KHM 500 PS - CC/CV

Service manual

Valid for serial No 135 - XXX - XXXX (50Hz version)

Valid for serial No 135 - XXX - XXXX (60Hz version)
0794 999 921 01/10 Valid for serial No 135 - XXX - XXXX (110V version)
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TABLE OF CONTENENTS SM 1
READ THIS FIRST SM 2
TROUBLE SHOOTING SM 3
TESTING SM 4
COMPONENT POSITION ON THE WELDING CONTROL PCB SM 5

:,5,1*',$*5$0 M 61.1-2-3-4-5-6

'(6&5,37,21±:,5,1*',$*5$0 M 60

*(1(5$/,1)250$7,21 M 2, 2.1, 2.5, 2.5.1, 2.7,4, 6.3, 2.6

23(5$7,21 M 3, 20, 21.3, 22.1, 31, 32, 38.7, 43, 43.3,

44.2, 45, 51, 52, 53
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ORDERING OF SPARE PARTS R 1,
SPARE PARTS EE 1, EE 1.1,
SPARE PARTS EE 2, EE 2.1,
SPARE PARTS EE 3, EE 3.1,
SPARE PARTS EE 4, EE 4.1,
KIT DECAL
SITE TOW FOR KHM 500/600 KA 9
PHG 1 KD 10
20/3/01 76503SM1GB
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This service manual is intended for use by technicians
with electrical/electronic traning, for help in connection
with fault-tracing and/or repair.

Use the wiring diagram on pages M 61.1-2-3-4-5-6, 60

and the description of operation on pages SM 5 when
foult-tracing.

A brief user guide is included on page M 2, 2.1, 2.5,

2.5.1, 2.7,4, 6.3, 2.6, 3, 20, 21.3, 22.1, 31, 32, 38.7,
43, 43.3, 44.2, 45, 51, 52, 53 to assist understand-
ing how the machine is used.

The manuals contains details of all design modifications

up to and including May 2000.



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• Install and earth the welding unit in accordance with applicable standards.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
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• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and the
general area.
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• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
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• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
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• Protect your ears. Use ear defenders or other hearing protection.
• Warm bystanders of the risk.
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This product is intended for industrial use. In a domestic
20/3/01 76503SM2GB

environment this product may cause radio interference.

It is the user’s responsibility to take adeguate precaution.
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1) Low battery voltage. 1) Check battery level electrolyte. 2
2) Defective engine protection
The engine doesn’t start. 2) Check voltage supply and fuse F1. 1
unit.
3) Defective fuel cut off valve. 3) Check voltage supply. 6

The engine starts badly. 1) Defective glow plug. 1) Check voltage supply and fuse F2. 9

1) Defective fuel cut off valve. 1) Check voltage supply. 6

2) Defective oil pressure sen-
The engine stops just 2) Check voltage supply and sensor. 3-4
sor.
after starting.
3) Defective temperature
3) Check voltage supply. 5
gauge.

The fuel indicator doesn’t

1) Defective fuel gauge. 1) Check voltage supply. 7-8
work.

Low battery voltage while

1) Defective battery charge. 1) Check battery charge voltage. 11
running.

1) Check the open circuit welding voltage.

1) Defective diode bridge. 18
If it is OK the main diode bridge is OK.
2) Defective references on from 19
2) Check reference values.
No welding current but welding PCB. to 24
auxiliary output is OK. 3) Defective diode bridge. 3) Check the thyristors of bridge. 25
4.1) Is the remote control switch in the local position? -
4) Problem with welding cur-
4.2) Check the supply to the thyristor bridge.
rent control PCB. 15
If it is OK replace the PCB.

1.1) Check the open circuit welding voltage.

18
If it is OK the diode main bridge is OK.
1.2) Check the open circuit welding voltage of base
1) Defective diode bridge. 17, a.
current bridge.
Welds poorly.
1.3) If it is 1/3 or 2/3 of the nominal value check the
25
thyristors and diodes.
2) Problem with welding cur-
2) If the main diode bridge is OK replace the PCB. -
rent control PCB.

1.1) Check that the pins of the connectors are clean

1) Bad connections to welding -
and making good contact.
Intermittently welds current PCB.
1.2) Check that shunt connections are tight. -
poorly.
2) Problem with welding cur-
2) Replace the welding current control PCB. -
rent control PCB.

No auxiliary power at the 1) Defective G.F.I (ground fault 1.1) Check operation of G.F.I (ground fault inter-
14
sockets. interrupter). rupter).
20/3/01 76503SM3GB
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1) Check the wiring inside the welder for a short cir-
1) Short circuit in wiring. -
cuit between cables or to ground.
2) If the wiring is OK, short circuit the capacitor box to
2) Defective capacitor box. be sure that it is discharged, disconnect all wires from 10
it and check the capacitance.
3) If the capacitor box is OK, disconnect all leads from 12, a, b
the stator except for those going to the capacitor box – 13, a,
No welding output and no 3) Defective stator. and check the output from the alternator. b, c.
auxiliary power output. If there is no output from the welding winding and the 15 –
auxiliary winding, replace the stator. 16, a.
4) If there is output from all windings reconnect the
15 –
4) Short circuited diode bridge. diode bridge and check if there is welding voltage.
16, a.
If not the diode bridge is defective.
5) If there is welding voltage connect the auxiliary 12, a, b
5) Short circuit in the line. power leads one at a time until there is no output; at – 13, a,
this point, the short circuit is in that line. b, c.

Low power and quality of 1) Before replacing the PCB, check the dip switches
1) Setting of welding PCB. 26 - 27
welding current. position and trimmer setting.

1.1) Check fuse F – 0.5A

No voltage at the welding 1) Defective wire feeder con-
1.2) Check inibit relay N3 28
sockets in CV mode nections circuit.
1.3) Check voltage supply SS - TS

20/3/01 76503SM3GB

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Turn ignition on and make sure all the LED’s momen-
tarily light up on the Engine Protection Unit.
 Check the supply to the Engine Protection Unit.
Measure between terminal 15 and ground (battery
voltage).
It should be between ___12___VDC and
___13.6___VDC
If there is no supply, check fuse ___F1___.
 Check the battery voltage;
It should be between ___12___VDC and
___13.6___VDC (average value 12.8 VDC).
 Check the supply to the oil pressure sensor. Re-
move wire number 4 from the sensor and measure
voltage to ground;
it should be___5.5___VDC.
 Check the oil pressure sensor. Measure the resis-
tance between the sensor and ground.
The resistance should be ___0___Ÿ
 Check the supply to the water temperature gauge.
Measure between wire number 3 and ground.
The voltage should be ___5.5___VDC.
 Check the supply to the fuel cut off valve. Measure
voltage between wire number 5 and ground;
it should be ___12___VDC.
 Check the supply to the fuel gauge sensor switch.
Remove wire number 6 from the sensor and measure
voltage to ground.
The voltage should be ___12___VDC.
 Check the voltage from the fuel gauge sensor.
Remove wire number 8 from the gouge and measure
voltage to ground.
The voltage should be ___10___VDC.
F 1RWH: the voltage corresponds to a full
tank should be ___0.4___VDC.
The voltage corresponds to an empty tank
should be ___8___VDC.
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 Check the supply to the glow-plug. Measure be-
tween wire 12 and ground while pressing the glow-
plug button on the front panel.
The voltage should be ___12___VDC.
If there is no supply, check fuse___F2___.
 Check excitation capacitors. Remove the wires
and busbars from the capacitors and measure the
capacitance between the terminals on each capaci-
tor.
The capacitance for each capacitor should be
___90BBB )
Reconnect busbars and wires to capacitor bank.
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 Check that the battery is being charged.
Measure the voltage across the battery; it should be
___14___VDC.
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Check the exitation voltage. Measure between R1
and S1, R1 and T1, and S1 and T1 at the capacitors.
The voltage should be ___480___VAC.
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Check the exitation voltage. Measure between R1
and S1, R1 and T1, and S1 and T1 at the capacitors.
The voltage should be ___440___VAC.
E Check the generator output for auxiliary power.
Measure between R and S, R and T, and S and T on
the terminal board.
The voltage should be ___430___VAC.
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Check single phase voltage. Measure between Y
(neutral) and R, S and T.
The voltage should be ___250___VAC.
D IRU+]YHUVLRQ
Check single phase voltage. Measure between Y
(neutral) and R1, S1 and T1.
The voltage should be ___250___VAC.
10/5/01 76503SM4GB
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Check 110 single phase voltage. Measure between R2
and T2.
The voltage should be ___115___VAC.

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Check 110 single phase voltage. Measure between Y
and T2.
The voltage should be ___120___VAC.

 Check operation of Ground Fault Interrupter 

(G.F.I.). Push test button and check that the circuit
breaker switches off.
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 Check the supply to the thyristor bridge. Measure
between RS, SS, and TS.
The voltage should be ___45___VAC.
Check Current/Voltage control potentiometer value.
Remove the CN3-cable from PCB. Make sure remote
control switch is in the ‘’Off’’ position and that the
CV/CC switch is in the CV position. Measure the resis-
tance between pin 6 and pin 9 on CN3-cable.
The resistance should be ___5k___Ÿ

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Check the supply to the Base current bridge. Meas-
ure between 11, 12 and 13.
The voltage should be ___13___VAC.

D IRU+]YHUVLRQ
Check the supply to the Base current bridge. Meas-
ure between 11, 12 and 13.
The voltage should be ___10___VAC.

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Check output from Base current Bridge. Measure
across the + and - terminals on the bridge.
The voltage should be ___18___VDC.  Check potentiometer operation. Switch settings
should remain the same as in number 20 above.
D IRU+]YHUVLRQ Measure the resistance between pin 8 and pin 9 on
Check output from Base current Bridge. Measure CN3-cable while turning potentiometer from minimum
to maximum setting.
across the + and - terminals on the bridge.
The resistance should be ___0 – 5k___Ÿ
The voltage should be ___14___VDC.
 Reconnect CN3-cable to the PCB. Measure voltage
 Check open circuit voltage. Measure across the
on PCB. Check voltage across pin 10 and pin 11 on
welding output terminals.
connector CN3.
The voltage should be ___60___VDC.
With switch in CC position the voltage should
be ___0___VDC.
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With switch in CV position the voltage should

be ___3.3___VDC.

Check voltage feedback to PCB. Measure across pins
D Check voltage supply to Current/Voltage control
10/5/01 76503SM4GB

13 and 14 at connector CN5 on the PCB. Voltage

pot. Measure between pin 9 and 6 on connector CN3.
should correspond to OCV and it should be
___60___ VDC.
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Make sure CV/CC switch is in CV position and the Output CC
current range switch is in the max position.
The voltage should be between ___3.8___
and ___4.2___ VDC. 77

7
E Check voltage supply to Current/Voltage control 21 > 1
2>
pot. Measure between pin 9 and 7 on connector CN3.
Make sure CV/CC switch is in CC position and the
current range switch is in the max position.
The voltage should be between ___4.2___ 1) Ch 1: 20 Volt 2 ms
2) Ref A: 20 Volt 10 ms
and ___4.6___ VDC.
Output CV
 Check voltage across pins pin 3 and pin 5 on con-
nector CN3.
With switch in CC position the voltage should T

be ___14___VDC.
With switch in CV position the voltage should T
21 >
be ___6.6___VDC.

:DYHIRUP

 1) C h 1: 20 Volt 2 ms
2) Ref A: 20 Volt 5 ms

GATE WAVE FORM: PCB OUTPUT-THYRISTOR Measure:

(0794000099 p.c.b. code). Between “+“ welding diode bridge and each gate
thyristor (1-2-3).
Condition:
a) no load
b) max position welding current knob.

Measure:
Between “-“ welding diode bridge and each gate thyristor
(7-8-9).

Output CC or CV

21 > T
10/5/01 76503SM4GB

1) Ch 1: 20 Volt 2 ms
2) Ref A: 1 Volt 10 ms
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'LSVZLWFK - between A and B: the voltage should be 45 V.a.c.
- between SS* and F: the voltage should be 0 V.a.c.
Note: - between B and F: the voltage should be 45 V.a.c.
switch setting: ON (* see electrical diagram).
DIP 1,2,3 – filtering for hall sensor current signal
(no for ESAB machines). Connect together B and F (temporary connection): you
DIP 4,5,6 – filtering – voltage signal. must have voltage at the welding sockets.
DIP 7,8 - filtering for shunt current signal (on F1RWH - between N and C:
ESAB machines). welding voltage to wire feeder instrument
- L – K – J: voltage reference to P.C.B.
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R 49 ⇒ minimum welding current value (turn in clock

wise direction to increase).
R 49 setting: →value checked in factory.

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!CV mode
!Wire feeder supply “ARC VOLTAGE”
!Knob, welding current regulation, max position
F1RWHo.c.v. 50 VDC
R 131 ⇒ trigger setting
(turn in clock wise direction to increase).
R 131 setting: →always in max position (totally clock
wise direction).

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With switches in:

- CV mode
- 42 V.a.c. supply
measure the voltage on the terminal strip:
10/5/01 76503SM4GB
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A : Alternator S6: Wire feeder supply switch
B : Wire connection unit T6: Wire feeder socket
C : Capacitor
D : G.F.I. (ground fault interrupter)
F : Fuse
G : 400V 3-phase socket
H : 230V 1phase socket
I : 110V 1-phase socket
M : Hour-counter
N : Voltmeter
R : Welding control P.C.B.
S : Welding current ammeter
T : Welding current regulator
U : Current transformer
V : Welding voltage voltmeter
Z : Welding sockets
X : Shunt
W : D.C. inductor
Y : Welding diode bridge

G1 : Fuel level transmitter

H1 : Oil or water thermostat
L1 : Oil pressure switch
Q1 : Starter key
R1 : Starter motor
S1 : Battery
T1 : Battery charge alternator
U1 : Battery charge voltage regulator
Z1 : Solenoid valve
W1: Remote control switch
X1 : Remote control socket
Y1 : Remote control plug

C2 : Fuel level gauge

F3 : Stop push-button
I3 : Range switch
N3 : Relay
O3 : Resistor

G4 : Preheating glow plugs

I4 : Preheating indicator
P4 : Circuit breaker
X4 : Base current diode bridge

A5 : Base current switch

M5 : Engine protection EP5
N5 : Pre-heat push-button
20/3/01 76503M60G

M6 : Switch CC/CV
R6: EMC filter
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- In the envelope where you found this manual you will The headings used in this manual are designed to call your
also find an Owner’s manual for the engine, and ac- attention to potential hazards and important aspects of the
cessories (if required). operation of the machine…

This product has been designed for welding and genera-
tion of electrical power for tools and other electrical devices
used in construction; ANY OTHER USE, is not permitted
and we cannot be held responsible for injuries or damages
resulting from such incorrect use.
 ü '$1*(5286
lndìcates a strong possíbility of severe personal injury or
Our products are made in conformity with the safety norms death ìf ínstructions are not followed.
in force in order to avoid injury to persons or damage to the
machine or other things.
 ü :$51,1*
+ :DUUDQW\ LV QRW YDOLG LI QRW FDUULHG RXW E\
(6$%DXWKRUL]HGVHUYLFHDJHQW lndìcates a possibìlìty of personal ínjury or equipment dam-
age if ìnstructions are not followed
Making modifications to the machine without our written
authorization will void the warranty and release us from
any liability.  ü &$87,21

lndícates that equipment or property damage can result if
 instructions are not followed.
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Before using the machine please read this manual atten-
tively and follow the instructions contained in it. This will  ü ,03257$17
help avoid problems, possible injury and damage to the
machine. ü 127(
The manual is written for experienced, qualified personnel,
who are familiar with health and safety laws and related
 ü $77(17,21
regulations. These headings give helpful information about the prepara-
tion, operation and care of the machine.
This manual is an integral part of the product and should be
kept in a safe place so that it will be available for consulta-
tion during the life of the product. If the machine is sold the
manual should be transferred to the new owner.

Some figures contained in this manual are designed to help

identify certain parts and may not correspond to the ma-
chine in your possession.

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6723²Read with great attention LQJEHLQJGRQH
Use protective clothing, etc. specifically
designed for the type of welding being done.

Read with attention 3URWHFW\RXUVHOIZKHQGRLQJPDLQWHQDQFHRQWKHPD
FKLQH
It is advisable to protect yourself when carrying
out maintenance, such as filling the battery, refu-
:5(1&+Use the correct tools for the type of
elling, etc.
work being done
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PDFKLQH
Refer to the instructions before moving the ma-
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$77(17,21 If this advice is not followed peo- 
ple or things can be hurt or damaged. :HDULQGLFDWHGVDIHW\FORWKLQJ
It is compulsory to wear the personal pro-
tection items shown when using the equip-
+,*+92/7$*( Do not touch – risk of injury ment.
or death.
 8VHUHTXLUHGVDIHW\GHYLFHV
 Safety devices suitable for the type of welding
),5( Risk of fire. and the location of the job must be used.

'RQRWXVHZDWHURQHOHFWULFDOILUHV
 It is prohibited to use water to put our fires in
+($7 Hot surfaces. electrical equipment.

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(;3/26,9(   Explosive material or danger of HOHFWULFLW\
explosion, in general. It is prohibited to work on the machine until the
 electricity has been turned off.

12:$7(5'RQRWXVHZater as it can cause 
shortcircuits or other damage. :HOGLQJSURKLELWHG
 It is forbidden to weld in areas containing explo-
 sive gases.
12602.,1*&igarettes, matches or lighters 
can start a fire or explosion. 


$&,'6Danger of corrosion or burns.

06/03/00 ESABM2-1GB





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ü ,03257$17 ⇒ Stop engine when fuelling.
+ Read and understand these instructions. ⇒ Do not smoke, avoid open flames and sparks, and
+ Before installing, operating or servicing this equipment, read do not use electric tools when fueling.
the operating manuals of the welder and of the engine. ⇒ Unscrew the fuel cap slowly to let out the fuel va-
+ Not observing the information in the manuals can result in pours.
personal injury and/or damage to the equipment and other ⇒ Do not over-fill the tank.
property.
⇒ Avoid spilling fuel on hot engine.
+ Respect all safety regulations and laws when operting this
⇒ Wipe up spilled fuel before starting engine.
equipment.

⇒ Shut off fuel cock, if present, or remove fuel from
ü:$51,1* tank before moving machine
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Removing or disabling protective devices on the ma- ⇒ Sparks may cause the explosion of battery vapours
chine is prohibited.
:$7(5&22/('(1*,1(621/<
'RQRWXVHWKHPDFKLQHLILWLVQRWLQJRRGWHFKQLFDOFRQ ⇒ Slowly unscrew the cooling liquid cap of a hot en-
GLWLRQ gine to allow vapours to escape.
The machine must be in good working order before be- ⇒ Hot vapor and heated cooling liquid under pressure
ing used. Defects, especially those which. regard the can burn face, eyes, skin.
safety of the machine, must be repaired before using
the machine.
F ),567$,' In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gas or what-
ever event which may cause serious injuries or death, predispose the first aid in accordance with the ruling labour
accident standards or of local instructions.
Skin contact Wash with water and soap
Eyes contact Irrigate with plenty of water, if the irritation persists contact a specialist
Ingestion Do not induce vomit as to avoid the intake of vomit into the lungs, send for a doctor
Suction of liquids from lungs If you suppose that vomit has entered the lungs ( as in case of spontaneous vomit ) take the
subject to the hospital with the utmost urgency
Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone
the person involved


F),5(35(9(17,21 In case the working zone,for whatsoever cause goes on fire with flames liable to cause se-
vere wounds or death, follow the first aid as described by the ruling norms or local ones.
(;7,1&7,210($16
Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Not to be used Avoid the use of water jets
Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces
close to the fire
Particular protection Wear an autorespiratory mask when heavy smoke is present
Useful warnings Avoid, by appropriate means to have oil sprays over metallic hot surfaces or over electric
contacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep in mind
that the inflamability point is very low.

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06/03/00 ESABM2-5GB

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35(&$87,216
The operator of the welder is responsible for the security of the people who work with the welder and for those in the vi-
cinity.
The security measures must satisfy the rules and regulations for engine driven welders.
The information given below is in addition to the local security norms.

$77(17,21

⇒ Make sure that the area is safe before starting any

welding operation.
⇒ Do not touch any bare wires, leads or contacts as they
may be live and there is danger of electric shock which can
cause death or serious burns. The electrode and welding
cables, etc. are live when the unit is operating.
⇒ Do not touch any electrical parts or the electrode while
standing in water or with wet hands, feet or clothes.
⇒ Insulate yourself from the work surface while welding.
Use carpets or other insulating materials to avoid physical
contact with the work surface and the floor.
⇒ Always wear dry, insulating gloves, without holes, and
body protection.
⇒ Do not wind cables around the body.
⇒ Use ear protections if the noise level is high.
⇒ Keep flamable material away from the welding area.
⇒ Do not weld on containers which contain flamable ma-
terial.
⇒ Do not weld near refuellng areas.
⇒ Do not weld on easily flamable surfaces.
⇒ Do not use the welder to defrost (thaw) pipes.
⇒ Remove the electrode from the electrode holder, when
not welding.
⇒ Avoid inhaling fumes by providing a ventilation system
or, if not possible, use an approved air breather.
⇒ Do not work in closed areas where there is no fresh air
flow.
⇒ Protect face and eyes (protective mask with suitable
dark lens and side screens), ears and body (non-flamable
19/6/00 ESABM2-5-1GB

protective clothes).
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ü127(
In case you have to move or transport or move the machine, follow the instructions as shown in the figures.
Transport the machine ZLWKRXW petrol in the tank, ZLWKRXW oil in the engine and ZLWKRXW electrolyte in the battery. Be sure
that the transportation devices are adequate for the size 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.
Not following these instructions could cause injury or damage to the machine.
&7/6,7(72:
The machines provided for assembling the CTL accessory (slow towing trolley) can be towed up to a PD[LPXP speed of 
.PVKRXU on asphalted surfaces.
☞Towing on public roads or turnpikes of any type ,6 (;&/8'(', because QRW in possesion of the requirements by
national and foreign traffic norms.

LIFT ONLY THE MACHINE


DO NOT LIFT THE MACHINE AND
TRAILER
22/6/00 ESABM4GB

'$1*(5LIFTING EYE IS NOT DESIGNED TO SUPPORT

ADDED WEIGHT OF ROAD TOW TRAILER
.
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E1RWH For assembling the generating set on the site tow
please keep to following instructions:

1) - Lift the generating set (by means of suitable hook).

2) - Slightly fix the jaw (3) of the parking foot to the bar with
the M10x20 screws, the M10 nuts and the washers (so
as to let the foot sprag go through.
3) - Split (unscrewing them) the two parts of the foot (4S-
4I) to be able later to assemble them on the jaw.
4) - Introduce into the jaw (3) the upper part (4S) of the foot
and screw again the lower part (4I), then tighten the
screws (4V) of the jaw to the towbar and block
momentaneously with the lever (4L) the whole foot.
5) - Assemble the tool holder (6) on the towbar with the
M8x14 screws, nuts and washers.
6) - Assemble on the machine the towbar (5) complete of
foot with the M10x20 screws, nuts and washers 7) -
Assemble the axle (7) to the base of the machine with
the M 10x25 screws and relative washers (two per
part) so that their supports coincide.
8) - Insert the wheel (9) on the axle then screw the self
blocking nuts (8).
9) - Pump the tyre (9) bringing the pressure to four atms.
10) - Lower the machine to the ground and place the
parking foot definitively (regulating at the best height).

ü $77(17,21
Do not substitute the original tires with other types.

75$,/(56
The machines provided for assembling the CTL accessory
(slow towing trolley) can be towed up to a PD[LPXP speed
of .PVKRXU on asphalted surfaces.

Towing on public roads or turnpikes of any type ,6

(;&/8'(', because QRW in possesion of the requirements
by national and foreign traffic norms. ü $77(17,21
The 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.
22/1/01 ESABM6-3GB
 86($1'0$,17(1$1&( 0
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,167$//$7,21,1)250$7,21
,167$//$7,21,1)250$7,21 + Assure that the hot air and/or exhaust gas from the
machine are vented and are not recirculated in the ma-
DIESEL ENGINES chine. Hot air and/or exhaust gas which is recirculated wll
• Use in open space with fresh air flow or vent exhaust cause overheating of the machine and poor combustion
gases far from the work area. in the engine

+ Make sure that the machine does not move during

operation.

Protect the machine from rain and do not put

it in a location where there is danger of flood-
ing. 

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EH GDQJHURXV IRU SHUVRQV DQG FDQ GDPDJH WKH PD
FKLQH
The degree of protection, of the machine is written the
rating plate and in this manual at the "Technical Data"
page.

MOVING THE MACHINE

Before moving the machine turn off the engine and dis-
connect all cables, which could impede the move.

POSITIONING THE MACHINE

Place the machine on a level surface at a distance of at
least 1,5 m from buildings or other structures. 

P


P


7
8
73
8
2
7
6
8
$
+
;
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If the surface is not level be sure that the angle of the ma-
chine does not exceed the values shown in the drawings
below.
20/6/00 ESABM2-6GB
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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.

Packing materials must be disposed of

according to local regulations.

813$&.,1*7+(0$&+,1(

1) Take the machine (C) out of the carton.

Locate the User’s Manual (B), which is
packed together with the engine
manual and accessories in a plastic
envelope (A). This envelope may be
under or inside the machine.
2) Check the rating plate on the machine
and confirm that the serial number and
model are the same as shown on the
packing note/invoice.

1% For further information on preparing

the unit for use refer to the related parts of
this manual.


02/03/00 ESABM3G
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%$77(5< 
)8(/
Take the battery out of
the machine.
Fill the tank with good quality diesel fuel.
Fill the battery to the
maximum level with + ATTENTION: Diesel fuel is highly inflammable;
electrolyte. Wait for before filling the tank, stop the en-
about 30 minutes and gine. Do not fuel in the presence of
top up with electrolyte. open flames.

In case of spilled acid, rinse with water before putting the If fuel is spilled on the engine, clean it
battery back into the machine and reconnecting cables. immediately before starting up the engine.

ü:$51,1*
Sulfuric acid is corrosive.
Protect hands, eyes and FORWKHV....
Take the battery out of the machine for filling.
Warranty 92,'(' for damages due to spilled
acid.

&22/,1*/,48,'
Pour the cooling liquid through the hole at the
top of the radiator until it reaches the opening.
For the type of cooling liquid to be used and for mainte-
nance of the cooling system, refer to the engine manual..

/8%5,&$17

Check the level of the engine oil using *5281'&211(&7,21

0$; the oil dipstick. The level should be
between the minimum and maximum A good ground is obligatory for all models with GFI
0,1 marks. lf necessary, add more oil. (ground fault interrupter). This protective device will not
protect the operator unless there is a good ground.

If the air filter is of the oil bath type, fill it with the same oil
up to the level indicated on the filter.
5(&200(1'('6$(9,6&26,7<*5$'(6
For the type and viscosity of oil refer to owner’s manual
for the engine (supplied with the machine).
+ Use a good quality ground cable and connect it to
the grounding point of the machine. Follow all local
rules and/or regulations in force.
Machines with Isometer protection do not need to be
grounded.

+ 127( %HIRUHVWDUWLQJWKHHQJLQHUHDGWKHLQVWUXF Once the above operations have been completed, the
WLRQVLQWKHRZQHU
VPDQXDOIRUWKHHQJLQH machine can be used.
20/6/00 ESABM20GB
 86($1'0$,17(1$1&( 0
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(1*,1(67$57,1*$1'86(',(6(/(1*,1(6
Check daily M5.1(yellow) Fuel reserve
M5.2(yellow) Battery
charge
 M5.3(red) Overspeed
M5.4(red) High tempera-

ture

 ü 127(
M5.5(red) Low oil pres-
 sure
 'RQRWDOWHUWKHIDFWRU\DGMXVWPHQWRIWKHHQ
M5.6(green)Protection
unit on
 JLQHDQGGRQRWWRXFKWKHVHDOHGSDUWV

530(1*,1(6 /2:2,/35(6685(0)
In the event of low oil pressure the LED lights and the en-
These engines start their normal operating speed. gine is shut-down.

,*1,7,21.(< +,*+7(03(5$785(0

If the water temperature is too high the LED lights and the
The ingnition key is a part of the EP5 engine is shut-down.
engine protection device and has three
positions. 29(563(('0
If the engine speed goes over the preset value the LED
35(+($7(5 lights and the engine is shutdown. The nominal frequency
(50 or 60 Hz) is monitored .
The preheater must be used for starting these
engines at low temperatures (below –5°C) and )8(/5(6(59(0
is activated by a push button.  If the fuel level reaches the reserve level the LED lights and
the sirene sounds and the engine is shut-down.
67$57,1*7+((1*,1(
At temperatures below –5°C push and hold the glow plug
button for about 10 seconds. The glow plug indicator will
come on. After 10 seconds release the glow plug button and
turn the starter key completely clockwise to the START
position. Once the engine starts release the key and leave it
in the ON postion.
At normal tempertures the glow plug is not required. Turn
the starter key completely clockwise to the START position.
Once the engine starts release the key and leave it in the
ON postion.
%$77(5<&+$5*(0
It the battery is not being charged the LED light but the
engine does not stop.The visual signal will stay on until until
the charging system is repaired.
6723%87721
The stop button can be used to stop the engine at any time.
Push and hold the button until the engine stops.


Let the engine run for a few minutes to warm-up before

loading it.


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ü &$87,21
The EP5 device monitors the engine oil pressure, the en- 5811,1*,1
gine water temperature and the rpm of the engine. If the oil 'XULQJWKHILUVWKRXUVRIRSHUDWLRQGRQRWXVHPRUH
pressure is too low, the water temperature too high or the WKDQ  RI WKH PD[LPXP RXWSXW SRZHU RI WKH XQLW
20/6/00 ESABM21-3GB

speed too high, the device shuts-down the engine. For a few DQGFKHFNWKHRLOOHYHOIUHTXHQWO\LQDQ\FDVHSOHDVH
seconds after the engine is started the shut-down function is VWLFNWRWKHUXOHVJLYHQLQWKHHQJLQHXVHPDQXDO
inhibited to allow the engine to start.
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+ Before stopping the engine LWLVFRPSXOVRU\ to:

- disconnect or shut off any loads which are connected to

the unit auxiliary outputs.

- stop welding.

7RVWRSWKHHQJLQH

Turn the starter key to the off position.



8/5/00 ESABM22_1GB
 .+036&&&9 0
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9 Welding socket ( + ) G1 Fuel level transmitter

10 Welding socket ( - ) I3 Welding scale switch
12 Earth terminal I4 Preheating indicator
15 A.C. socket M Hour counter
'(6&5,37,21

26 Fuel tank cap M5 Engine control unit EP5

27 Muffler M6 Switch CC/CV
31 Oil drain tap N Voltmeter
31C Exhaust tap for tank fuel N5 Pre-heat push-button
59B Aux current circuit breaker S Welding ammeter
59C Supply thermal switch wire feeder-42V S1 Battery
17/3/01 76503M31GB

C2 Fuel level light S6 Wire feeder supply switch

D Ground fault interrupter ( 30 mA ) T Welding current regulator
F Fuse X1 Remote control socket
F6 Arc-Force selector W1 Remote control switch
 .+036²&&&9 0
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After having prepared the machine (charged the bat-

tery, put in oil and fuel) the machine is ready for opera-
tion.

Before starting the engine please note the following:

• The welder should only be operated by qualified

personnel with experience in working with engine
driven welders.

• Check the oil level daily. Fuel should be put in

before starting the engine.

• Before using the welder or the auxiliary power let

the engine warm up and before stopping the en-
gine let it run without load to cool down.

Refer to the following instructions regarding the func-

tion of the various controls on the front panel.

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20/3/01 76503M32G
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The welding current/voltage potentiometer regulates This switch is used to select the CC (constant current)
the welding current when the CC/CV switch (see be- mode for welding electrodes or the CV (constant volt-
low) is in the CC (constant current) position. Select the age) mode for welding wire. The current or voltage is
appropriate current scale (20-200A and 20-500A) for regulated by the welding current/voltage regulation
the size of electrodes to be welded using current range potentiometer (see above).
selector (see below).
The welding current/voltage potentiometer regulates
the welding voltage when the CC/CV switch (see be-
low) is in the CV (constant voltage) position. Select the
correct voltage for the type and size of wire being
used.

5HPRWHFRQWUROFRQQHFWLRQ

The optional PHG1 remote control is used to control

the current or voltage at a distance. When the switch is
“ON” (pointing toward the remote control connector),
the current/voltage is regulated by the remote control.
When the switch is “OFF” the current/voltage is regu-
lated by the front panel potentiometer.

:HOGLQJFXUUHQWUDQJHVHOHFWLRQ PUSH AND

SCREW TIGHT
Front panel control regulates welding current

Remote control regulates welding current

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This welder is equipped with base current for improved The welder is equipped with the output for the wire
welding with cellulose electrodes. The base current feeder connection; on the front panel you can choose
functions when the arc force selector is turned on. This the voltage supply between the d.c. arc voltage or the
base current can also be used when welding with wire. 42 V a.c.:

in this case, behind the front panel, the wires at the

connector are available : follow the letters and colours
shown on the terminal strip and on the electrical dia-
20/3/01 76503M32G

gram.
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The 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.

ü$77(17,21 disconnect the remote control

PHG1 when the wire feeder is connected in CV mode.

:HOGLQJFDEOHFRQQHFWLRQV
For direct current electrode positive, connect work
cable to negative (-) terminal and electrode holder to
positive (+) terminal. For direct current electrode nega-
tive, reverse cable connections. When gouging con-
nect the positive lead to the socket marked “ONLY
GOUGING.”
+ Make sure that the ground clamp makes a
good connection and is near the welding posítion.
(3HQJLQHSURWHFWLRQPRGXOHDQGVWDUWHUNH\
The engine protection module contains the starter key,
an emergency stop switch and a set of LED’s which
show the status of the alarms. The fuse located below
the module protects the engine starting system.
Fuse for engine electrical circuit

IGNITION KEY
The ignition key has
three positions:
a) OFF
b) ON
c) START(with auto-
matic return)
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STOP BUTTON
The unit is equipped with 4 auxiliary output sockets – Stops the engine at any
one three phase and three single phase. The voltages time.
depend on the version selected. The three phase Push the button until the engine stops.
socket requires no protection as the asynchronous
alternator protects itself. The single phase sockets are OVERSPEED (M5.3)
supplied with thermal circuit breakers which pop out It signals the intervention of the overspeed protection.
when overloaded. After they have been activated give The optical and acoustic signal is activated, and the
them a short time to cool down before re-inserting. If engine stopped.
they continue to pop out check that the load is not too
large for the output of the socket. HIGH TEMPERATURE (M5.4)
It signals, through the temperature sensor, a high tem-
perature anomaly.
The optical and acoustic signal is activated, and the
engine stopped.
Check: the air inlets (there must be no obstruction), the
cooling liquid
(if engine is water-cooled), the oil level, etc....
20/3/01 76503M32G

LOW OIL PRESSURE (M5.5)

It signals, through the pressure sensor, a low oil pres-
sure anomaly.
 .+036²&&&9 0
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The optical and acoustic signal is activated, and the Optionally an ammeter and a voltmeter for the welding
engine stopped. output are available.
Check the oil level and, if it is correct, call the Service.

FUEL RESERVE (M5.1)

It signals the fuel running out, acoustically with the
siren and optically,
without stopping the engine (the signal lasts until the
cause is eliminated).

BATTERY CHARGE (M5.2)

It signals a failure of the battery charge generator and
therefore the battery charging.
The visual signal will last without stopping the engine,
until the cause is eliminated.

UNIT OK (M5.6)
The signal shows that the device is working.

&ROGVWDUWLQJ

The engine has a glow plug for cold starting. Turn the
starter key to the “ON” position, push the black glow
plug button for 10 seconds. Release the button and
turn the starter key to the start position until the engine
starts. The glow plug lamp shows that the glow plug is
energized.

,QVWUXPHQWV

Standard instruments include a fuel level gauge, an

operating hour counter and a voltmeter for the auxiliary
power which shows the three phase voltage (400V). If
the voltmeter does not show any voltage check that the
GFI (ground fault interrupter) is inserted. The voltage
shown will vary depending on the load and the welding
current being drawn. At no load and when not welding,
the voltage can be as high as 440V. The auxiliary
power cannot be used when it drops below 360V.
20/3/01 76503M32G
 86($1'0$,17(1$1&( 0
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The remote control device for regulating the welding cur-

rent is connected to the front panel by means of a multi-
pole connector.

To regulate the current from the PHG 1, move the

switch (7), located above the multipole connector (8), to
"ON" position.

Position welding current adjusting knob at the necessary 386+$1'

current value for the diameter and type of electrode. 6&5(:7,*+7

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• Maintenance and repair work should only be done by TXDOLILHG personnel.
• Stop the engine before doing any work on the machine. If for any reason the
machine must be operated while working on it, EHFDUHIXOQRWWRWRXFK rotating
parts, hot surfaces, live wires, etc. which may be unprotected.
• Remove protective guards only when necessary to perform maintenance and re-
029,1* place them immediately after the maintenance is completed. +27VXUIDFH
3$576 • Use suitable tools and wear suitable clothes. FDQ
FDQLQMXUH • Do not modify the machine without prior authorization. KXUW\RX

0$,17(1$1&(2)7+(0$&+,1(

Maintenance 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, oil and battery acid, and
the regular cleaning of the machine.

Repairs refers to the substitution of worn or damaged parts

and repairs should be carried out by Authorized Service
Centers.

Refer to the Engine Manufacturer’s Manual for the mainte-

nance instructions for the engine. Periodic maintenance
should be performed according to the schedule shown in
this manual.

On 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.
20/6/00 ESABM43GB
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Check the electrolyte level in the battery periodically, es- Check warning labels and decals once a year and UH
pecially after long periods of inactivity. SODFHG if missing or unreadable.

☞ $77(17,21: the battery must have all its elements &$%/(6$1'&211(&7,216

in good condition and must be filled with electrolyte. Periodically check the condition of the cables and tighten
the connections.
The battery is automatically charged while the engine is
running.

☞ If the battery does not charge check the circuit

breaker.

352&('85()255(&+$5*,1*%$77(5<
Remove the breather caps.
Check the electrolyte level in all compartements and, If
necessary, add distilled water to the indicated level.
Replace the breather caps.
Use a densimeter to determine the charge state of the
battery.

63(&,),&:(,*+7 &+$5*(
3(5&(17$*(
1.265 100%
1.230 75%
1.200 50%
1.170 25%

'5<$,5),/7(5
Replace the air filter cartridge every 200 hours under
normal conditions and every 100 hours in dusty envi-
ronents.

5$',$725
Check the liquid level in the radiator regularly and
refill as required. In the fall check the amount of anti-
freeze and add required to prevent freezing during
the winter months.
ü ,03257$17
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.

$6<1&+521286$/7(51$725
No maintenance is necessary, as the alternator has no
brushes or slip rings, and there are no devices for regula-
tion of the output.
20/6/00 TSGEM43-3GB




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In case the machine will not be used for more than 30

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. 

',(6(/(1*,1(6

If the machine will be stored for short periods of time it is

advisable to start the engine every 10 days and operate it
for 15-30 minutes under load. This will distribute the oil,
recharge the battery and prevent blockage of the injection
system.

For long periods of storage, refer to the engine manufac-

turer’s manual.

Clean the machine carefully.

Cover the machine with a plastic cover and store in a dry

place.

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The KHM 500 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.
 Type: 3/1-phase, asynchronous, self-excited, self-regulated, brushless
 Insulation class H
 T M M
 3(5)250$1&( 400 230 110V
 V V c.t.e
$&*(1(5$725 Duty cycle % 100 100 100
Power ( 50 Hz ) kVA 20 12 6
Power ( 60 Hz ) kVA 24 12 6
Voltage V 400 230 110
Current ( 50 Hz ) A 28.8 52.2 54.5
Current ( 60 Hz ) A 34.7 52.2 54.5
Frequency Hz 50/60 50/60 50/60
Cos Ø 0.8 0.8 0.8
 Make PERKINS
 Model 3.1524
 Type 4 – stroke
 Displacement cc 2500
Cylinder nr. 3

Power ( 50 Hz – 60 Hz ) (**) kW ( HP ) 27.1 (36.3) – 32 (42.9)
(1*,1(
Speed ( 50 Hz – 60 Hz ) rpm 1500 / 1800
Cooling system Liquid
Cooling system capacity Liter 12
Engine oil capacity Liter 6.2
Starter Electric
Battery 12V 100Ah
Acid capacity Liter 10
Fuel Diesel
 Protection IP 23
*(1(5$/63(&,),&$7,21 Weight, version on base Kg 925
Dimensions Lxwxh version on base mm 1950x872x1120
Fuel tank capacity Liter 60
Note :T=three-phase M=single-phase (**) = Maximum output (not overloadable) according to ISO 3046/1

287387$&2867,&32:(5/(9(/
+ The output indicated is guaranteed at 20°C and at a pressure of 1 bar (up to 1000 m no correction for atmosphere
pressure is required). At high temperature and above 1000 m altitude the engine output will decrease and the engine
may need adjustment for optional performances.
+ 1% at high altitudes, the standard mix air-fuel is excessively rich, the efficiency of the engine is reduced and,
therefore, the fuel consumption will increase.
+ Max. acoustic power level admitted according to the EEC norms of 17/09/84 n. 84/535-536.
The machine respects the noise limits, expressed in sound power, given in the a.m. directives.
These limits can be used to judge the sound level produced on site.
For example: the sound power level of 100 LWA.
The sound pressure (noise produced) at 7 meters distance is about 75dBA (the limit value less 25).
17/6/00 76503M51GB

To calculate the sound level at other distances use this formula:

ry² 7²
dBAx = dBAy + 10 log At 4 meters the noise level becomes: 75 dBA + 10 log 4² = 80 dBA
rx²
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 Max DC welding current ( 50 Hz ) A 500/35% - 450/60% - 400/100%

:(/',1*81,7 Max DC welding current ( 60 Hz ) A 500/35% - 470/60% - 430/100%
Welding current electronic regulation A 20 - 200
&& (on two scales) 20 - 500
Striking voltage (OCV) V 60
Electrode diameter mm 2 - 8
(rutile, basic, cellulosic)

OUTPUT CARACTERISTIC
WITH ARC-FORCE (BC)

 Max DC welding current ( 50 Hz ) A 450/60% - 400/100%

:(/',1*81,7 Max DC welding current ( 60 Hz ) A 470/60% - 430/100%
Welding voltage - Electronic regulation V 15 - 50
&9 Wire diameter mm 0.8 – 2..8

MAX

MIN.

6,08/7$1(28687,/,=$7,21)$&7256


In case :HOGLQJand*HQHUDWLRQ can be used simultaneously, however, the engine FDQQRW be overloaded.
The table below gives the maximum limits to be respected:

 :(/',1*&855(17 >300 A 225 A 150 A 80 A 0

+] $8;,/,$5<32:(5 0 6.5 kVA 14 kVA 20 kVA 20 kVA

 :(/',1*&855(17
30/10/00 76503M52GB

>300 A 250 A 200 A 100 A 0

+] $8;,/,$5<32:(5 0 6.5 kVA 11 kVA 24 kVA 24 kVA
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7/2/00 76503M53
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Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as designation and spare part
number, according to the spare parts list.
This will simplify dispatch and ensure you get the right part.

:KHQRUGHULQJWKHVSDUHSDUWVLWLV
UHFRPPHQGHGWRLQGLFDWH

1) “ serial number
2) “ model of welder and/or generating set
3) u part number
5) quantity


+ “The requested data are to be found on the rating
plate of the machine. 
06/03/00 ESABR1GB
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30/3/01 76503EE1
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QR QR 
1 1 0794000148 GENERATOR CONVEYOR
2 1 0794000149 RING
3 1 0794000150 FAN
4 1 0794000084 RING SEEGER
5 1 0794000151 BEARING
1 Delivered up to A
6 0794000152 STATOR WITH HOUSING (50Hz) 001 – XXX - XXXX
1 Delivered from A
6 0794222204 STATOR WITH HOUSING (50Hz) 002 – XXX - XXXX
1 Delivered up to A
6a 0794000156 STATOR WITH HOUSING (60Hz) 001 – XXX - XXXX
1 Delivered from A
6a 0794000156 STATOR WITH HOUSING (60Hz) 114 – XXX - XXXX
7 1 0794000153 SHAFT WITH ROTOR
8 4 0794000154 SHAFT WITH ROTOR DISC
9 2 0794000082 VIBRATION DAMPER
10 1 0794000155 ALTERNATOR BRACKET
11 1 PERKINS ENGINE 3.1524
12 2 0794000157 VIBRATION DAMPER
13 1 0794000290 GENERATOR COVER
14 2 0794000291 BRACKET
15 1 0794000292 SUPPORT
16 1 0794000190 OIL EXAUST TUBE
17 3 0794000293 COVER BRACKET
C = component designation in the electrical system
30/3/01 76503EE1.1
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30/3/01 76503EE2
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20 1 0794000158 BLACK WELDING SOCKET Z
21 2 0794000159 RED WELDING SOCKET Z
22 1 0794000073 CONNECTOR X1
23 1 0794000301 CIRCUIT BREAKER 10A/250V P4
24 5 0794000074 CAP
25 3 0794000077 SWITCH A5/I3
26 2 0794000075 SWITCH 4 pole M6/W1
27 1 0794000060 KNOB, WELDING CURRENT REGUL.
28 1 0794000147 POTENTIOMETER T
29 1 0794000038 WARNING LIGHT 48V I4
30 1 0794000160 WELD-AMMETER/VOLTMETER KIT OPTION S/V
31 1 0794000161 GROUND FAULT INTERRUPTOR (GFI) 30 mA D
32 1 0794000047 BRACKET
33 1 0794000046 COVER GFI
34 1 0794000062 CIRCUIT BREAKER 30A/250V P4
34 2 0794000062 CIRCUIT BREAKER 30A/250V (110V version) P4
35 1 0794000162 VOLTMETER N
36 1 0794000063 HOURMETER 50 Hz M
36a 1 0794000007 HOURMETER 60 Hz M
37 1 0794000163 ENGINE PROTECTION EP5 M5
38 1 0794000164 PUSH BUTTON N5
39 1 0794000165 FUEL LEVEL GAUGE C2
40 2 0794000057 CIRCUIT BREAKER 15A/250V P4
40 1 0794000057 CIRCUIT BREAKER 15A/250V (110V version) P4
41 2 0794000034 EEC SOCKET SINGLE-PHASE 16A, 230V 2P+T H
41a 1 0794000121 EEC SOCKET SINGLE-PHASE 16A, 110V 2P+T I
42 1 0794000069 EEC SOCKET SINGLE-PHASE 32A, 230V 2P+T H
42a 1 0794000044 EEC SOCKET SINGLE-PHASE 32A, 110V 2P+T I
43 1 0794000070 EEC SOCKET THREE-PHASE 32A, 400V 3P+N+T G
1 Delivered up to
44 0794000166 FRONT PANEL 002 – XXX - XXXX
1 Delivered from
44 0794000294 FRONT PANEL 109 – XXX - XXXX
45 3 0794000071 FUSE HOLDER
46 1 0794000072 FUSE 0.1A (5x20) F
47 1 0794000167 FUSE 15A (5x20 F
48 1 0794000168 FUSE HOLDER
49 1 0794000113 FUSE 30A (6.3x32) F
96 1 0794000300 FUSE 0.5A (5x20) F
97 1 0794000295 TOROID (EMC FILTER) R6
C = component designation in the electrical system
26/3/01 76503EE2.1
.+036&&&9 ((
3


30/3/01 76503EE3
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50 1 0794000169 EXHAUST MUFFLER
51 1 0794000142 LATCH
52 1 0794000170 OUT AIR GRATE
53 0794000120 STRIP SEALING order q.ty in meter
54 2 0794000171 HANDLE
55 1 0794000172 REAR COVER
56 1 0794000173 FRONT COVER
57 1 0794000174 LEFT SIDE FRON COVER
58 1 0794000175 COVERING FRONT COVER
59 2 0794000176 LATCH
60 1 0794000177 ROLL BAR
61 1 0794000178 BOTTOM FRAME
62 1 0794000179 ELECTRICAL BOX COVER
63 1 0794000180 BATTERY 100Ah S1
1 Delivered up to
64 0794000181 BRACKET 002 – XXX - XXXX
1 Delivered from
64 0794000296 BRACKET 109 – XXX - XXXX
65 2 0794000182 LATCH COVER
66 1 0794000183 RIGHT SIDE FRONT COVER
67 1 0794000107 FUEL TANK CAP
68 1 0794000184 FUEL LEVEL GAUGE G1
69 2 0794000185 PARKING STAND
70 1 0794000186 GAS PISTON
71 1 0794000187 CAP FUEL TANK
72 1 0794000188 GASKET
74 2 0794000102 TIE ROD BATTERY
C = component designation in the electrical system
26/3/01 76503EE3.1
.+036&&&9 ((
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30/3/01 76503EE4
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75 1 0794000189 EXHAUST TUBE
77 1 0794000191 ELECTRICAL BOX
78 3 0794000192 CAPACITORS BOX BRACKET
79 3 0794000193 CAPACITORS BOX  ) C
80 1 0794000098 TERMINAL BOARD
81 1 0794000194 ALTERNATOR TOP COVER
82 1 0794000195 BRACKET PANEL
83 1 0794000196 BRACKET PANEL
Delivered up to R
85 1 0794000099 WELDING CONTROL PCB 109(50Hz)/114(60Hz) – XXX -
XXXX
1 Delivered from R
85 0794000309 WELDING CONTROL PCB 135 – XXX - XXXX
86 1 0794000097 RELAY N3
1 Delivered up to W
87 0794000197 INDUCTOR 001 – XXX - XXXX
Delivered from
87 1 0794000205 INDUCTOR 002 – XXX - XXXX
W
88 1 0794000198 CAPACITORS BOX FIXING BRACKET
89 1 0794000199 REACTANCE BRACKET
90 2 0794000200 RECTIFIER ASSY BRACKET
91 1 0794000201 RECTIFIER ASSY Y/X4
92 1 0794000092 POWER RESISTANCE O3
93 2 0794000094 WASHER
94 2 0794000093 SPACER
95 1 0794000100 TRANSFORMER U
96 1 0794000297 RELAY 48V N3
97 1 0794000298 BASE
98 1 0794000299 COVER P.C.B.
C = component designation in the electrical system
19/9/01 76503EE4.1
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30/3/01 76503 KIT DECAL

 6,7(72:)25.+0<636 .$
9
²

.$
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1 1 0794000273 KIT SITE-TOW
2 1 0794000263 PARKING STAND
3 1 0794000274 TOW BAR
4 1 0794000275 KIT WHEELS AND HANDLES
5 1 0794000276 AXLE
6 1 0794000277 WHEEL
7 1 0794000268 KIT SITE-TOW
8 1 0794000263 PARKING STAND
9 1 0794000269 TOW BAR
10 1 0794000270 KIT WHEELS AND HANDLES
11 1 0794000271 AXLE
12 1 0794000272 WHEEL
13 1 0794000262 KIT SITE-TOW
14 1 0794000263 PARKING STAND
15 1 0794000264 TOW BAR
16 1 0794000265 KIT WHEELS AND HANDLES
17 1 0794000266 AXLE
7/2/01 CTL KA9

18 1 0794000267 WHEEL
C = component designation in the electrical system
 3+* .'
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3 1 0794000278 FEMALE CONNECTOR Y1
4 1 0794000279 CABLE
5 1 0794000206 KNOB
7 1 0794000207 WELDING CURRENT REGULATOR A2
8 1 0794000280 BOX
9 1 0794000281 HANDLE
11 1 0794000282 REMOTE CONTROL ASSY
C = component designation in the electrical system
7/2/01 PHG 1
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020314