HUGONG EDGE 190L User manual

EDGE 190L Gasoline
Welding Generator
USER’S MANUALS

1
Respected Customer:
The detailed information provided here in below, which contains the installation, trial run,
operation and maintenance of “EDGE 190L Gasoline Dynamotor and Welding machine”, is
intended for your kind perusal to help you minimize the operational problems so that the
product can work as smoothly as it is expected.
Warning！* TO OPERATE AND MAINTAIN BY SPECIALIZED PERSONNEL, REPAIRED
BY THE PROFESSIONAL PERSONNE ONLY.
* ANY OPERATION AND MAINTAINECE BEFORE READING THIS MANUL IS NOT
ALLOWED.
Attention！* Please use the SAE10W30 engine oil, replace the oil 10 hours for the
first usage, and then changes the oil every 50 hours.
*Donotconnectwithgeneralalternatingcurrent!
* Please read this manual carefully!
INDEX
1、Brief introduction to EDGE190L
Gasoline Welding Generator
2、Safety Operation
2.1. Safety Notice
2.2 Operator’s self-protection
2.3 Operator’s notice
2.4. Safe Measures to be taken to assure the
correct Installation and Position
2.5 Safety Check
3、Technical Specification
3.1 Environment to Which the Product is
Subject
3.2.Welding Generator’s Principle
3.3．Main Technical Data
3.4．Standard applied
3.5. Remark & Sign of Illustration
4. Control Panel
4.1.Control panel, parts name
and function
4.2．Control Panel
5、Operation Environment
5.1. Outdoor operation
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2
2
2
4
4
5
5
5
5
6
6
7
7
7
7
8
8
8
6.4 ．Protection grounding
check
6.5．Check to make sure no oil
leakage
6.6．Check whether the parts are loose
6.7．Check whether there are
foreign objects inside or
outside of the machine
6.8．Loading Matching
7. Pre-starting Procedure
8. Starting Procedure
9. Stop Procedure
10. Welder, generator operation
11. Simple fault examination
guidance
12. Failure and repair
12.1 Regular check and maintenance
table
12.2. Notices
12.3 The fault and removes
13. Main circuit chart
14. Complete Set Specification
9
9
9
9
9
9
9
9
10
10
10
11
11
11
12
12
13
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5.2. Indoor operation
6、Checking Before Started
6.1．Check gasoline engine oil
6.2．Fuel check
6.3．Oil pipe check
9
9
9
9
9
Table
15、Packing list
16、Transportation and storage
17、Quality Guarantee
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1、Brief introduction to EDGE 190L Gasoline Welding Generator
EDGE 190L Gasoline welding generator is using gasoline engine for power generating.
Gasoline chemical energy is transformed to mechanical energy, then to electric energy. The
product could be used as welder and generator. The advantage is that it could not be
influenced by the power grids, also it can be used at no power supply field for electric generating
and welding, which is necessary equipment for mining and mechanical engineering, and
also could be applied to enterprise and public institution.
EDGE 190 Gasoline welding generator function features:
1. Power output: 120/240V,50Hz, 2.0KW;
2. Welding current: 65A-190A;
3. Electrode diameter: 1.6-4mm;
4. Welding current is adjustable by knob;
2. Safety Operation
2.1 Safety Notice
⑴Electric shock may cause death
●Wear dry labor protection appliance;●Don’t touch work piece or to
ground line；
●Don’t touch electriferous parts；●Don’t touch “+” and “–”；
●Use recommended welding cable; ●Earth cable clamp should be
near welding area;
●Close power output main switch during welding.
⑵Exhaust gas from generating and welding is hazardous to health
● Read generator and welding rods spec. carefully;
● Keep away from exhaust gas；
● Exhaust gas may cause serious nausea, dizziness, even death;
● Work in house, keep good ventilation, or wear respiratory protective
devices;
● Work outside, choose clear field with good ventilation.

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⑶Welding arc light is harmful to eyes
●Wear welding protective mask, watch welding arc through filter glass;
●Use welding mask conforming to national standards;
●Protect exposed skin in case of any hurt;
●Notice peoples around before welding work.
⑷Battery explosion may cause blindness even death
● Power off before repair work;
● Don’t take repair work around naked flame area;
● Wear protective mask and rubber gloves;
⑸Fire prevention
●Keep away from explosive and flammable materials at least 11 meters;
●Prevent sparks to cracks or shady place;
●Fire extinguisher should be allocated at working area;
●No welding sealed vessel.
⑹Acid liquor in battery may cause textile to corrode;
●Wear exposure suit and rubber gloves;
●Keep vertical shifting of battery, avoid any slant.
⑺Hot parts may scald people
● No touching on just finished welding parts;
● No touching on just finished welding electrode holder.
⑻Welding may cause harmful magnetic field
●Irrelevant people keep away from welding area;
●When welding, put welding holder cable and earth cable at the same
side of worker;
●When welding，do not wind the welding cable around worker’s body;

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⑼Welding may cause fire or explosion
●Do not do welding work near flammable and explosive materials;
●Allocate the fire extinguisher in case of fire;
●No welding at the parts’ flammable surface;
●No welding sealed vessel.
⑽Parts may cause serious personal injury during working
●Keep away from working parts;
●Switch off before repairing machine;
●Lock all machine doors, panels, covers and protector or be located at
safe position.
2.2 Operator’s self-protection
* Be sure to follow labor’s safety and sanitation rules, wear suitable labor protection
appliance in case of any injury to eyes and skin.
* Shield the head with protective mask during welding work, and watch arc only
through filter glass window on the mask.
* No touch on work piece in case of any electric shock accident in welding;
* No touching on the both poles (Electrode holder pole and work piece pole) from
welder output at the same time by any parts of body without insulation.
* No welding vessel with flammable and explosive materials or sealed vessel.
* No operating at very humid filed.
* Prevent flying sparks from hurting people.
* No touching on any position of engine or load by hands no matter they are wet or
not.
* Exhaust gas from welding and generating is harmful to health. Keep good
ventilation.
* Welding arc light is harmful to health, keep eyes away from arc light.
* Do not approach the machine working parts with the hands, hair, tools or loose
clothes.
* Only professional staff should install, test and repair the machine.
* When switch off engine, repairing work, fuel and engine oil charging should be start
till engine cooling.
* No smoking, and keep away from any flame when charging fuel.
2.3 Operator’s notice
* EDGE 190L gasoline welding generator belongs to electrical products. Do not
switch or modulate over exert in case of damage to components.
* Check welding cable every time before work, connection right and reliable or not,
earth connection reliable or not.
* Exhaust smoke is not good for health. Operation should be at ventilation and smoke
evacuation area.

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* There will be sparks flying during operating, keep distance between working field
and vicinity.
* Operating should be within duty-cycle. Over load will cause accelerated components
aging and decreased use life, even machine damage.
* Do not modulate or move the machine during operation.
* Welders have strong electromagnetism and frequency interference, so keep away people with heart
pacemaker or the articles which can be interfered by electromagnetism and frequency.
* Do not squeeze or smite the welding cable.
* Do not allow irrelevant people go to welding operation field.
2.4. Safe Measures to be taken to assure the correct Installation and Position
* Precaution must be taken to keep the operator and the machine from the foreign materials falling
from up above.
* The machine must be installed in the place where it can not be exposed to sun and rain. Also it
must be stored in less humid place with the temperature range at −10~40°C.
* The machine should be placed at horizontal position, in case of turnover or shift.
* There should be 50cm space about for the welding machine to have good ventilation.
* Make sure that there is no metal-like foreign body to enter the welding machine
* Make sure that there is no interference with the surrounding area at the installation site.
* Take measures to prevent wind while operating in the strong wind since the welder is gas shielded.
2.5 SafetyCheck
Each item listed below must be carefully checked before operation:
* Make sure that the welding machine has reliable earth connection.
* Make sure input/output cable in good condition and no exposure.
Regular check needs to be conducted by the qualified personnel after the welder has been installed
over a period of six months, which involves as follows:
* Routine cleaning needs to be done to make sure that there is no abnormal loose parts happening in
the welding machine.
* The parts installed on the panel must guarantee that the welder works properly.
* Check the welding cable to see if it can continue to be used before it is worn out.
Notice: Cut off the power supply before opening the case to check.
Please do not hesitate to contact us for technical assistance whenever you come across the problems
you can not work out or you may deem difficult to fix.
3. Technical Specification
3.1 Environment to Which the Product is Subject
* The surrounding temperature range: when working: -5 ～＋40 ℃
During transport or in storage: －25～＋55℃。
* Relative humidity: when at 40℃: ≤50%,
when at 20℃: ≤90%.
*The height above the sea: below 1000m
* Keep from raining when it is used outdoor.

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3.2. Welding Generator’s Principle（see the electric principle sketch）
3.3．Main Technical Data Table（1）
Model
Item EDGE 190L
Generator
AC
output
Rated Frequency Hz 50
Rated Voltage V 120/240
Rated current A 16.7/8.3
Max. power KVA 2.2
Rated power KVA 2.0
Phase Single
Power factor COSφ1.0
Welding
current
DC
No-load voltage V 55-65
Rated current A 130
Working voltage V 22.6-27.6
Current range A 65-190
Duty cycle（%）50
Excitation type Self-excitation and constant
voltage
Starting type Manual
Work type 8 hours continuous working
Gasoline
generator
Model LC188F
Type Single cylinder,
fan-cooled, four stroke
Output volume CC 389
Tank Dia. X Journey mm 88×64
Rated rotated speed rpm 3000
Fuel Unleaded gasoline for
vehicle
Fuel capacity L 1.1L
Rated power 13HP
Tank capacity 30.5L
Structure Open
Rectifie
r
Assistant power supply output
DC welding current
Gas engine transfer
chemical energy to
mechanical energy
Generator transfer
mechanical energy to
electrical energy

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Fuel consume rate g/HP-H 395
Unit
（Length ×Wide ×Height ）
mm
700×540×650（with
wheel）
NW(Kg) 90
3.4．Standard applied:
* JB/T 9528-1999
* GB 15579.1-2004
* GB/T8118-1995
* GB 4208-93
3.5. Remark & Sign of Illustration
4. Control Panel
4.1．Control panel, parts name and function
Item Name Qty. Function
1 Start handle 1 Start engine（refer to engine manual）
2 Engine power switch 1 Start engine（refer to engine manual）
3 Fuel tank cap /dipstick 2 Fuel charging and fuel quantity
measurement
4 Welding current
modulate knob 1 Adjust welding current
5 Toggle switch 1 Turn ON/OFF the engine
U0
X
I2
U2

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6 Air switch 1 Main power switch
7 three pronged outlet 1 Provide out power source as 120/240V
8 Welding current output
terminal
2 Connect welding cable
9 Fuel margin display 1 Indicate the remained quantity of fuel
10 Fuel tank cover 1 Fuel tank cover
4.2．Control Panel
Drawing（1）
5、Operation enviroment
5.1. Outdoor operation
5.1.1 The welder must be loaded in the place where less dust.
5.1.2 Avoid direct sunlight and place the machine at shady and cool area.
5.1.3 Place the machine at flat field in case of any shift.
5.2. Indoor operation
5.2.1 Operation should be at well ventilated place and exhaust waste gas to outside. Keep
away from air inlet and keep good ventilation during work.
5.2.2 There should be at least 1.5m space between any obstacle and air inlet or gas outlet.
75
80
90
100 110
130
150
170
70
190
AMPERAGE ADJUST
AMPERAGE ADJUST
1 2
3
1 2 3
7
875
80
90
100 110
130
150
170
70
190
6
5
4
910

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5.2.3 Place the machine at flat field in case of any shift the brake wheel should be
locked.
6. Checking Before Started
Check each part accordingly, keep safe environment and notice people before start.
6.1．Check gasoline engine oil
6.1.1 Check engine oil dipstick (refer to engine Manual)
6.1.2 Make up engine oil if it’s lower than limit.
Notice:
After long-time running, the engine oil will reduce. Check and avoid engine oil
lack.
6.2．Fuel check
Check fuel whether enough before start work. (Take off the sediment of fuel tank
filter sieve periodically)
6.3．Oil pipe check
6.4．Protection grounding check
Check the protection grounding. The case should be reliably grounding.
6.5．Check to make sure no oil leakage
If leaking, please contact us or seller immediately.
6.6．Check whether the parts are loose.
Check and make sure not loosen of bolts, nuts and all the fasteners, especially air and acoustic filter.
There should be no circuit broken, short and loose.
6.7．Check whether there are foreign objects inside or outside of the machine
6.7.1 Check whether there are tools or waste left inside, and get rid of them.
6.7.2 Check whether there are waste and flammable bodies around acoustic filter.
6.7.3 Check whether there are waste at air inlet and outlet of engine.
6.8．Loading Matching
6.8.1 Make sure the capacitance can match the loading, which can make the machine work
properly.
6.8.2 The welding cable diameter should be correct.
7、Pre-starting Procedure
7.1. Check engine oil could meet scale every time before operation.
7.2. Check whether fuel is sufficient.
7.3. Turn fuel switch to “ON”.
7.4. Air door position
(1)Switch the air door to ‘close’ position
(2) When warmed or at the high temperature, the air door of engine should be switched to
start position

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7.5. Turn the switch of engine to “start” position
7.6. The pre-warning time should be 3-5mins
Notice: speed is adjusted in place before shipment. Do not adjust at will, which
will cause engine rotation speed quicker or slower.
8. Starting Procedure
8.1. Process pre-starting procedure 7.1 to 7.6 completely。
8.2. Switch the air door to” on”。
8.3. Connect loading at normal loading ranges and check the voltage
9. Stop Procedure
9.1. Closing loading process so as to keep the machine at no-load status.
9.2. Switch the engine to “stop” position
9.3. Shut down the fuel switch
10. Welder, generator operation
10.1. Prepare machine and all relative work.
10.2. Choose correct welding cable and connect the power supply. Connecting lug and
terminal must be reliable in case of poor contact burning. Cable diameter should
match the standard 5~7A/mm2current flow.
10.3. Keep good ventilation; do not put other things on the machine so as to avoid any
negative influence to heat elimination.
10.4. Choose correct welding electrode according to work piece thickness.
10.5. Start machine step by step according the Operator Manual. After 5 minutes stable
running under no load status to heat engine, then start welding or power outlet.
10.6. Welding current should be adjusted according work piece thickness and electrode.
There is welding adjusting knob.
10.7. Welding current for different electrode diameter
Table（2）
Welding Dia.(mm) 2.0 2.5 3.2 4.0
Welding current（A）50-65 60-80 100-130 140-190

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Notice: when welding, not using generating. Switch off power outlet in case of
any hurt to people by wrong operation.
Notice: when generating, remove welding cable.
11. Simple fault examination guidance
Repairman could distinguish “Normal” and “Abnormal” situation. The guidance is
useful for you under the condition that you don’t have any test equipment or measure
instrument repairman. Control panel components failure checking needs measure
instrument. If you doubt of control system problem and could not figure out by vision,
please ask distributor for help.
12. Failure and repair
12.1. Regular check and maintenance table (3) (Besides Daily check, others by hour）
Regular check is important to gasoline engine function and lifetime. Check items and
agenda as below.
△check and clean ◆Replace
Table（3)
Note：“ ★”means check should be carried by technician or with special tool, please contact
distributor.
For“1st” it should be the initial checking and process regular checking hereafter。
Machine Check and maintenance items Daily
check 50 250 500 1000
Engine
Check engine oil volume and purity △
Fuel and waste check △△
Check oil leakage △
Check components looseness △
Check exhaust gas color △
Change engine oil 1st ◆
Clean air filter △
Change piston ring ◆
Clean engine oil filter △
Change air filter components ◆
★check engine valve space 1st △
★Adjust fuel nozzle △
★Checking fuel spout time △
★Check anti-shock feet △
Check nylon tube and rubber tube △
Generat
or
Check ground connection △
Measure Insulation resistance △
Check circuit terminal and connection
parts △

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12.2. Notices:
11.2.1 Rotation parts: Danger！
There are high-speed moving parts in the machine.
Stop the machine before Inside check and maintenance
11.2.2 Electric shock Hazard！
There is high voltage part in working machine.
Stop the machine before Inside check and maintenance
11.2.3. There are some high temperature parts inside of the machine, it’s very dangerous.
①Please stop the machine firstly, and then maintain the inner of the machine.
②The engine cover is still heat after the machine shut down. Please be carefully.
12.3 The fault and removes
（table 4）
Breakdown Analysis Solutions
The
engine can
not start
Motor doesn’t
work,
Or the running
speed is too slow.
Imperfect earth Repair
Starting switch is bad Replace
Starter is bad Replace
Lead short circuit Repair
The starter running,
But not start-up.
Lack fuel Filling Fuel
The hole on the fuel oil filter is blocks
up Clean or replace
Take off the air is bad Let out the air
Fuel cylinder type winding not
working
Examine the fuse. If it
breaks off, please replace a
new one. Check and replace
the cylinder type winding
Under low
temperature The
machine cannot
start
Fuel frozen Use winter oil
Some frozen water in oil system.
Heating. Discharge the
water in the fuel tank , fuel
filter and inner of fuel
pipeline inner
Poor air discharge in oil pipe Let out the air
The machine auto-stop, and the
running speed can not reach the
standard.
The hole on the fuel oil filter is
blocked up
Replace the accessories of
fuel filter, after cleaned,
please replace the filter
Air filter is blocks up Replace the element of air
filter
Machine Stops because oil
pressure comes down
Lack oil Filling oil
Oil pressure switch is bad Replace switch
The hole on the engine filter is blocks
up Replace filter
Can not reach the highest
running speed
Adjuster pole location is incorrect Adjust（step on the gas）
There are air interfused the fuel pipe Let out the air
Unload running speed is too
high
Adjuster pole location is incorrect Adjust （slow down the
accelerograph）
Unload running speed is too low Adjuster pole location is incorrect Adjust（step on the gas）
There are air interfused the fuel pipe Let out the air

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Large Shake
Anti- shake feet was not Tighten Tighten
Generator was not tighten Tighten
Noise
Engine Noise Repair
Generator Bad bearing Replace
Loose fasten screw Fasten
Cover Noise Repair
Over heat Check the enviornment Get rid of objects
surrounded
Wrong voltage
Short circuit when loading Check
Abnormal rotate speed Adjust rotate speed to
rated value
Rotor cable short circuit Repair
Engine cable burning Repair
Can not reach the rated
voltage
Over load Reduce loading to rated
value
Low rotate speed Adjust accelerograph to
rated speed
Generator cable burning Repair
Low rotate speed Increase the rotate
speed
The length of cable between
generater and loading is too long
or the section of cable is too
small
Adjust fix position
toshorten the distance,
and oversticking the
cable dia.
Voltage drops when loading
Main winding and the winding are
burned Replace motor
Overload Reduce loading to rated
power
Welding winding is burned Replace motor
Welding current is abnormality Running speed is too low
Adjust the accelerograph
and increase the running
speed
13. Components List
13.1. Explored drawing (refer to drawing 2)
13.2. Components list（refer to drawing）Table（5）

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Table(5）
Item on drawing Description Quantity
1 Gasoline machine 1
2 Gasoline tank 1
3 Frame 1
4 Protector comp., muffler inner 1
5 Protector comp., muffler outer 1
6 Protector, muffler side 1
7 Generator 1
8 Anti-shock feet 4
9 Universal wheel 1
10 Directional wheel 2
11 Winding 3
12 Electricity appliance housing 1
13 AVR 1
14 Welding current output terminal 2
15 Cantalever resistor 5W 6Ω1
16 Operation board 1
17 Underpan grounding screw 1
18 Welding current adjustment knob 1
19 Three-hole socket 2
20 Toggle switch 1
21 Electric power switch 1
14. Main circuit chart (Refer to drawing 3)
15. Complete Set Specification Table（6）
Item Description Quantity
1 EDGE190L gasoline welding generator 1set
2 Manual 1pc
3 Engine manual 1pc
4 Warranty Card 1pc
5 Spark plug sleeve spanner 1pc
16. Transport & Storage
The machines should be free from rain and snow during transportation and storage. The
warehouse should keep dry & ventilation and free from corrosive gas or dust. The tolerable temperature
ranges from ﹣25 (with no cooling water) ～﹢55℃and the relative humidity can not be more than
85％.
17、Quality Guarantee
Users are advised to operate in compliance with the stipulations given in the manual. On condition
that the welder is installed, stored, used, maintained, kept properly in compliance with the guideline, we

15
guarantee to get the welder repaired at our expense within 12 months upon the purchase of welder if and
when the welder is found either damaged partially or working improperly.
Explosive view（2）
21
20
19
12 11 10 9 8
7
6
5
18
17 16 15 14 13
4
3
2
1

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Drawing 3 Main circuit chart