Page 1
KHM 2x400 PS
Instruction manual
KHM 2x400 PS
0794 999 944 08/01 Valid for serial No. 802 - XXX - XXXX
Page 2
Page 3
KHM 2x400 PS M
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. The use of non-original spare parts will void the warranty.
1
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
INSTALLATION INFORMATION 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 M 32...
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
SPARE PARTS ED9, ED9.1
KIT DECAL
SITE TOW FOR KHM 2x400 KA12
PHG1A KD11
ED8, ED8.1
23/01/08 78410-GB
Page 4
INFO KHM
M
2
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.
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…
DANGEROUS
lndìcates a strong possíbility of severe personal injury or
death ìf ínstructions are not followed.
WARNING
lndìcates a possibìlìty of personal ínjury or equipment damage
if ìnstructions are not followed
CAUTION
lndícates that equipment or property damage can result if
instructions are not followed.
IMPORTANT
NOTE
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.
ATTENTION
These headings give helpful information about the
preparation, operation and care of the machine.
Notice: the manufacturer may make improvements or
☞
modifications to the product or its accessories as described
in this manual without updating the manual.
07/01/08 M2GB
Page 5
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.
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.
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.
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.
Page 6
INSTALLATION AND ADVICE BEFORE USE KHM
M
2.5
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.
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
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.
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
EXTINCTION MEANS
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.
WARNING CAUTION
WARNING
THE MACHINE MUST NOT BE USED IN AREAS WITH
EXPLOSIVE ATMOSPHERE
06/03/00 M2.5GB
Page 7
M
PRECAUTION (ENGINE DRIVEN WELDER) KHM
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
Page 8
M
TRANSPORT
4-2
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.
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
he machines provided for assembling the accessory slow towing trolley can be towed up to a
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
national and foreign traffic norms.
maximum speed
ES
Page 9
M
ASSEMBLY OF SITE TOW FOR KHM 595/2x400
6.8
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.
owing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements by
national and foreign traffic norms.
Nota: ift the machine and assemble the parts as shown in the drawing
CTL 35
CTL 45
COMANDS
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.
ssemble the axle to the base of the machine with
the x screws and relative washers two per part
so that their supports coincide.
Insert the wheel on the axle then twist the
selfblocking nut .
ump the tyre bringing the pressure to atms for
the .
ower the machine to the ground and place the parking
foot definitively regulating at the best height .
ATTENTION
Do not substituite the original tyres with other types.
CTL 35
5
CTL 45
5
9
7
8
ES
Page 10
PRECAUTION (ENGINE DRIVEN WELDER) KHM
M
2.6
DIESEL ENGINES
· Use in open space with fresh air flow or vent exhaust
gases far from the work area.
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.
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.
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.
1,5 m
1,5 m
1,5 m
GAS DI SCARICO
If the surface is not level be sure that the angle of the machine
does not exceed the values shown in the drawings below.
20/06/00 M2.6GB
Page 11
INSTALLATION
KHM 2x400 PS M
2-7
KHM 2x400 PS
KHM 2x400 PS
Page 12
UNPACKING KHM
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.
M
3
2
1
A
C
B
UNPAC ING T E MAC INE
ake the machine out of the carton. ocate the User s
anual , which is packed together with the engine manual
and accessories in a plastic envelope . his envelope
may be under or inside the machine.
heck the rating plate on the machine and confirm that the
serial number and model are the same as shown on the
packing note invoice.
NB. or further information on preparing the unit for use refer
to the related parts of this manual.
ES
Page 13
KHM 2x400 PS M
TECHNICAL DATA
1.5
he H x 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.
Technical data KHM 2x400 PS
GENERATOR
Output three-phase 40 kVA / 400 V / 57.8 A
Output single-phase 20 kVA / 230 V / 87 A
Output single-phase 10 kVA / 110 V / 90.9 A
Frequency 50 Hz
ϕϕ
Cos
ϕ 0.8
ϕϕ
ALTERNATOR Self-excited, self-regulated, brushless
Type three-phase, asynchronous
Insulating class H
ENGINE
Mark / Model PERKINS / 1103C - 33TG3
Type / Cooling system 4-Stroke / Liquid
Cylinders / Displacement 3 / 3300 cm
Output max 45.6 kW (62.1 HP)
Speed 1500 rpm
Fuel / Fuel consumption (P.R.P.) Diesel / 215 g/kWh
Cooling system capacity 10.2 l
Engine oil capacity 8.3 l
Starter Electric
GENERAL SPECIFICATIONS
Battery 12V - 100Ah
Tank capacity 102 l
Running time (at duty cycle 60%) 13 h
Protection IP 44
Dimensions Lxwxh (mm) * 2490x1030x1300 (1480)
Weight * 1300 Kg
Measured acoustic power 93 LWA (68 dB(A) - 7m)
Guaranteed acoustic power 94 LWA (69 dB(A) - 7m)
Dimensions and weight are inclusive of all parts without wheels and towbar.
3
2000/14/CE
POWER
Declared power according toIS temperature , relative humidity, altitude m above sea level .
It s admitted overload of each hour every h.
In an approximative way one reduces of every m altitude and of . for every above .
ACOUSTIC POWER LEVEL
ATTENTION: he concrete risk due to the machine depends on the conditions in which it is used. herefore, it is up
to the end user and under his direct responsibility to make a correct evaluation of the same risk and to adopt
specific precautions for instance, adopting a I. .D. Individual rotection Device
Acoustic Noise Level (LWA) - Measure Unit dB(A): it stands for acoustic noise released in a certain delay of time.
his is not submitted to the distance of measurement.
Acoustic Pressure (Lp) - Measure Unit dB(A): it measures the pressure originated by sound waves emission. Its
value changes in proportion to the distance of measurement.
he here below table shows examples of acoustic pressure p at different distances from a machine with coustic
oise evel LWA of d
p a meter d d d p a meters d d d
p a meters d d d p a meters d d d
PLEASE NOTE: the symbol when with acoustic noise values, indicates that the device respects noise
2000/14/CE
emission limits according to E directive.
Page 14
TECHNICAL DATA
C.C. WELDING
Welding current 2x400A/35% - 2x360A/60% - 2x330A/100%
Starting voltage 68V
C.V. WELDING
Welding current 2x360A/60% - 2x330A/100%
Welding voltage 16 - 36V
KHM 2x400 PS M
1.6
70
60
50
40
30
20
10
STATIC CARACTERISTIC
C.C.
C.C.
V
C.C.
C.C. TIG
C.V.
max
min.
A
10
100 200
300 400 500
SIMULTANEOUS UTILI ATION FACTORS
In case Welding and Generation can be used simultaneously, however, the engine
overloaded. he table below gives the maximum limits to be respected
WELDING CURRENT
SINGLE POSITION
AU ILIAR POWER
WELDING CURRENT
DOUBLE POSITION
00A400A
5 kVA0kVA25kVA
40 kVA 40 kVA
2x 00A2x400A
0 kVA20 kVA10kVAAU ILIAR POWER
40 kVA 40 kVA
0200A 100A
02x200A 2x100A
cannot be
Page 15
PREPARING THE UNIT (DIESEL ENGINES) KHM
M
20
BATTERY WITHOUT MAINTENANCE
onnect the cable positive
to the pole positive of the
battery after having taken
away the protection , by
properly tightening the clamp.
heck the state of the battery
from the colour of the warning light which is in the
upper part.
reen colour battery
lack colour battery to be recharged
hite colour battery to be replaced
DO NOT OPEN THE BATTERY.
LUBRICANT
ASTINALIVELLO
OLIO
MAX
LIVELLO
OPERATIVO
MIN
heck the level of the engine oil using the
oil dipstick. he level should be between
the minimum and maximum marks. lf
necessary, add more oil.
FUEL
ill the tank with good quality diesel fuel.
☞ ATTENTION Diesel fuel is highly
inflammable before filling the tank, stop the
engine. Do not fuel in the presence of open
flames.
If fuel is spilled on the engine, clean it
immediately before starting up the engine.
COOLING LIQUID (Water-cooled
engines only)
our the cooling liquid through the hole at the
top of the radiator until it reaches the opening. or
the type of cooling liquid to be used and for
maintenance of the cooling system, refer to the
engine manual.
If the air filter is of the oil bath type, fill it with the
same oil up to the level indicated on the filter.
RECOMMENDED SAE VISCOSITY GRADES
or the type and viscosity of oil refer to owner s
manual for the engine supplied with the machine .
NOTE: Before starting the engine read the instructions
in the owner’s manual for the engine.
GROUND CONNECTION
good ground is obligatory for all models with I
ground fault interrupter E earth leakage
circuit breaker . hese protective devices will not
protect the operator unless there is a good ground.
☞ Use a good quality ground cable and connect it
to the grounding point of the machine .
ollow all local rules and or regulations in force.
achines with Isometer protection do not need to
be grounded.
nce the above operations have been completed,
the machine can be used.
ES
Page 16
STARTING AND STOPPING THE ENGINE
KHM 2x400 PS M
21
heck daily
NOTE
Do not alter the primary conditions of regulation
and do not touch the sealed parts.
STARTING THE ENGINE
1500 1 00 RPM ENGINES
hese engines start their normal operating speed.
IGNITION KE
O
ON
START
o start the engine introduce the key , turn it
clockwise completely, leaving it as soon as the
engine starts.
he ingnition key is a part of the E
engine protection device and has three
positions.
STOPPING THE ENGINE
efore stopping the engine it is compulsory
to
disconnect or shut off any loads which are
connected to the unit auxiliary outputs.
stop welding.
To stop the engine:
O
ON
START
for safety reason the key must be kept by
NB.:
ualified personel.
et the engine run for some minutes before drawing
the load.
urn the starter key to the off position.
Page 17
CONTROLS
O8
59C
Q7
(OPTION)
V4
KHM 2x400 PS M
31
T
M5
M
59F
59A
C2
0000101 h
WELDINGDIGITAL CONTROL
CONTACT
STARTING
TIG
STANDBY
190
220
160
250
ON
EP5
WIRE
FEEDER
25
130
280
30
100
310
20
340
70
370
40
36V
16
CV
CC
400A
10
POLARITY
RANGE
INVERTER
CURRENTCC
MAX
50%
REMOTE
CONTROL
WELDINGDIGITAL CONTROL
CONTACT
STARTING
TIG
STANDBY
190
160
ON
25
130
100
20
70
40
16
CV
10
CC
CURRENTCC
REMOTE
CONTROL
220
250
280
30
310
340
370
36V
WIRE
V
FEEDER
400A
POLARITY
RANGE
INVERTER
MAX
50%
D
N
X1
I3
59C
59B
10
9
59B
1512
15
os. Description Descriptionos.
Welding socket ( + )
9
Welding socket ( - )
10
Earth terminal
12
A.C. socket
15
Engine thermal switch
59A
Aux current thermal switch
59B
59C
Supply thermal switch wire feeder-42V
59F
Fuel injection pump thermal switch
C2
Fuel level gauge
D
Ground fault interrupter ( 30 mA)
I3
Welding scale switch
M
Hour counter
M5
Engine control unit EP5
N
Voltmeter
O8
Q7
V4
X1
V/A digital instruments PCB and Led V.R.D. PCB
Welding selector mode
Welding current regulator
T
Polarity inverter control (Optional)
Remote control socket
Page 18
OPERATING
4/4
½
0
KHM 2x400 PS M
32
Auxiliary power outlets and thermal circuit
breaker
he unit is equipped with auxiliary output sockets
three phase and single phase. he voltages
depend on the version selected. he three phase
socket requires no protection as the asynchronous
alternator protects itself. he single phase sockets
are supplied with thermal circuit breakers which pop
out when overloaded. fter they have been activated
give them a short time to cool down before re
inserting. If they continue to pop out check that the
load is not too large for the output of the socket.
circuit breaker auxiliary
auxiliary power socket
I SER
auxiliary power plug
Ground fault interrupter
he ground fault interrupter protects the operator
from injury in the event of a ground fault. If it is
activated, raise the plastic cover and push the lever
up to reset.
ground fault interrupter
raise lever to reset
ERS EED .
It signals the intervention of the overspeed protection.
he optical and acoustic signal is activated, and the
engine stopped.
HI H E ER URE .
It signals, through the temperature sensor, a high
temperature anomaly.
he optical and acoustic signal is activated, and the
engine stopped.
heck the air inlets there must be no obstruction ,
the cooling liquid
if engine is water cooled , the oil level, etc....
I RESSURE .
It signals, through the pressure sensor, a low oil
pressure anomaly.
he optical and acoustic signal is activated, and the
engine stopped.
heck the oil level and, if it is correct, call the Service.
UE RESER E .
It signals the fuel running out, acoustically with the
siren and optically,
without stopping the engine the signal lasts until the
cause is eliminated .
ER H R E .
It signals a failure of the battery charge generator
and therefore the battery charging.
he visual signal will last without stopping the engine,
until the cause is eliminated.
EP5 engine protection module and starter key
he engine protection module contains the starter
key, an emergency stop switch and a set of EDs
which show the status of the alarms. or a few
seconds after the engine is started the shut down
function is inhibited to allow the engine to start. he
two thermal switches located below the module protect
the starting system and the fuel injection pump
thermal switch .
Starting system thermal switch
uel injection pump thermal switch
III E
he ignition key has three
positions
a
b
c S R with automatic
return
M5.6
M5.5
OFF
M5.4
a
M5.2
M5.3
M5.1
b
c
M
STOP
S U
Stops the engine at any time. ush the button until
the engine stops.
UI .
he signal shows that the device is working.
Instruments
Standard instruments include a fuel level gauge, an
operating hour counter and a voltmeter for the
auxiliary power which shows the three phase voltage
. If the voltmeter does not show any voltage
check that the I ground fault interrupter is
inserted. he voltage shown will vary depending on
the load and the welding current being drawn. t no
load and when not welding, the voltage can be as
high as . he auxiliary power cannot be used
when it drops below .
ptionally an ammeter and a voltmeter for the
welding output are available.
30
uel
gauge
20
10
auxiliary
power
voltmeter
operating
hours
Page 19
USE WELDING DIGITAL CONTROLM33.1
GETTING STARTED
1) 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.
heck the oil level daily. uel should be put in
before starting the engine.
efore using the welder or the auxiliary power let
the engine warm up and before stopping the engine
let it run without load to cool down.
Refer to the following instructions regarding the
function of the various controls on the front panel.
OFF
ON
START
Start the engine of the welder
2)
3) urn the welding current voltage
adjusting knob to the minimum
setting.
SETTING THE WELDING PROCESS
here is a manual switch for selecting the various
welding processes on the welding control panel.
here are processes to choose from
for I welding
for S I welding electrode
for I welding continuous wire .
he switch can also be set to stand by first
position . In this position there is no current at the
welding connections led off.
he process can be selected either before or after
starting the motor powered welder.
fter selecting the mode, the ED lights up. If
the wirefeeder connector is connected on remote
control connector the ED light only when the
button torch is pressed.
D
Page 20
USE WELDING DIGITAL CONTROLM33.2
TIG MODE
ontact starting I
his position is specifically for I welding. o cre
ate the arc simply place the tip of the I electrode
on the piece that requires welding then gently move
the tip away. he arc starts automatically and at the
same time the welding current rises to the preset
value, first using the welding current adjustment
knob which is on the lower part of the control panel.
he welding current can be adjusted continuously
from a minimum of to a maximum which
depends on the power of the machine , ,
.
WARNING
or E version it is compulsory to accelerate
the engine manually.
STICK MODE (Electrode)
eatures . . onstant urrent
here are three stick modes which feature
increasing arc forces so that the arc has different
levels of penetration according to the electrode
and or welding position.
MIG/MAG MODE (continuous wire)
eatures . . onstant oltage
ll wire type welding processes can be carried out,
naked or coated.
he voltage can be adjusted using the same knob
which adjusts the current in S I mode.
djustment is continuous and goes from a minimum
of to a maximum of , .
Optional remote control
he welding current can also be set from a distance
using the optional remote control. nce the remote
control is connected to the connector , the
current is controlled by the remote control. o return
to front panel control remove the connector.
Optional VRD program oltage Reduction Device
RD
hen you choose the program stick or stick arc
force the pen ircuit oltage go up, red
light switch and green light switch , bat
only for about , than the go down, green
light switch on and red light switch , about
and stop there, until the welder start welding.
hen you make a short circuit with the stick the
immediately go up, so you can start to welding.
RD don t work with the program I .
Inversion of polarity (Optional, available on
request)
In order to invert polarity, press the switch on the
remote control unit.
y selecting inversion the ED switches off
and the voltage at the welding socket becomes
ero. he power contactor is witched inside the
electrical box and the voltage reappears at the
welding sockets. he ED switches back on
at the same time.
he Invert polarity ED on the front panel near the
welding current adjuster switches on .
ou cannot invert polarity in “MIG/MAG” mode.
PROTECTIONS
he elding Digital ontrol features protections
for the control and chopper.
1) “ON” LED blinking
hen the engine of the welder is
started the control unit automatically
goes to the stand by mode for few istants stand by
ED on and performs a self diagnosis of the current
sensor connector and power source voltage
than the last process is loaded on led turned .
In case of malfunction the “ON” LED blinks.
2) Red LED blinking
he chopper has a thermal protection,
which intervenes in case the operating
temperature exceeds .
If the protection intervenes, the red ED begins to
flash and the welding current voltage goes to ero.
In this case do not switch off the welder, since the
alternator fan will help cool down the chopper more
quickly.
fter a few minutes, the ED will automatically
switch itself off and the welding voltage current will
once again be available at the plugs.
3) Red LED continuously lit
If an anomalous current is detected in
the chopper, the control blocks the
conversion immediately, the output
welding current voltage goes to ero and the red
ED lights up. o reset everything, it is necessary
to switch off the machine.
If the protections and should intervene, it is
best to immediately contact the nearest authorised
Service entre.
DIGITAL INSTRUMENTS
wo digital instruments showed the operating value
of welding current and welding voltage.
D
Page 21
USE WELDING DIGITAL CONTROLM33.3
WIRE FEEDER CONNECTED WITH REMOTE
CONTROL CONNECTOR
Wire feeder connection
onnect the wire feeder to the welder with the
welder turned off
elding cable between the machine s welding
plug and the wire feeder.
elding cable between the machine s welding
plug and the piece to be welded.
ontrol power cable between the machine s
connector and the corresponding connector
on the wire feeder.
Start the machine welder
he ED will be off and will turn on only when
there is voltage at the welding plugs and therefore
at the wire .
he voltage is only present when the welding torch
button is pressed.
he setting of the welding voltage is done using the
knob on the wire feeder.
he adjusting knob on the welder is automatically
inhibited.
WARNING
ou can use the wire feeder only by respecting
the pin configuration as shown on the below
mentioned table.
“WIRE FEEDER NOT CONNECTED WITH REMOTE CONTROL CONNECTOR”
elding voltage is always present on welding
sockets and also RD is active.
elding cable between the machine s welding
plug and the wire feeder.
elding cable between the machine s welding
plug and the piece to be welded.
he setting of the welding voltage is done by using
the knob on the front panel.
NAME OF
CONTACT
electric ground
d.c.
D
E
d.c.
H welding ground
I a.c.
a.c.
DESCRIPTION
o potentiometer R terminal
a
o potentiometer R central b
o potentiometer R terminal
c
short circuit with contact
o switch olarity Inverter
lose for negative polarity
Return from switch on welding
gun, phase a.c.
elding ground for d.c. voltmeter
on wire feeder
D
oltage supply for wire feeder
Page 22
ONLY PL
VERSION
REMOTE CONTROL PHG1A-PHG1A/PL KHM
M
38.9
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.
The remote control can also be connected to the connector on
the wire feeder front panel but in this case it is necessary to
switch the wire feeder commutator so it can operate.
The polarity inverter (64A), if installed, can be operated from
the remote control.
Adjust the welding current control knob to the correct current
for the diameter and type of electrode being welded.
PUSH AND
SCREW TIGHT
ATTENTION
When the PHG1A is not used, it is necessary to disconnect
the multipole connector
02/11/04 79405-GB
Page 23
MAINTENANCE KHM
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,
attention moving parts, hot parts exhaust manifold and muffler,
etc. electrical parts which may be unprotected when the machine
is open.
● Remove guards only when necessary to perform maintenance, and
replace them when the maintenance requiring their removal is
complete.
MOVING
PARTS
can in re
MAINTENANCE OF THE MACHINE
aintenance refers to all operations regarding the control
and replacement of mechanical and electrical parts subject to
wear. In addition it refers to the control and topping up or
replacement of fluids such as fuel, and the regular cleaning of
the machine.
● Use suitable tools and clothes.
● Do not modify the components if not authori ed.
M
43
ay
HOT s r ace
can
rt yo
Repairs refers to the substitution of worn or damaged parts
and repairs should be carried out by uthori ed Service
enters.
Refer to the Engine anufacturer s anual for the
maintenance instructions for the engine. eriodic maintenance
should be performed according to the schedule shown in this
manual.
n a regular basis check that there are no obstructions in the
aspiration exhaust ducts of the alternator, the engine or the
housing which could restrict the flow of cooling air.
ES
Page 24
MAINTENANCE KHM
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
DRY AIR FILTER
Replace the air filter cartridge every 200 hours under normal
conditions and every 100 hours in dusty environents.
RADIATOR
Check the liquid level in the radiator regularly and refill as
required. In the fall check the amount of antifreeze and add
required to prevent freezing during the winter months.
M
43.3
ASYNCHRONOUS ALTERNATOR
No maintenance is necessary, as the alternator has no brushes
or slip rings, and there are no devices for regulation of the
output.
WARNING LABELS AND DECALS
Check warning labels and decals once a year and replaced if
missing or unreadable.
CABLES AND CONNECTIONS
Periodically check the condition of the cables and tighten the
connections.
IMPORTANT
When carrying out maintenance operations be
careful to avoid polluting the environment with
the materials used during maintenance. Follow
all local health and safety regulations.
15/09/05 ESABM43.3GB
Page 25
WARNING AND MAINTENANCE
KHM 2x400 PS
M
44.2
Page 26
STORAGE KHM
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
minutes under load. his will distribute the oil, recharge
the battery and prevent blockage of the injection system.
or long periods of storage, refer to the engine manufacturer s
manual.
lean the machine carefully.
over the machine with a plastic cover and store in a dry
place.
M
45
IMPORTANT
en n out t e o e t ons to e e t e ne
o sto e e e u to o o ut n t e en on ent
w t t e te s use u n nten n e o ow
o e t n s et eu tons
ES
Page 27
1300
180
TECHNICAL DATA
KHM 2x400 PS M
53
2490
2260
KHM 2x400 PS
125
305 1650
1030
n°4 fori 16∅
1480
900 50
Page 28
Page 29
PE I OS E REP ESTOS ERSAT TEIL ESTELL N
E
OR INA IONE RI AM I OR ERIN O SPARE PARTS
I
ɂȻɅȻɂ ɂȻɊȻɌɈɖɐ ɒȻɌɍɀɄ OMMAN ES E PIE ES TA ES
RS
R
E
E
C
E
! "
#
E E
E
E E
E
E
C
1
PPɊɫɣ ɢɛɥɛɢɠ ɢɛɪɛɬɨɶɰ ɲɛɬɭɠɤ ɮɥɛɢɛɭɷ
E
1
2 / / /
/
#
25/11/02 ESABR1-E-I-RUS-D-GB-F
Page 30
Electric System
43
KHM 2x400 PS M
61.1
7
of n°
di n°
Approved:
Approvato:
2
Pag.n°
Page n°
43
43
43
OIL
PRESS.
SWITCH
Desi.
22 18
F3
STOP PUSH-BUTTON
(1)
(2)
a2
16
P4
C.B.
10A
1
11
5
6
a1
K1
stop
12
(87) (87a)
(30)
N3
stop
K1
(86)
nero/black
(85)
12
10
105
5
68
68
C2
FUEL
-
GAUGE
(1)
12
1212
10
68
White Red
1
()
(2)
H1 L1
WATER
TEMP.
SWITCH
Data Dis. Appr.
Date Appr.
16.11.2007
Progetto:
Project:
Dwg. n°:
Dis. n°:
78410.S.010-B
E8
COLD START
TEMP. SWITCH
ADVANCE WITH
20.10.2005
Data:
Date:
2
()
H6
FUEL
ELECTRO
PUMP 12Vc.c.
Disegnatore:
Designer:
Z1
VALV E
SOLENOID
(2)
(1)
5
L5
STOP
PUSH-BUTTON
LEVEL
SENDER
con motore Perkins 1103C-33TG3 14.01.2007
Modifica
Modification
Denominazione:
Pag.
Da
Engine Perkins 1103C-33TG3 78410.prg
Macchina:
Denomination:
Machine:
KHM 2x400 PS-CT
From Page
Alla Pag.
To Page
G1
EMERGENCY
FUEL
8
STARTER KEY
ON
Q1
+
nero/black
M5
b1 21 25
EP5-ENGINE PROTECTION
24
7
2
P4
C.B.
15 b2
30
15 50
START
OFF
1
51
30A
1
52
pr.
K2
(1)
(85)
(87)
(2)
9
19
N5
894100157
FUSE
F
F1
30A
20
OPTIONAL :
G4
18
18
PREHEATING
GLOWS
(86)
N3
K2
pr.
(30)
1
B Sostituito motore Perkins 1003A-33TG1
PLUGS
Aggiunto optional PRH6.A
Esp.
Exp.
U1
7
7
2
1
2
1
7
1
B+ D+
+
M
-
+
nero/black nero/black
T1
CHARGE
BATTERY
ALTERNATOR
R1
-
S1
ENGINE
BATTERY START
B
230V
50/60Hz
3
3
Page 31
Electric System
R2
S
R2
S
R2
T
KHM 2x400 PS M
P4
15A
I
110V/16A
H
230V/16A
I
110V/16A
H
230V/16A
SOCKETS
I
110V/32A
H
230V/32A
C.B. C.B. C.B. C.B. C.B. C.B.
P4
P4
P4
P4
P4
S2 R2
15A
S
N
15A
S2 R2
15A
S
30A
S2 R2
30A
n°
n°
7
di
of
3
Pag.n°
Page n°
Desi.
Progetto:
Project:
Data Dis. Appr.
Date Appr.
Modifica
Modification
Aux. (400Tx2/230Mx3110CTEx3) DT 78410.prg
Denominazione:
Denomination:
Pag.
Da
From Page
61.2
Approved:
Approvato:
78400.S.020
Dwg. n°:
Dis. n°:
09.10.2002
Data:
Date:
Designer:
Disegnatore:
KHM 2x400 PS-CT
Macchina:
Machine:
To Page
Alla Pag.
G
400V/32A
Esp.
Exp.
CAPACITOR
VOLTMETER
2
N
RST RST T
V
53 54
T
N
S
R
N
G.F.I.
Id Id Id Id
2
N
HOUR
COUNTER
D
7
7
M
6
NNN N
6
G
400V/32A
C
h
51 52
T1
S1
A
R1
R2
S2
T
51 52
Y
S
R
RS1
SS1
TS1
RS2
SS2
TS2
EXCITATION AND
AUXILIARY
WINDINGS
MAIN WELDING
WINDINGS
(POWER)
MAIN WELDING
WINDINGS
(POWER)
Page 32
Electric System
WELDING SOCKETS
Z
KHM 2x400 PS M
61.3
n°
7
of
di n°
Approved:
Approvato:
4
Pag.n°
Page n°
Desi.
Project:
Progetto:
Date Appr.
Data Dis. Appr.
+
+
-
Dwg. n°:
Dis. n°:
78410.S.030
(HALL-1)
6
V/A DIGITAL INSTRUMENTS
O8
AND LED V.R.D. PCB
RED
WHITE
YELLOW
BLUE
13
14
V+
V-
FF1
FF2
VA
2
4
6
8
2
J2
J1
1
3
5
7
1
V.R.D.
4
6
3
5
13
8
7
RED
WHITE
YELLOW
BLUE
R.C.
GAIN
+15V
-15V
NET
OUT A
OFFSET
GND
R7
W6
6
13
HALL SENSOR
6
14
+
+
14
Modification
--
W
-
D.C. INDUCTOR
Modifica
Denomination:
Denominazione:
Pag.
Da
From Page
31.01.2008
Date:
Data:
Disegnatore:
Designer:
Welding Power (station 1) 78410.prg
Machine:
KHM 2x400 PS-CT
Macchina:
Page
To
Alla Pag.
-
-
6
(BRIDGE-1)
Exp.
Esp.
WELDING DIODE BRIDGE
Y
~
TS1
+
~
~
SS1
RS1
WINDINGS
MAIN WELDING
(POWER)
(25°C)
t°
NTC 10 Kohm
6
6
TS1
SS1
A
Page 33
Electric System
WELDING SOCKETS
Z
KHM 2x400 PS M
61.4
n°
7
di n°
of
Approvato:
Approved:
5
Pag.n°
Page n°
Desi.
Progetto:
Project:
Data Dis. Appr.
Date Appr.
+
+
-
78410.S.031
Dis. n°:
Dwg. n°:
(HALL-2)
7
V/A DIGITAL INSTRUMENTS
AND LED V.R.D. PCB
O8
RED
WHITE
BLUE
13
V+
FF1
VA
2
4
6
8
J2
J1
1
3
5
7
YELLOW
13
R7
NET
R.C.
14
Data:
Date:
31.01.2008
14
V-
FF2
7
7
13
14
Designer:
Disegnatore:
V.R.D.
GAIN
OFFSET
2
4
6
8
1
3
5
7
+15V
W6
-15V
GND
OUT A
HALL SENSOR
RED
WHITE
YELLOW
BLUE
+
+
--
W
-
D.C. INDUCTOR
-
-
Modifica
Modification
Welding Power (station 2) 78410.prg
Denominazione:
Denomination:
Da Pag.
From Page
Macchina:
Machine:
KHM 2x400 PS-CT
Page
Alla Pag.
To
7
(BRIDGE-2)
Esp.
Exp.
t°
+
NTC 10 Kohm (25°C)
WELDING DIODE BRIDGE
Y
~
~
~
TS2
SS2
RS2
7
7
TS2
SS2
A
MAIN WELDING
WINDINGS
(POWER)
Page 34
SS1
4
C.B.
Electric System
SS1
TS1TS1
10A
P4
14
13
4
4
16 PIN MOLEX FEMAL CONNECTOR
4
KHM 2x400 PS M
61.5
n°
n°
7
of
di
Approved:
Approvato:
6
Pag.n°
Page n°
Desi.
Progetto:
Project:
Data Dis. Appr.
Date Appr.
Dwg. n°:
Dis. n°:
78401.S.040-A
9 101112131415 16
12345678
B
29.10.2004
Data:
SS1
SS1
TS1
13
14
14
52
51
52
51
3
3
WHITE
19412116
16 107
8
BLUE
BLACK
GREY
VIOLET
BLACK
BLACK
WHITE-BLACK
WHITE-ORANGE
WHITE-YELLOW
220V
Modifica
Modification
E
26V
18V
18V
BLUE
BLACK
YELLOW
10V
PINK
ORANGE
WELDING P.C.B.
TRANSFORMER
RED
WHITE
GREEN
BROWN
14
Date:
Disegnatore:
Designer:
Welding Control (station 1) 78410.prg
Denominazione:
Macchina:
Denomination:
Da Pag.
From Page
KHM 2x400 PS-CT
Machine:
Alla Pag.
To Page
WELDING CONTROL P.C.B.
R
Q7
A Aggiunto commutatore di scala (I3) 01.06.2006
Exp.
Esp.
4
4
(BRIDGE-1)
(HALL-1)
RED
GREEN
WHITE
VIOLET
YELLOW
PINK
BLUE
ORANGE
BLACK
GREY
BROWN
WHITE-YELLOW
WHITE-BLACK
WHITE-ORANGE
ORANGE (G1)
YELLOW (S2)
WHITE (G3)
WHITE-RED
BLACK (S4)
BROWN (G5)
BLUE (S6)
GREEN (G7)
RED (S8)
GREY (G9)
PINK (S10)
VIOLET
AZUR
34
12
TIG
STAND BY
WELDING
56
SELECTOR MODE
910
78
11
12
P1
ON
12
78
56
34
9
13
1516
14
1314
11
12
10
P2
T
WELDING
P4
CURRENT
RED
WHITE
YELLOW
BLUE
56
34
12
78
P5
P3
I3
50%
MAX
RANGE
CURRENT CC
REMOTE
CONTROL
SOCKET
F
G
I
H
X1
REGULATOR
J
A
DE
B
C
BLACK
WHITE
BLUE
Page 35
SS2
SS2
C.B.
P4
Electric System
16 PIN MOLEX FEMAL CONNECTOR
10A
KHM 2x400 PS M
61.6
7
di n°
of n°
Approved:
Approvato:
7
Pag.n°
Page n°
Desi.
Progetto:
Project:
Data Dis. Appr.
Date Appr.
Dwg. n°:
78401.S.041-A
9 101112131415 16
12345678
B
BROWN
14
SS2
SS2
TS2
13
14
14
52
51
WHITE
19412
11
6
16 107
8
WHITE-BLACK
BLUE
WHITE-ORANGE
WHITE-YELLOW
BLACK
GREY
VIOLET
BLACK
BLACK
Dis. n°:
29.10.2004
Data:
Date:
Disegnatore:
Designer:
Modifica
TS2 TS2
14
52
13
5
5
5
51
5
3
3
WELDING P.C.B.
E
TRANSFORMER
220V
26V
18V
18V
10V
RED
WHITE
GREEN
BLUE
BLACK
YELLOW
PINK
ORANGE
Modification
Denominazione:
Denomination:
Pag.
From Page
Da
A Aggiunto commutatore di scala (I3) 01.06.2006
Esp.
Exp.
Welding Control (station 2) 78410.prg
Macchina:
Machine:
KHM 2x400 PS-CT
Page
To
Alla Pag.
5
5
(BRIDGE-2)
(HALL-2)
WELDING CONTROL P.C.B.
R
Q7
RED
GREEN
WHITE
VIOLET
BLACK
SELECTOR MODE
PINK
ORANGE
78
9
10
P1
ON
GREY
BROWN
WHITE-BLACK
1112
WHITE-YELLOW
WHITE-ORANGE
WHITE-RED
1314
15
16
ORANGE (G1)
12
P4
YELLOW (S2)
WHITE (G3)
34
BLACK (S4)
BROWN (G5)
BLUE (S6)
GREEN (G7)
RED (S8)
GREY (G9)
PINK (S10)
VIOLET
AZUR
56
910
78
11
13
14
12
P2
T
WELDING
CURRENT
YELLOW
BLUE
12
56
34
WELDING
TIG
STAND BY
RED
WHITE
YELLOW
BLUE
56
34
12
78
P5
REGULATOR
REMOTE
CONTROL
X1
RANGE
CURRENT CC
SOCKET
G
I
H
A
B
P3
I3
50%
MAX
BLACK
F
J
C
DE
WHITE
BLUE
Page 36
Spare parts
KHM 2x400 PS ED
6
Page 37
Spare parts
KHM 2x400 PS ED
6.1
ED
Item
no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
22
23
24
25
26
27
27
Q.ty
1
1
1
1
1
1
1
1
1
1
3
1
2
1
1
1
2
6
4
2
4
2
2
Ordering no. Denomination NOTES C
0794000149
0794000320
0794000354
0794000355
0794000319
0794000318
0794000084
0794000151
0794000356
RING FIXING FAN
FAN
ALTERNATOR AIR CONVEYOR
ALTERNATOR COVEER
HOUSING
STATOR
RING, SEEGER
BEARING
SHAFT ROTOR (COMPL.)
PERKINS ENGINE 1103C-33TG3
0794000293
0794000358
0794000366
0794000359
0794000448
0794000449
0794000211
0794000109
0794000025
0794000450
0794000369
0794000370
0794000491
ALTERNATOR COVER SUPPORT
ALTERNATOR BRACKET (COMPL.)
COVERS BRACKET
BRACKET LIFT
ENGINE AIR EXHAUST SITE
REACTOR HOLDING STEEL SHEET
CAPACITOR BOX BRACKET
CAPACITOR BOX BRACKET
CAPACITOR BOX
CAPACITOR BOX FIXING PLATE (COMPL)
SUPPORT BRACKET REACTOR
INDUCTOR
LEVEL REACTOR
3x80 UF
Delivered up to
538 - XXX - XXXX
Delivered up to
538 - XXX - XXXX
Delivered from
623 - XXX - XXXX
W
W
A
C
C = component designation in the electrical system.
Page 38
Spare parts
KHM 2x400 PS ED
7
38
28
27
25
24
23
12 3
WIRE
FEEDER
RANGE
CURRENTCC
POLARITY
INVERTER
MAX
50%
67 89
4
5
36
31
35
EL IN I ITAL ONTROL
ONT
AT
STARTIN
TI
STAN
ON
WIRE
FEEDE
R
RANGE
CURRENTCC
POLARITY
INVERTER
MAX
50%
REMOTE
ONTROL
16 17 5
42
V
20
19
32
10
33
42
15
39 41
11
13
40
34
12
11
39
Page 39
Item
no.
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
17
19
20
23
24
25
27
28
29
30
31
32
33
34
35
36
38
39
40
41
42
Q.ty
1
3
2
4
3
13
4
1
1
1
2
1
2
2
2
2
1
1
2
2
1
1
1
2
2
1
1
1
1
2
2
1
2
1
1
4
KHM 2x400 PS ED
Spare parts
14.1
ED14
Ordering no. Denomination NOTES C
0794000371
0794000301
0794000330
0794000372
0794000381
0794000373
0794000374
0794000097
0794000375
0794000098
0794000034
0794000377
0794000070
0794000019
0794000020
0794000380
0794000161
0794000162
0794000382
0794000383
0794000165
0794000063
0794000163
0794000384
0794000385
0794000386
0794000387
0794000388
0794000510
0794000350
0794000351
0794000508
0794000307
0794000121
0794000069
0794000057
ENGINE SIDE FRONT PANEL
CIRCUIT BREAKER
W.D.C.
LATCH X FRONT COVER
CIRCUIT BREAKER
TERMINAL
PLATE
RELAY
TERMINAL GUIDE
TERMINAL BOARD
EEC SOCKET 230V 16A
SOCKET HOLDER PANEL, WELDER SIDE
EEC SOCKET 400V 32A
WELDING SOCKET (+)
WELDING SOCKET (-)
SHUNT
GROUND FAULT INTERRUPTOR (GFI)
VOLTMETER
FRONT COVER LOCK
ELECTRICAL BOARD KEY
FUEL LEVEL INDICATOR
HOURMETER
ENGINE PROTECTION EP5
WELDING VOLTMETER 100V DC
WELDING AMMETER 600A, 90mV
ELECTRICAL BOX ENGINE SIDE
FRONT PANEL GENERATION SIDE
ELECTRICAL BOX GENERATION SIDE
SOCKETS HOLDER FRONT PANEL
HALL SENSOR
WELDING PCB TRANSFORMER
LED V.R.D. PCB and V/A DIGITAL INSTRUMENTS PCB
EEC SOCKET 110V 16A
EEC SOCKET 110V 32A
EEC SOCKET 230V 32A
CIRCUIT BREAKER
10A/250V
30A/250V
4mmq
order q.ty in meter
230V 50Hz
Delivered up to
623 - XXX - XXXX
Delivered up to
623 - XXX - XXXX
Delivered from
802 - XXX - XXXX
15A
P4
P4
N3
C2
M
M5
W6
O8
P4
R
H
G
Z
Z
X
D
N
V
S
E
I
I
H
C = component designation in the electrical system.
Page 40
Spare parts
KHM 2x400 PS ED
8
Page 41
Spare parts
KHM 2x400 PS ED
8.1
ED
Item
no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Q.ty Ordering no. Denomination NOTES C
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
0794000390
0794000391
0794000392
0794000393
0794000394
0794000107
0794000395
0794000396
0794000343
0794000451
0794000446
0794000398
0794000452
0794000453
0794000454
0794000361
0794000455
0794000456
0794000190
COVER GRATE
REAR COVER
FUEL COVER
PIPE
COVER
CAP, FUEL TANK
TIE-ROD
FUEL LEVEL SENSOR
VIBRATION DAMPER
BASE
BATTERY (Without maintenance)
BATTERY BRACKET
FUEL TANK
EXHAUST PIPE
GASKET
SUPPORT FILTER
COCK
OLEODYNAMIC NIPPLE
OIL EXHAUST TUBE
12V 100 Ah
G1
S1
C = component designation in the electrical system.
Page 42
Spare parts
KHM 2x400 PS ED
9
Page 43
Spare parts
KHM 2x400 PS ED
9.1
ED
Item
no.
1
2
3
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Q.ty Ordering no. Denomination NOTES C
1
2
2
2
1
1
1
4
4
2
1
1
4
1
2
1
4
2
10
1
1
1
1
1
1
1
1
0794000400
0794000353
0794000352
0794000481
0794000401
0794000402
0794000403
0794000404
0794000405
0794000406
0794000457
0794000408
0794000409
0794000410
0794000411
0794000412
0794000413
0794000414
0794000176
0794000415
0794000416
0794000417
0794000146
0794000418
0794000419
0794000458
0794000459
RIGHT SIDE ELECTRICAL BOX COVER
CHOPPER BRIDGE
R.C. NET (VRD)
R.C. NET (VRD)
INTAKE CASE (COMPL.)
EMERGENCY PUSH BUTTON STOP
FRONT COVER (COMPL.)
SUPPORT BRACKET DIODE BRIDGE
SUPPORT BRACKET ELECTRIC BOX
ELECTRICAL DEVICES HOLDING BOX
TOP COVER
INSTRUMENTS SIDE
FIXING BRACKET DOOR SCREEN
AIR INTAKE BOX
GLASS COVER
COVER COMMANDS SIDE
HANDLE
MIDDLE COVER
LATCH
GASKET
EXHAUST MUFFLER
RADIATOR COVER CAP
TIE-ROD
FLANGE FOR EXHAUST PIPE
CAP
SOCKET PROTECTING BOX
THERMAL PROTECTION
Delivered up to
538 - XXX - XXXX
Delivered from
623 - XXX - XXXX
R7
R7
L5
Y
C = component designation in the electrical system.
Page 44
KIT DECAL 0794 999 859
*
KHM 2x400 PS
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
V
*
*
*
*
*
*
*
23/01/08 78410-GB
Page 45
SITE TOW FOR KHM 2x400
0794 015 880
KA
12
Item
C = component designation in the electrical system.
Q.ty Ordering no. Denomination NOTES C
no.
1
2
3
4
1
1
1
1
0794000424
0794000426
0794000427
0794000425
KIT SITE TOW
AXLE
WHEEL
KIT WHEELS AND HANDLES
Page 46
PHG1A
0794008881
KD
11
Item
Q.ty Ordering no. Denomination NOTES C
no.
3
4
5
7
8
9
11
13
15
1
1
1
1
1
1
1
1
1
0794000278
0794000420
0794000206
0794000207
0794000280
0794000281
0794000421
0794000422
0794000423
FEMALE CONNECTOR
REMOTE CONTROL CABLE
KNOB, REGULATOR COMPLETE
WELDING CURRENT REGULATOR
BOX TCPL3
REMOTE CONTROL HANDLE
REMOTE CONTROL ASSY
CAP
COMMUTATOR
C = component designation in the electrical system.
Y1
A2
U4
Page 47
Page 48
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
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Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
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Aktieselskabet ESAB
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Tel:+45 36 30 01 11
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FINLAND
ESAB Oy
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Tel: +358 9 547 761
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ESAB France S.A.
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Tel:+33 1 30 75 55 00
Fax:+33 1 30 75 55 24
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ESAB GmbH
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Tel: +49 212 298 0
Fax: +49 212 298 204
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AS ESAB
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Tel: +55 31 333 43 33
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Tel: +1 905 670 02 20
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Tel: +52 8 350 5959
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ESAB Welding & Cutting
Products
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Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
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AUSTRALIA
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Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
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Fax: +65 861 31 95
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Representative offices
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Tel/Fax: +359 2 974 42 88
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Tel/Fax: +40 1 322 36 74
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ESAB Representative Office
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Tel: +7 095 937 98 20
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St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
ESAB AB SSC Nordic Region
Box 80040
S-402 77 Göteborg
SWEDEN
Phone + 46 31 509000
Fax +46 31 509195
www.esab.com
050211
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