The following instructions are intended to
assist the user in the installation of the
GAW180HE “Regulator Conversion Kit”, P/N
REGUPGKIT180. Please read instructions
before installing regulator conversion kit.
GAW180HE Regulator Conversion
Conversion Kit Installation Instructions
Tools
■
7/16-inch Wrench
■
Phillips-Head Screwdriver
■
Wire Cutters
■
Crimp Tool
AC CIRCUIT
BREAKER
0N
OFF
OFF
ON
120
V
20A
20A
OPERATION
SWITCH
START SWITCH
120 V
IDLE
CONTROL
MIN
CURRENT
MAX
REGULATOR
100
NORMAL
30
50 140
SOFT
ARC FORCE
HARD
REGULATOR
REMOVE
SCREWS (6)
Front Panel Removal
1. Place the generator on a suitable workbench. Make
sure the area is clear of clutter.
2. Using a phillips-head screwdriver, remove the 6 screws
(Figure 1) that secure the front panel to the generator.
Figure 1. Front Panel Removal
3. Tilt the front panel downward (Figure 2) to gain access
to the control box wiring. If necessary support the front
panel to reduce the strain on the internal wiring.
Rectifer Removal
4. Using wire cutters, cut all wires connected at the
terminal leads of rectifer Re1 (Figure 2).
5. Using a phillips-head screwdriver, remove the screw and
nut that secures rectifier Re1 to the generator.
6. Discard rectifier Re1, it will not be used any more.
Figure 2. Rectifier Re1 Removal Removal
Preparing the Wiring
7. Strip off 3/8-inch insulation (Figure 3) from all wires
that were connected to rectifer Re1.
STRIP INSULATION
BACK 3/8-INCH FOR
ALL WIRES.
BLACK (2)
ORANGE (2)
PINK (2)
Figure 3. Wire Insulation Removal
8. Insert, then crimp both black wires (Figure 4) into the
female crimp connector.
9. Remove the BLACK 7.5-inch wire from the kit. Insert
the male crimp end of this wire into the female crimp
connector with the two black wires.
BLACK
BLACK
FEMALE CRIMP
CONNECTOR
MALE CRIMP
CONNECTOR
BLACK
7.5 INCHES
(190.5 MM)
TERMINAL
RING
Figure 4. Black Wire Crimp Connection
PINK
CUT
HERE
Re1
TILT
DOWNWARD
REMOVE
NUT AND
SCREW
ORANGE (2)
PINK
BLACK (2)
1
2
3
4
5
6
9
8
7
NEVER work on the welder/generator
when the battery is connected. Electrial
shock or short circuit could occur, causing
harm to personnel or damage to the
equipment. ONLY have qualified service
personnel perform this modification.
NOTE
Form 19732 (12/01)
© COPYRIGHT 2005, MULTIQUIP INC.
Atlanta • Boise • Dallas • Houston • Newark
Montreal, Canada • Manchester, UK
Rio De Janiero, Brazil • Guadalajara, Mexico
MULTIQUIP INC.
POST OFFICE BOX 6254 • CARSON, CA 90749
310-537-3700 • 800-421-1244 • FAX: 310-537-3927
E-MAIL: [email protected] • WWW: multiquip.com
10. Insert, then crimp both orange wires (Figure 5) into the
female crimp connector.
11. Remove the ORANGE 11.5-inch wire from the kit. Insert
the male crimp end of this wire into the female crimp
connector with the two orange wires.
ORANGE
ORANGE
FEMALE CRIMP
CONNECTOR
MALE CRIMP
CONNECTOR
ORANGE
11.5 INCHES
(292.1 MM)
FEMALE CRIMP
CONNECTOR
12. Connect the other end of the ORANGE wire (female
crimp) onto the RED wire on to the voltage regulator
(Figure 6) with the male crimp connector
Figure 5. Orange Wire Crimp Connection
FEMALE CRIMP
CONNECTOR
ORANGE
ORANGE
MALE CRIMP
CONNECTOR
ORANGE
RED
VOLTAGE
REGULATOR
Figure 6. Regulator Red Wire Connection
13. Crimp each pink wire (Figure 7) with a female crimp
connector.
14. Insert, pink wire (2) with the female crimp connector into
blue wire (2) on the voltage regulator with the male
crimp connector. Orientation of wires does not matter.
Figure 7. Regulator Blue Wire Connections
Voltage Regulator Mounting
16. Using a 1/4-inch drill, drill a hole into the triangular
wall behind the control panel as shown in Figure 9.
17. Locate green and black wires that have a terminal ring
at each end. Place terminal ring of each wire onto 1/4-
28 x 1 screw.
18. Place regulator behind wall, insert 1/4-28 x 1 screw
with green and black wires through mounting hole to
hold regulator in place. Secure regulator with lock
washers (2), and nut. Tighten securely.
19. Use the supplied tie-wraps to secure wiring.
20. Clean up any shavings or debris that might have
accumulated during drilling.
21. Re-install front panel securing all 6 screws.
PINK
BLUE
VOLTAGE
REGULATOR
BLUE
PINK
MALE CRIMP
CONNECTORS
FEMALE CRIMP
CONNECTORS
15. Remove the GREEN 5.5-inch wire from the kit. Insert
the male crimp connector of this wire (Figure 8) into
green wire on the voltage regulator with the female crimp
connector.
VOLTAGE
REGULATOR
GREEN
GREEN
MALE CRIMP
CONNECTOR
FEMALE CRIMP
CONNECTOR
TERMINAL
RING
5.5 INCHES
(139.7 MM)
Figure 8. Regulator Green Wire Connection
Figure 9. Voltage Regulator Mounting
1-INCH
(25.4 MM)
1-INCH
(25.4 MM)
VOLTAGE
REGULATOR
DIA.
3/8-INCH
(9.52 MM)
DRILL
HOLE
1/4-28 NUT
1/4-28 X 1
SCREW
1/4-INCH
LOCK-
WASHER
GREEN
WIRE
BLACK
WIRE
TRIANGULAR
WALL
TERMINAL
RING
1/4-INCH
LOCK-WASHER
1
2
3
4
5
6
9
8
7
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