ESAB KHM 190 YS is a welding machine with the capacity to weld and generate electricity for tools and devices used in construction. It comes with an Owner's manual for the engine and accessories. Despite its welding capabilities, the ESAB KHM 190 YS is not suitable for any other use, and the manufacturer is not liable for injuries or damages resulting from incorrect usage. The product adheres to safety norms to prevent harm to individuals or damage to property. Unauthorized modifications void the warranty and release the manufacturer from any liability.
ESAB KHM 190 YS is a welding machine with the capacity to weld and generate electricity for tools and devices used in construction. It comes with an Owner's manual for the engine and accessories. Despite its welding capabilities, the ESAB KHM 190 YS is not suitable for any other use, and the manufacturer is not liable for injuries or damages resulting from incorrect usage. The product adheres to safety norms to prevent harm to individuals or damage to property. Unauthorized modifications void the warranty and release the manufacturer from any liability.
KHM 190 YS
Service manual
0794 999 907 01/10
Valid for serial No 113 - XXX - XXXX (0794000882)
Valid for serial No 142 - XXX - XXXX (0794000883)
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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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23(5$7,21 M 3, 20.1, 21, 22, 31, 34, 37,39.6, 43, 43.2,
45, 51, 51.1
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ORDERING OF SPARE PARTS R 1,
SPARE PARTS DR 3, DR 3.1,
SPARE PARTS DR 5, DR 5.1,
SPARE PARTS DR 7, DR 7.1,
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, 2.7, 20.1, 21, 22, 31, 34, 37, 39.6,
43, 43.2, 45, 51, 51.1 to assist understanding 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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The engine doesn’t start. 1) Low battery voltage. 1) Check battery level electrolyte. 1
1) Low oil level 1) Check oil
2) Defective supply of pressure
sensor
2) Check voltage supply. 2
The warning light O1 (low
oil pressure) is on with
engine running
3) Defective pressure sensor 3) Check sensor 3
Low battery voltage while
running.
1) Defective battery charge. 1) Check battery charge voltage. 5
1) Defective power diode
bridge
1.1) Check the voltage supply.
1.2) Check the open circuit voltage
9
12
2). Defective base diode
bridge
2.1) Check the voltage supply.
2.2) Check the open circuit voltage
10
11
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
13
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).
8
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.
4
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.
6 – 7
9 - 10
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.
9 - 10
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.
6 - 7
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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 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 between ___12___VDC. and
___13.6___VDC (average value 12.8 VDC).
Check the oil pressure sensor. Measure the resis-
tance between the sensor and ground.
The resistance should be ___0___
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
)
Reconnect busbars and wires to capacitor bank.
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+]
7HVWLQJFKDUJLQJDQGDX[LOLDU\SRZHUFLUFXLWV
Check that the battery is being charged.
Measure the voltage across the battery; it should be
___13___VDC.
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.
7HVWLQJ:HOGLQJFLUFXLWV
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.
Measure 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 12 of testing
b) wave form “OUTPUT 100A” corresponds at check
point 11 of testing .
OUTPUT 190 A
OUTPUT 100 A
T
1
1
1
)
Ref A: 20 Volt 5 ms
T
T
T
1
1
1
)
Ref A: 20 Volt 5 ms
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A : Alternator
B : Wire connection unit
C : Capacitor
D : G.F.I. (ground fault interrupter)
G : 400V 3-phase socket
H : 230V 1phase socket
L : Socket warning light
Q : 230V EEC (220V) 3-phase socket
Z : Welding sockets
W : D.C. inductor
Y : Welding diode bridge
L1 : Oil pressure switch
N1 : Battery charge warning light
O1 : Oil pressure warning light
Q1 : Starter key
R1 : Starter motor
S1 : Battery
U1 : Battery charge voltage regulator
O2 : 42V 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.
+ :DUUDQW\ LV QRW YDOLG LI QRW FDUULHG RXW E\
(6$%DXWKRUL]HGVHUYLFHDJHQW
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.
+ 1RWLFHWKHPDQXIDFWXUHUPD\PDNHLPSURYHPHQWVRU
PRGLILFDWLRQVWRWKHSURGXFWRULWVDFFHVVRULHVDVGH
VFULEHGLQWKLVPDQXDOZLWKRXWXSGDWLQJWKHPDQXDO
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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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$77(17,21 If this advice is not followed peo-
ple or things can be hurt or damaged.
+,*+92/7$*( 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'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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8VHWKHFRUUHFWSURWHFWLYHGHYLFHVIRUWKHW\SHRIZHOG
LQJEHLQJGRQH
Use protective clothing, etc. specifically
designed for the type of welding being done.
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FKLQH
It is advisable to protect yourself when carrying
out maintenance, such as filling the battery, refu-
elling, etc.
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PDFKLQH
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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HOHFWULFLW\
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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GLWLRQ
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 ZLWKRXWpetrol in the tank, ZLWKRXW oil in the engine and ZLWKRXWelectrolyte
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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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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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.
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ESAB KHM 190 YS is a welding machine with the capacity to weld and generate electricity for tools and devices used in construction. It comes with an Owner's manual for the engine and accessories. Despite its welding capabilities, the ESAB KHM 190 YS is not suitable for any other use, and the manufacturer is not liable for injuries or damages resulting from incorrect usage. The product adheres to safety norms to prevent harm to individuals or damage to property. Unauthorized modifications void the warranty and release the manufacturer from any liability.
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