language USE AND MAINTENANCE MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS – ENGLISH WELDING GENERATOR GM 5-200 HBM GM 7-200 HBT • • • • Motosaldatrice • Schweißaggregat Engine Driven Welder • Motosoldadora Motosoudeuse • По Вышкам Motosoldadoras M A D E I N I T A L Y Codice Code Code Codigo Kodezahl Código Код C1UN70209003 Edizione Edition Édition Edición Ausgabe Edição Издание 10.
REV.0-10/20 INDEX M1.1 M1.4.2 M2 M2.1 M2.5... INTRODUCTION.................................................................................................................. PAG. CE MARK............................................................................................................................ PAG. SYMBOLS AND SAFETY PRECAUTIONS............................................................................... PAG. WARNINGS.......................................................................
+ In case you do not profit on these Services and some arts are replaced, please ask and be sure that are used exclusively original parts; this to guarantee that the performances and the initial safety prescribed by the norms in force are re-established. +The use of non original spare parts will cancel immediately any guarantee and Technical Service obligation. NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively.
M 1.4.2 REV.7-02/18 CE MARKING ENGINE DRIVEN WELDER ENGLISH CE marking is clearly readable and unerasable and it can be either part of the data-plate. 1 5 6 7 10 8 9 6 15 28 1. 2. 3. 4. 5. Manufacturer name or brand Year of production Engine Driven Welder model Serial number | registration number Reference to the standard confirming that the Engine Driven Welder complies with its requirements 6. Welding process symbol 7.
- The symbols used in this manual are designed to call your attention to important aspects of the operation of the machine as well as potential hazards and dangers for persons and things. Moreover, this symbolism intends to draw your attention with the aim to give you indications for a correct use and, as a result, to obtain a good operation of the machine or equipment used. DANGER ! HIGH VOLTAGE - Attention High Voltage.There can be parts in voltage, dangerous to touch.
FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas or whatever event which may cause serious injuries or death, predispose the first aid in accordance with the ruling labour accident standards or of local instructions.
The instructions in this manual are intended as indicative only. It is the responsibility of the owner/operator to evaluate risks and potential damages in relation to the use of the product in the specific conditions of application. Remember that the non observance of the indications of this manual may result in damage to people or things. In all cases, however, it is understood that the use shall be in compliance with the applicable laws/regulations.
M 2.5.1 REV.0-01/18 SAFETY RULES ENGINE DRIVEN WELDERS SAFETY PRECAUTIONS DURING INSTALLATION AND USE 10° = 20° max 10° 10° = 20° max Always locate the machine on a flat and solid ground, so as to avoid tipping, slipping or falling during operation. Avoid using the machine on slopes greater than 10 degrees. ENGLISH ENGLISH Do not instal equipments closed to heat source, to explosion or fire risk area.
M 2.5.2 REV.0-01/18 SAFETY RULES ENGINE DRIVEN WELDERS SAFETY PRECAUTIONS DURING MAINTENANCE Make use of qualified personnel to carry out maintenance and troubleshooting It is mandatory to stop the engine before performing any maintenance on the machine. ENGLISH ENGLISH Always use protective devices and suitable equipment. Do not touch the engine, the exhaust pipes and the muffler during operation or immediately after.
M 2.5.3 REV.0-01/18 SAFETY RULES ENGINE DRIVEN WELDERS ADDITIONAL REQUIREMENTS FOR ENGINE DRIVEN WELDERS Do not manage electric devices and welding stick whit feet, hands or wet dresses. ENGLISH Protect yourself from electric shock by insulating yourself from work and ground. Use non-flammable, dry insulating material if possible, or use dry rubber amts, dry wood or plywood, or other dry insulating material. Magnetic fields can affect pace-makers.
M 0 REV.0-10/20 DESCRIPTION OF THE MACHINE Unit meant for industrial and professional use, powered by an endothermic engine; it is composed of various main parts such as: engine, alternator, electric and electronic controls, the fairing or a protective structure. The assembling is made on a steel structure, on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise.
0.1 REV.1-11/14 RECORDING DATA The manual is for the range of machines indicated on the front cover. With the scope to facilitate the search of the spare parts and maintain information of the bought machine, is necessary to record some data. 1. 2. 3. 4. 5. 6. 7. 8. Model of machine Serial number of the machine Serial number of the engine Name of the dealer where bought the machine Address of the dealer Phone number of the dealer Date of the bought machine Notes ENGLISH RECORDING DATA 1. 2. 3. 4. 5.
! M 3 REV.1-02/04 MACHINE UNPACKING NOTE + Be sure that the lifting devices are: correctly mounted, ENGLISH ENGLISH adequate for the weight of the machine with it’s packaging, and conforms to local rules and regulations. When receiving the goods make sure that the product has not suffered damage during the transport, that there has not been rough handling or taking away of parts contained inside the packing or in the set.
! M 4.1 REV.2-09/11 TRANSPORT AND HANDLING COVERED UNITS ATTENTION ENGLISH DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION. IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with no CTM accessory). If you did not keep to the instructions, you could damage the structure of the machine. Weight max. per person: 35 kg Total max.
M 2.7 REV.0-10/20 INSTALLAZIONE - INSTALLATION - INSTALLATION INSTALACIÓN - LUFTZIRKULATION - INSTALAÇÃO УСТАНОВКА - INSTALLATIE 29/11/19 C1UN7020_IT M1.
INSTALLATION INSTALLATION AND ADVICE BEFORE USE Always instal the welder machine on a hard and plan surface in order to avoid rollovers, slips or falls while working; avoid to use the welder machine with slope more than 10°. The operator of the welder is responsible for the security of the people who work with the welder and for those in the vicinity. Particulary remember: - installing operation must be made by authorized and qualified person.
warning this Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. Installation and use The user is responsible for installing and using the arc welding equipment according to the manufacturer’s instructions.
The supplied battery is generally ready for use. Connect the cable + (positive) to the pole + (positive) of the battery (after having taken away the protection), by properly tightening the clamp. On some models, the battery must be activated. To activate it (fill the included acid) please follow the instructions shown on the manual attached to the battery. When battery is activated, DON’T add any other liquid.
The protection against electric shock from contact indirect is ensured by the “electrical separation” with equipotential bonding between all the exposed conductive parts of the generating set. Machines equipped with insulation resistance monitor allow intentionally not to connect the ground terminal PE (12) to an earthing system. Located on the front of the machine the insulation resistance monitor has the function of continuously monitoring the ground insulation of live parts.
Check daily M 26 REV.0-10/20 STARTING AND STOPPING ATTENTION: ! NOTE 5. Once the engine is started, with the starter off, let it turn for a few minutes before drawing the load. ENGLISH Do not alter the primary conditions of regulation and do not touch the sealed parts. STARTING 1. Turn the fuel cock to ON FUEL VALVE STARTER GRIP STOPPING To stop the engine in an emergency, simply turn the engine switch to the OFF position. 2. Switch the choke control to CLOSE N.B.
9 GM 5-200 HBM 40-100-160 Welding Current 50-110-170 2 x 230V CEE 80-140-200 Generator 160A/220A 40A/90A 100A/150A Range Selection 15 59B 59B ENGLISH 59B 15 GM 7-200 HBT 40-100-160 Welding Current T 0 D (x G.F.I. vers.) Pos. 9 10 T 50 15 D 59B 12 Description c.c. welding sockets (+) c.c. welding sockets (-) Welding current regulator Function/Current switch A.C.
This symbol (Norm EN 60974-1 security standards for arc welders ) signifies that the welder can be used in areas with increased risk of electrical shock. Assure the right ground connection (12) (when and if needed). For this purpose see chapter “GROUND CONNECTION”. STARTING OF THE SET During every start, selector must be on position “GENERATOR” to guarantee the alternator selfenergising. M 34 REV.
! WARNING Access forbidden to area adjacent to electricitygenerating group for all non-authorized personnel. ! WARNING For the canopy generator sets provided with doors, the following instruction shall be observed. During the normal operation, the doors of the engine compartment and/or the electrical box shall be kept closed, locked up if possible, as they must be considered in all respects as protection barriers.
ELECTRIC PROTECTIONS + NotE: for some types of alternators (asynchronous alternators) it is not necessary to protect the three-phase output against short circuits and overcurrents, as the asynchronous alternator self-protects itself. The electricity-generating group is protected against short-circuits and against overloads by a thermal-magnetic switch (Z2) situated upstream from the installation. Operating currents, both thermic and magnetic, can be fixed or adjustable in relation to the switch model.
M 55 REV.0-10/03 RECOMMENDED ELECTRODES (IN ACCORDANCE WITH A.W.S STANDARD) The information here below are to be intended only as indicative since the above norm is much larger. For further details please see the specific norms and/or the manufacturers of the product to be used in the welding process. ENGLISH BASIC ELECTRODES: E 7015 Basic electrrodes wels onlu in d.c. with inverse polarity (+ on the electrode holder) ; there are also types for a.c. Suitable for impure carbon steels.
WARNING ! ● Have qualified personnel do maintenance and troubleshooting work. ● Stop the engine before doing any work inside the machine. If for any reason the machine must be operated while working inside, pay attention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open. ● Remove guards only when necessary to perform maintenance, and replace them when the maintenance requiring their removal is complete.
Problem Low no-load voltage Solution 1) Insufficient residual voltage 1) Excite the rotor using a battery 2) Connection break 2) Reset the connection 3) Three-phase diode bridge is broken 3) Replace three-phase diode bridge 4) Insufficient speed 4) Adjust speed regulator of the drive motor 5) Windings breakdown 5) Check winding resistances and replace damaged part 6) Poor contact of the brushes 6) Clean and check the slipring 1) Low revolving speed 1) Adjust speed regulator of the drive moto
MOVING PARTS can injure WARNING ● Have qualified personnel do maintenance and troubleshooting work. ● Stop the engine before doing any work inside the machine. If for any reason the machine must be operated while working inside, pay attention moving parts, hot parts (exhaust manifold and muffler, etc.) electrical parts which may be unprotected when the machine is open. ● Remove guards only when necessary to perform maintenance, and replace them when the maintenance requiring their removal is complete.
+ REV.0-07/18 MAINTENANCE SCHEDULED HONDA IMPORTANT The information given in the table is only indicative. Specific instructions are given in the operation manuals.
DISASSEMBLE In case the machine should not be used for more than 30 days, make sure that the room in which it is stored presents a suitable shelter from heat sources, weather changes or anything which can cause rust, corrosion or damages to the machine. + + Have qualified personnel prepare the machine for storage. GASOLINE ENGINE Start the engine: lt will run until it stops due to the lack of fuel. Drain the oil from the engine sump and fill it with new oil (see page M25).
Single-phase, synchronous GM 7-200 HBT 7 kVA (5.6 kW) / 400 V / 10.1 A 6.5 kVA (5.2 kW) / 400 V / 9.4 A --4 kVA / 230 V / 17.4 A ----- 50 Hz Self-excited, self-regulated H Three-phase, synchronous HONDA GX 390 (STAGE V) Gasoline OHV 4-Stroke / Air 1 / 389 cm3 8.2 kW (11.1 HP) 3000 rpm 2.1 l/h 1.1 l Recoil * Maximum output (not overloadable) according to SAE J 1349 GENERAL SPECIFICATIONS Fuel tank capacity Running time (Welding 60%) Protection *Dimensions max.
GM 5-200 HBM SMAW (STIK - Shielded Metal Arc) 40A / 21.6V - 200A / 20V 85V 160A / 26.4V - 60%, 120A / 24.8 - 100% GM 7-200 HBT ENGLISH ENGLISH C.C. WELDING Welding processes Range of current No-load voltage Service M 1.6 REV.0-10/20 TECHNICAL DATA OUTPUT CARACTERISTIC 90 80 70 60 50 40 30 20 10 0 50 NEMA 100 MIN.
570 REV.0-10/20 DIMENSIONI - DIMENSIONS - DIMENSIONS M DIMENSIONES - ABMESSUNGEN - DIMENSÕES РАЗМЕРЫ - AFMETINGEN 2.7.
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