
PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
VICE DEP
AR
TMENT
SER
DEPAR
ARTMENT
SERVICE
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
Manufactured for Multiquip Inc.
by
DENYO MANUFACTURING, CO., USA
MULTIQUIP INC.
18910 WILMINGTON AVE.
CARSON, CALIFORNIA 90746
310-537-3700
800-421-1244
FAX: 310-537-3927
E-mail:[email protected] • www:multiquip.com
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