ESAB KHM 190 HS User manual

KHM 190 HS

Service manual

0794 999 901 01/10

Valid for serial No 108 - XXX - XXXX (0794000880)

Valid for serial No 119 - XXX - XXXX (0794000881)

Valid for serial No 142 - XXX - XXXX (0794000884)

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TABLE OF CONTENENTS SM 1

READ THIS FIRST SM 2

TROUBLE SHOOTING SM 3

TESTING SM 4

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51.1

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ORDERING OF SPARE PARTS R 1,

SPARE PARTS CG 4, CG 4.1,

SPARE PARTS CG 5, CG 5.1,

SPARE PARTS CG 6, CG 6.1,

KIT DECAL

TROLLEY KA 4

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This service manual is intended for use by technicians

with electrical/electronic traning, for help in connection

with fault-tracing and/or repair.

Use the wiring diagram on pages

M 61.1-2-3-4-5, 60

and the description of operation on pages SM 4 when

foult-tracing.

A brief user guide is included on page M 2, 2.1, 2.5,

2.5.1, 4.1, 6, 2.6.1, 2.7, 25, 26, 27, 31, 34, 37, 43.1,

45.1, 51, 51.1 to assist understanding how the ma-

chine is used.

The manuals contains details of all design modifications

up to and including May 2000.

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This product is intended for industrial use. In a domestic

environment this product may cause radio interference.

It is the user’s responsibility to take adeguate precaution.

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• Install and earth the welding unit in accordance with applicable standards.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe.

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• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and the

general area.

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• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

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• Protect your ears. Use ear defenders or other hearing protection.

• Warm bystanders of the risk.

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1) Defective power diode

bridge

1.1) Check the voltage supply.

1.2) Check the open circuit voltage

5

8

2). Defective base diode

bridge

2.1) Check the voltage supply.

2.2) Check the open circuit voltage

6

7

No welding current but

auxiliary output is OK or

welds poorly

3) Open circuit voltage is 1/3

or 2/3 of nominal value

3) Check wave form and, in case, replace the diode

bridge

9

No auxiliary power at the

sockets.

1) Defective G.F.I (ground fault

interrupter).

1.1) Check operation of G.F.I (ground fault inter-

rupter).

4

1) Short circuit in wiring.

1) Check the wiring inside the welder for a short cir-

cuit between cables or to ground.

-

2) Defective capacitor box.

2) If the wiring is OK, short circuit the capacitor box to

be sure that it is discharged, disconnect all wires from

it and check the capacitance.

1

3) Defective stator.

3) If the capacitor box is OK, disconnect all leads from

the stator except for those going to the capacitor box

and check the output from the alternator.

If there is no output from the welding winding and the

auxiliary winding, replace the stator.

2 – 3

5 - 6

4) Short circuited diode bridge.

4) If there is output from all windings reconnect the

diode bridge and check if there is welding voltage.

If not the diode bridge is defective.

5 - 6

No welding output and no

auxiliary power output.

5) Short circuit in the line.

5) If there is welding voltage connect the auxiliary

power leads one at a time until there is no output; at

this point, the short circuit is in that line.

2 - 3

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Turn ignition on and make sure all the LED’s momen-

tarily light up on the Engine Protection Unit.

 Check excitation capacitors. Remove the wires and

busbars from the capacitors and measure the capaci-

tance between the terminals on each capacitor.

The capacitance for each capacitor should be

___120BBB

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Reconnect busbars and wires to capacitor bank.

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 Check the exitation voltage; it is the three-phase

auxiliary voltage as well. Measure between R1 and

S1, R1 and T1, and S1 and T1 at the capacitors.

The voltage should be ___425___VAC.

 Check single phase voltage. Measure between Y

(neutral) and R1, S1 and T1.

The voltage should be ___245___VAC.

 Check operation of Ground Fault Interrupter

(G.F.I.). Push test button and check that the circuit

breaker switches off.

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 Check the supply to the power diode bridge.

Measure between RS, SS, and TS.

The voltage should be ___38___VAC.

 Check the supply to the base diode bridge. Meas-

ure between R3, S3 and T3.

The voltage should be ___73___VAC.

 Check the open circuit voltage of base diode

bridge. Measure across the

+ and - terminals on the

bridge.

The voltage should be ___100___VDC.

 Check the open circuit voltage of power diode

bridge. Measure across the + and - terminals on the

bridge.

The voltage should be ___77___VDC.

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Condition:

a) no load

b) max engine speed

Measure:

Between “-“ of base and power diode bridges

(common point) and “+” of each of them;

a) wave form “OUTPUT 190A” corresponds at

check point 8 of testing

b) wave form “OUTPUT 100A” corresponds at check

point 7 of testing .

OUTPUT 190 A

OUTPUT 100 A

T

1

)

Ref A: 20 Volt 5 ms

T

1

)

Ref A: 20 Volt 5 ms

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A : Alternator

C : Capacitor

D : G.F.I. (ground fault interrupter)

G : 400V EEC 3-phase socket

H : 230V EEC (220V) 1-phase socket

I : 120V EEC 1-phase socket

L : Socket warning light

Q : 230V EEC (220V) 3-phase socket

Z : Welding sockets

W : D.C. inductor

Y : Welding diode bridge

O2 : 48V EEC. socket

O3 : Resistor

P3 : A.C. Reactor

P4 : Circuit breaker

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- In the envelope where you found this manual you will

also find an Owner’s manual for the engine, and ac-

cessories (if required).



This product has been designed for welding and genera-

tion of electrical power for tools and other electrical devices

used in construction; ANY OTHER USE, is not permitted

and we cannot be held responsible for injuries or damages

resulting from such incorrect use.

Our products are made in conformity with the safety norms

in force in order to avoid injury to persons or damage to the

machine or other things.

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Making modifications to the machine without our written

authorization will void the warranty and release us from

any liability.

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Before using the machine please read this manual atten-

tively and follow the instructions contained in it. This will

help avoid problems, possible injury and damage to the

machine.

The manual is written for experienced, qualified personnel,

who are familiar with health and safety laws and related

regulations.

This manual is an integral part of the product and should be

kept in a safe place so that it will be available for consulta-

tion during the life of the product. If the machine is sold the

manual should be transferred to the new owner.

Some figures contained in this manual are designed to help

identify certain parts and may not correspond to the ma-

chine in your possession.

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The headings used in this manual are designed to call your

attention to potential hazards and important aspects of the

operation of the machine…

lndìcates a strong possíbility of severe personal injury or

death ìf ínstructions are not followed.

lndìcates a possibìlìty of personal ínjury or equipment dam-

age if ìnstructions are not followed

lndícates that equipment or property damage can result if

instructions are not followed.

These headings give helpful information about the prepara-

tion, operation and care of the machine.

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6723²Read with great attention

Read with attention

:5(1&+Use the correct tools for the type of

work being done

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$77(17,21 If this advice is not followed peo-

ple or things can be hurt or damaged.

+,*+92/7$*( Do not touch – risk of injury

or death.



),5( Risk of fire.



+($7 Hot surfaces.



(;3/26,9(  Explosive material or danger of

explosion, in general.



12:$7(5'RQRWXVHZater as it can cause

shortcircuits or other damage.





12602.,1*&igarettes, matches or lighters

can start a fire or explosion.



$&,'6Danger of corrosion or burns.

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Use protective clothing, etc. specifically

designed for the type of welding being done.

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It is advisable to protect yourself when carrying

out maintenance, such as filling the battery, refu-

elling, etc.

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Refer to the instructions before moving the ma-

chine

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It is compulsory to wear the personal pro-

tection items shown when using the equip-

ment.

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Safety devices suitable for the type of welding

and the location of the job must be used.

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It is prohibited to use water to put our fires in

electrical equipment.

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It is prohibited to work on the machine until the

electricity has been turned off.

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It is forbidden to weld in areas containing explo-

sive gases.

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+ Read and understand these instructions.

+

Before installing, operating or servicing this equipment, read

the operating manuals of the welder and of the engine

.

+

Not observing the information in the manuals can result in

personal injury and/or damage to the equipment and other

property.

+

Respect all safety regulations and laws when operting this

equipment.

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Removing or disabling protective devices on the ma-

chine is prohibited.

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The machine must be in good working order before be-

ing used. Defects, especially those which. regard the

safety of the machine, must be repaired before using

the machine.

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⇒ Stop engine when fuelling.

⇒ Do not smoke, avoid open flames and sparks, and

do not use electric tools when fueling.

⇒ Unscrew the fuel cap slowly to let out the fuel va-

pours.

⇒ Do not over-fill the tank.

⇒ Avoid spilling fuel on hot engine.

⇒ Wipe up spilled fuel before starting engine.

⇒ Shut off fuel cock, if present, or remove fuel from

tank before moving machine

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⇒ Sparks may cause the explosion of battery vapours

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⇒ Slowly unscrew the cooling liquid cap of a hot en-

gine to allow vapours to escape.

⇒ Hot vapor and heated cooling liquid under pressure

can burn face, eyes, skin.

F),567$,' In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas or what-

ever event which may cause serious injuries or death, predispose the first aid in accordance with the ruling labour

accident standards or of local instructions.

Skin contact Wash with water and soap

Eyes contact Irrigate with plenty of water, if the irritation persists contact a specialist

Ingestion Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor

Suction of liquids from lungs If you suppose that vomit has entered the lungs ( as in case of spontaneous vomit ) take the

subject to the hospital with the utmost urgency

Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone

the person involved

F),5(35(9(17,21 In case the working zone,for whatsoever cause goes on fire with flames liable to cause se-

vere wounds or death, follow the first aid as described by the ruling norms or local ones.

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Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water

Not to be used Avoid the use of water jets

Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces

close to the fire

Particular protection Wear an autorespiratory mask when heavy smoke is present

Useful warnings Avoid, by appropriate means to have oil sprays over metallic hot surfaces or over electric

contacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep in mind

that the inflamability point is very low.

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The operator of the welder is responsible for the security of the people who work with the welder and for those in the vi-

cinity.

The security measures must satisfy the rules and regulations for engine driven welders.

The information given below is in addition to the local security norms.

⇒ Make sure that the area is safe before starting any

welding operation.

⇒ Do not touch any bare wires, leads or contacts as they

may be live and there is danger of electric shock which can

cause death or serious burns. The electrode and welding

cables, etc. are live when the unit is operating.

⇒ Do not touch any electrical parts or the electrode while

standing in water or with wet hands, feet or clothes.

⇒ Insulate yourself from the work surface while welding.

Use carpets or other insulating materials to avoid physical

contact with the work surface and the floor.

⇒ Always wear dry, insulating gloves, without holes, and

body protection.

⇒ Do not wind cables around the body.

⇒ Use ear protections if the noise level is high.

⇒ Keep flamable material away from the welding area.

⇒ Do not weld on containers which contain flamable ma-

terial.

⇒ Do not weld near refuellng areas.

⇒ Do not weld on easily flamable surfaces.

⇒ Do not use the welder to defrost (thaw) pipes.

⇒ Remove the electrode from the electrode holder, when

not welding.

⇒ Avoid inhaling fumes by providing a ventilation system

or, if not possible, use an approved air breather.

⇒ Do not work in closed areas where there is no fresh air

flow.

⇒ Protect face and eyes (protective mask with suitable

dark lens and side screens), ears and body (non-flamable

protective clothes).

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In case you have to move or transport the machine, follow the instructions as shown in the

figures.

Ship the machine ZLWKRXWpetrol in the tank, ZLWKRXW oil in the engine and ZLWKRXWelectrolyte

in the battery. Be sure that the transportation devices are adequate for the size and wei

g

ht of

the machine.

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Not following these instructions could cause injury or damage to the machine.

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The accessory cannot be removed from the machine

and used separately (actioned manually) for the

transport of loads or anyway for used different from

the machine movements.





E

 1RWH For assembling the generating set on the

trolley please keep to following instructions:

1) -

Lift the generating set (by means of suitable hook).

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Do not substitute the original tires with other types

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GASOLINE ENGINES

• Use in open space with fresh air flow or vent exhaust

gases, which contain the deadly carbon-monoxide,

away from the work area.

POSITIONING THE MACHINE

Place the machine on a level surface at a distance of at

least 1,5 m from buildings or other structures.

If the surface is not level be sure that the angle of the ma-

chine does not exceed the values shown in the drawings

below.

+ Assure that the hot air and/or exhaust gas from the

machine are vented and are not recirculated in the ma-

chine. Hot air and/or exhaust gas which is recirculated wll

cause overheating of the machine and poor combustion

in the engine.

+ Make sure that the machine does not move during

operation.

Protect the machine from rain and do not put

it in a location where there is danger of flood-

ing.

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The degree of protection, of the machine is written the

rating plate and in this manual at the "Technical Data"

page.

MOVING THE MACHINE

Before moving the machine turn off the engine and dis-

connect all cables, which could impede the move.

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ESAB KHM 190 HS User manual

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