ESAB KHM 2x400 PS User manual

KHM 2x400 PS
Instruction manual
0794 999 944 08/01 Valid for serial No. 802 - XXX - XXXX
KHM 2x400 PS

Index
KHM 2x400 PS M
1
23/01/08 78410-GB
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. The use of non-original spare parts will void the warranty.
TABLE OF CONTENTS
DESCRIPTION PAGE
GENERAL INFORMATION
INFORMATION ABOUT THIS MANUAL M 2
DESCRIPTION - SYMBOLS M 2.1
PRECAUTIONS - GENERAL M 2.5
PRECAUTIONS - ENGINE DRIVEN WELDERS M 2.5.1
TRANSPORT M 4.2
ASSEMBLY OF SITE TOW FOR KHM 2x400 M 6.8
INSTALLATIONINFORMATION M 2.6
INSTALLATION M 2.7
OPERATION
UNPACKING M 3
TECHNICAL DATA AND MACHINE DESCRIPTION M 1.5, M 1.6
PREPARING THE UNIT M 20
STARTING AND STOPPING THE ENGINE M 21
CONTROLS M 31
OPERATING M32...
USE - WELDING DIGITAL CONTROL M 33.1, 33.2, 33.3
REMOTE CONTROL PHG1A M 38.9
MAINTENANCE M 43, M 43.3,M 44.2
STORAGE M 45
TECHNICAL DATA M 53
SCHEMATICS AND SPARE PARTS
ORDERING OF SPARE PARTS R 1
WIRING DIAGRAM – ENGINE EP5 M 61.1
WIRING DIAGRAM – AUXILIARY 2xY400V / 3xI230V / 3xI110V M 61.2
WIRING DIAGRAM – WELDING POWER M 61.3, 61.4
WIRING DIAGRAM – WELDING CONTROL M 61.5, 61.6
SPARE PARTS ED6, ED6.1
SPARE PARTS ED14, ED14.1
SPARE PARTS ED8, ED8.1
SPARE PARTS ED9, ED9.1
KIT DECAL
SITE TOW FOR KHM 2x400 KA12
PHG1A KD11

INFO KHM
M
2
07/01/08 M2GB
GENERAL INFORMATION
−In the envelope where you found this manual you will also
find an Owner’s manual for the engine, and accessories (if
required).
This product has been designed for welding and generation
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.
☞Warranty is not valid if not carried out by ESAB
authorized service agent.
Making modifications to the machine without our written
authorization will void the warranty and release us from any
liability.
ABOUT THIS MANUAL
Before using the machine please read this manual attentively
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 consultation
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 machine
in your possession.
☞Notice: the manufacturer may make improvements or
modifications to the product or its accessories as described
in this manual without updating the manual.
ATTENTION
NOTE
IMPORTANT
CAUTION
WARNING
DANGEROUS
HEADINGS USED IN THIS MANUAL
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 damage
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
preparation, operation and care of the machine.

SYMBOLS KHM
M
2.1
GENERAL SYMBOLS
STOP – Read with great attention
Read with attention
WRENCH - Use the correct tools for the type of
work being done
WARNING SYMBOLS
ATTENTION - If this advice is not followed people
or things can be hurt or damaged.
HIGH VOLTAGE - Do not touch – risk of injury or
death.
FIRE - Risk of fire.
HEAT - Hot surfaces.
EXPLOSIVE - Explosive material or danger of
explosion, in general.
NO WATER - Do not use water as it can cause
shortcircuits or other damage.
NO SMOKING - Cigarettes, matches or lighters
can start a fire or explosion.
ACIDS - Danger of corrosion or burns.
SAFETY SYMBOLS
Use the correct protective devices for the type of welding
being done
Use protective clothing, etc. specifically
designed for the type of welding being done.
Protect yourself when doing maintenance on the machine
-
It is advisable to protect yourself when carrying
out maintenance, such as filling the battery,
refuelling, etc.
Pay attention to safety precautions when moving the
machine
Refer to the instructions before moving the
machine
Wear indicated safety clothing -
It is compulsory to wear the personal
protection items shown when using the
equipment.
Use required safety devices -
Safety devices suitable for the type of welding
and the location of the job must be used.
Do not use water on electrical fires -
It is prohibited to use water to put our fires in
electrical equipment.
Do not touch without having disconnected the electricity -
It is prohibited to work on the machine until the
electricity has been turned off.
Welding prohibited -
It is forbidden to weld in areas containing
explosive gases.

IMPORTANT
☞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.
WARNING
Do not remove or disable protective devices
Removing or disabling protective devices on the machine is
prohibited.
Do not use the machine if it is not in good technical
condition
The machine must be in good working order before being
used. Defects, especially those which. regard the safety of
the machine, must be repaired before using the machine.
ENGINE FUELLING
⇒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 vapours.
⇒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
FOR BATTERY EQUIPPED UNITS ONLY
⇒Sparks may cause the explosion of battery vapours
WATER COOLED ENGINES ONLY
⇒Slowly unscrew the cooling liquid cap of a hot engine to
allow vapours to escape.
⇒Hot vapor and heated cooling liquid under pressure can
burn face, eyes, skin.
INSTALLATION AND ADVICE BEFORE USE KHM
☞FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas
or whatever 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
Eyes contact
Ingestion
Suction of liquids from
lungs
Inhalation
Wash with water and soap
Irrigate with plenty of water, if the irritation persists contact a specialist
Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor
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
In case of exposure to high concentration of vapours take immediately to a non polluted zone
the person involved
☞FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable to
cause severe wounds or death, follow the first aid as described by the ruling norms or local ones.
Appropriated
Not to be used
Other indications
Particular protection
Useful warnings
Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Avoid the use of water jets
Cover eventual shedding not on fire with foam or sand, use water jets to cool off the
surfaces close to the fire
Wear an autorespiratory mask when heavy smoke is present
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.
EXTINCTION MEANS
WARNING CAUTION
WARNING THE MACHINE MUST NOT BE USED IN AREAS WITH
EXPLOSIVE ATMOSPHERE
M
2.5
06/03/00 M2.5GB

PRECAUTION (ENGINE DRIVEN WELDER) KHM
M
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.
ATTENTION
➠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
material.
➠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).
19/06/00 M2.5.1GB

TRANSPORT
M
4-2
NOTE
ES
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.
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.
ot following these instructions could cause injury or damage to the machine.
“CTL” SITE TOW
hemachinesprovidedforassemblingthe accessory slowtowingtrolley canbetoweduptoamaximum speed
of 40 Kms/hour on asphalted surfaces.
☞owing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements by
nationaland foreign traffic norms.

ASSEMBLY OF SITE TOW FOR KHM 595/2x400
M
6.8
or assembling the generating set on the trolley
please keep to following instructions
ift the generating set by means of suitable hook
ssemble on the machine the towbar complete of
foot with the x , screws, nuts and washers.
ssembletheaxle tothebaseofthemachinewith
the x screwsandrelativewashers twoperpart
so that their supports coincide.
Insert the wheel on the axle then twist the
selfblockingnut .
ump the tyre bringing the pressure to atms for
the .
owerthemachinetothegroundandplacetheparking
footdefinitively regulatingat the best height .
ATTENTION
Do not substituite the original tyres with other types.
ATTENTION
ES
TRAILERS
hemachinesprovidedforassemblingthe accessory slowtowingtrolley canbetoweduptoamaximum speed
of 40 Kms/hour on asphalted surfaces.
owing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements by
nationaland foreign traffic norms.
Nota: ift the machine and assemble the parts as shown in the drawing
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.
78
9
5
5
CTL 35
CTL 45
CTL 35
CTL 45
COMANDS

PRECAUTION (ENGINE DRIVEN WELDER) KHM
M
2.6
1,5 m
1,5 m
1,5 m
GAS DI SCARICO
DIESEL ENGINES
· Use in open space with fresh air flow or vent exhaust
gases far from the work area.
POSITIONING T E MAC INE
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 machine
does not exceed the values shown in the drawings below.
MOVES OF T E MAC INE
☞At any move check that the engine is off, that there
are no connections with cables which impede the
moves.
PLACE OF T E MAC INE
ATTENTION
For a safer use from the operator DO NOT
fit the machine in locations with high risk of
flood.
Please do not use the machine in weather
conditions which are beyond IP protection
shown both in the data plate and on page
named "technical data" in this same manual.
☞Assure that the hot air and/or exhaust gas from the
machine are vented and are not recirculated in the machine.
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.
20/06/00 M2.6GB