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ESAB KHM 2x400 PS Instruction Manual
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ESAB KHM 2x400 PS Instruction Manual

ESAB KHM 2x400 PS Instruction Manual

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KHM 2x400 PS
0 P S
2 x 4 0
K H M
Instruction manual
0794 999 944
08/01
Valid for serial No. 802 - XXX - XXXX

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Summary of Contents for ESAB KHM 2x400 PS

  • Page 1 KHM 2x400 PS 0 P S 2 x 4 0 K H M Instruction manual 0794 999 944 08/01 Valid for serial No. 802 - XXX - XXXX...
  • Page 3 KHM 2x400 PS Index Dear Customer, We wish to thank you for having bought this product. Please take time to read this manual and familiarize yourself with the machine before attempting to use it. If you should have questions or problems please contact the nearest authorized Service Center. They have the experience and original spare parts.
  • Page 4 ìnstructions are not followed machine or other things. CAUTION ☞ Warranty is not valid if not carried out by ESAB lndícates that equipment or property damage can result if instructions are not followed. authorized service agent. IMPORTANT...
  • Page 5 SYMBOLS GENERAL SYMBOLS SAFETY SYMBOLS Use the correct protective devices for the type of welding being done STOP – Read with great attention Use protective clothing, etc. specifically designed for the type of welding being done. Protect yourself when doing maintenance on the machine Read with attention It is advisable to protect yourself when carrying out maintenance, such as filling the battery,...
  • Page 6 INSTALLATION AND ADVICE BEFORE USE IMPORTANT ENGINE FUELLING ⇒ Stop engine when fuelling. ☞ ⇒ Do not smoke, avoid open flames and sparks, and do not Read and understand these instructions. ☞ Before installing, operating or servicing this use electric tools when fueling. ⇒...
  • Page 7 PRECAUTION (ENGINE DRIVEN WELDER) 2.5.1 PRECAUTIONS The operator of the welder is responsible for the security of the people who work with the welder and for those in the vicinity. 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.
  • Page 8 TRANSPORT NOTE In case you have to move or transport or move the machine, follow the instructions as shown in the figures. ransport the machine without petrol in the tank, without oil in the engine and without electrolyte in the battery. e sure that the transportation devices are adequate for the si e and weight of the machine.
  • Page 9 ASSEMBLY OF SITE TOW FOR KHM 595/2x400 ATTENTION he 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. TRAILERS he machines provided for assembling the accessory slow towing trolley can be towed up to a maximum speed of 40 Kms/hour on asphalted surfaces.
  • Page 10 PRECAUTION (ENGINE DRIVEN WELDER) ☞ DIESEL ENGINES Assure that the hot air and/or exhaust gas from the machine are vented and are not recirculated in the machine. · Use in open space with fresh air flow or vent exhaust Hot air and/or exhaust gas which is recirculated wll cause gases far from the work area.
  • Page 11 KHM 2x400 PS INSTALLATION 0 P S 2 x 4 0 K H M 0 P S 2 x 4 0 K H M...
  • Page 12 UNPACKING GENERAL PACKING INFORMATION Upon receipt of the goods make sure that the product has not been damaged during transport. In case of damage or missing items you must inform your freight forwarder immediately. acking materials must be disposed of according to local regulations.
  • Page 13 KHM 2x400 PS TECHNICAL DATA he H engine driven welder is a unit which function as a a current source for arc welding b an electric auxiliary power generator It is meant for industrial and professional use, powered by an internal combustion engine. It is composed of an engine, alternator, electric and electronic controls, and a protective housing.
  • Page 14 KHM 2x400 PS TECHNICAL DATA C.C. WELDING Welding current 2x400A/35% - 2x360A/60% - 2x330A/100% Starting voltage C.V. WELDING Welding current 2x360A/60% - 2x330A/100% Welding voltage 16 - 36V C.C. STATIC CARACTERISTIC C.C. C.C. C.C. TIG C.V. min. SIMULTANEOUS UTILI ATION FACTORS In case Welding and Generation can be used simultaneously, however, the engine cannot overloaded.
  • Page 15 PREPARING THE UNIT (DIESEL ENGINES) BATTERY WITHOUT MAINTENANCE FUEL onnect the cable positive ill the tank with good quality diesel fuel. to the pole positive of the battery after having taken ☞ away the protection , by ATTENTION Diesel fuel is highly properly tightening the clamp.
  • Page 16 KHM 2x400 PS STARTING AND STOPPING THE ENGINE heck daily STOPPING THE ENGINE efore stopping the engine it is compulsory disconnect or shut off any loads which are NOTE connected to the unit auxiliary outputs. Do not alter the primary conditions of regulation and do not touch the sealed parts.
  • Page 17 KHM 2x400 PS CONTROLS (OPTION) WELDING DIGITAL CONTROL WELDING DIGITAL CONTROL CONTACT CONTACT STARTING STARTING STAND BY STAND BY 0000101 h WIRE WIRE FEEDER FEEDER 400A 400A RANGE POLARITY RANGE POLARITY INVERTER CURRENT CC INVERTER CURRENT CC REMOTE REMOTE CONTROL...
  • Page 18 KHM 2x400 PS OPERATING ERS EED Auxiliary power outlets and thermal circuit It signals the intervention of the overspeed protection. breaker he unit is equipped with auxiliary output sockets he optical and acoustic signal is activated, and the three phase and single phase.
  • Page 19 WELDING DIGITAL CONTROL GETTING STARTED SETTING THE WELDING PROCESS fter having prepared the machine charged the battery, put in oil and fuel the machine is ready for operation. efore starting the engine please note the following he welder should only be operated by qualified personnel with experience in working with engine driven welders.
  • Page 20 WELDING DIGITAL CONTROL TIG MODE Inversion of polarity (Optional, available on ontact starting I request) his position is specifically for I welding. o cre In order to invert polarity, press the switch on the ate the arc simply place the tip of the I electrode remote control unit.
  • Page 21 WELDING DIGITAL CONTROL WIRE FEEDER CONNECTED WITH REMOTE WARNING CONTROL CONNECTOR ou can use the wire feeder only by respecting Wire feeder connection the pin configuration as shown on the below onnect the wire feeder to the welder with the mentioned table.
  • Page 22 REMOTE CONTROL PHG1A-PHG1A/PL 38.9 ONLY PL VERSION PUSH AND SCREW TIGHT The remote control PHG1A, which regulates the welding current in the CC (STICK welding) mode and the welding voltage in the CV (MIG/MAG welding) mode, is connected to the front panel by means of a multipole connector. When the remote control is connected to the remote control connector (8), it is functional and automatically excludes the front panel regulation.
  • Page 23 MAINTENANCE WARNING Have ali ied 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, ay attention moving parts, hot parts exhaust manifold and muffler, etc.
  • Page 24 MAINTENANCE 43.3 BATTERY WITHOUT MAINTENANCE DO NOT OPEN THE BATTERY The battery is charged automatically from the battery charger circuit supplied with the engine. Check the state of the battery from the colour of the warning light which is in the upper part. - Green colour: battery OK - Black colour: battery to be recharged - White colour: battery to be replaced...
  • Page 25 KHM 2x400 PS 44.2 WARNING AND MAINTENANCE...
  • Page 26 STORAGE In case the machine will not be used for more than days, it should be stored in a suitable area where it is protected from the elements to prevent rusting, corrosion and other damage to the machine. DIESEL ENGINES If the machine will be stored for short periods of time it is advisable to start the engine every days and operate it for...
  • Page 27 KHM 2x400 PS TECHNICAL DATA 2490 2260 KHM 2x400 PS 1650 ∅ n°4 fori 1030...
  • Page 29 PE I OS E REP ESTOS ERSAT TEIL ESTELL N OR INA IONE RI AM I OR ERIN O SPARE PARTS OMMAN ES E PIE ES 1 “ 2 “ ‹  “ “ “ “ “ “...
  • Page 30 KHM 2x400 PS Electric System 61.1...
  • Page 31 KHM 2x400 PS Electric System 61.2...
  • Page 32 KHM 2x400 PS Electric System 61.3...
  • Page 33 KHM 2x400 PS Electric System 61.4...
  • Page 34 KHM 2x400 PS Electric System 61.5...
  • Page 35 KHM 2x400 PS Electric System 61.6...
  • Page 36 KHM 2x400 PS Spare parts...
  • Page 37 KHM 2x400 PS Spare parts Item no. Q.ty Ordering no. Denomination NOTES 0794000149 RING FIXING FAN 0794000320 0794000354 ALTERNATOR AIR CONVEYOR 0794000355 ALTERNATOR COVEER 0794000319 HOUSING 0794000318 STATOR 0794000084 RING, SEEGER 0794000151 BEARING 0794000356 SHAFT ROTOR (COMPL.) PERKINS ENGINE 1103C-33TG3...
  • Page 38 KHM 2x400 PS Spare parts W IR E FE ED ER RAN GE CUR REN PO LAR T CC INV ER TER MA X EL IN I IT A L O N TR O L ON TA STA RT STA N...
  • Page 39 KHM 2x400 PS Spare parts 14.1 ED14 Item no. Q.ty Ordering no. Denomination NOTES 0794000371 ENGINE SIDE FRONT PANEL 0794000301 CIRCUIT BREAKER 10A/250V 0794000330 W.D.C. 0794000372 LATCH X FRONT COVER 0794000381 CIRCUIT BREAKER 30A/250V 0794000373 TERMINAL 4mmq 0794000374 PLATE 0794000097...
  • Page 40 KHM 2x400 PS Spare parts...
  • Page 41 KHM 2x400 PS Spare parts Item no. Q.ty Ordering no. Denomination NOTES 0794000390 COVER GRATE 0794000391 REAR COVER 0794000392 FUEL COVER 0794000393 PIPE 0794000394 COVER 0794000107 CAP, FUEL TANK 0794000395 TIE-ROD 0794000396 FUEL LEVEL SENSOR 0794000343 VIBRATION DAMPER 0794000451 BASE...
  • Page 42 KHM 2x400 PS Spare parts...
  • Page 43 KHM 2x400 PS Spare parts Item no. Q.ty Ordering no. Denomination NOTES 0794000400 RIGHT SIDE ELECTRICAL BOX COVER 0794000353 CHOPPER BRIDGE Delivered up to 0794000352 R.C. NET (VRD) 538 - XXX - XXXX Delivered from 0794000481 R.C. NET (VRD) 623 - XXX - XXXX 0794000401 INTAKE CASE (COMPL.)
  • Page 44 KHM 2x400 PS KIT DECAL 0794 999 859...
  • Page 45 SITE TOW FOR KHM 2x400 0794 015 880 Item Q.ty Ordering no. Denomination NOTES KIT SITE TOW 0794000424 AXLE 0794000426 WHEEL 0794000427 KIT WHEELS AND HANDLES 0794000425 C = component designation in the electrical system.
  • Page 46 PHG1A 0794008881 Item no. Q.ty Ordering no. Denomination NOTES 0794000278 FEMALE CONNECTOR 0794000420 REMOTE CONTROL CABLE 0794000206 KNOB, REGULATOR COMPLETE WELDING CURRENT REGULATOR 0794000207 0794000280 BOX TCPL3 0794000281 REMOTE CONTROL HANDLE 0794000421 REMOTE CONTROL ASSY 0794000422 0794000423 COMMUTATOR C = component designation in the electrical system.
  • Page 48 ESAB subsidiaries and representative offices Europe THE NETHERLANDS CANADA SOUTH KOREA ESAB Nederland B.V. ESAB Group Canada Inc. ESAB SeAH Corporation AUSTRIA Utrecht Missisauga, Ontario Kyung--Nam ESAB Ges.m.b.H Tel: +31 30 248 59 22 Tel: +1 905 670 02 20...