KOVO EW240G User manual

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FORWARD
Firstly,thankyouverymuchforpurchasingKOVOEngineDrivenWelders.
Thismanualistheguidancethatleadsyoutooperatetheenginedrivenwelderincorrectand
safeway.Pleasegooverandunderstandthecorrectwaysofinstallation,inspection,operation
andmaintenancebeforetouchingthewelder.
Asforthedetailofengine,pleaserefertotheEngineManualissuedbytheengine
manufacturer.
Pleasekeepthemanualinavailablewheneveryouwantinstructionsaboutthemachine.
TheOperationManualissubjecttochangewithoutnoticeduetotheredesignfor
improvementofquality.Ifyouhavequestion,pleasecontactourlocaldistributor.
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SIGNSFORSAFETY
Thefollowingsignsindicateastrongpossibilityofseverepersonalinjury,lossoflifeand
equipmentdamageifinstructionsarenotfollowed.
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Causinglossoflifeorinjuryifmisusing
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Causinginjuryorequipmentdamage
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Shorteningthewelderlifeandperformance
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CONTENTS
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ITEMPAGE
1．SafetyPrecautions3
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2．Specifications5
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3．OutlineandComponents6
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4．Pre‐check7
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5．Thefeaturesofmachine7
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6．Operation8
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7．MaintenanceSchedule11
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8．TroubleShooting13
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9．Preparationforstorage14
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10．WiringDiagram15
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Appendix
*WarrantyPolicy
*RegistrationForm
*AccessoriesList
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1. Safetyprecautions
1‐1General
Fuelprecautions
●Pleaseusethenon‐leadgasolineasfuel,andkeepfarawayfromfirewhenrefueling.
●Yourmuststoptheenginebeforerefueling.Wipeoffthespilledgasoline.Donotleavefueland
otherinflammablesneartheexhaustpipe.
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Emissionprecautions:
●Donotoperatethewelderinsidearoom,caveandotherinsufficientventilatedareabecauseof
poisonousemissiontopeopleandanimals.
Operatingprecautions
●Dostoptheenginefordailycheck,regularinspection,oilrefillingandcleaningwithreferenceto
“OperationManual”
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Electricshock
●Pleasedonotoperatewithwethand(s)andinrainyandsnowyday.
●Pleaseconnecttheweldingterminalsafterstopping.Donottouchtheweldingterminalsduring
operating.
●Donotusecablewithinjuredinsulatingcover.
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Cleaning
●Usedryclothorpressurizedairforcleaning.Donotusewaterordetergentincaseinsulation
trouble.
Alsopleasebewareofothersafeprecautionsnotcoveredbythismanual.
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1‐2Transportation
●Pleasetiethepipeframeofmachinetothecarrierofvehiclewhentransportation.Alsoput
wheel‐stopper.
●Whenloadingorunloading,pleasehangtheframebyropeandpulleyhorizontally.Donotlift
theengineorgeneratorportion.
1‐3Installation
●Placethemachineinthelevelground.Thegradientdoesnotexceed5o
●Pleaseremoveobstaclesblockingairinletandoutletofmachineawayformwall.
●Whenyouoperatethemachineonsandysoil,putawoodenboardonthegroundtoavoidsand
comingintothemachine.Thesandmaycauseinsulationtroubles.

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●Pleaseplacethemachineoutofweldingspatter
●Pleasereferto1‐1
1‐4Beforeoperation
●Pleasewearproperprotectiveclothes,leathergloves,hatandhelmet.
●Pleasecheckbeforestartingengine.Repairbeforerestartingifanyabnormaloccur.
●Pleasereferto1‐1
1‐5Duringoperation
●Pleasebewareofinjurybyheatbecausetheexhaustpipewithhigh‐temperaturewheninthe
operationorjustafterstop.
●Pleasereferto1‐1
1‐6Storageofmachine
●Keepinadry,cleanandlow‐saltroomhorizontally.
●Donotcoverthemachinewithplasticclothforlong‐termastoavoidgettingrustyandinefficient
insulation.
●Whenyouputthemachineinstorageforlongtime,removebatteryfrommachine,drainbattery
liquid.Ifanydefectiveparts,repairthemforthenextoperation.
●Pleaserunengineatleastoncefor3monthsandconfirmthemachine’scondition.
●Referto1‐1
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yAuxiliarypowerofthemachineisONLYforgeneralpowertoolequipment.
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2.Specifications
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MODELEW240G
BrushlessYES
W
E
L
D
E
R
RatedPowerKW6.3
RatedCurrentA220
RatedVoltageV28.8
Open‐circuitVoltageV75
DutyCycle%50
CurrentRangeA55~240
ApplicableElectrodeφmm2.0~5.0
A
U
X.
RatedPowerKW3.0
RatedVoltageDCV220/120
RatedCurrentDCA13.7/25
PowerFactor%100
Coupling —DirectCoupling
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E
N
G
I
N
E
Name—
HONDAGX390/
KOHLERCH440
Type—4‐stroke,singlecylinder
Displacement L0.389/0.429
OutputH.P13/14
No‐loadSpeedrpm3300
RatedSpeedrpm3100
StartSystem—Recoil/Electric
Fuel—Gasoline
CoolingSystem—Air‐cooled
Lub.OilCapacityL1.1
FuelTankCapacityL6.5/16
Dimensions mm725×540×570
WeightKg90
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3.OutlineandComponents
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OUTLINE
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
CONTROLPANEL
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4.Pre‐check
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4‐1Lubricatingoil
●Checktheamountandconditionoflubricatingoilbeforeoperation.Pleaseinserttheoildipstick
fully,andthenpullouttocheckit.MakesuretheoilstainisbetweenLowandFulllevels.Adding
toomuchoil(higherthanFULLlevel)maycausedamagestotheengine.
●Donotpulloutthedipstickduringoperation.Hotoilwillbespout,causingdanger.
●PleaseadoptSEclassofSFclassification,andrecommendSE10W30forallseason.Inferioroil
shortensenginelife.
●Donotmixtwoormoredifferenttypesoil.
4‐2Fuel
●Makesuretheamountoffuelisenoughforyouroperation
●Pleaseadoptnon‐leadgasoline(forautomobiles)
4‐3Wiringandconnector
●Pleasecheckandmakesureallthewiresandconnectorsarenotinjuredornotloosened.Ifso,
pleasedealwithintime.Afterchecking,starttheenginetoobserveiftheoilandfuelareleaked.
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5.Featuresofmachine
5‐1Characteristics
●Brushlessalternatorforeasymaintenance
●Goodweldingperformanceformeetingkindsofweldingrequirement
●Auto‐throttledevicesforsavingthefuel(*)

Weldingpowerandauxiliarypowercannotbeoperatedsimultaneously.
5‐3Protectionsystem
●Oncethewelderorauxiliarypowerisgoneout,stoptheengineandrestarttilltheproblemis
workedout.
●Pleasecheckfuseoncenooutput
●Breakercannotbeusedforswitchfunction.
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6.Operation
6‐1Enginestart
●Turn“OFF”theauxiliarypowerBREAKER
●Openthefuelcock
●Closethechoke
●Turn“ON”theAUTO‐THROTTLE(*)
●Pulltherecoilstarttostarttheengine,thenopenthechoke(recoilstart)
●Warmuptheengineabout5minutesinidlespeed
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●Whenyoustartengine,donotrestartincasecausetherecoilingsystemproblem.
●Pleasewarmuptheengineforapprox.5minutesinidlingspeed.Immediateloadingoncold
enginemakesshorterenginelife.
●Thealternatorwillbebrokenifwelderorauxiliarypowernotusedatratedspeed.
●Pleasemakesurethereisnoleakageoffueloroilduringengineoperation.
●Thespeedcontrolleverispaintedbymanufacturer.Donotadjustitbyyourself.Theenginewill
beinabnormalspeedanddamagedifyoudonotfollownotesabove.
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6‐2Enginestop
●Disconnecttheload,andruntheengineinlowerspeedwithoutload
●Turntheswitchto“OFF”positiontostopengine
●Closethefuelcockafterstoppingengine
6‐3Weldingoperation
6‐3‐1Procedure
●Pleasechooseadequateweldingcableaccordingtotheweldingwork.Connectthewelding
cablesbeforeyoustarttheengine.
●Starttheengine(referto6‐1)
●Selectthecurrent(LOWorHIGH)foryourweldingoperationbyswitchingcurrentrange.And
adjustpropercurrentwiththeweldingoutputcontroller.
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WELDINGCURRENTRANGETABLE
CURRENTCHANGERLOWHIGH
WELDINGOUTPUT
CONTROLLER(A)
60~105100~240
WELDINGRODUSED(mm)2.0~3.22.5~5.0
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
●Incaseofengineoverload,reduceyourload.
●Thesymptom:Exhaustgasbecomesblackcolor;revolvingspeedbecomesslowapparently.
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●Donottouchtheweldingterminals,weldingholders,andearthwirebecauseofelectricshock
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●Donotswitchoverthecurrentchangerwitch(HIGH‐LOW)duringweldingoperation.Thatmay
burntheswitch.
●DonotleavetheCURRENTRANGEatthemiddlepointbetweenHIGHandLOWpositions,
otherwise,itwillbeburnt.
6‐3‐2Autothrottle
●Turn“OFF”theautothrottle,theengineruninratedspeedcondition.
●Turn“ON”theautothrottle,theengineislowerspeedforfuelsavingandnoisereducing;when
usingauxiliarypowerorwelding,theenginespeedrisestotheratedspeed,andtheninlower
speedinsecondsifnoload.
6‐3‐3WeldingCables
Pleaserefertothetablebelowforproperweldingcables
A
L20m30m40m50m60m80m100m
100A22222222223038
150A22222230385060
200A22223038506080
（UNIT：mm2）
Note:lengthmeansroundcablelength.voltageregulationdropwith5V

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6‐3‐4Weldingpolarity
WeldingpolarityStraightReverse
Illustration
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Thickmetalplate,andsteelalloyThinsteelplate,andstainlesssteel
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6‐4AuxiliaryPower
6‐4‐1Procedures
●PuttheBREAKER“ON”position
●Connecttheplugtothereceptacle(thecurrentcannotexceedratedcurrent)
●Turn“ON”thebreakertosupplythepowertothetool(s)
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●Donotconnectordisconnectauxiliaryplug(s)whenthebreakeris“ON”
●Donotconnectthepowertothecommercialmainsupply.Thatcauseseriouselectricalaccidents,
fireandetc.

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●Donotuseauxiliarypowerinover‐loadcondition.(within3KW)
●Ifthebreakeristripped,stoptheengineandchecktheloadbeforeyoustartoveragain.
●BreakercannotbeusedforChangerSwitch.
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7.MaintenanceSchedule
Tokeepthebestconditionandsafetyoperationofthemachine,dailyorperiodicalmaintenance
shouldbedonecorrectly.Pleasefollowthischapterformaintenance.
7‐1Dailymaintenance
●Checkwiringconnectionsandscrewsifloosenorbroken
●Removingtheremainsfromthefueltank
●Checktheamountofoilanditscolor
●Drainwaterformfuelfilter
●Checkscrewsifloosenorbroken
7‐2Maintenanceforthefirst8operatedhours
●Oilrecommendation(referto4‐1)
●Thetotalamountofoilis1.0L
●PleaseuseSE10W‐30typeoil
7‐3Maintenanceforeach25hours
Cleantheairfilter
●Theairfiltershouldbetakenoutforcleaning,andchangedifitissodirty.
●Screwtheknobtightly.Otherwise,oncethedirtythinginhaled,thepistonisworn,resultingin
impotentoutput.
7‐4Maintenanceforeach50hours
●Replacelubricatingoilintonew
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Tablefortemperatureandoilviscosity
Ambienttemperature（°C）
‐30‐20‐10010203040
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ViscositySAE10W—30
SAE15W—40
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7‐5Maintenanceforeach100hours
●Replacelubricatingoilfilterintonewone
●Inspectfuelpipeandwiring.
●Replaceenginesparkplugwithresistor
●Iftheenginesparkplughasnoresistor,electricalnoisemayappearinelectricaltoolssuchas
radio.
●Makesuretheconnectorsandotherpartsaretightlyconnected.Ifsomeofthoseconnections
areloose,electricalheatmaybegenerated.Thatmaycausefire.

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7‐6Maintenanceforeach200hours
Measuretheinsulationresistanceofgenerator
●Disconnectalltheloadandweldingload.
●Disconnectallwiretothegenerator
●Measuretheinsulationresistancebetweenmachineframeandeachgeneratorcoilsby500VMΩ‐
tester:1MΩ
●Whenmeasurement,stoptheengine.
●Incasethemachineisoutofoperationforlongperiod,orincasethemachinehasbeenwet,
measuretheresistance.Ifthevaluesislessthan1MΩ,drythemachineuntilitregainsthenormal
value(1MΩ)
7‐7Maintenanceforeach500hours
Cleanthefueltank
●Drainthefuelbyremovingtheplugoffueltank,andcleantheremainsfromtank.
●Screwtheplugtightlyaftercleaning.
●Donotcleanduringengineoperation.
7‐8Maintenanceforeach600hours
●Inspectbearing
●Dismantletheend‐bracketofgeneratortocheckifthereisanyunusualnoiseorvibration.
●Ifanyofabove,pleasereplacethebearing.Thebearingissealedsothatyoudonotneedgrease
forit.
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8.TroubleShooting
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Symptom Causes Treatment
Startingmotordoesnotstart
Startingmotorisslow
Enginedoesnotstart
Nofuel
Inferiorfuel
Fuelfilterchoked
FuelCockclosed
Lub.oillack
Aircleanerchoked
Badsparkplug
Badwireconnection
Badignitioncoil
Insufficientbatter
Fueling
Replace
Clean
Open
Fill
Replace
Replace
Repairorreplace
Repairorreplace
Recharge
Noweldingpower
Noaux.power
BadWCR1010
Alternatorbroken
Badconnection
Brokenfuse
Repair
Repair
Repair
Replace
Highvoltage
Lowvoltage
BadWCR1010
Badrectifier
Badcurrenttrans(CTCA)
Over‐loaded
Badenginespeed
Badgenerator,fieldorexciter
Repair
Replace
Replace
Reduceload
Inspect
Repair
Cannotweld
Frequentarccut
Lowweldingcurrent
Noweldingcontroller
function
Badcurrentadjustment
Notpropercable
Badcurrentcontroller
BadWCR1010
Badenginespeed
Badweldingrod
Sensorbroken
Adjust
Changecable
Replace
Repair
Inspect
Changerod
Replace
Engineoverloaded(black
smoke,lowspeed)

Inferiorfuel
Baddiode
Generatorwindingshort
Replace
Replace
Repair
Unusualvibration
Unusualnoise
Frequentenginestop
Badshockabsorber
Loosenbolts
Lessoil
Badgeneratorbearing
Fix
Repair
Addoil
Replace
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9.PreparationforStorage
9‐1Dailystorage
Placemachinehorizontallyinalesshumidityandnodustarea,andfarawayfromseawater.
9‐2Storageforlongperiod
●Keepthemachineindryandless‐dustroom.Donotcoveritbyplasticclothforlongtimeincase
itgotrusty.Ifpossible,keepitintheceilingroominwildarea.
●Cleaninsidetheenginewithnewoilbeforestorageforlongtime.Replacetheoilandoperate
theengineforawhile,thendrainitbeforestorage.
●Putalittleoilonmovingpartsofengine.
●Drainallfuelfromthetank.
●Toavoiddustorhumidaircomingintoengine,putcoveronexhaustoutletorairinletpartwhen
storage.
●Allnecessaryrepairsshouldbedoneforthenextoperation.
●Conductmaintenanceoperationatleastoncefor3month.
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●Keepitinthehardandlevelground.
●Donotpileotherthingonthemachine.
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10.WireDiagram
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
WarrantyPolicy
1.Duringthewarrantyperiod
①One(1)yearafterthedateofsaletotheoriginalpurchaser
②Servicesstations:Manufacturer,orauthorizedservicesshop.
③Thewelderwillbewarrantedagainstthedefaultindesignofmanufacturer
④Thewelderwillbewarrantedagainstthedefectinmaterialandworkmanship
⑤Thelimitedwarrantyshallnotapplytoconsumableparts,thedamagescausedbymisuse,
negligence,accidentandfailuretofollowtheoperationmanual.
⑥Thelimitedwarrantyisinapplicableforfading,corrosionandrustduetothenormaluseor
improperstorage.
⑦Thechargeswillbeoncustomer’saccountiftheserviceshappenoutsideoftheservices
station.Amount=railwayticket(hardbed)forroundtrip+200RMB*person/day
⑧WeshallarrangethetrainingprograminBeijingregularlyastoinstructthecustomersto
graspoperation,installandmaintenanceinrightway.
⑨Webuildthecustomers’documentforone‐to‐oneservices.
2.Outofwarrantyperiod
Onlypartsandrepaircostneedpayingiftherepairhappensintheservicesstations.
Thecustomersshouldchargethefeeforaccommodationbesidesthebasiccostandparts
onceservicesonsite.
Amount=railwayticket(hardbed)forroundtrip+parts’price+200RMB*person/day
Thecustomershouldtransportthemachinetothefactoryorthenearestservicesstationif
thestaffcannotrepaironsite.
3.Others
ThiswarrantypolicyonlyappliestoChinaMainland.Theseparatewarrantypolicywillbe
stipulatedfortheoverseacustomers.
Pleasecontactservicesstationsorourcompanydirectlyifanyquestions.
Thewarrantywillbeeffectiveafterthecustomerreturnthe“warrantypolicy”
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
RegistrationForm
Companyname:_________________________________________
Address:__________________________________________
Tel:ContactPerson:______________________
E‐mail:___________________
ModelPurchased：SerialNo.:______________________
PurchasedDate:__________________________
Applications:(pipelinewelding)(roadconstruction)(emergencywork)(weldingjob
outdoors)(others)
Registereddate:______________________________
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Pleasereadthewarrantycarefully
Pleasereturntheregistrationformafter20dayssinceyoupurchased.
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