Service manual
KHM 400 YS
0794 999 937 05/02 Valid for serial No. 443 - XXX - XXXX
Index
KHM 400 YS SM
1
02/11/04 79405-GB
TABLE OF CONTENTS
DESCRIPTION PAGE
SERVICE MANUAL
TABLE OF CONTENENTS SM 1
READ THIS FIRST SM 2
THOUBLE SHOOTING SM 3
WIRING DIAGRAM
M 61.1, 61.2, 61.3, 61.4
DESCRIPTION - WIRING DIAGRAM
M 60
GENERAL INFORMATION
M 2, 2.1,2.5, 2.5.1, 4, 6.2, 2.6, 2.7
OPERATION
M 3, 20, 21.3, 22.1, 31, 32, 33, 38.9,
M 43, 43.3, 44.2, 45, 51, 52, 53
SPARE PARTS
ORDERING OF SPARE PARTS R 1,
SPARE PARTS DS 35, DS35.1
SPARE PARTS DS 36, DS36.1
SPARE PARTS DS 37, DS37.1
SPARE PARTS DS 38, DS38.1
KIT DECAL DS 39
SITE TOW FOR KHM 400 KA9
PHG1A KD11
SERVICE MANUAL
KHM 400 YS SM
2
02/11/04 79405-GB
READ THIS FIRST
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, 60
and the description of operation on pages SM 3
when fault-tracing.
A brief user guide is included on page M 2, 2.1, 2.5,
2.5.1, 2.7, 4, 6.2, 2.6, 3, 20, 21.3, 22.1, 31, 32, 33...,
38.9, 43, 43.3, 44.2, 45..., 51, 52, 53 to assist
understanding how the machine is used.
The manuals contains details of all design
modifications up to and including Feb 2005.
WARNING
!
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN
WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURES’
HAZARD DATA.
ELECTRIC SHOCK – Can kill
• 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.
FUMES AND GASES – Can be dangerous to health
• 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.
ARC RAYS – Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE– Excessive noise can damage hearing
• Protect your ears. Use ear defenders or other hearing protection.
• Warm bystanders of the risk.
MALFUNCTION – Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS !
WARNING
!
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.
SERVICE MANUAL
KHM 400 YS SM
3
02/11/04 79405-GB
WELDING PROBLEM POSSIBLE CAUSE WHAT TO DO
P1 All functions performed
by the WDC are regular,
but there is no tension
on the welding sockets
1) Position of regulation poten-
tiometer incorrect knob
1) Adjust the position of the WDC regulation knob on the
potentiometer spindle so that the potentiometer is not
completely at the end of its travel when the knob reaches its
minimum position. Idem for the RC1 remote control knob.
1) Replace the WDC.1) WDC defectiveP2 Malfunction in the
selection of welding
processes or in their
confirmation on other
functions performed
by the WDC
P3
Blinking “ON” LED 1) Current sensor connector
P3
2)Aux power voltage value
(±15V) too high or too low
1) Connector P3 not inserted or defective - see drawing 5
2) Check the aux trasformer, see drawing 1
P4 Blinking red LED 1) The chopper thermic
protection is intervening
2) Temperature sensor situated
on chopper (NTC resistor)
short circuited or open.
3) WDC defective
1) The output is inhibited automatically; let the motor continue
to run to cool down the chopper, and after a few minutes the
LED will automatically switch off and there will be current/
voltage once again at the welding sockets.
2) Check chopper connector, drawing 2, from pin 13-14. The
resistor must be bigger than 1800 Ω and less than 25 KΩ,
otherwise the led blinking.
Replace the chopper.
In the meantime you can work cutting the wire which arrives
to pin 13 - pin 14 and put on it one resistor 10 KΩ
In this case the thermic protection don’t work but you can
use the machine.
3) Replace the WDC.
P5 Red LED always on
1) WDC defective
2) Chopper defective
3) Current sensor defective
1) Switch off the machine and start it up again; if the LED remains
off try to weld, verifying that the welding is regular; if the LED
lights up again. Replace the WDC.
2) Check the chopper as shown on drawing 2.
3) Replace the sensor.
1) Check the remote control as drawing 4
2) Replace the WDC
P6 PHG1 remote does not
operate.
1) Remote control (or cable)
defective.
2) WDC defective.
P7 The welding current
is always at max or
always at minimum
1)Potentiometer on WDC
defective
2) WDC defective
3)Welding current sensor
defective
1) Check from pin 1-12 connector P4 (pin 1 - ground see
drawing 3)
2) Replace the WDC
3) Replace the current sensor
P8 No voltage at the
welding sockets in
CV mode
1) Defective wire feeder cable
2) Defective wire feeder
3) Defective WDC
1) Check the connections pin to pin of the wire
2) Check the wire feeder
3) Without wire feeder cable put the pin I in short circuit with G
on remote control connector, the led ON must be light - WDC
ok otherwise change WDC
P9
No welding or
generation output
1) Short circuit of chopper.
2) Short circuit of generation
unit.
3) Alternator defective.
1) Disconnect the chopper and re-start the machine; if there is
now an output present, replace the chopper
2) Disconnect the auxiliary output circuit and re-start the machine;
if there is now an output present, there is a short circuit in the
auxiliary output circuit or in one of the components
3) Disconnect all outputs on the alternator (welding and
generation unless the output going to the condensers) and
SERVICE MANUAL
KHM 400 YS SM
3.1
02/11/04 79405-GB
PROBLEMS POSSIBLE CAUSE WHAT TO DO
P1 Voltmeter shows no voltage
or low voltage but actual
voltage at the sockets is OK.
1) Voltmeter malfunction 1) Replace the voltmeter.
P2 No three-phase voltage
present at the socket(s).
1)Differential switch not
inserted
2)Differential switch
malfunction
1) Turn on the switch.
2) Replace the switch.
P3 No single phase voltage one
socket but voltmeter reading
is normal and there is
voltage on the other sockets.
1) Push in the thermal switch.
2) Replace the thermal switch.
1) Check the level of the electrolyte. Fill or replace the
battery.
2) Carry out de-aeration on the fuel system. See engine
operating manual.
3) Replace. In case the problem persists, check the
electrical circuit and eliminate the problem.
Call an authorised service centre.
4) See engine manual
1) Check oil level.
2) Replace the malfunctioning sensor.
3) Replace the protection.
1)Intervention of thermal
switch due to excessive
current.
2) Thermal switch malfunction.
MOTOR PROBLEMS
1) Disconnect all outputs on the generator except for
those on the condensers and re-start machine; check
for voltage on condensers.
P4 No voltage present.
(See problem P7)
1) Short circuit present on the
generator outputs.
1) Low battery voltage, battery
dead or defective.
2) Presence of air in the fuel
supply circuit.
3) Engine protection fuse blown
4) Engine solenoid
P1 The engine does not start
or stops immediately after
startup.
P2 Engine stops due to
intervention of EP1 / EP5.
1) Engine temperature too high
or insufficient oil pressure.
2) High temperature sensor or
oil pressure defective.
3)EP1 / EP5 protection
defective.
P3 The battery is not charged. 1) Battery charger alternator
defective.
2) Battery charger warning light
defective.
1) Replace
2) Replace
P4 For other problems, refer to
the attached engine manual
WELDING WITH V.R.D.
P9 The welding tension after 3
sec isn’t less enough (plus
in 12V dc)
1)Net R.C. defective or
disconnected from + or -
welding socket
2) WDC defective.
1) Check the net R.C. Check the connections.
2) Replace the WDC.
GENERETING PROBLEMS
check the capacity of the condensers. Restart the
machine, if there is still no output, replace the alternator.
EP1 PROBLEMS
P1 Low voltage at idle 1) Low engine r.p.m. at idle 1) Check the idle. Measure the following: engine speed: it
should be 2400 r.p.m.; frequency at single-phase
socket: it should be 40Hz; o.c.v. at welding socket (CC
mode): it should be 38 - 40 VDC
P2 The engine doesn’t speed
up in CC/CV (NO TIG) mode
and/or with auxiliary load.
1) Defective connections at EP1 1) Verify the connection wires continuity of: current
transformer U at the terminals 3 and 5 of EP1; current
transformer U at the terminals 4 and 6 of EP1
2) Check the output voltage between the terminal 8 of
EP1 and ground; the voltage should be 14 VDC.
SERVICE MANUAL
KHM 400 YS SM
3.2
02/11/04 79405-GB
DRAWING 1
CHECK THE CHOPPER FROM THE
CONNECTOR
10 Vca
OUTPUT
Check the transformer in this way:
14
12
10
8
6
4
2
13
11
9
7
5
3
1
DRAWING 2
CHOPPER CONNECTOR
CHECK MOSFET ON CHOPPER
FOR THE CHECK HOLD THE CONNECTOR AS SHOWED ABOVE
WITH A TESTER CHECK THERE ARE
input 1-2
input 3-4
input 5-6
input 7-8
input 9-10
input 11-12
(free)
input 13-14 1,8 ÷ 2,5 KΩ
KHM 400
KHM 2x400
KHM 600
DRAWING 3
How to check the potentiometer put on WDC
1)Start the welding without load (at max RPM)
2)Take the voltage from pin 1 - pin 12 on
connector P4
3)
Position
Knob
Voltage
from pin 1 - pin 4
on pin 4
Minimum
Max
0 Vdc
4,5 - 4,7 Vdc
OUTPUT
18 Vca
OUTPUT
25 Vca
OUTPUT
18 Vca
input: 220 Vac
output: 18 Vac, 25 Vac, 10 Vac
SERVICE MANUAL
KHM 400 YS SM
3.3
02/11/04 79405-GB
DRAWING 5
P1
P2
P5
P3
P4
DRAWING 4
Put the knob on PHG1 / PHG1A at minimum/max, put one
ohmmeter from pin A - B and measure the resistance.
Knob
Resistance
Minimum
Max
50 ÷ 100 Ω
4,5 - 4,7 KΩ
Electric System
KHM 400 YS M
61.1
02/11/04 79405-GB
Electrical System
KHM 400 YS
M
61.2
02/11/04 79405-GB
Electrical System
KHM 400 YS M
61.3
02/11/04 79405-GB
Electrical System
KHM 400 YS M
61.4
02/11/04 79405-GB
Description - Electrical System
KHM 400 YS M
60
A : Alternator
C : Capacitor
D : G.F.I. (ground fault interrupter)
E : Welding PCB. transformer
G : 400V 3-phase socket
H : 230V 1phase socket
M : Hour-counter
R : Welding control PCB
T : Welding current regulator
U : Current transformer
V : Welding voltmeter
Z : Welding sockets
W : D.C. inductor
Y : Welding diode bridge
D1 : E.P.1 Engine protection
E1 : Engine stop soleniod
F1 : Acceleration solenoid
G1 : Fuel level transmitter
H1 : Oil or water thermostat
L1 : Oil pressure switch
M1 : Fuel warning light
N1 : Battery charge warning light
Q1 : Starter key
R1 : Starter motor
S1 : Battery
T1 : Battery charge alternator
U1 : Battery charge voltage regulator
X1 : Remote control and/or wire feeder socket
N3 : Relay
G4 : Preheating glow plugs
I4 : Preheating indicator
P4 : Circuit breaker
W6 : Hall sensor
I7 : Solenid stop timer
Q7 : Welding selector mode
R7 : R.C. net
02/11/04 79405-GB
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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.
$%2877+,60$18$/
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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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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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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LIFT ONLY THE MACHINE
DO NOT LIFT THE MACHINE AND
TRAILER
'$1*(5LIFTING EYE IS NOT DESIGNED TO SUPPORT
ADDED WEIGHT OF ROAD TOW TRAILER
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In case you have to move or transport or move the machine, follow the instructions as shown in the figures.
Transport 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 weight of the machine.
DO NOT
TRANSPORT ACCESSORIES OR OTHER ITEMS WHICH COULD INCREASE THE
WEIGHT AND/OR CHANGE THE CENTER OF GRAVITY OF THE MACHINE.
DO NOT DRAG THE MACHINE OR TOW IT ON PUBLIC ROADS UNLESS
IT IS MOUNTED ON A
HOMOLOGATED TRAILER.
Not following these instructions could cause injury or damage to the machine.
&7/6,7(72:
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a PD[LPXP speed of
.PVKRXU on asphalted surfaces.
☞Towing on public roads or turnpikes of any type ,6 (;&/8'(', because QRW in possesion of the requirements by
national and foreign traffic norms.
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ASSEMBLY OF SITE TOW FOR KHM 350 - 400
M
6.2
Nota
: Lift the machine and assemble the parts as shown in the drawing
The accessory cannot be removed from the machine and used separately (actioned manually or following vehicles)
for the transport of loads or anyway for used different from the machine movements.
For assembling the generating set on the site tow please
keep to following instructions:
1) - Lift the generating set (by means of suitable hook).
2) - Slightly fix the jaw (3) of the parking foot to the bar
with the M10x20 screws, the M10 nuts and the
washers (so as to let the foot sprag go through.
3) - Split (unscrewing them) the two parts of the foot
(4S-4I) to be able later to assemble them on the jaw.
4) - Introduce into the jaw (3) the upper part (4S) of the
foot and screw again the lower part (4I), then tighten
the screws (4V) of the jaw to the towbar and block
momentaneously with the lever (4L) the whole foot.
5) - Assemble on the machine the towbar (5) complete
of foot with the M10x20 screws, nuts and washers
(see fig. page M6.2).
6) - Assemble the axle (7) to the base of the machine
(see fig. page M6.2) with the M 10x20 screws and
relative washers (two per part) so that their supports
coincide.
8) - Insert the wheel (9) on the axle then screw the self
blocking nuts (8).
9) - Pump the tyre (9) bringing the pressure to four atms.
10) - Lower the machine to the ground and place the
parking foot definitively (regulating at the best height).
ATTENTION
Do not substitute the original tires with other types.
!
!
ATTENTION
4
5
3
4S
4I
4L
4V
7
8
9
TRAILERS
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a
maximum speed
of
40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type
IS EXCLUDED, because not in possesion of the requirements by
national and foreign traffic norms.
10/06/00 M6-2GB_ESAB
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DIESEL ENGINES
• Use in open space with fresh air flow or vent exhaust
gases far 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.
86($1'0$,17(1$1&(
,167$//$7,21,1)250$7,21
0
2.6
20/6/00 ESABM2-6GB
*%
KHM 400 YS
KHM 400 YS
Central lifting eye
Cover opening
Opening cover front
panel
Air inlet
Fuel filling
Air outlet
HOT SURFACE
Gas exhaust pipe
Air outlet
INSTALLATION
KHM 400 YS M
2-7
02/11/04 79405-GB
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