ESAB | KHM 600 PS - BC | Instruction manual | ESAB KHM 600 PS - BC User manual

ESAB KHM 600 PS - BC User manual
KHM 600 PS - BC
Instruction manual
0794 999 926 01/09
Valid for serial No 127 - XXX - XXXX (50Hz version)
Valid for serial No 136 - XXX - XXXX (60Hz version)
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ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that the engine driven
welder KHM 600 PS – BC with the code number 0794004880/1 complies with the Community Directives and
related modifications 98/37/CE - 73/23/CE - 89/336/CE and, in order to check the conformity, the following
harmonized standards EN 292-1 - EN 292-2 - EN 60974-1 - EN 60204-1 - EN 50199 and other standards or
directives like 84/535/CE - ISO 8528 have been consulted.
Laxå 2001
Joakim Cahlin
Tel. + 46 58 481000
fax +46 584 411924
19/9/01 DC 600 P-GB
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN
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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.
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INFORMATION ABOUT THIS MANUAL
DESCRIPTION - SYMBOLS
PRECAUTIONS - GENERAL
PRECAUTIONS - ENGINE DRIVEN WELDERS
INSTALLATION
TRANSPORT
ASSEMBLY OF SITE TOW FOR KHM 500/600
INSTALLATION INFORMATION
M2
M 2.1
M 2.5
M 2.5.1
M 2.7
M4
M 6.3
M 2.6
23(5$7,21
UNPACKING
PREPARING THE UNIT
STARTING THE ENGINE THE USE
STOPPING THE DIESEL ENGINE
CONTROLS
OPERATING
REMOTE CONTROL PHG 1
MAINTENANCE
STORAGE
TECHNICAL DATA AND MACHINE DESCRIPTION
TECHNICAL DATA
M3
M 20
M 21.3
M 22.1
M 31
M 32
M 38.7
M 43, M 43.3,M 44.2
M 45
M 51, M 52, M52.1
M 53
KIT DECAL
SITE TOW FOR KHM 500/600
PHG 1
KA 9
KD 10
19/9/01 76602M1GB
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ORDERING SPARE PARTS
R 1,
WIRING DIAGRAM – ENGINE EP5
M 61.1,
WIRING DIAGRAM – CONTROL WELDING
M 61.2,
WIRING DIAGRAM – POWER WELDING
M 61.3,
WIRING DIAGRAM – AUXILIARY Y400V / 3x I230V
M 61.4,
WIRING DIAGRAM – AUXILIARY Y400V / I230V / 2x I110V (60Hz) M 61.5,
DESCRIPTION - ELECTRICAL SYSTEM
M 60
SPARE PARTS
EF 10, EF 10.1,
SPARE PARTS
EF 11, EF 11.1,
SPARE PARTS
EF 12, EF 12.1,
SPARE PARTS
EF 13, EF 13.1,
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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.
+
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Making modifications to the machine without our written
authorization will void the warranty and release us from
any liability.
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The headings used in this manual are designed to call your
attention to potential hazards and important aspects of the
operation of the machine…
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lndìcates a strong possíbility of severe personal injury or
death ìf ínstructions are not followed.
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lndìcates a possibìlìty of personal ínjury or equipment damage if ìnstructions are not followed
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lndícates that equipment or property damage can result if
instructions are not followed.
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.
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The manual is written for experienced, qualified personnel,
who are familiar with health and safety laws and related
regulations.
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These headings give helpful information about the preparation, 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 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.
+ 1RWLFHWKHPDQXIDFWXUHUPD\PDNHLPSURYHPHQWVRU
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6723²Read with great attention
Read with attention
:5(1&+Use the correct tools for the type of
work being done
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$77(17,21 If this advice is not followed people or things can be hurt or damaged.
+,*+92/7$*( Do not touch – risk of injury
or death.
),5( Risk of fire.
+($7 Hot surfaces.
(;3/26,9( Explosive material or danger of
explosion, in general.
12:$7(5'RQRWXVHZater as it can cause
shortcircuits or other damage.
12602.,1*&igarettes, matches or lighters
can start a fire or explosion.
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Use protective clothing, etc. specifically
designed for the type of welding being done.
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It is advisable to protect yourself when carrying
out maintenance, such as filling the battery, refuelling, etc.
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Refer to the instructions before moving the machine
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It is compulsory to wear the personal protection items shown when using the equipment.
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Safety devices suitable for the type of welding
and the location of the job must be used.
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It is prohibited to use water to put our fires in
electrical equipment.
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It is prohibited to work on the machine until the
electricity has been turned off.
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It is forbidden to weld in areas containing explosive gases.
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$&,'6Danger of corrosion or burns.
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+ 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.
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Removing or disabling protective devices on the machine is prohibited.
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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.
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⇒ 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
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⇒ Sparks may cause the explosion of battery vapours
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⇒ 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.
F ),567$,' 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
F),5(35(9(17,21 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.
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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.
Particular protection
Useful warnings
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Appropriated
Not to be used
Other indications
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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.
⇒ 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).
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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.
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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
'$1*(5LIFTING EYE IS NOT DESIGNED TO SUPPORT
ADDED WEIGHT OF ROAD TOW TRAILER
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DO NOT LIFT THE MACHINE AND
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 (4S4I) 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).
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Do not substitute the original tires with other types.
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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.
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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.
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Towing on public roads or turnpikes of any type ,6
(;&/8'(', because QRW in possesion of the requirements
by national and foreign traffic norms.
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+ Assure that the hot air and/or exhaust gas from the
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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
DIESEL ENGINES
• Use in open space with fresh air flow or vent exhaust
gases far from the work area.
+
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 flooding. :DWHULQILOWUDWLRQFDQFDXVHVKRUWFLUFXLWVZKLFKFDQ
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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 disconnect 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.
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If the surface is not level be sure that the angle of the machine does not exceed the values shown in the drawings
below.
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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.
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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.
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Take the battery out of
the machine.
Fill the battery to the
maximum level with
electrolyte. Wait for
about 30 minutes and
top up with electrolyte.
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Fill 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.
In case of spilled acid, rinse with water before putting the
battery back into the machine and reconnecting cables.
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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.
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 maintenance of the cooling system, refer to the engine manual..
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Check the level of the engine oil using
the oil dipstick. The level should be
between the minimum and maximum
marks. lf necessary, add more oil.
If the air filter is of the oil bath type, fill it with the same oil
up to the level indicated on the filter.
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For the type and viscosity of oil refer to owner’s manual
for the engine (supplied with the machine).
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A good ground is obligatory for all models with GFI
(ground fault interrupter). This protective device 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. Follow all local
rules and/or regulations in force.
Machines with Isometer protection do not need to be
grounded.
Once the above operations have been completed, the
machine can be used.
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M5.1(yellow) Fuel reserve
M5.2(yellow) Battery
charge
M5.3(red) Overspeed
M5.4(red) High temperature
M5.5(red) Low oil pressure
M5.6(green)Protection
unit on
These engines start their normal operating speed.
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In the event of low oil pressure the LED lights and the engine is shut-down.
Check daily
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The ingnition key is a part of the EP5
engine protection device and has three
positions.
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The preheater must be used for starting these
engines at low temperatures (below –5°C) and
is activated by a push button. 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.
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If the water temperature is too high the LED lights and the
engine is shut-down.
29(563((' 0 If the engine speed goes over the preset value the LED
lights and the engine is shutdown. The nominal frequency
(50 or 60 Hz) is monitored .
)8(/5(6(59( 0 If the fuel level reaches the reserve level the LED lights and
the sirene sounds and the engine is shut-down.
%$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.
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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.
The EP5 device monitors the engine oil pressure, the engine water temperature and the rpm of the engine. If the oil
pressure is too low, the water temperature too high or the
speed too high, the device shuts-down the engine. For a few
seconds after the engine is started the shut-down function is
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.
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Turn the starter key to the off position.
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10
12
15
26
27
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59B
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Welding socket ( + )
Welding socket ( - )
Earth terminal
A.C. socket
Fuel tank cap
Muffler
Oil drain tap
Exhaust tap for tank fuel
Aux current circuit breaker
Fuel level light
Ground fault interrupter ( 30 mA )
Fuse
Arc-Force selector
G1
I3
I4
M
M5
N
N5
S
S1
T
X1
W1
Fuel level transmitter
Welding scale switch
Preheating indicator
Hour counter
Engine control unit EP5
Voltmeter
Pre-heat push-button
Welding ammeter
Battery
Welding current regulator
Remote control socket
Remote control switch
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After having prepared the machine (charged the
battery, put in oil and fuel) the machine is ready for
operation.
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 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.
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The welding current potentiometer regulates the
welding current in the. Select the appropriate current
for the size of electrodes to be welded using current
range selector (see below).
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For all welding except for air arc gouging the cables
should be attached to the + and – sockets. When
gouging connect the positive lead to the socket
marked “ONLY GOUGING.”
Loose connections can cause arcing and damage to
both plugs and sockets. To avoid this insert the
plugs completely into the sockets and twist in a
clockwise direction until they are tight.
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This welder is equipped with base current for improved welding with cellulose electrodes. The base
current functions when the arc force selector is
turned on.
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The unit is equipped with 3 auxiliary output sockets
single phase. The single phase sockets are supplied
with thermal circuit breakers which pop out when
overloaded. After 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.
3/7/01 76602M32GB
The optional PHG1 remote control is used to control
the current at a distance. When the switch is “ON”
(pointing toward the remote control connector), the
current is regulated by the remote control. When the
switch is “OFF” (pointing up) the current is regulated
by the front panel potentiometer.
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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.
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LOW OIL PRESSURE (M5.5)
It signals, through the pressure sensor, a low oil
pressure anomaly.
The optical and acoustic signal is activated, and the
engine stopped.
Check the oil level and, if it is correct, call the Service.
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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).
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.
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.
Fuse for engine electrical circuit
UNIT OK (M5.6)
The signal shows that the device is working.
IGNITION KEY
The ignition key
has three positions:
a) OFF
b) ON
c)
START(with
automatic return)
STOP BUTTON
Stops the engine at
any time.
Push the button until the engine stops.
OVERSPEED (M5.3)
It signals the intervention of the overspeed protection.
The optical and acoustic signal is activated, and the
engine stopped.
HIGH TEMPERATURE (M5.4)
It signals, through the temperature sensor, a high
temperature 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....
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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.
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Standard instruments include a fuel level gauge, an
operating hour counter and a voltmeter for the auxiliary power which shows the single phase voltage
(230V).. 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 250V. The auxiliary power cannot be used
when it drops below 205V.
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The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector.
To regulate the current from the PHG 1, move the
switch (7), located above the multipole connector (8), to
"ON" position.
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Position welding current adjusting knob at the necessary
current value for the diameter and type of electrode.
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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
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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 replace them immediately after the maintenance is completed.
• Use suitable tools and wear suitable clothes.
• Do not modify the machine without prior authorization.
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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.
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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 maintenance instructions for the engine. Periodic maintenance
should be performed according to the schedule shown in
this manual.
20/6/00 ESABM43GB
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.
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Check the electrolyte level in the battery periodically, especially after long periods of inactivity.
Check warning labels and decals once a year and UH
SODFHG if missing or unreadable.
☞ $77(17,21: the battery must have all its elements
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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.
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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.
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1.230
1.200
1.170
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75%
50%
25%
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Replace the air filter cartridge every 200 hours under
normal conditions and every 100 hours in dusty environents.
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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.
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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.
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No maintenance is necessary, as the alternator has no
brushes or slip rings, and there are no devices for regulation of the output.
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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 manufacturer’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 600 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
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3(5)250$1&(
400
230 110
V
V
V
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100
100 100
Power ( 50 Hz )
kVA
30
15
Power ( 60 Hz )
kVA
30
15 10
Voltage
V
400
230 110
43.3
65.2
Current ( 50 Hz )
A
43.3
65.2 90.9
Current ( 60 Hz )
A
50/60
50/60
50/60
Frequency
Hz
Cos
Ø
0.8
0.8 0.8
Make
PERKINS
Model
1004 G NFE
Type
4 – stroke
Displacement
cc
3990
Cylinder
nr.
4
Power ( 50 Hz - 60 Hz) (**)
kW ( HP ) 45 (61) - 51 (68.5)
(1*,1(
Speed ( 50 Hz - 60 Hz)
rpm
1500 / 1800
Cooling system
Liquid
Cooling system capacity
Liter
15.7
Engine oil capacity
Liter
8.1
Starter
Electric
Battery
12V
100Ah
Acid capacity
Liter
10
Fuel
Diesel
Protection
IP
23
Kg
1100
*(1(5$/63(&,),&$7,21 Weight, version on base
Dimensions Lxwxh version on base
mm
2100x872x1120
Fuel tank capacity
Liter
66
M=single-phase
(**) = Maximum output (not overloadable) according to ISO 3046/1
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+ 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).
To calculate the sound level at other distances use this formula:
7²
ry²
dBAx = dBAy + 10 log
At 4 meters the noise level becomes: 75 dBA + 10 log 4² = 80 dBA
rx²
17/9/01 76602M51GB
Note :T=three-phase
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Max DC welding current
A
Welding current electronic regulation
(on two scales)
Striking voltage (OCV)
Electrode diameter
(rutile, basic, cellulosic)
A
V
mm
0
52
600/35% - 550/60% 450/100%
20 - 200
20 - 600
60
2-8
OUTPUT CARACTERISTIC
ARC-FORCE (BC)
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:
>550 A
0
500 A
5 kVA
300 A
13 kVA
150 A
20 kVA
0
30 kVA
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A
Welding current electronic regulation
(on two scales)
Striking voltage (OCV)
Electrode diameter
(rutile, basic, cellulosic)
A
V
mm
0
52.1
650/35% - 550/60% 450/100%
20 - 200
20 - 650
65
2-8
OUTPUT CARACTERISTIC
ARC-FORCE (BC)
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:
>450 A
0
400 A
5 kVA
300 A
13 kVA
150 A
20 kVA
0
30 kVA
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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.
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“ serial number
“ model of welder and/or generating set
u part number
quantity
+
“The requested data are to be found on the rating
plate of the machine. 06/03/00 ESABR1GB
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2)
3)
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: Alternator
: Wire connection unit
: Capacitor
: G.F.I. (ground fault interrupter)
: Fuse
: 400V 3-phase socket
: 230V 1phase socket
: 110V 1phase socket
: Hour-counter
: Voltmeter
: Welding control P.C.B.
: Welding current ammeter
: Welding current regulator
: Current transformer
: Welding voltage voltmeter
: Welding sockets
: Shunt
: D.C. inductor
: 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
M6 : Switch CC/CV
R6: EMC filter
17/9/01 76602M60G
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2
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3
1
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FAN
4
1
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RING SEEGER
5
1
0794000151
BEARING
6
1
0794000310
STATOR WITH HOUSING (50Hz)
6a
1
0794000311
STATOR WITH HOUSING (60Hz)
7
1
0794000249
SHAFT WITH ROTOR
8
4
0794000154
SHAFT WITH ROTOR DISC
9
2
0794000082
VIBRATION DAMPER
10
1
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ALTERNATOR BRACKET
11
1
PERKINS ENGINE 1004 G NFE
12
2
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VIBRATION DAMPER
13
1
0794000190
OIL EXAUST TUBE
14
1
0794000290
GENERATOR COVER
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2
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22
1
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24
5
0794000074
CAP
25
3
0794000077
SWITCH
27
1
0794000060
KNOB, WELDING CURRENT REGUL.
28
1
0794000147
POTENTIOMETER
29
1
0794000038
WARNING LIGHT
30
1
0794000160
WELD-AMMETER/VOLTMETER KIT
31
1
0794000161
GROUND FAULT INTERRUPTOR (GFI)
32
1
0794000047
BRACKET
33
1
0794000046
COVER GFI
35
1
0794000162
VOLTMETER
36
1
0794000063
HOURMETER
36a
1
0794000007
HOURMETER
37
1
0794000163
ENGINE PROTECTION EP5
38
1
0794000164
PUSH BUTTON
39
1
0794000165
FUEL LEVEL GAUGE
40
1
0794000057
CIRCUIT BREAKER
40a
2
0794000057
CIRCUIT BREAKER
41
2
0794000034
EEC SOCKET SINGLE-PHASE
41a
2
0794000121
EEC SOCKET SINGLE-PHASE
42
1
0794000069
EEC SOCKET SINGLE-PHASE
42a
1
0794000044
EEC SOCKET SINGLE-PHASE
43
1
0794000070
EEC SOCKET THREE-PHASE
44
1
0794000166
FRONT PANEL
45
3
0794000071
FUSE HOLDER
46
1
0794000072
FUSE
47
1
0794000167
FUSE
48
1
0794000168
FUSE HOLDER
49
1
0794000113
FUSE
55
4
0794000192
CAPACITOR BOX BRACKET
56
4
0794000213
CAPACITOR BOX
56a
4
0794000193
CAPACITOR BOX
57
1
0794000098
TERMINAL BOARD
58
1
0794000097
RELAY
59
1
0794000198
CAPACITOR BOX FIXING BRACKET
60
1
0794000299
COVER P.C.B.
61
1
0794000309
WELDING CONTROL PCB
62
1
0794000191
ELECTRICAL BOX
63
1
0794000201
RECTIFIER ASSY
64
2
0794000200
RECTIFIER ASSY BRACKET
65
1
0794000199
REACTANCE BRACKET
66
1
0794000260
INDUCTOR
67
1
0794000092
POWER RESISTENCE
68
2
0794000094
WASHER
69
2
0794000093
SPACER
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30 mA
T
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15A/250V
16A, 230V 2P+T
16A, 110V 2P+T
32A, 230V 2P+T
32A, 110V 2P+T
32A, 400V 3P+N+T
N
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N5
C2
P4
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H
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15A (5x20)
F
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70 µ F (50 Hz)
60 µ F (60 Hz)
C
C
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60 Hz
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0794000170 OUT AIR GRATE
76
1
0794000256 EXHAUST TUBE
77
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0794000290 ALTERNATOR COVER
78
1
0794000195 BRACKET PANEL
79
2
0794000102 TIE ROD BATTERY
80
1
0794000296 BRACKET
81
1
0794000180 BATTERY
82
1
0794000179 ELECTRICAL BOX COVER
83
1
0794000196 BRACKET PANEL
84
1
0794000188 GASKET
85
1
0794000187 CAP FUEL TANK
89
1
0794000184 FUEL LEVEL GAUGE
90
1
0794000107 FUEL TANK CAP
91
1
0794000169 EXHAUST MUFFLER
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96 4
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97 1
0794000254 ROLL BAR
98 1
0794000175 COVERING FRONT COVER
99 2
0794000182 LATCH COVER
100 1
0794000174 LEFT SIDE FRONT COVER
101 1
0794000255 BOTTOM FRAME
102
0794000120 STRIP SEALING
103 1
0794018600 GAS PISTON
104 1
0794000185 PARKING STAND
105 1
0794000142 LATCH
106 2
0794000171 HANDLE
107 1
0794000173 FRONT COVER
108 1
0794000183 RIGHT SIDE FRONT COVER
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0794000263
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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
18
1
0794000267
WHEEL
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4
1
0794000279
CABLE
5
1
0794000206
KNOB
7
1
0794000207
WELDING CURRENT REGULATOR
8
1
0794000280
BOX
9
1
0794000281
HANDLE
11
1
0794000282
REMOTE CONTROL ASSY
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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
S.A. ESAB N.V.
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
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
AUSTRALIA
ESAB Australia Pty Ltd
Ermington
Tel: +61 2 9647 1232
Fax: +61 2 9748 1685
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
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 Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 333 43 33
Fax: +55 31 361 31 51
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
020314
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