LONCIN WG6500M-1 User manual

Thank you for purchasing a welding/generating set produced by Loncin Company.
Please keep this Manual in a reliable way for you convenient reference at any time.
This Manual should be considered a permanent part of the generator and should
remain with it if it is resold.
Loncin adheres to a strategy of sustainable development, so Loncin reserves the right
to make changes or improvements without notice to any product described in this
publication.
Copyright © Loncin Motor Co., Ltd. All rights reserved.
No part of this publication may be reproduced, transmitted, distributed or stored without
prior written permission of Loncin Motor Co., Ltd.

Safety Warnings
Personal and property safety of you and other persons are of great concern to us.
Please carefully read the each safety warning preceded by the symbol and each
safety indication preceded by the symbol of , details of which are as follows:
You WILL BE VERY SERIOUSLY HURT if you don’t follow instructions.
You CAN BE SERIOUSLY HERT if you don’t’ follow instructions.
You CAN BE HURT if you don’t follow instructions.
Your generator or other property could be damaged if you don’t follow
instructions.

Contents
- 1 -
Contents
I. Safety·························································································································2
II. Brief introduction of functions····················································································6
III. Description of the set’s parts and components and their functions ·························· 7
Engine switch·········································································································8
Fuel switch············································································································· 8
Choke switch ·········································································································8
Recoil starter·········································································································· 9
AC circuit breaker ··································································································9
IV. Preoperation check ································································································ 11
Routine check ······································································································ 11
Oil check ·············································································································· 11
Fuel check ··········································································································· 11
Air filter check ······································································································12
V. Operation and use of the set···················································································13
Starting the engine·······························································································13
Use of the generator ····························································································13
Use of welding power supply ···············································································15
Stopping the engine ·····························································································16
VI. Maintenance of the set ··························································································17
Engine Oil change ·······························································································18
Air filter maintenance ···························································································18
Cleaning fuel sediment cup·················································································· 19
Spark plug check ·································································································20
VII. Storage ·················································································································21
VIII. Troubleshooting ··································································································· 22
Engine doesn’t start ·····························································································22
No output voltage·································································································22
Solving common problems of welding power supply ···········································23
IX. Technical parameters·····························································································24
X. Schematic diagram·································································································25
Ⅺ. Wheel and handle Set(In Optional) ······································································ 26

Safety
- 2 -
Never use it indoors
Never use it in a wet condition
Never connect it directly to the
home power supply
I. Safety
Please carefully read and understand this Manual before operating the engine; safe
operation procedures can help you avoid personal injury or damage to the set.
1) General descriptions
This type of welding/generating set is produced in accordance with
technical regulations governing generators and welding machines, and it
conforms to all relevant safety regulations; but misoperation or misuse still
can result in the following hazards:
zThe set’s hazard to the life safety of the operator and any other person,
zDamage to the public or private property,
zAdverse influence on the effective work of the equipment.
2) Duty of the owner/keeper
zBe familiar with basic work safety rules and operation method of welding
machines.
zRead safety rules and warnings of the Manual and be clear about relevant
signals.
zBe able to conduct routine check to ensure operator’s safety during work.
3) Duty of the operator
zObey basic work safety rules, understand basic knowledge of generators and
welding machines, and have relevant qualifications and certificates.
zRead the part contained in the Manual’s safety warning section, and operate in
accordance with the Manual’s instructions.
zSign to indicate understanding of the above.
4) Safety operation and protection
zInsulation measures, such as wearing insulation shoes,
must be taken for operation in a wet condition.
zWear insulation gloves before welding.
zWearing a welding mask to protect eyes from being
hurt by ultraviolet radiation.
!

Safety
- 3 -
zWear a protective working suit.
zWear a pair of noise protectors in any place with a
loud noise.
If there is any other person nearby during welding,
you must
zInform him or her of the danger,
zUse protective equipment or other means to protect
such person,
zErect a separator or hang a screen.
5) Eliminating poisonous gases and fumes
zTake measures to eliminate all fumes and poisonous
gases in the working room.
zEnsure air ventilation.
zTake measures to separate arc radiation.
zPrevent hazards from weld spatter
zRemove all inflammable matters from the welding
site.
zNever weld the containers with residual inflammable
gases, fuel or oil, or an explosion may be caused.
zA safety place must be assigned for hazardous
emergencies.
6) Prevent electric shock from network voltage and
welding voltage
zElectric shock can cause extremely dangerous effect,
including to life safety.
zA strong current will create a magnetic field, which can
disturb functions of important electronic devices like
the cardiac pacemakers.
zAny person equipped with a cardiac pacemaker must
check if there is any magnetic field beside or in the
working room before entering it.
zEnsure all earth wires are reliably connected without any damage
Never spill when fueling
Never smoke when fueling
Stop engine before
fueling
Keep inflammable materials at
least 1 meter away

Safety
- 4 -
and are entirely insulated. If there is any loose connection,
loss of insulation, or burned section in any earth wire, replace such earth wire
immediately.
zMain power lines and branch lines must be regularly inspected by a qualified
and experienced electrician to ensure semiconductor parts work normally.
zBefore dismantling the set to take any part down, make sure the set is reliably
shut off.
zIf any such work must be done while the set is running, a second person must
be available on the site to guarantee the ability to perform an emergency
stopping of the set.
7) Cautions
zNever put your hands near any of the revolving gears of the wire feeder.
zFor any operation with the probability of spark, explosion or other dangers, a
separate welding place has to be applied for.
zThe welding power supply may not be used for high-voltage application unless
it has passed relevant safety certification.
zWelding of special safety equipment must be performed by welders that have
received professional training.
zWhen any equipment is going to be lifted using a lifting machine, for the
purpose of lifting as perpendicularly as possible, generally chains or ropes can
be used to help lifting.
8) General safety measures
zAlways following the instructions of this Manual.
zIn addition to the Manual, two copies respectively of rules for general accident
prevention and for environment protection shall be prepared. Of course, any
other applicable regulation also has to be observed.
zAll safety instructions and hazard warnings must be kept clear and legible
enough.
9) Safety measures for installing the set
zThe set must be put upright on a level ground to prevent its falling and personal
injury.
zFor any work that might involve spark, explosion or other hazardous factors, a

Safety
- 5 -
separate welding space must be applied for. Please refer to relevant
regulations of China and other countries.
zUse internal inspection and test means to ensure the working environment is
clean and orderly.
10) Safety measures to guarantee normal work of welding/generating
set
zBefore running the set, check whether all safety protection requirements are
met.
zDon’t touch any hot part of the set within 30 minutes after the set is shut down,
so as to ensure no personal injury will occur when you start the workstation.
zInspect the set at least once a week, conduct a check of the set’s external
surface for any damage, and test its safety performance.
11) Safety inspection and test
zAll operations about the set’s modification, installation of accessories,
maintenance and repair of parts and components, regular maintenance, overall
inspection and test (which must be performed once for every period not
exceeding 6 months), etc. shall be assigned by the owner/ keeper of the set to
electric experts.
12) Modification of welding/generating set
zIt is better not to make any modification to the set, to install any accessory to it,
or to change any preset parameter of it without the manufacturer’s permission.
zDefective parts or components must be replaced timely.
13) Spare parts and wearing parts
zOnly the spare parts and wearing parts supplied by the manufacturer of the set
may be used, because it cannot be ensured that the parts from other suppliers
can meet the special design requirements and other requirements relating to
voltage endurance and safety of this set.
zBefore purchasing spare parts, please mark the specific names of the parts and
relevant part numbers, and give relevant descriptions in the list of the spare
parts.

Brief introduction of functions
- 6 -
II. Brief introduction of functions
WG6500-1 is a series of integrated welding/generating set.
zThe set employs a 50Hz/230VAC generating set with a rated output of 5kW and
maximum output of 5.5 kW, and guarantees a stable and adequate output voltage.
zThe engine’s fuel consumption rate is ≤370g/kW.h; it is equipped with a 25L large
fuel tank to meet the need of long-time operation.
zManual welding, DC argon-arc welding and pulse argon-arc welding are available.
zMaximum welding current values of manual welding, DC argon-arc welding and
pulse argon-arc welding are respectively 150A, 200A, and 200A (pulse frequency is
30Hz), the current can be adjusted in a continuous way from the minimum value of
15 A to the maximum values; current values are shown in a digital display, and
observation of them is very easy
zHigh-frequency arc starting is employed by the argon-arc welding to achieve an
easy arc starting.
zThe total power of the equipment can be used for welding, or 5 kW of it can be all
used for supply to the 50Hz/230VAC power network; in addition, the residual power
during welding can also be used for supply to the external power grid.
zThe welding unit of the set has self-protection functions against over current, under
voltage, and over heating, so that safe work of the equipment is guaranteed.

Description of the set’s parts and components and their functions
- 7 -
III. Description of the set’s parts and components and their
functions
Oil drain
plug
Control
panel
Weldin
g
chamber
control cabinet
Fuel tank
guard
Fuel switch
Throttle
lever
Starter
Air filter
Spark plug
Muffler
Carburetor
Frame Fuel tank

Description of the set’s parts and components and their functions
- 8 -
1) Engine switch
2) Fuel switch
The fuel switch is for opening and closing the passage of fuel flow from the fuel tank to
the carburetor.
If the fuel switch is not put in the ON position, the engine cannot run. When the engine
is not to be used, the fuel switch must be put in the OFF position to prevent fuel leak.
3) Choke switch
The choke switch is for opening and closing the choke inside the carburetor.
If the engine should have a cold start, put the choke lever in the OFF position. When
the engine is running normally after starting, the choke lever shall be put in the ON
position.
Engine switch
OFF
ON
Fuel valve
ON
OFF

Description of the set’s parts and components and their functions
- 9 -
4) Recoil starter
Pulling the recoil starter grip enables the recoil starter to drive the engine’s crank shaft,
which in turn starts the engine.
Don’t let the starter grip spring back abruptly after starting; the starter grip
should be let back gently.
5) AC circuit breaker
The AC circuit breaker will be automatically shut off in the event of overload current.
Overload and short-circuiting of the loads shall be avoided. If the circuit breaker is
automatically shut off, please check the load before reputing the circuit breaker in the
ON position.
Throttle leve
r
ON
OFF
Starter grip

Description of the set’s parts and components and their functions
- 10 -
1—AC voltage meter 2—Engine switch 3—Main circuit breaker 4—Generator circuit breaker
5—Welding switch 6—Receptacle 7—Earthing terminal
3
4
5
7
1
2
6

Preoperation check
- 11 -
IV. Preoperation check
1) Routine check
zObserve whether there is any leak of engine oil or fuel.
zObserve whether there is any trace of damage.
zCheck the positions of all guards and covers, and tightness of all bolts, nuts and
screws.
2) Oil check
Stop the engine and put it on a level place, then check engine oil.
①Remove the oil dipstick from the oil filler hole and wipe it clean;
②Insert the dipstick without screwing it in tight to check the engine oil level;
③If the engine oil level is too low, add recommended engine oil until oil level reaches
the upper limit;
④After adding oil, remember to rescrew in and tighten the oil dipstick.
The Oil Alert system (applicable engine types) will automatically stop the engine before
the oil level falls below safe limits. However, to avoid the inconvenience of an
unexpected shutdown, always check the engine oil level before starting.
3) Fuel check
With the engine stopped, remove the fuel tank cap and check the fuel level. Refill the
tank if the fuel level is too low. After adding fuel, reinstall and tighten fuel tank cap.
During adding fuel, take care not
to let fuel level rise above the fuel strainer
shoulder (he maximum fuel level)
Fuel tank capacity: 25L
Engine oil
di
p
stick
油位上限
油位下限
Upper limit
Lower limit
最高燃油油位
Highest fuel level

Preoperation check
- 12 -
Use unleaded gasoline with an octane rating of 90 or higher.
Unleaded gasoline produces fewer engine and spark plug deposits and extends
exhaust system life.
Never use stale or contaminated gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
4) Air filter check
Remove the air filter cover and inspect the filter. Clean dirty filter elements. Always
replace damaged filter elements.

Operation and use of the set
- 13 -
V. Operation and use of the set
1) Starting the engine
①Remove all loads from the output end.
②Open fuel switch
③Put AC circuit breaker in the OFF position.
④Put throttle lever in the OFF position.
Do not shut off the choke if the engine is started when it is warm.
⑤Put the engine switch in the ON position.
⑥Gently pull up the starter grip and pull it out briskly when a resistance is felt.
⑦When the engine has warmed up, put choke lever in the ON position.
2) Use of the generator
①Connecting to home power supply
If the generator is to be connected to a home power supply as a standby,
connection shall be performed by a professional electrician or by another person with
proficient electrical skill.
When the loads are connected to the generator, please carefully check whether
electrical connections are safe and reliable. Any improper connection may cause
damage to the generator, or a fire.
Good
ProhibitedGood

Operation and use of the set
- 14 -
②Before starting the generator, it should be confirmed that the total of all loads’
power values doesn’t exceed the generator’s rated power.
Overload use will significantly shorten the generator’s service life.
If the generator is be connected to multiple loads or electricity consumers, please
remember to first connect the one with the highest starting current, then the one with
the second highest starting current... and last connect the one with the lowest starting
current.
Generally, capacitive and inductive loads, especially motor driven devices will generate
a very high starting current. The following table serves as a reference for your
connecting the generator to the electricity consumers as shown in the table.
Type Wattage Typical device Example
Starting Rating Device Starting Rating
●Incandescent
lamp
●Heating
device
X1 X1
Incandescent lamp
TV set
Incandescent
lamp
100W
100VA
（W）
100VA
（W）
●Fluorescent
tube X2 X1.5
Fluorescent tube
Fluorescent tube
40W
80VA
(W)
60VA
(W)

Operation and use of the set
- 15 -
●Motor
driven device X3～5X2
Refrigerator
Electric fan
Refrigerator
150W
450～
750VA
(W)
300VA
(W)
3) Use of welding power supply
①Description of welding chamber panel’s functions
②Selection of welding mode and connection
Connection of manual welding
Welding cable-
Welding cable+
Work piece
Overheating
indicator
Pushing force
adjusting knob
Welding output
(positive)
Gas inlet
Display of preset
current values
Welding mode
selection switch
Gas outlet
Welding output
(negative)
Current adjusting
knob
Electric torch
switch
Electrode holders

Operation and use of the set
- 16 -
Connection of argon-arc welding
③Turn on the power switch of welding power supply
Wait for about 2 to 3 minutes after turning on the power switch and
the no-load voltage has been generated, then you may start
welding operation.
④Select the appropriate welding current as per needs of welding.
⑤Weld
⑥Turn off power switch of the welding power supply.
4) Stopping the engine
①Turn off the AC circuit breaker
②Turn off the engine switch
③Turn off the fuel switch
If an emergency stop of the engine is needed, the engine switch shall be
up in the OFF position.
Welding cable-
Welding
cable+ Work piece
Gas meter
A
i
r
tank
T
orches