NGW 190H Service Manual
Contents
1. EQUIPMENT OWNER S MANUAL GENERATOR WELDER NGW 190H MMD Equipment Inc 121 High Hill Road Swedesboro NJ 08085 Tel 800 433 1382 Fax 856 467 5235 www mmdequipment com CONSTRUCTION EQUIPMENT 400 LIVELY BLVD ELK GROVE VILLAGE IL 60007 800 869 0321 NGW 190H Gen Welder Heavy duty butt welded rectangular roll cage Vacuum Assisted Auto matic Choke Large air filter for longer engine life Idle control reduces fuel consumption and engine wear a e TT AS e Alv Honda OHV with auto decompression and elec trnic ignition ne Oil Alert protects the engine The NGW 190H offers true versatility for the contractor or rental yard This simultaneous use AC 120 240V DC 50 180A generator welder is designed for reliable output in tough construction jobs Advance technology allows for the more compact design and lighter weight that can withstand the rigors of the job site day and night Automatic Voltage regulation and 100 copper windings provide consistent power full output for motor starting and the ability to with stand the surges caused by electric motors and tools The DC welder offers an excellent open cir cuit voltage for superior welding The shielded lugs allow easy access and extra protection The adjustable stable voltage output makes this welder ideal for a broad range of applications Designed for reliability the steel fuel tank weather proof control box bu2. G amp 4 g D OF Ji ak SW N C EE G00 M i 55 5 S R tee a a ty aA ER a a a Ee Rech del at ne ge ALP air 7 5 s HONDA GX240K1 GX270 GX340K1 GX3S0K1 Measure the resistance of the spark plug cap by touching one test lead at the wire end of the cap and the other at the spark plug end Replace the spark plug cap if the resistance is not within the range specified SPARK PLUG CAP Measure the resistance between the wire terminals We el 6V 25W 0 21 0 27 Q 0 36 0 462 gt Refer to P 1 3 2 to properly identify the lamp coil before testing e CHARGE COIL Model with electric starter Measure the resistance between the wire terminal and ground e STARTER SOLENOID Connect a 12V battery between the starter terminal and the solenoid body and check for continuity between the terminals Continuity should exist when the battery is connected and not exist when the battery is disconnected T7 7 T D a ai M ZA AT a TA eg e ge T Ath ba e gi obs T Ep vi H Seen be ZER AD WK ewen g e n r Mil e o ka LE an Cen wech A B w it bf emm gp Eege a e ey Bn pue t M HONDA be aat H E KA Ep e ef 3 e GX240K1 GX270 GX340K1 GX390K1 FLYWHEEL IGNITION COIL STARTER MOTOR sw FLYWHEEL a DISASSEMBLY REASSEMBLY DISASSEMBLY lt GX240K1 GX270 gt e Remove the ignition coil before STARTER MOTOR
3. the resistance within the standard brush extrudes pech the is continuity higher than AC differs larger differs larger value in the normal more than 5 unit before between 12V If not itis than 10 of than 10 of direction and infinite in mm It is replacement is respective lead abnormal standard value standard value the reverse direction If defective if it is defective wires It is is defective if even one less than 5 mm defective the Of them is not indefinite resistance is in the reverse direction infinite AVR Assy replacement Rotor CP replacement Initial exciting coil replacement Countermeasure Lead wire repair Diode module Brush holder Assy replacement replacement or replacement Engine can be started but unable to weld or generate power Phenomenon Slow down unit does not function Subject parts Laii s S output side Slow down circuit fuse Slow down Solenoid unit Slow down unit Welding cable switch Wiring Shortcircuit 1 Broken wire 1 Defective contactor on cable 2 Miswiring Defective slow 2 Switch lever OFF down unit Load is connected to the power outlet Broken coil 1 Continuity check with a circuit tester 2 Check if the wiring is passed through ZCT of slow down unit 1 Visual check 2 Continuity check on the fuse with a ci
4. EQUIPPED TYPE removing the flywheel Measure starter performance while cranking the engine Do not hit the flywheel with a lf performance is not within service limits disassemble and in hammer Remove with the spe spect as described on pages 8 4 cial tool GX240K1 GX270 Leier U 9 7VDC Cranking current Below 80A Engine cranking More than speed 393 min rpm A 3 ACK OIE CHARGE COIL REASSEMBLY e Insert securely into the two ribs on the crank case as shown FLYWHEEL PULLER 07935 8950002 REASSEMBLY Clean the crankshaft tapered sur 8 x 40 2 face before installation 12 WOODRUFF KEY REASSEMBLY After installing the flywheel check to be K WIRES EXIT ENGINE HERE sure that the woodruff RD gt key is still in its slot on KIR the crankshaft Z J T 10 HIGH TENSION CORD 6 x 28 2 REASSEMBLY 9 IGNITION COIL Check for cracked or damaged insulation INSPECTION ADJUST 7 replace if necessary MENT P 8 5 2 S M STARTER PULLEY _ REASSEMBLY COOLING FAN Ee Align the hole of the CAUTION 8 1 8 2 starter pulley with the When disassembling FLYWHEEL COOLING FAN boss of the cooling fan and reassembling take 8 3 2 l care not to damage the ALIGN 6 tan blades 16 mm FLANGE NUT REASSEMBLY TORQUE _ Attach by aligning the 115 Nem 11 5 k
5. is placed in the 120V position all the rated current may be drawn from each of the 120V receptacles but no current may be drawn from the 240V receptacle NOTE When the circuit breaker trips during operation the generator is overloaded or the appliance is defective Turn the generator off immediately and calculate the total wattage being used voltage x total amperage wattage The rated A C output varies from 600W to 3300W depending on the D C amperage being used simultaneously Rated A C output if not welding is 3300W Rated A C output while welding at 180A simultaneously is 600W For example The full power switch is in the 120V 240V position and the generator is being used to power a 5A appliance from the GFCI and a 10A appliance from the 240V receptacle Wattage consumed from GFCI is SA x 120V 600W Wattage consumed by the 240V receptacle is 10A x 240V 2400W Total wattage consumed 1s 600W 2400W 3000W If the total wattage exceeds the rated A C output of the gen welder see above reduce the number of tools being used or use a larger generator If the total wattage does not exceed the rated A C output of the gen welder check the appliances for shorts If all appliances test normal take the gen welder to an authorized service center for repair PRECAUTIONS FOR D C WELDING READ HONDA ENGINE OWNER S MANUAL BEFORE OPERATING GEN WELDER 1 Electric shock is extremely dangerous Please adhere to the foll
6. T SOLENOID AT BASE OF CARB ISNITION COIL SIDE WITH METAL PLATE ORDER OF WIRES FROM LEFT TO RIGHT LAMP COIL EXCITER GREEN ORANGE CIRCUIT BREAKER RE REC gt FULL POWER SWITCH BROWN GENERATOR GROUND NGW190H WELDER TROUBLESHOOTING GUIDELINES First verify the engine rpm is set to 3750 rpm at no load Then check the lamp coil from the Honda engine 0 36W 0 46W This coil provides the initial excitation voltage for the generator welder pages 8 2 and 8 6 of the Honda shop manual for the GX 390 engine Next check the brush length they must be longer than 5 mm If the brushes are less than 5 mm long the brush holder must be replaced Brushes should also move smoothly in and out of the brush holder Ensure the brushes are smooth and the slip rings on the rotor are also clean and smooth Measure the resistance between the two slip rings on the rotor It should be between 7 1 Ohms 7 2 Ohms If the resistance is outside these parameters replace the rotor Ensure your readings are accurate Measure the resistance of the stator coils See attached pages If the resistance is outside these parameters replace the rotor Ensure your readings are accurate Test AVR Your multi meter must be very accurate to 0 01W You must also determine the resistance in your meter leads by holding the tips of the leads togethe
7. equired cable size is determined by the amount of amperage used when welding and the length of cable to be used The longer the length of cable or the higher the welding current the larger the diameter of the cable must be Length dt 50 100 125 150 200 250 300 Current A 100 3 3 3 3 3 3 2 150 3 3 3 3 2 1 1 180 3 3 3 2 1 1 0 1 0 2 Select the polarity of welding cables The polarity positive or negative 1s indicated at the welding lugs on the control panel Select the polarity according to the appropriate welding application Polarity Connection method Application Electrode Grounding base metal Welding structural steels or thick plates positive Electrode holder Electrode Electrode holder Build up welding Negative Grounding base metal Arc welding thin plates Arc welding stainless steel 3 Duty cycle for NGW 190H gen welder This welder is not designed to withstand continuous welding To avoid overloading the gen welder adhere to the appropriate duty cycle Duty cycle is a percentage of a 10 minute period of time Welding current A 110 or less 120 140 170 190 Duty cycle 100 80 60 50 40 Example If the duty cycle is 40 you can weld up to 4 minutes in a 10 minute period NGW 190H Full Power Sw UP 120V 240V Full Power Sw Down 120V only ENGINE CONTROL BOX ON OFF SWITCH 1 4 J U BLACK d A 6 DIODE 1 W BLUE O O BLACK FUEL CU
8. fuel tank with fresh clean unleaded gasoline 4 5 gallons Check gen welder control panel Circuit breakers should be off idle control switch Should be off and on off switch should be on Turn fuel cock to the open position lever is vertical Pull choke lever out choke is on with lever pulled out Pull starter grip lightly until you feel resistance Return the grip gently to its original position and then pull briskly Return the grip gently Repeat this process until the engine starts Push choke lever inward choke 1s off 10 Allow the engine to run for 3 5 minutes before connecting any equipment or welding 11 Place circuit breakers in the on position USING A C RECEPTACLES READ HONDA ENGINE OWNER S MANUAL BEFORE OPERATING GEN WELDER 1 Check pilot lamp is illuminated 2 Ensure all appliances are turned off before connecting them to the generator 3 Insert appliance plugs into receptacles on generator e Check the amperage of the receptacles being used and be sure not to exceed that amperage GFCI 20 amps of 120V NEMA L14 10R 10 amps of 240V four pronged locking receptacle NEMA L5 30R 30 amps of 120V three pronged locking receptacle NOTE ON OPERATION OF THE FULL POWER SWITCH When the full power switch is placed in the AC 120 240 position only half the rated current may be drawn from the 120V receptacles while all the rated current may be drawn from the 240V receptacle When the full power switch
9. g m 83 ft lb three lugs on the rear DISASSEMBLY REASSEMBLY side of the fan with the small holes in the flywheel e Apply oil to the thread e Hold the flywheel by placing screwdriver into the pulley 9 TROUBLESHOOTING When the engine starts but unable to weld or generate power Subject parts Cannot weld or use the auxiliary power supply _ Possible Cause Broken wire Broken wire or shortcircuit or shortcircuit Remove T Ka f coupler of red wire from AVR Assy and check the voltage with a circuit tester Initial exciting coil mounted on engine Broken wire or shortcircuit site Abnormal wear or Et Shortcircuit Defective Assy Broken wire Measure the resistance between slip rings with a circuit tester Check the resistance value on each Jead wire with a circuit tester Replace with a new AVR Assy and check the result Check resistance values of diodes 6 pcs Measure the resistance between respective lead Removing the brush holder Assy measure the dimension of brush which is protruding from the holder face with vernier calipers on the module t is acceptableifitis It is good if the It is good if there It is defective if It is normal if It is defective if If it operates the voltage is the resistance
10. owing precautions 2 3 a b c d e Wear protective clothing such as welding gloves welding apron and face shield Filter lens should conform to ANSTI Z87 1 Standard Damaged welding cables may cause shorting to occur or electrical shock to personnel Always inspect cables for damage before connecting them to the welding lugs Never touch welding lugs while engine is running Always ensure the protective cover over the welding lugs is closed whenever the engine is running Never operate the gen welder in any wet area Fumes from engine and welder are noxious and may cause sickness or even death a b Avoid breathing fumes from engine and welder Ensure adequate ventilation near gen welder especially when welding on galvanized lead or cadmium plated steel and other metals that produce toxic fumes Avoid circumstances that could cause fire or explosion a b c Keep the area clear of combustible material Sparks from welding can ignite flammables Do not weld and heat drums tanks or any enclosed containers unless precautions have been taken to keep fumes from concentrating inside Keep approved fire extinguishers readily available when welding USING D C OUTPUT FOR WELDING READ HONDA ENGINE OWNER S MANUAL BEFORE OPERATING GEN WELDER NOTE To avoid serious injury never connect welding cables while engine is running 1 Select the proper cables using the guidelines below The r
11. r and recording the value from your meter probably 0 1 W or 0 2 W Subtract this value from all test values read on the meter display NGW190H WELDER COMPONENT CHECKS ROTOR 1 From one slip ring to the other 7 5 ohms 2 From each slip ring to the bobbin Infinity CURRENT TRANSFORMER 1 Should get a reading of 57 ohms STATOR 1 Red to brown brush leads Infinity 2 Red to white 0 3 ohms 3 Black to blue 0 3 ohms 4 Between red white and black blue Infinity 5 Three wire plug A Red to white 0 3 ohms B Red or white to brown Infinity C Red to red brush lead 0 ohms D Brown to brown brush lead 0 ohms E Brown to any lead Infinity DC LEADS 1 Red to red test lead amp Black to black test lead 1 08 to 1 3 Mg ohms 2 Red to black test lead amp Black to red test lead 63 5K ohms DIODE BLOCK 1 AC terminals to Minus Black test lead on AC terminal and Red test lead on Minus 5 9K ohms 2 Red test lead on AC terminal and Black test lead on Minus 1 7 Mg ohms 3 Black test lead on AC terminal and Red test lead on Plus 1 7 Mq ohms Oo DS Black test lead on Plus and Red test lead on Minus 7OKohms Red test lead on Plus and Black test lead on Minus 2 0 Mg ohms Red test lead on AC terminal and Black test lead on Plus 5 9K ohms Pa an AR Fa VYYIF UM OU UN IOs HEEMECHT oe s abg n Oe it a H 0047 m 0 044 A tg oe A e
12. rcuit tester Visual inspection Check for contact between welding holders 1 Check for continuity with a circuit tester 2 Check the switch lever position Check the Replace with a resistance witha new slow down circuit tester unit Inspection Check for any Mer equipment tool etc connected to AC output side It is good if Trouble by there is a shortcircuit continuity or not good if it is infinite 2 Switching error If it operates properly the unit before replacement is defective It is defective if the resistance is infinite It is not good if any load is connected Ces 1 Visual check It is defective if an infinite is detected at a place Miswiring if ZCT wire of slow down unit is not passed of fusing 2 It is fused if there is an infinite resistance 1 Replace if it is infinite 2 Turn the switch lever io ON side Replacement of 1 Lead wire replacement shortcircuited section Slow down unit replacement Load removal from Solenoid unit 2 Pass the wiring through Baier power outlet replacement Engine can be started but unable to weld or generate power Phenomenon auxiliary power supply can be used Subject parts Possible cause Check the circuit tester Judgement It is good if the G resistance is app
13. rox Q It is not if it is nearly infinite Countermeasure Volume switch replacement Cannot weld but the Current adjusting variable resistor resistance with a Interna trouble Setting the breaker lever at ON position check the continuity between terminals witha tester It is good if there is a continuity between terminals It is not if there is no continuity Can weld but the auxiliary power supply cannot be used AVR Assy Replace with a new AVR Assy If it operates properly the unit before replacement is defective AVR Assy replacement Defective Assy It is good if there infinite Lead wire repair Broken wire Check the resistance with a circuit tester wire witha circuit tester It is good if the resistance is equal to the standard value of approx 570 is a continuity between respective lead wires It is defective if the resistance value is infinite Current detection transformer replacement or replacemant Can weld and provide a powerful auxiliary power supply 1 Improper adjustment of 2 Shortcircuit on the circuit It is defective if the resistance is 1 Adjust the dial at the proper 2 Variable resistor replacement Variable resistor current adjustment dial 1 Check the po
14. sition of current adjustment dial 2 Check the resistance with a circuit tester 1 Current adjustment dial is set at a larger value current 2 It is if the resistance is equal to the standard value of approx 1 2 It is defective it is nearly in the conductive condition close to 0Q position
15. tt welded double rectangular frame and 6 heavy duty diagonal vi vation isolators offer investment protection _ Deluxe features like the full power switch low oil shutdown panel mounted on off switch in tank fuel gauge large easy fill opening with filter all assure you of easy operation and extended life AC Voltage V DC hja V DC Amps Duty Cycle IAC Outlets DC Output Engine Horse Power Tank Capacity G Run Time at rated load Auto Idle Control Dimensions LxWxH Dre Waioht T ha Max x ple ol E 55V Open Circuit een Large super silent muf fler All Day Steel Gas Tank Full power switch 120V or 120 240V use 120V GFCI s protect from tool shock Shielded welding lugs Electro Magnetic Break ers stop generator and tool burn out from over loads 6 heavy duty vibration isolators NGW 190H 120 240V 3 800W 31 7A 3 300W 27 5A dia 50 180A _ 40 o I x 120V 20A GFCI I x 120V 30A Twist Lock I x 240V 20A Twist Lock 3 8 ioe with Wing Nuts Honda GX 390 _ STARTING THE NGW 190H GEN WELDER READ HONDA ENGINE OWNER S MANUAL BEFORE OPERATING GEN WELDER 1 2 3 4 5 6 7 8 9 Place generator on a stable and level surface Inspect engine for oil or gas leaks Check engine oil See Honda engine owner s manual NGW 190H uses a 13hp Honda GX 390 engine Oil capacity is 1 16 U S quarts Fill
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