technical service manual for kempomat
Contents
1. 99 04444440 E 000000 202072088 VARAOSAT SPARE PARTS 1921790 RESERVDELAR ERSATZTEILE KEMPOMAT 2500 RESERVE DELER ONDERDELEN V21416 RESERVEDELE PIECES DETACHEES 25 014 815 833 2070720 KEMPOMAT 2501 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 025 005 ISEPTEDINS VARAOSAT SPARE PARTS 1921250 RESERVDELAR ERSATZTEILE KEMPOMAT 250 RESERVE DELER ONDERDELEN Vol11202 RESERVEDELE PIECES DETACHEES 289 0n103 812R001 813 XW1082 XW181 2020500 VARAOSAT SPARE PARTS 1921750 RESERVDELAR ERSATZTEILE 2501 RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 021 023 016 2020500 KEMPOMAT 3200 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETA2. SR VARAOSAT SPARE PARTS 1921200 S L K 5 5 0 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN V923502 RESERVEDELE PIECES DETACHEES 2069110
3. NAUHA KAAPELI MSDI MU RU 16 NAP NAUHA KAAPELI N o N N N N N N x x x TED 2T 4 LN 29 01 2001 314B19BA kemppi KEMPOMAT 1800 VALM OHJE 5 54 002 2 21 1 2 2 5 4 gt gt Bl 2 2 8 5001 5002 a 3 K13 K15 n 2x2 b 7 17 D 2x2 5 002 2 5790 5003 1 4 SALZER K amp N SALZER 2 4 3 5 N 12 3 i HOO1 kel y M LISATOI MINTA YKSIKKO 16 NAP NAUHA KAAPELI START X108 127 a x003 35 C N 5 8 a n Lo 3l 1001 x005 35 2 L 4 em 5 2001 MU TARRA PJIRT LN TARK 12 02 2001 KOKO VALM OHJE KES 54 002 3144190A XBB4 Ki 5
4. SL K400 7 11 2002 923501 2066990A 1921600 Orderno Part Description 4265040 4265080 00080 PRESS SPRING SL 500 4265050 00090 SPRING BUSHING SL 500 4265070 00100 PRESS DIVIDER SL 500 4265060 4266130 4265240 4265250 420506 134100 4268680 CONTROL CONNECTOR BK7 4270770 133700 134120 4267220 420510 4292030 ACCESSORIES ACCESSORIES 133810 10040 EED ROLL WHITE 0 6 0 8 SL500 133820 133880 133940 FEED ROLL KNURLED 1 0 1 2 133990 134030 133960 134140 134130 134290 134710 20190 JFRONT GUIDE TUBE AL D3 134110 134300 134720 4270180 4267030 426540 4265080 4265050 426570 426560 426613 4265240 426520 4268680 4270770 4267220 42923 313360 31370 4270180 4267030 SL K550 7 11 2002 923502 2069110A 1921700 Order no Part _ Pe 3139090 01 F WIRE FEEDE 151 00 550 1 3133380 00010 PRESSLEVER LEFT 5500 1 3133390 0020 PRESSLEVER RIGHT_ 8500 1 9476513 00030 SEEGERRING8 679 2 3142210 00040 FEEDROLLORANGE 12 12 4 9592112 00050 FASTENNGSCREW 6 0 4 4266100 0060 SELECTORPLATEFOR GROOVESL500 4 4265040 00070 REGULATION KNOB 81500 1 4265080 7 0000 5 SPRING 5590 1 4265050 0000 SPRING BUSHING 5 50 1 4265070 000
5. SYNKRONOINTIK 1 VA 2 5 gt NALIHA KAAPELI x u 2500 N N L T T 16 NAP NAUHA KAAPELI 27 Tp AES 4T TARRA PIIRT 23 81 2081 LN KOKO VALM OHJE KES 54 02 3 14 B 200 B ROO3 2 55 90 START X107 3 2 Sw1 1 z003 RW101 1 jal 3 2 4 19 d 2 2 FOO1 3 1 10 3 2 RW102 yoo XOO2 PL 3 i A M d 3 16 NAUHA KAAPELI LISATOI MINTA YKSIKKO 5002 5003 K amp N SALZER K amp N SALZER PURT LN TARRA KEMPOMAT KOKO VALM OHJE LE 2504 es s4 oo2 3144 200A 12 02 2001 2 5 n L2 25 L3 O 225 5001 RBB3 5 X188 X107 T T RWI
6. EL ACCESSORIES KMG20 25 32 40 30 01 2003 V251012 4291050 A 1925700 29 9 Order Description 7 Pc 2 KMG20253240 7 41250 00100 5 MPMT 1 9769112 20 JFLATGONTACT 2 42323 00 CONTROLCONNECTOR 2 9580158 25059 1 876673 0 050 580159 0 060 592105 769142 769141 074810 2 5 144110 144120 144630 4290060 77KMG32KMG40 _ 144140 144640 4248700 475009 LOCKING SPRING MT32 38 580217 LOCKING NUT MT32 38 4259160 1 4259480 1 4259491 1 KMG40 127990 ASSEMBLV 45 MT38 1 127980 NECK ASSEMBLV LONG 60 MT38 3128000 NECK ASSEMBLV 60 MT38 SL K250 18 25 7 11 2002 214120 2067850A 1921650 592112 4265040 4265050 006 SPRING BUSHING SL 500 4265240 4265070 4265080 PRESS SPRING SL 500 4266100 SELECTOR PLATE FOR GROOVE SL 500 4265060 133700 476513 4285900 REAR GUIDE TUBE SL250 420506 134100 4102283 4292030 022 4 ACCESSORIES 7 00 O 133210 133810 FEED ROLL WHITE 0 6 0 8 SL500 FEED ROLL YELLOW 1 6 2 0 SL500 4102283 4292030 3133820 3133880 FEED ROLL BLACK 2 4 SL500 3133940 FEED ROLL KNURLED 10 12 3133960 FEED ROLL U GROOVE 1 0 1 2 RED 3133700 4283310 133990 134030 3133700 134130 134140 134290 134710 FRONT GUIDE TUBE AL D3 4283310 REAR GUIDE TUBE D2 SL250
7. FEN 3118 IBNAP 5081 5002 5003 SALZER KAN SALZER K amp N ge tet cee 2 1 2 12 5 5 9 18 1 T 14 17 18 u 3 U 2 2 1 B VI 6 v 4 WI 15 w 13 7 m mmm 375 C E u2 Z B 3 3 6 CD MSDI vi iv 7 18 8 31 i w2 B 2 4 12 35 14 15 3 16 8 16 18 17 3 8 H 20 21 22 23 SYNKRONOINTIK 24 19 2 ABBI Im N N N N NON 2 T 16 NAUHA KAAPELI nl wl sl 2 2 2 5 2 2 2T 4 4000 LN 25 01 2000 VALM OHJE KES 54 UU2 3 14 B 22 e C 1800 7 11 2002 214150 2070710A 1921780 Order no 4279550 280180 cor CAPACITOR 9 UF 28V 772551 750161 L 287420 775729 Hor SIGNALLAMP YELLOW 764310 1 C 138470 Loy enoe SOS 544213 IM001 COOLING FAN MASTER 1500 2200 754156 RW101 POTENTIOMETER 100 CERMET 754141 292100 266150 R002 7 SHUNTRESISTOR 300 60 761375 761370 761225 FLIP FLOP SWITCH WITH PILOT LAMP 770455 771530 MACHINE SOCKET 50 70 134100 563002 144740 07
8. TECHNICAL SERVICE MANUAL FOR KEMPOMAT The Joy of Welding TECHNICAL SERVICE MANUAL FOR GENERAL MAINTENANCE OF KEMPOMAT Maintenance of Kempomat power source will normallv consist of general cleaning of unit with soft brush and vacuum cleaner and checking of wearing for parts like switches connectors potentiometers and fuses If vou use compressed air for cleaning there is a risk that is packed even more tightly into gaps of connectors or components so be carefull with those Maintenance of the wire feeder and mig gun will normallv consist of general cleaning and change of consumable parts like contact tube contact tip contact adapter gas nozzle wire conduit feeding rolls guide tubes and gear wheel The number of machines in will determine to what extend consumable and spare parts will be stocked WARNING Watch out for the mains voltage Disconnect the power source from mains voltage before removing cover plates or any testing or measurement and before troubleshooting look for signs of over heating fractures and damages from internal components and power semiconductors TROUBLESHOOTING CHART TROUBLE CAUSE REMEDY The KEMPOMAT doesn t start at Blown fuse in mains supply voltage Check all three supply voltage all The signal lamps of the machine phases check fuses are not switched on Faulty mains cable Check mains voltage from terminal block X001 re
9. F007 750161 287420 775729 Hoo 764111 cONTACTOR 138480 Lo enoe RMAT2500 _ 544213 Moot FAN MASTER 1500 2200 754156 RW101 POTENTIOMETER 100 CERMET 754141 292090 266150 R002 7 SHUNTRESISTOR 7 300 60 761375 761370 761225 FLIP FLOP SWITCH WITH PILOT LAMP 770455 771530 134100 56300201 144740 0 001 UNDERCARRIAGE KMAT 1800 2500 070590 0 002 FRONT PLATE KMAT 1800 2500 144750 0 003 070610 144300 0 005 SIDE PLATE LEFT KEMPOMAT 144310 070320 1921650 0 008 SPARE PART LIST SL K250 H 568911 547105 0 010 200 50 20 55 547770 279940 279940 0 FLAT CABLE L 380 KNOB 036 9759126 0077 LOCKPLATEFKNOB DRED 1 2062600 1000 PLASTICHANDLE 1 1026670 SAFETYFRAMEFDISPL 1026880 022 COVERPLATE FORDISP 1 4282460 WIREFEEDSTICKER 0 028 BRAKE PIECE PROMIG 500 510 6425216 003 6219200 7020 CIRCUIT DIAGRAM KEMPOMAT 2500 olo oj lt A N 921650 2501 7 11 2002 211202 2070500 1921750 143880 1 56300201 144020 2001 2501 2070030 144300 0 005 SIDE PLATE LEFT KEMPOMAT 144310 2070320 1921650 0 008 SPARE PART LIST SL K250 568911 547105 WHEEL 200 50 20 55 547770 0 011 4279940 4279940 FLAT CABLE L 380 759111 0 014 D36
10. If some other push pull torch than Binzel or Hulftegger is in use the torch might pull to fast Ribbon cable between KMW timer and control card A001 is loose or cut Faulty KMW timer unit Voltage for the motor of push pull torch is too high Faulty connection in connector X1 Check and repair connection according to PICTURE 1 Check and tighten the ribbon cable Check and change the KMW timer unit See also potentiometers from PICTURE 3 By connecting the jumper on the connectors X1 and X2 on the KMW sync PCB is possible to decrease the voltage TECHNICAL SERVICE MANUAL FOR TROUBLESHOOTING CHART KWM SVNC KWM TIMER AND MSD 1 TROUBLE CAUSE REMEDV MSD 1 meter unit doesn t work Ribbon cable between MSD 1 and Check and tighten the cable check control card A001 is loose or cut also the control voltage for MSD 1 from 001 X7 16 and X7 1 control voltage should be 12 V Faultv MSD 1 unit Replace MSD 1 unit PICTURE 1 KMW SVNC HC start gt TECHNICAL SERVICE MANUAL FOR PICTURE 2 PCB OF KWM SVNC P DEP o X1 X2 X3 A004 PICTURE 3 PCB OF K400 TIMER TIMER R 15 R 11 X 1 Potentiometers R11 Gas post flow R15 Cycle time R 19 Pause time TECHNICAL SERVICE MANUAL FOR PIC
11. 4000 400Y VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES 130 4 018 2003 7020 170 ISEPTDPINM VARAOSAT SPARE PARTS 1421810 RESERVDELAR ERSATZTEILE 4000 400V RESERVE DELER ONDERDELEN V214180 RESERVEDELE PIECES DETACHEES 4291500 KM 20 25 32 40 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES k Hg The Jou of Welding 42910588 VARAOSAT SPARE PARTS 1925700 RESERVDELAR ERSATZTEILE KMG20 25 82 40 RESERVE DELER ONDERDELEN V251012 RESERVEDELE 5 DETACHEES eim 40
12. 759122 LOCK PLATE F KNOB D36 759109 KNOB D15 759126 LOCK PLATE F KNOB D15 RED 2062900 0 026 HUB FOR WIRE REEL PROMIG 133500 CLAMP PROMIG 4267970 4265820 4270940 425216 134270 140560 9764123 6219200 1 185666 1 3144200 2070030 207020 1921650 4279940 4279940 2062900 1026870 2062270 4267970 4265820 427040 9764123 m 6219200 314400 3200 7 11 2002 V214170 4291460 1921800 Order no Pat 0 4279550 1260180 cor CAPACITOR 04 5 772551 279200 H001 E Ko Q O 287420 60022 PARALLEL DIODE KEMPOWELD 775729 Hoot JSIGNALLAMP YELLOW 544214 IM001 JCOOLINGFAN MASTER 2800 3500 754156 RW101 POTENTIOMETER 100 CERMET 754141 RW102 POTENTIOMETER 10 CERMET 287840 R001 0 23 OHM KWELD 266150 761375 761370 141290 100227 JAUXIL TRANSFORMER 770450 770117 770458 770460 770455 770449 FEMALE CONTACT BODY 9 POLES 977150 x003 IMACHINESOCKET PDIXBESUT0 2 9563002 vo SOLENODVALVE 1 moan RC PROTECTION 1 2062070 020 HUBFORWIRE REEL 133500 9425216 095 WASHER 076 4267970 BRAKEPIECE 55 1 4270940 o4s PRESSSPRNG PROMG 265820 070060 144050 070650 lt 144780 SIDE PLATE RIGHT KEMPOMAT 3200 4000 144770 SID
13. 0 KMG32 Y 4291060 SL K250 KMAT18 25 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES KEMPE VARAOSAT SPARE PARTS 1921650 RESERVDELAR ERSATZTEILE SL K280 KWAT18 25 RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 2067858 A VARAOSAT SPARE PARTS 1921650 RESERVDELAR ERSATZTEILE SL K250 8 35 RESERVE DELER ONDERDELEN 1 2 RESERVEDELE 5 5 eg67850n VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE ONDERDELEN RESERVEDELE PIECES DETAGHEES 020 080 090 IA KE TIP S L u KA 0 0 VARAOSAT SPARE PARTS 1921600 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN 933501 RESERVEDELE PIECES DETACHEES 2066990 A VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE ONDERDELEN RESERVEDELE PIEGES DETACHEES 070 080 030 100 020 040 050 060
14. 0590 RONT PLATE KMAT 1800 2500 144750 070610 144300 0 005 SIDE PLATE LEFT KEMPOMAT 144310 0 006 SIDE PLATE RIGHT KEMPOMAT 070320 0 007 DOOR KEMPOMAT 1921650 SPARE PART LIST SL K250 568911 547105 0 547770 279940 279940 0 KNOB D36 LOCK PLATE F KNOB D36 075428 007 Di5RED 1 2062900 00202 PLASTICHANDLE 26x50Xx217488 1 1026870 7 00277 sAFETYFRAMEFDISEL N 026880 0022 7 COVERPLATEFORDSP 1 4282460 7 0022 WIREFEEDSTICKER KMAN STICKER FOR PANEL KMAT 1800 HUB FOR WIRE REEL PROMIG WASHER D16 6219200 1020 CIRCUIT DIAGRAM KEMPOMAT 1800 olo lt A N 1921650 2001 7 11 2002 V211201 2070510 A 1921740 3143990 6002 CAPACITORUNT KEMPOMAT2001 2501 1 9772551 101 JFUSEBOXRNUP 1 97515 6501 J RECTIFICATIONUNIT 1 9776729 0041 SIGNAL LAMP YELLOW 1 9764112 CONTACTOR 143880 CHOKE 14 9544213 MO01 COOLINGFAN 1500 2200 1 9753625 R003 RESISTOR 52597 1 9754156 101 100KOHMCERMET 1 9754141 102 POTENTIOMETER 10KOHMCERMET 1 9761375 5 01 LEVERSWITCH 1 9761225 S001 FLIP FLOP SWITCH WITHPILOTLAMP 1 9760603 502 1
15. 21280 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE Vel4l58 RESERVE DELER ONDERDELEN RESERVEDELE 5 DETACHEES 022 021 023 RW101 B16 SN101 000000 000000 e o 000000 2070710 A KEMPOMAT 2004 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES 025 nim S STIL VARAOSAT SPARE PARTS 1921240 RESERVDELAR ERSATZTEILE 200 IREserve DELER ONDERDELEN 211201 RESERVEDELE PIECES DETACHEES 2083 103101218800118013 102 XWIBI 207051 VARAOSAT SPARE PARTS 1921740 RESERVDELAR ERSATZTEILE 2001 Reserve DELER ONDERDELEN 911201 RESERVEDELE PIECES DETACHEES pura 817 SW1G1 023 016 20205108 KEMPOMAT 2500 222 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 016 VARAOSAT SPARE PARTS 1921290 RESERVDELAR ERSATZTEILE KEMPOMAT 2500 RESERVE DELER ONDERDELEN VP141682 RESERVEDELE PIECES DETACHEES Faa 868 3 12 1 AL N 4 1 034
16. 3143840 101 KEMPOMAT2001 1 3141290 102 JAUXIL TRANSFORMER 91 1 9770458 xwi01 PLUG BPOLES 1 9770460 02 JPLUG15POLES 1 97704600 XW103 JPLUG1SPOLES 1 9770455 04 PLUG 9POLES 1 977444 XW104 FEMALE CONTACT 9POLES 1 9771530 01 1 5 0 3 31340 X02 SNAPCONNECTOR 1 56300201 Yo01 SOLENOID VALVE 3144010 0001 IUNDERCARRIAGE 2001 2501 1 20717 2 001 1 144020 2001 2501 2070030 144300 0 005 SIDE PLATE LEFT KEMPOMAT 144310 2070320 1921650 0 008 SPARE PART LIST SL K250 568911 547105 WHEEL 200 50 20 55 547770 0 011 4279940 4279940 FLAT CABLE L 380 759111 0 014 D36 759122 LOCK PLATE F KNOB D36 759109 KNOB D15 759126 LOCK PLATE F KNOB D15 RED 2062900 0 026 HUB FOR WIRE REEL PROMIG 133500 CLAMP PROMIG 4267970 4265820 4270940 425216 134270 140560 9764123 6219200 1 185666 1 3144190 207003 207020 1921650 4279940 4279940 2062900 1026870 2062270 4267970 4265820 427040 9764123 6219200 3144190 2500 7 11 2002 214160 2070720A 1921790 Order no 4279550 280180 cor CAPACHOR 9UF 28V 772551 FOOT 001 L
17. 4270 1028320 140220 775730 764130 3138540 427040 4265820 2070060 207050 207070 2070660 4000 230 7 11 2002 214181 4291940 1921820 rderno Part_ Description Pc EDI ACCESSORIES O j SYNCHRONIZAT UNIT KMW SYNC 4000 400 7 11 2002 214180 4291490 1921810 Order no 4279550 001 CARD 001 K400 550 4280180 C001 CAPACITOR 0 1 UF 250V 772551 F001 FUSE BOX NUT 4279200 G001 RECTIFICATION UNIT SCOMES M001 003 004 2 o N 4287420 G002 PARALLEL DIODE KEMPOWELD 775729 H001 SIGNAL LAMP YELLOW 544214 M001 MASTER 2800 3500 754156 754141 4287840 RESISTOR 0 23 OHM KWELD 4266150 R002 300460 761375 761370 141290 770450 770117 10 POLES 770458 770460 770455 770449 771530 563002 133500 4270940 4265820 2070060 144050 2070650 2070670 144780 144770 2070660 090 I cO cO 549064 549066 2062900 568911 139410 141040 4282460 001873 001875 547105 547770 1026870 1026880 138810 139110 2279940 2 2061410 i 1921600 1 134270 1028320 1 140220 1 775730 764130 3138540 Pc 4000 400 7 11 2002 214180 4291490 1921810 Order no Pat Deseription Tepo 76051501 S007 A 076052101 6002 025 12 2067790 T001 TRANSFORMER KMAT 4000 40V 1
18. BI p N 4 14 a 1 415 Lop 2 4 1 3 2 4 3 8 1 fee su gas gt 2 X6 1 16 NAUHA 5002 5003 ENA S SALZEN SA KAAPELI 9 E i el ne 18 J x BR X X X CREE 2 1 1 jie 4 5 N m m 7 m MM m 2T kigi MSDI 3 re 29 18 8 12 2 y 14 15 5 ir 18 17 10 l 20 21 22 23 3 en 24 18 SYNKRONDINTIK PIIRT TARK 2 5 8 LN 392323 8 va 3200 KES 54 aa2 3140210C 26 47 4 L lt 42 3 D D 4 12 L2 7 n 140 13 L3 o L 258 Wi B 2 8 48 a 12 PE 15 2 5801 4 5 SWIBI m 3 2 N i M 2 4 3 11 2
19. DIVIDER 5590 1 4265060 0010 REGULATIONLEVER 51500 1 4266130 00120 LINK TUBE 5590 1 4265240 00130 GEARWHEELD28 j 1 4265250 0040 GEARWHEELD40 1 9420506 00150 WASHER 1 3134100 01600 SNAPCONNECTORR 4268680 070 CONTROL CONNECTOR 8712 427070 00180 SPRING 5590 1124 3133700 000 FRONT GUIDE TUBE 06 25 500 1 3134120 00200 MIDDLE GUIDE TUBE 0 6 166D2ORANGE 1 4267220 REAR GUIDE TUBE 02 SL 500 420510 4292030 ACCESSORIES ACCESSORIES 138650 10040 FEED ROLL 1 0 1 0 RED BALL BEARING 142200 142230 142240 FEED ROLL BLACK 24 24 141590 133960 134130 134290 FRONT GUIDE TUBE AL D2 134710 134110 134300 134720 4270180 4267030 1 41 41 1 11 114 14 141 14 14 4 1 1 1 KEMPOMAT 1800 222 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES 032 025 033 KEMPOMAT 1800 1921780 SPARE PARTS VARAOSAT RESERVDELAR ERSATZTEILE 214 158 RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETACHEES 013 XN102 XWIB1 1 FOB1 003 xXN103 012 A001 o 99 000000 o 2070710 A KEMPOMAT 1800 19
20. E PLATE LEFT KEMPOMAT 3200 4000 D 070660 549064 PLASTIC HANDLE 26X50X217 188 568911 i30 HOSECONNECTOR 3139410 i40 WIREPATH WELDSTICK 3141040 160 STICRERFORPANEL 3200 4000 428240 WIREFEEDSTICKER KMAT 001873 CLAMP D30 3001875 iso NSULAT PLATEFOR CAMP 9547770 210 WHEELROTAHNNG 1 2 1026870 220 SAFETYFRAMEFDISPL 1 1026880 23 COVERPLATE FORDISP 1 513840 24 EFTHNGE C 10 3139110 po 4279940 061410 1921600 070670 ooo 134270 1028250 FRONT PLATE KEMPOMAT 3200 3140210 300 CIRCUITDIAGRAM KMAT3 00 1 areo 1 5138510 CHOKE KWELDKMAT3200 9761225 S00 FLIP FLOPSWITCH WITHPILOTLAMP f SWITCH 0225 20661980 Toot TRANSFORMER KWELDKMAT3200 x e N 4000 230 7 11 2002 214181 4291940 1921820 4279200 G001 RECTIFICATION UNIT SCOMES 4287420 775729 544214 754156 754141 4287840 4266150 761375 761370 141290 770450 770117 770458 770460 4270940 4265820 2070060 144050 2070650 2070670 144780 060 SIDE PLATE RIGHT 3200 400 090 cO cO 144770 2070660 549064 547770 1026870 1026880 138810 139110 4279940 2061410 1921600 13
21. GHEES 2 130 4 018 2003 7020 170 Qu OTI P VARAOSAT SPARE PARTS 1921800 KEMBOMAT 3200 RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN V214170 RESERVEDELE PIECES DETACHEES 4291470 4000 99809 VARAOSAT SPARE PARTS RESERVDELAR ERSATZTEILE RESERVE DELER ONDERDELEN RESERVEDELE PIECES DETAGHEES 130 4 018 2003 7020 170 ISEPTDPINS VARAOSAT SPARE PARTS 1321820 RESERVDELAR ERSATZTEILE KEMPOMAT 4000 280V RESERVE DELER ONDERDELEN V214181 RESERVEDELE PIECES DETACHEES 4291500 KEMPOMAT
22. TURE 4 001 V2 V3 X6 R24 X7 4 Potentiometer R24 Adjustment of wire feed speed TROUBLESHOOTING FOR PCB A001 1 30 over the anodes of the thvristors 40 V over the capacitor 15 V over the diode V17 SYNCRONIZATION TP 19 rectified sine wave RAMP WAVE over the capacitor C11 the wave is only active when start or wire feeding is on START TP13 OV ON 15 V STOP BREAK CONTROL TP24 OV active 15 V stop BURN BACK POST GAS TIMER TP33 15 V stop under 2V on CONTACTOR CONTROL TP 32 under 1 V off over 5 V on FAN CONTROL TP 34 under 1 V off over 10 V on ll FAN CONTROL voltage over the capacitor C17 lt 2 V fan off lt 6V fan on SET VALUE FOR WIRE FEEDING SPEED pin X2 1 and GND voltage between 0 V 15 V depending on potentiometer setting t 6 _ 8 9 50801 112 SALZER K amp N gt 1582 RBB3 B 35 x3 5 4 RI I IO N Ve 3 3 G gt 2 5 5 weri L 35 901 Y R2 N
23. ine type and the settings of the step switches Check and replace the rectifier G001 if needed Check and replace the switch if needed Check the control wires and the connestors and repair if needed Check the 24 VDC voltage from fan connector X3 3 and 3 4 if it is all right replace the fan if it is not replace the PCB A001 TECHNICAL SERVICE MANUAL FOR TROUBLESHOOTING CHART TROUBLE CAUSE REMEDV The wire feeding unit doesn t work The solenoid valve VOO1 doesn t work Wire feeding speed set value can t adjusted Blown fuse F001 8A Motor doesn t run Control voltages for the PCB A001 are missing Faulty solenoid valve or PCB A001 The set value potentiometer RW102 is faulty Replace the fuse F001 If the fuse burns once more the PCB A001 is bad Check the control voltage max c 24 VDC for the motor connectors X4 12 X4 13 on the PCB A001 If the control voltage is correct the PCB is in order replace the motor Check the voltages connectors X3 2 X3 8 and X3 10 X3 9 on the PCB A001 If the voltages are not correct the transformer T002 is bad Check the 24 VDC from connector X3 5 and X3 6 Replace the PCB or solenoid valve Check and replace the 10 set value potentiometer RW102 if needed TROUBLESHOOTING CHART KWM SYNC KWM TIMER AND MSD 1 TROUBLE CAUSE REMEDY KMW sync is not working Occasional disturbances with KMW timer unit
24. pair cable if needed Broken main switch Check the main supply voltage before and after main switch change Switch if needed Faulty auxiliary transformer 002 or Check transformer repair bad connection in connector X006 transformer connection or change 400 or OV if needed Blown fuse F001 8A Check fuse and change if needed TECHNICAL SERVICE MANUAL FOR TROUBLESHOOTING CHART TROUBLE Welding qualitv is bad arc is not stable there are lot of spatters bad arc start not enough arc voltage Welding stops occasionally or some other occasional disturbances Machine is overheating because the fan doesn t start CAUSE REMEDY One phase is missing Shielding gas is missing Gas hose of the torch is leaking or connection is loose Faulty main switch S001 or contactor K001 Faulty main transformer T001 Broken diode in the rectifier 5001 Faulty switch in the mig torch Bad connection in the control wires of the torch or in the connector X003 or X109 Faulty fan or PCB A001 Check all phases from the terminal block X001 Change mains fuse if needed or tighten mains cables Check the operation of solenoid valve See section solenoid valve 001 doesn t work Check repair the mig torch Measure first main switch if it is all right check the contactor Check that voltages are symmetrical on the secondary 001 voltage values depends on the mach
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