KHM 500 PS - CC/CV
Service manual
0794 999 921 01/04
Valid for serial No 109 - XXX - XXXX (50Hz version)
Valid for serial No 114 - XXX - XXXX (60Hz version)
Valid for serial No 109 - XXX - XXXX (110V version)
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TABLE OF CONTENENTS SM 1
READ THIS FIRST SM 2
TROUBLE SHOOTING SM 3
TESTING SM 4
COMPONENT POSITION ON THE WELDING CONTROL PCB SM 5
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*(1(5$/,1)250$7,21 M 2, 2.1, 2.5, 2.5.1, 2.7,4, 6.3, 2.6
23(5$7,21 M 3, 20, 21.3, 22.1, 31, 32, 38.7, 43, 43.3,
44.2, 45, 51, 52, 53
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ORDERING OF SPARE PARTS R 1,
SPARE PARTS EE 1, EE 1.1,
SPARE PARTS EE 2, EE 2.1,
SPARE PARTS EE 3, EE 3.1,
SPARE PARTS EE 4, EE 4.1,
KIT DECAL
SITE TOW FOR KHM 500/600 KA 9
PHG 1 KD 10
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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 61.1-2-3-4-5-6, 60
and the description of operation on pages SM 5 when
foult-tracing.
A brief user guide is included on page M 2, 2.1, 2.5,
2.5.1, 2.7,4, 6.3, 2.6, 3, 20, 21.3, 22.1, 31, 32, 38.7,
43, 43.3, 44.2, 45, 51, 52, 53 to assist understand-
ing how the machine 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) Low battery voltage. 1) Check battery level electrolyte. 2
2) Defective engine protection
unit.
2) Check voltage supply and fuse F1. 1
The engine doesn’t start.
3) Defective fuel cut off valve. 3) Check voltage supply. 6
The engine starts badly. 1) Defective glow plug. 1) Check voltage supply and fuse F2. 9
1) Defective fuel cut off valve. 1) Check voltage supply. 6
2) Defective oil pressure sen-
sor.
2) Check voltage supply and sensor. 3 - 4
The engine stops just
after starting.
3) Defective temperature
gauge.
3) Check voltage supply. 5
The fuel indicator doesn’t
work.
1) Defective fuel gauge. 1) Check voltage supply. 7 - 8
Low battery voltage while
running.
1) Defective battery charge. 1) Check battery charge voltage. 11
1) Defective diode bridge.
1) Check the open circuit welding voltage.
If it is OK the main diode bridge is OK.
18
2) Defective references on
welding PCB.
2) Check reference values.
from 19
to 24
3) Defective diode bridge. 3) Check the thyristors of bridge. 25
4.1) Is the remote control switch in the local position? -
No welding current but
auxiliary output is OK.
4) Problem with welding cur-
rent control PCB.
4.2) Check the supply to the thyristor bridge.
If it is OK replace the PCB.
15
1.1) Check the open circuit welding voltage.
If it is OK the diode main bridge is OK.
18
1.2) Check the open circuit welding voltage of base
current bridge.
17, a.
1) Defective diode bridge.
1.3) If it is 1/3 or 2/3 of the nominal value check the
thyristors and diodes.
25
Welds poorly.
2) Problem with welding cur-
rent control PCB.
2) If the main diode bridge is OK replace the PCB. -
1.1) Check that the pins of the connectors are clean
and making good contact.
-
1) Bad connections to welding
current PCB.
1.2) Check that shunt connections are tight. -
Intermittently welds
poorly.
2) Problem with welding cur-
rent control PCB.
2) Replace the welding current control PCB. -
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).
14
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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.
10
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.
12, a, b
– 13, a,
b, c.
15 –
16, a.
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.
15 –
16, a.
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.
12, a, b
– 13, a,
b, c.
Low power and quality of
welding current.
1) Setting of welding PCB.
1) Before replacing the PCB, check the dip switches
position and trimmer setting.
26 - 27
1.1) Check fuse F – 0.5A
1.2) Check inibit relay N3
No voltage at the welding
sockets in CV mode
1) Defective wire feeder con-
nections circuit.
1.3) Check voltage supply SS - TS
28
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Turn ignition on and make sure all the LED’s momen-
tarily light up on the Engine Protection Unit.
Check the supply to the Engine Protection Unit.
Measure between terminal 15 and ground (battery
voltage).
It should be between ___12___VDC and
___13.6___VDC
If there is no supply, check fuse ___F1___.
Check the battery voltage;
It should be between ___12___VDC and
___13.6___VDC (average value 12.8 VDC).
Check the supply to the oil pressure sensor. Re-
move wire number 4 from the sensor and measure
voltage to ground;
it should be___5.5___VDC.
Check the oil pressure sensor. Measure the resis-
tance between the sensor and ground.
The resistance should be ___0___
Check the supply to the water temperature gauge.
Measure between wire number 3 and ground.
The voltage should be ___5.5___VDC.
Check the supply to the fuel cut off valve. Measure
voltage between wire number 5 and ground;
it should be ___12___VDC.
Check the supply to the fuel gauge sensor switch.
Remove wire number 6 from the sensor and measure
voltage to ground.
The voltage should be ___12___VDC.
Check the voltage from the fuel gauge sensor.
Remove wire number 8 from the gouge and measure
voltage to ground.
The voltage should be ___10___VDC.
F 1RWH: the voltage corresponds to a full
tank should be ___0.4___VDC.
The voltage corresponds to an empty tank
should be ___8___VDC.
Check the supply to the glow-plug. Measure be-
tween wire 12 and ground while pressing the glow-
plug button on the front panel.
The voltage should be ___12___VDC.
If there is no supply, check fuse___F2___.
Check excitation capacitors. Remove the wires
and busbars from the capacitors and measure the
capacitance between the terminals on each capaci-
tor.
The capacitance for each capacitor should be
___90BBB )
Reconnect busbars and wires to capacitor bank.
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Check that the battery is being charged.
Measure the voltage across the battery; it should be
___14___VDC.
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Check the exitation voltage. Measure between R1
and S1, R1 and T1, and S1 and T1 at the capacitors.
The voltage should be ___480___VAC.
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Check the exitation voltage. Measure between R1
and S1, R1 and T1, and S1 and T1 at the capacitors.
The voltage should be ___440___VAC.
E Check the generator output for auxiliary power.
Measure between R and S, R and T, and S and T on
the terminal board.
The voltage should be ___430___VAC.
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Check single phase voltage. Measure between Y
(neutral) and R, S and T.
The voltage should be ___250___VAC.
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Check single phase voltage. Measure between Y
(neutral) and R1, S1 and T1.
The voltage should be ___250___VAC.
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Check 110 single phase voltage. Measure between R2
and T2.
The voltage should be ___115___VAC.
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Check 110 single phase voltage. Measure between Y
and T2.
The voltage should be ___120___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 thyristor bridge. Measure
between RS, SS, and TS.
The voltage should be ___45___VAC.
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Check the supply to the Base current bridge. Meas-
ure between 11, 12 and 13.
The voltage should be ___13___VAC.
D IRU+]YHUVLRQ
Check the supply to the Base current bridge. Meas-
ure between 11, 12 and 13.
The voltage should be ___10___VAC.
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Check output from Base current Bridge. Measure
across the
+ and - terminals on the bridge.
The voltage should be ___18___VDC.
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Check output from Base current Bridge. Measure
across the + and - terminals on the bridge.
The voltage should be ___14___VDC.
Check open circuit voltage. Measure across the
welding output terminals.
The voltage should be ___60___VDC.
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Check voltage feedback to PCB. Measure across pins
13 and 14 at connector CN5 on the PCB. Voltage
should correspond to OCV and it should be
___60___ VDC.
Check Current/Voltage control potentiometer value.
Remove the CN3-cable from PCB. Make sure remote
control switch is in the ‘’Off’’ position and that the
CV/CC switch is in the CV position. Measure the resis-
tance between pin 6 and pin 9 on CN3-cable.
The resistance should be ___5k___
Check potentiometer operation. Switch settings
should remain the same as in number 20 above.
Measure the resistance between pin 8 and pin 9 on
CN3-cable while turning potentiometer from minimum
to maximum setting.
The resistance should be ___0 – 5k___
Reconnect CN3-cable to the PCB. Measure voltage
on PCB. Check voltage across pin 10 and pin 11 on
connector CN3.
With switch in CC position the voltage should
be ___0___VDC.
With switch in CV position the voltage should
be ___3.3___VDC.
D Check voltage supply to Current/Voltage control
pot. Measure between pin 9 and 6 on connector CN3.
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2 >
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1) Ch 1: 20 Volt 2 ms
2
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Ref A: 20 Volt 10 ms
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1) Ch 1: 20 Volt 2 ms
2) Ref A: 20 Volt 5 ms
T
T
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2
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1) Ch 1: 20 Volt 2 ms
2) Ref A: 1 Volt 10 ms
Make sure CV/CC switch is in CV position and the
current range switch is in the max position.
The voltage should be between ___3.8___
and ___4.2___ VDC.
E Check voltage supply to Current/Voltage control
pot. Measure between pin 9 and 7 on connector CN3.
Make sure CV/CC switch is in CC position and the
current range switch is in the max position.
The voltage should be between ___4.2___
and ___4.6___ VDC.
Check voltage across pins pin 3 and pin 5 on con-
nector CN3.
With switch in CC position the voltage should
be ___14___VDC.
With switch in CV position the voltage should
be ___6.6___VDC.
:DYHIRUP
GATE WAVE FORM: PCB OUTPUT-THYRISTOR
(0794000099 p.c.b. code).
Condition:
a) no load
b) max position welding current knob.
Measure:
Between “-“ welding diode bridge and each gate thyristor
(7-8-9).
Output CC
Output CV
Measure:
Between “+“ welding diode bridge and each gate
thyristor (1-2-3).
Output CC or CV
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Note:
switch setting: ON
DIP 1,2,3 – filtering for hall sensor current signal
(no for ESAB machines).
DIP 4,5,6 – filtering – voltage signal.
DIP 7,8 - filtering for shunt current signal (on
ESAB machines).
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R 49 ⇒ minimum welding current value (turn in clock
wise direction to increase).
R 49 setting: →value checked in factory.
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!CV mode
!Wire feeder supply “ARC VOLTAGE”
!Knob, welding current regulation, max position
F1RWHo.c.v. 50 VDC
R 131 ⇒ trigger setting
(turn in clock wise direction to increase).
R 131 setting: →always in max position (totally clock
wise direction).
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With switches in:
- CV mode
- 42 V.a.c. supply
measure the voltage on the terminal strip:
- between A and B: the voltage should be 45 V.a.c.
- between SS* and F: the voltage should be 0 V.a.c.
- between B and F: the voltage should be 45 V.a.c.
(* see electrical diagram).
Connect together B and F (temporary connection): you
must have voltage at the welding sockets.
F1RWH - between N and C:
welding voltage to wire feeder instrument
- L – K – J: voltage reference to P.C.B.
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A : Alternator
B : Wire connection unit
C : Capacitor
D : G.F.I. (ground fault interrupter)
F : Fuse
G : 400V 3-phase socket
H : 230V 1phase socket
I : 110V 1-phase socket
M : Hour-counter
N : Voltmeter
R : Welding control P.C.B.
S : Welding current ammeter
T : Welding current regulator
U : Current transformer
V : Welding voltage voltmeter
Z : Welding sockets
X : Shunt
W : D.C. inductor
Y : Welding diode bridge
G1 : Fuel level transmitter
H1 : Oil or water thermostat
L1 : Oil pressure switch
Q1 : Starter key
R1 : Starter motor
S1 : Battery
T1 : Battery charge alternator
U1 : Battery charge voltage regulator
Z1 : Solenoid valve
W1: Remote control switch
X1 : Remote control socket
Y1 : Remote control plug
C2 : Fuel level gauge
F3 : Stop push-button
I3 : Range switch
N3 : Relay
O3 : Resistor
G4 : Preheating glow plugs
I4 : Preheating indicator
P4 : Circuit breaker
X4 : Base current diode bridge
A5 : Base current switch
M5 : Engine protection EP5
N5 : Pre-heat push-button
M6 : Switch CC/CV
R6: EMC filter
S6: Wire feeder supply switch
T6: Wire feeder socket
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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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6723²Read with great attention
Read with attention
:5(1&+Use the correct tools for the type of
work being done
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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'RQRWXVHZater as it can cause
shortcircuits or other damage.
12602.,1*&igarettes, matches or lighters
can start a fire or explosion.
$&,'6Danger 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.
(;7,1&7,210($16
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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