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3. e Ad ONVIS 8 1 9 S r 5 5 gt 3 45 Qo L Gb ch W OL 6 gt lt gt lt N a e ICO N N HOLO3NNOO VIA343 X3 OIN 9L CD Schema elettr CD Stromlaufplan Electric diagram OSA REV 1 04 08 I CLV88 50 11 81 MOSA guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement of MOSA spare parts is required always ask for genuine parts only lt gt The requested data are to be found on the data plate located on the machine structure quite visible and easy to consult When ordering the spare parts it is recom mended to indicate O Europa 59 20090 CUSAGO MI ITALY Tel 39 02 90352 1 fax 39 02 90390466 1 serial number cum TS 0000 GE 2 model of welder and or generating set lt 4 n position Em 9 quantity 3 n table 5 MES O TWOLARICANBI SPARE PARTS PIECES DE RECHANGE ERSATZTEILE au T EA 3 4 19 13 18 17 16 20 21 22 o 21 22 23 ABBREVIATIONS AND 5 5 EV When ordering specify the engine type and the auxiliary voltage ER Engine with recoil starter only ES Engine with electric starter only VE E A S version only QM When ordering specify the length in meters VS Special version only SR By reque
4. Table pi ces de rechange QD Cod M784017080 M306467109 M0000794057425 M884127425 M744508103 M873407107 M1240020 M1241010 M306479199 M1243020 M105111830 M218137280 M884027085 M307017240 M105111520 M102301310 M102044400 M107509890 M105111510 M305027105 M305717300 M744508112 M744507057 M325507210 M105511810 M744509770 M765007300 M765007305 M784007010 M784017020 M784007090 M884027065 M282005107 M282009869 M101131220 Cod M784017080 M306467109 M0000794057425 M884127425 M744508103 M873407107 M1240020 M1241010 M306479199 M1243020 M105111830 M218137280 M884027085 M307017240 M105111520 M102301310 M102044400 M107509890 M105111510 M305027105 M305717300 M744508112 M744507057 M325507210 M105511810 M744509770 M765007300 M765007305 M784007010 M784017020 M784007090 M884027065 M282005107 M282009869 M101131220 Descr FRONTALE LATO MOTORE PROTEZIONE TERMICA C B FRONT CONTR SALD PROGRAMMATO WDC 400 FRONT CONTR SALD PROGRAMMATO WDC 400 CERNIERA X COPERCHIO FRONTALE DISGIUNTORE TERMICO 30A 250V MORSETTO 4mmq PIASTRINA RELE AVV ELETTRICO GUIDA PER MORSETTIERA MORSETTIERA PRESA CEE 48V 32A PANNELLO PORTA PRESE LATO SALD PRESA 220V 16A PRESA CEE 220V MONOF 2P T PRESA DI SALDATURA PRESA DI SALDATURA SHUNT DI MISURA PRESA CEE 380V TRIFASE INTERRUTTORE DIFFERENZIALE VOLTMETRO SERRATURA PER COPERCHIO FRONT CHIAVE SERRATURA QUADRO ELETT INDICATORE LIVELLO
5. GENERATION IN AC ALTERNATING CURRENT Make certain of the efficiency of the ground connec tion 12 See page M20 Position the switch to ON Voltage is now immediately available to the Sockets Verify that the voltmeter displays the nominal vol tage value at no load it is close to 10 of the nominal value Connect the electric devices to be powered to the AC sockets using suitable plugs and cables in good condition Verify that the electrical characteristics voltage frequency power of the device being powered are compatible with those of the generator Low frequency and or voltage can irreparably damage some electrical devices Verify that the ground lead of the electrical applian ce tool to be powered is correctly connected to the terminal of the plug rs For double insulation devices with the symbol the plug s ground terminal does not need to be grounded THERMAL PROTECTION The monophase outputs are protected against over loads by the thermal protection 59B When the rated current is exceeded the protection intervenes to cut off the voltage to the AC socket t Notes the intervention of the thermal protection is not instantaneous but reacts according to an overcurrent time characteristic whereby the greater the overcurrent the quicker the intervention In case of intervention by the protection device verify that the total power for the loads connected does not exceed th
6. Remote start socket Transfer fuel pump control Ammeter selector switch 400V 230V 115V commutator 50 60 Hz switch Cold start advance with temp switch START STOP switch Polarity inverter two way switch Engine protection EP7 AUTOIDLE switch AUTOIDLE PCB A4E2 ECM engine PCB Remote emergency stop connector V A digital instruments and led VRD PCB Water in fuel Battery disconnect switch Inverter Overload led Main IT TN selector NATO socket 12V Diesel pressure switch Remote control PCB Pressure turbo protection 26 07 04 M60GB I 21188 50 11 81 22 ens ezues 722 3 Y OTIPOTUNMOD OJ9TATP uoo oubestp ejuesezd Y TS YSON VI 8 010 5 2 782 900201 02 eoeuoder Sd 007 5 _ wesourwww dnu eubrseq ouruoen oz ODWSNI 0600Z eurgooeg Sea CITY 2 6116 1782 os JO oU uorqeuiuoueq oU Tp 01 uorzeuruou q ea RI LEM MIO Es 02 02 _Q TN 700249 I I TN 700010 O O O dcc gt lt CN e o Z O O O 1 LL 9 von 7 855 3 85 ret ips lt E E E 2 09 04 5 S
7. 24 M307809880 BOX CONDENSATORI 3X80 UF 25 M784109887 PIASTRA FISS BOX COND COMPL 26 M786104100 REATTORE DI LIVELLO Pos Rev Cod Descr 1 M107301390 RING FIXING FAN 2 M107601470 FAN COMPLETE 3 M308306010 ALTERNATOR AIR CONVEYOR 4 M784008222 ALTERNATOR COVER 5 M766703010 HOUSING 6 M784003020 STATOR 7 6050050 RING SEEGER 8 M1001050 BEARING 9 M766703030 SHAFT ROTOR COMPL 10 M740552200 ENGINE PERKINS 1103A 33TG1 10 M840562200 ENGINE PERKINS 1103C 33TG3 11 M765008224 ALTERNATOR COVER SUPPORT 12 M323003101 ALTERNATOR BRACKET COMPL 12 M884123101 ALTERNATOR BRACKET COMPL 13 M744508430 COVERS BRACKET 14 M744501060 BRACKET LIFT 15 M840768215 ENGINE AIR EXHAUST SITE 16 M784104126 REACTOR HOLDING STEEL SHEET 22 M209719882 CAPACITOR BOX BRACKET 23 M107509041 CONNECTING PLATE CAPACITOR BOX 24 M307809880 CAPACITOR BOX 3X80 UF 25 M784109887 SUPPORT BRACKET REACTOR M786104100 CAPACITOR BOX Was 282004100 18 11 05 88412 Ricambi Ersatzteile M SA Spare parts Tabla de recambios DSP 2x400 PSX Rev 0 09 06 Pieces de rechanges QD 30 29 28 21 25 24 23 15 11 13 18 34 12 13 11 15 MOSA REV 1 11 06 Pos Rev O G NN gt O Q CO CO CO S N N N OR N 323230 N N VI O Y O NN O QD Tavola ricambi Spare parts table D Ersatzteile
8. ma 1 gt A gt 000 ow _ AN 0H 3 A 7 b NE AGA si Y AN AA 95 Y 2 Jr lt A Cn K 4 lt 7 e 4 572 8 2 7 m f c 2 7 f BAD 2 44 Y O 7 O vw E x 024 2 La i AN OY E 8 NAS xx i 26 eS R j jH _ 4 lt Sr 7 A 4 El 224 4 Y El Tavola ricambi D Ersatzteile CA Spare parts table Tabla recambios DSP 2x400 PSX REV 1 02 11 Table pi ces de rechange QD Pos Rev Cod Descr Note 1 M766708065 GRIGLIA PER CARENATURA 2 M766708035 CARENATURA POSTERIORE 3 M744501255 COPERCHIO VANO RIFORNIMENTO 4 M6095030 TUBO GOMMA 5 M305607032 COPERCHIO Fino a REV 0 09 06 Del 106 09 14 10 09 5 M841657032 COPERCHIO Da REV 1 02 11 Del 106 09 14 10 09 6 M342202026 TAPPO SERBATOIO 7 M740558073 TIRANTE M5x175 8 M840759975 SENSORE LIVELLO CARBURANTE L 355 9 M105611550 ANTIVIBRANTE 10 M840761050 BASAMENTO 11 M764409150 BATTERIA 12 M400409154 _ STAFFA FISSAGGIO BATTERIA 13 M840762020 SERBATOIO CARBURANTE capacit 1021 14 M784102070 TUBO DI SCARICO 15 M784102069 GUARNIZIONE SCARICO MOTORE 16 M766702241 STAFFA SUPP FILTRO GASOLIO 17 MJJ0062025 RUBINETTO M F 1 2 G 18 MJJ0062292 NIPPLO OLEODINAMICO 1 2 G 19 M744502212 TU
9. 1 04 08 a QUALITY SYSTEM COPYRIGHT NOTES CE MARK TECHNICAL DATA WELDING TECHNICAL DATA SYMBOLS AND SAFETY PRECAUTIONS INSTALLATION AND ADVICE BEFORE USE INSTALLATION AND ADVICE UNPACKING TRANSPORT AND DISPLACEMENTS COVERED UNITS ASSEMBLY CTL PREPARING THE UNIT START UP SHUTTING DOWN THE MOTOR CONTROLS USE AS AWELDER WELDER DSP USE USING THE GENERATOR REMOTE CONTROL TROUBLESHOOTING MAINTENANCE STORAGE CUST OFF RECOMMENDED ELECTRODES ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM SPARE PARTS 28 11 05 88412 GB MOSA O MOSA 1 0 10 02 N ATTENTION This use and maintenance manual is an important part of the machines in question The assistance and maintenance personel must keep said manual at disposal as well as that for the engine and alternator if the machine is synchronous and all other documentation about the machine GB Copyright CE We advise you to pay attention to the pages concerning the security see page M1 1 MOSA O All rights are reserved to said Company It is a property logo of MOSA division of B C S S p A All other possible logos contained in the documentation are registered by the respective owners The reproduction and total or partial use in any form and or with any means of the documentation is allowed to nobody without a written permission by MOSA division of B C S S p A To this aim is reminded the protection of the author s right a
10. B the plates fixed on the machine the data plate A 03 O I e CD G TRANSPORT AND DISPLACEMENTS COVERED UNITS AND SKID gum ET pec II MOSA REV 1 06 10 Transportation must always take place with the engine off electrical cables and starting battery disconnected fuel tank empty Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conform to local rules and regulations Only authorized persons involved in the transport of the machine should be in the area of movement DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE model with no CTL accessory If you did not keep to the instructions you could damage the structure of the machine 30 03 00 MAGB CD CTL 35 45 50 95 68 Es 1 OMOSA 1 1 04 06 CF AN ATTENTION The CTL accessory cannot be removed from the machine and used separately actioned manually or following vehicles for the transport of loads or anyway for used different from the machine movements TRAILERS The machines provided for assembling the C
11. DATA The DSP 2x400 engine driven welder ia a unit which ensures the function as a a current source for arc welding b a current source for the auxiliary power generation It is meant for industrial and professional use powered by an endothermic engine it is composed of various main parts such as engine alternator electric and electronic controls the fairing or a protective structure The assembling is made on a steel structure on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise Technical data DSP 2x400 PSX GENERATOR Output three phase 40 KVA 400V 57 8A Output single phase 20 kVA 230V 87 Output single phase 5kVA 48V 104A Frequency 90 Hz Cos y 0 8 ALTERNATOR Self excited self regulated brushless Type three phase asynchronous Insulating class H ENGINE Mark Model PERKINS 1103C 33TG3 Type Cooling system Diesel 4 Stroke water Cylinders Displacement 3 3300 cm Net output 45 6 kW 62 HP Speed 1500 rpm Fuel consumption welding 60 6 7 I h Cooling system capacity 10 2 Engine oil capacity 7 9 Starter Electric GENERAL SPECIFICATIONS Battery 12V 100Ah Tank capacity 1021 Running time welding 60 15h Protection IP 44 Dimensions Lxwxh mm 2490x1030x1480 Weight 1300 Kg Measured acoustic power LwA pressure LpA 89 dB A 64 dB A 7 19 Guaranteed acoustic power LWA pressure LpA 90 dB A 65 dB A 7 m Dimensions and w
12. F intervening down the chopper and after a few minutes the LED will automatically switch off and there will be current voltage once again at the welding sockets 2 Temperature sensor situated on 2 Check chopper connector drawing 2 from pin 1 2 The resistor must be chopper NTC resistor short cir bigger than 1800 and less than 25 otherwise the led blinking cuited or open Replace the chopper In the meantime you can work cutting the wire which arrives to pin 1 pin 2 and put on it one resistor 10 In this case the thermic protection don t work but you can use the machine 3 WDC defective 3 Replace the WDC P5 Red LED always on 1 WDC defective 1 Switch off the machine and start it up again if the LED remains off try O E to weld verifying that the welding is regular ifthe LED lights up again Replace the WDC 2 Chopper defective 2 Check the chopper as shown on drawing 2 3 Current sensor defective 3 Replace the sensor P6 PHG1 remote does not 1 Remote control or cable defecti 1 Check the remote control as drawing 4 operate ve 2 WDC defective 2 Replace the WDC P7 The welding current is 1 Potentiometer on WDC defective 1 Check from pin 1 12 connector P4 pin 1 ground see drawing 3 always at max or always 2 WDC defective 2 Replace the WDC at minimum 3 Welding current sensor defective 3 Replace the current sensor P8 No voltage at the welding 1 Defective wire feeder cable 1 Check
13. No three phase voltage 1 Differential switch not inserted 1 Turn on the switch present at the socket s 2 Differential switch malfunction 2 Replace the switch P3 No single phase voltage 1 Intervention of thermal switch due 1 Push in the thermal switch to excessive current one socket but voltmeter reading is normal and 2 Thermal switch malfunction there is voltage on the 2 Replace the thermal switch other sockets P4 No voltage present 1 Short circuit present on the gene 1 Disconnect all outputs on the generator except for those on the con See problem P9 rator outputs densers and re start machine check for voltage on condensers MOTOR P1 Theengine does not start 1 Low battery voltage battery dead 1 Check the warning light state of the battery Green colour battery or stops immediately after or defective OK Black colour battery to be recharged White colour battery to be startup replaced DO NOT OPEN THE BATTERY 2 Presence of air in the fuel supply 2 Carry out de aeration on the fuel system See engine operating manual circuit 3 Circuit breaker engine protection 3 Insert the circuit breaker In case the problem persists check the electrical circuit and eliminate the problem Call an authorised service centre 4 See engine manual 4 Engine solenoid P2 Engine stops due to 1 Engine temperature too high or intervention of EP5 EP7 insuf
14. TL accessory slow towing trolley can be towed up to a maximum speed of 40 Kms hour on asphalted surfaces Towing on public roads or turnpikes of any type IS EXCLUDED because not in possesion of the requirements by national and foreign traffic norms Nota Lift the machine and assemble the parts as shown in the drawing CTL 35 50 ag A CTL 45 iosa I COMANDS p For assembling the generating set on the trolley CTL 35 45 50 95 please keep to following instructions 1 Liftthr generating set by means of suitable hook 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 5 the M10x20 screws and relative washers two per part so that their supports coincide CTL 45 95 8 Insert the wheel 9 on the axle then twist the selfblocking nut 8 9 Pump the tyre 9 bringing the pressure to 4 atms for the CTL 35 45 50 and 5 6 for the CTL 95 10 Lowerthe machine to the ground and place the parking foot definitively regulating at the best height ATTENTION Do not substituite the original tires with other types 30 03 04 M6GB MOSA REV 1 09 05 CD Set up for operation PW BATTERY WITHOUT MAINTENANCE Connect the cable positive to the pole positive of the battery after having taken away the protection by properly tightening the clamp Check the state of
15. a careful cleaning of the cooling system which is not an easy job A lack in tacking these precautions would result in the mix of different additives used in different coolants which would originate gelatinous substances capable of obstructing the cooling system Water cooled systems e GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a diffe rential switch circuit breaker In these groups the generator star point is generally connected to the machine s earthing by employing the TN or TT di stribution system the differential switch guarantees protection against indirect contacts In the case of powering complex installations re quiring or employing additional electrical protection devices the coordination between the protection devices must be verified For the grounding connection use the terminal 12 comply to local and or current regulations in force for electrical installations and safety 90 30 12 06 03 M20 R HO2 GB CD O ENGINE STARTING AND USE Check daily tHe AN NOTE MOSA REV 0 11 05 Do not alter the factory adjustment of the engine and do not touch the sealed parts 1500 1800 RPM ENGINES These engines start their normal operating speed IGNITION KEY The ingnition key is a part ofthe EP5 engine protection device and has three positions STARTING THE ENGINE Introduce the key Q1 tu
16. fan will help cool down the chopper more quickly After a few minutes the LED will automatically switch itself off and the welding voltage current will once again be available at the plugs 3 Red LED continuously lit If an anomalous current is detected in Q E the chopper the control blocks the conversion immediately the output welding current voltage goes to zero and the red LED lights up To reset everything it is necessary to switch off the machine If the protections 1 and 3 should intervene it is best to immediately contact the nearest authorised Service Centre DIGITAL INSTRUMENTS Optional available on request Two digital instruments showed the operating value of welding current and welding voltage 11 10 04 M33 WDC GB OSA Suse MOSA REV 1 01 08 CF WIRE FEEDER CONNECTED WITH REMOTE CONTROL CONNECTOR Wire feeder connection Connect the wire feeder to the welder with the welder turned off Welding cable between the machine s 9 welding plug and the wire feeder Welding cable between the machine s 10 welding plug and the piece to be welded Control power cable between the machine s connector X1 and the corresponding connector on the wire feeder Start the machine welder The ON LED will be off and will turn on only when there is voltage at the welding plugs and therefore at the wire The voltage is only present when the welding torch button is pressed The setting o
17. which could happen or anyway from that which was agreed when selling the machine MOSA excludes any responsibility for damages to the machine to the things or to persons in this case Our products are made in conformity with the safety norms in force for which it is advisable to use all these devices or information so that the use does not bring damage to persons or things While working it is advisable to keep to the personal safety norms in force in the countries to which the product is destined clothing work tools etc Do not modify for any motive parts of the machine fastenings holes electric or mechanical devices others if not duly authorized in writing by MOSA the responsibility coming from any potential intervention will fall on the executioner as in fact he becomes maker of the machine t Notice this manual does not engage MOSA who keeps the faculty apart the essential characteristics of the model here described and illustrated to bring betterments and modifications to parts and accessories without putting this manual uptodate immediately 10 10 02 M 1 1 GB ur G ce mark EN REV 4 10 07 Any of our product is labelled with CE marking attesting its conformity to appliable directives also the fulfillment of safety requirements of the product itself the list of these directives 15 part of the declaration of conformity included in any machine standard equ
18. 000 14 CE directive 28 11 05 88412 GB CD MOSA o DSP 2x400 PSX REV 0 11 05 TECHNICAL DATA C C WELDING Welding current 2x400A 35 2x360A 60 2x330A 100 Starting voltage 68V C V WELDING Welding current 2x360A 60 2x330A 100 Welding voltage 16 36V STATIC CHARACTERISTIC N 10 100 200 300 400 500 SIMULTANEOUS UTILIZATION FACTORS In case Welding and Generation can be used simultaneously however the engine cannot overloaded The table below gives the maximum limits to be respected WELDING CURRENT 400A 300A 200A 100A O 25kVA 30kVA 35 kVA 40 kVA 40 kVA aa 2x300A 2 200 2 100 0 DOUBLE POSITION 10kVA 20 kVA 30 kVA 40 kVA 40 kVA 28 11 05 88412 GB CD MOSA 1 0 11 99 SYMBOLS IN THIS MANUAL The symbols used in this manual are designed to call your attention to important aspects of the operation of the machine as well as potential hazards and dangers for persons and things IMPORTANT ADVICE Advice to the User about the safety r gt N B The information contained in the manual can changed without notice Potential damages caused in relation to the use of these instructions will not be considered because these are only indicative Remember that the non observance of the indications reported by us might cause damage to persons or things It is understood that local dispositions and or laws must be respe
19. 1 Abbiategrasso MI Unit Operative Via Valbrina 17 19 42045 Luzzara RE Viale Europa 59 20090 Cusago MI Italia E CONFORME ALLA NORMA IS IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2008 PER LE SEGUENTI ATTIVITA FOR THE FOLLOWING AC TIVITIES EA 18 Progettazione produzione ed assistenza di trattori macchine per agricoltura e manutenzione del verde motosaldatrici e gruppi elettrogeni Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets Data Emissione corrente Data di scadenza Current issue Expiring date 19 10 2010 05 03 2012 IM SPA First issue 30 05 1994 o ACCREDIA S The advantages for MOSA clients are Constant quality of products and services at thehigh level which the client expects Continuous efforts to improve the products andtheir performance at competitive conditions Competent support in the solution of problems Information and training in the correct applicatio nand use of the products to assure the security ofthe operator and protect the environment Regular inspections by ICIM to confirm that the requirements of the company s quality systemand ISO 9001 are being respected All these advantages are guaranteed by the CER TIFICATE OF QUALITY SYSTEM No 0192 issued by ICIM S p A Milano Italy www icim it 10 10 02 M01 GB CD G nex DSP 28400 PSX REV
20. 209718073 23 M766702068 FLANGIA PER TUBO SCARICO FLANGE FOR EXHAUST PIPE 24 M305012053 COPERCHIETTO CAP 25 M766707203 SCATOLA PROTEZIONE PRESE PROTECTION SOCKETS BOX 26 M840762058 PROTEZIONE TERMICA THERMAL PROTECTION 27 M1018130 ANELLO OR OR RING 28 M841658361 GHIERA PER COPERCHIO ERMETICO FLANGE FOR AIR TIGHT SEALED COVER 29 M841659358 ANELLO DOPPIO DOUBLE RING 30 M273119654 SCATOLA PROTEZ SCHEDA SALDATURA BOX PROTECTION PCB WELDER 31 M785109625 SCHEDA ALIMENTAZIONE DRIVE POWER SUPPLY PCB 32 M102302060 DISTANZIALE SPACER 33 M273119756 STAFFA SUPP SCHEDA BRACKET WELDER SUPPORT 18 11 05 88412 0000744500141 225101160 325501170 0000225100142 a gt 10 al ii PI I Pa UN I E gt ol 4 4 4 CTL 45 744500140 97 Gi a a I I I I I I I I I I I A I Y I I I I I I I I I I I 55 X E rM e 258 I I I AAA di I 1 I I mm mm mm mm 7 4 4 4 Ne AAA GR TIMONE PIEDE X TRAINO LENTO KIT SITE TOW ASSALE AXLE RUOTA WHEEL GR ASSALE RUOTE TRAINO LENTO KIT WHEELS AND HANDLES 13 11 03 KA
21. BO SCARICO OLIO Pos Rev Cod Descr Note 1 M766708065 COVER GRATE 2 M766708035 REAR COVER 3 M744501255 FUEL COVER 4 M6095030 PIPE 5 M305607032 COVER Up to REV 0 09 06 Del 106 09 14 10 09 5 M841657032 COVER From REV 1 02 11 Del 106 09 14 10 09 6 M342202026 CAP FUEL TANK 7 M740558073 TIE ROD 8 M840759975 FUEL LEVEL SENSOR 9 M105611550 VIBRATION DAMPER 10 M840761050 BASE 11 M764409150 BATTERY 12 M400409154 BATTERY BRACKET 13 M840762020 FUEL TANK 14 M784102070 EXHAUST PIPE 15 M784102069 GASKET 16 M766702241 SUPPORT FILTER 17 MJJ0062025 COCK 18 MJJ0062292 OLEODYNAMIC NIPPLE cO M744502212 OIL EXHAUST TUBE 18 11 05 88412 ED DSP 2x400 PSX 13 VRD Version S A o y uf GALE Ay 7 Ma v 9 47971 A 090 Y A gt 9990 AN JEY yA Sy ae TOS Y QA YY CE Tabla de recambios QD c N o LLI Pieces de rechanges CD Ricambi Spare parts MOSA REV 1 02 11 Tavola ricambi D Ersatzteile M O CA Spare parts table Tabla de recambios DSP 2x400 PSX REV 2 02 11 Table pi ces de rechange QD Pos Cod Descr Note 1 M766707070 FIANCATA DX COPERT SCAT ELETTR RIGHT SIDE ELECTRICAL BOX COVER 2 M785005400 PONTE CHOPPER CHOPPER BRIDGE Fino a Up to Del 06 09 26 01 09 2 M784115400 PONTE CHOPPER CHOPPER BRIDGE Da From Del 06 09 26 01 09 Fin
22. CARBURANTE CONTAORE 230V 50Hz IP65 UNITACONTROLLO MOTORE VOLTMETRO DI SALD 100V F S DC AMPEROMETRO DI SALD 600A 90mV SCATOLA ELETTRICA LATO MOTORE FRONTALE LATO GENERAZIONE SCATOLA ELETTR LATO GENERAZ PANNELLO PORTA PRESE SENSORE DI HALL 400A TRASFORMATORE PRESA DINSE Descr ENGINE SIDE FRONT PANEL THERMOPROTECTION B C WDC FRONT WDC FRONT LATCH X FRONT COVER CIRCUIT BREAKER 30A 250V TERMINAL 4mmq PLATE RELAY ELECTRIC START TERMINAL GUIDE TERMINAL BOARD EEC SOCKET 48V 32A SOCKET HOLDER PANEL WELDING SIDE EEC SOCKET 16 220V 2P T EEC SOCKET SINGLE PH 220V 2P T WELDING SOCKET WELDING SOCKET SHUNT EEC SOCKET THREE PHASE 380V GROUNDFAULT INTERRUPTOR VOLTMETER FRONT COVER LOCK ELECTRICAL BOARD KEY FUEL LEVEL GAUGE HOURMETER 230V 50Hz IP65 PCB ENGINE CONTROL EP5 WELDING VOLTMETER 100V DC RANGE BOTTOM WELDING AMMETER 600 A 90mV ELECTRICAL BOX ENGINE SIDE FRONT PANEL GENERATION SIDE ELECTRICAL BOX GENERATION SIDE SOCKETS HOLDER FRONT PANEL HALL SENSOR TRANSFORMER SOCKET CE Tabla de recambios DSP 2x400 PSX Note Fino a REV 0 09 06 Del 193 06 13 11 06 Da REV 1 11 06 Del 193 06 13 11 06 Note Up to REV 0 09 06 Del 193 06 13 11 06 From REV 1 11 06 Del 193 06 13 11 06 18 11 05 88412 DSP 2x400 PSX Tabla de recambios ND CD Ersatzteile Pieces de rechanges CD Ricambi Spare parts MOSA REV 0 09 06 7 7 7
23. DON EUEN S TN 9001191 7 OY 9191 8 JV orocorec 6H epeuos ejuniBBy Em gt lt o gt lt N a e CO Lf 9 52 01 OLN Id d LSS 5 4 T 12 11 O ICO CD Schema elettr 60 Stromlaufplan Electric diagram OSA REV 0 11 05 2 7788 50 11 81 QUOIZEZZIJO NE ens 22195 1219 e Ip oJ IAIp uoo ouBesip u s d jap p 1410446 e IS VSON 7 CIA LeO S eL N S9eJoda7 XSd 0072 J esou WWWJ dyu Ji peAo1ddV SUC JeuDiseq 6010080 01 AWLI IW OO9VS 2 06007 QU eJojeubesiq 002080 Bed ___ gt ESTO FARE em mE aw a Ed R 3 90029090 M 9 4 4 ul 4 1 4 5 y 90021 4 OY 91 8 JV 38 1 orozorse 6H 1eddauieAup epayos 2 lt o gt lt N a e ICO CD Schema elettr CD Stromlaufplan Electric diagram QUO OSA REV 0 11 05 QUOIZEZZIIOMNE ens 22099 1219 e 0 1031010003 ojer ip uoo oubesip ejuesejd jap 16110040 e abba Ip e ees IS WSOW 27 S00Z S0 80
24. DSP 2x400 PSX 884129003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG 28 11 05 88412M00 preparato da UPT approvato da DITE G DESCRIPTION OF THE MACHINE DSP 2x400 PSX 0 02 1 D DSP 2x400 PS PL Main Characteristics of the unit e Control of current with CHOPPER technology at high frequency e Digital control technique by means of DSP e Major productivity of 15 in comparison to welders with diode controls and controlled diodes e 5 Welding processes TIG contact start STICK arcforce 1 STICK arcforce 2 STICK arcforce 3 MIGMAG e Maximum welding current 2x400A e Polarity change optional e Voltmeter and Ammeter of weld e 40 kVA of power in three phase generation 400 V 50 Hz e Perkins diesel engine 1103C 33TG3 emissioned EURO 2 e Noise level at 7m 64 dBA e Dimensions weight 2490x1030x1480 1300 Kg M EFLER SS EMERGENCY I BATTERY A base assembled to a heavy roll bar gives solidity to the whole structure Accessibility to both engine chamber and electrical box is granted by four doors A hinged air inlet box also gives access to the welding chopper units Two Plexiglas windows inserted in the front doors allow to check welding parameters and to give access to welding current voltage control devices The maintenance free battery reduces checks on the state of charge to a minimum sarir a MOSA Quality system REV 3 02 09 THE INTERNATI
25. ION Access to non qualified personnel is prohibited in proximity of these areas the control panel front end the engine exhaust fumes the welding process This symbol regulation EN 60974 1 on safety requirements for arc welding apparatus indicates that the engine driven welder is suitable for use in environments with an increased risk of electrical shock WELDING CABLE CONNECTION Fully insert the welding cable plugs into the corresponding sockets turning them clockwise to lock them in position PUSH AND TWIST rs Make sure that the ground clamp whose cable must be connected to the or terminal depending on the type of electrode makes a good connection and is near to the welding position Pay attention to the two polarities of the welding circuit which must not come in electric contact between themselves 21 04 04 M32_DSP_GB CONTACT STARTING REMOTE CONTROL GETTING STARTED 1 After having prepared the machine charged the battery put in oil and fuel the machine 15 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 follow
26. NT In the storage operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place AO I 04 06 07 M45GB Have qualified personnel disassemble the machine and dispose of the parts including the oil fuel etc in a correct manner when it is to be taken out of service As cust off we intend all operations to be made at utilizer s care at the end of the use of the machine This comprises the dismantling of the machine the subdivision of the several components for a further reutilization or for getting rid of them the eventual packing and transportation of the eliminated parts up to their delivery to the store or to the bureau encharged to the cust off or to the storage office etc The several operations concerning the cust off invol ve the manipulation of fluids potentially dangerous such as lubricating oil and battery electrolyte The dismantling of metallic parts liable to cause injuries or wounds must be made wearing heavy gloves and using suitable tools The getting rid of the various components of the machine must be made accordingly to rules in force of law a o local rules Particular attention must be paid when getting rid of lubricating oils battery electrolyte and infla mable liquids such as fuel cooling liquid T
27. ONAL CERTIFICATION NETWORK CERTIFICATE IQNet and its partner hereby cel ARAGIM organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 1 220081 Abbiategrasso Ml Operative Units Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 1 20090 Cusago for the following field of activities z Design production and servicing of tractors agricultural green maintenance machines engine driven welders and generating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2008 Issued on 2010 10 19 Validity date 2012 03 05 Registration Number IT 3722 Gianrenzo Prati President of CISQ ANCE Mex APCER Po CCC Cyprus ublic Cro Cert Croatic DOS Holding GmbH Ge ny DS Denmari vela HKQAA Hong Ko ng Chin 1 ICONTEC C 6 nbi ia IMNC Mexico JQA Japar yos MSZT Hungary Nemko AS No NSAI Ireland sia SII Israel SIQ Slovenia SIRIM RAS Internatic al Ma sil ia 9 SOS Switzerland SRAC Romania TEST Russia TSE Turkey YUQS Ser sented in the U SA by AFNOR Ce rtific ation CISQ DQS Holding G sen and NSAI Inc alid at the time of issue of this certificate Updated information is available under www ignet certification co Michael Drechsel President of IONET IQNet Partners AENOR Spain AFNOR Certification France AIB Vingotte Internatio Belgiu CISQ t
28. aly CQC China CQM China COS Czech i din ELOT Greece FCAV Brazil OR A Ver Inspecta Certification Finland IRAM Arg PCBC Poland Quality Austria Austria RR Rus IQNet is The list of IQNet partner m w E2Net ICIM I ISO 9001 2008 Cert 0192 UNI EN ISO 9001 2008 MOSA has certified its quality system according to UNI EN ISO 9001 2008 to ensure a constant highquality of its products This certification covers thedesign production and servicing of engine dri venwelders and generating sets The certifying institute ICIM which is a member ofthe International Certification Network IQNet awarded the official approval to MOSA after an examination of its operations at the head office andplant in Cusago MI Italy This certification is not a point of arrival but a pledgeon the part of the entire company to maintain a levelof quality of both its products and services whichwill continue to satisfy the needs of its clients aswell as to improve the transparency and thecom munications regarding all the company s activesin accordance with the official procedures and inhar mony with the MOSA Manual of Quality CISQ is a member of ICIM CERTIFICATO n 0192 5 CERTIFICATE No SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER L DI WE HEREBY CERTIFY THAT THE QUALITY MANAGEMENT SY ST TEM OPERATED BY BCS S p A UNITA OPERATIVE OPERATIVE UNITS Sede e Unit Operativa Viale Mazzini 161 2008
29. anical parts electrical parts and of the fluids subject to use or consumption during the normal operation of the machine For what concerns the fluids we must consider as main tenance even the periodical change and or the refills eventually necessary Maintenance operations also include machine cleaning operations when carried out on a periodic basis outside of the normal work cycle The repairs cannot be considered among the main tenance activities i e the replacement of parts subject to occasional damages and the replacement of electric and mechanic components consumed in normal use by the Assistance Authorized Center as well as by MOSA The replacement of tires for machines equipped with trolleys must be considered as repair since it is not de livered as standard equipment any lifting system The periodic maintenance should be performed accor ding to the schedule shown in the engine manual An optional hour counter M is available to simplify the determination of the working hours N IMPORTANT In the maintenance operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place ENGINE and ALTERNATOR PLEASE REFER TO THE SPECIFIC MANUALS PROVIDED Every engine and alternator manufacturer has e Do not modify the components if not
30. authorized HOT surface can hurt you maintenance intervals and specific checks for each model it is necessary to consult the specific engine or alternator USER AND MAINTENANCE manual VENTILATION Make certain there are no obstructions rags leaves or other in the air inlet and outlet openings on the machine alternator and motor ELECTRICAL PANELS Check condition of cables and connections daily Clean periodically using a vacuum cleaner DO NOT USE COMPRESSED AIR DECALS AND LABELS warning and decals should be checked once a year and replaced if missing or unreadable STRENUOUS OPERATING CONDITIONS Under extreme operating conditions frequent stops and starts dusty environment cold weather extended periods of no load operation fuel with over 0 596 sulphur content do maintenance more frequently BATTERY WITHOUT MAINTENANCE DO NOT OPEN THE BATTERY The battery is charged automatically from the battery charger circuit suppplied with the engine Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced THE ENGINE PROTECTION NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHARGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 05 09 05 M43GB a AP STORAGE REV 0 06 07 In case the machine should not be use
31. cted WARNING Situations of danger no harm to persons or things Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine SYMBOLS AND SAFETY PRECAUTIONS GE_ MS_ TS_ SAFETY PRECAUTIONS N DANGEROUS This heading warns of an immediate danger for persons as well for things Not following the advice can result in serious injury or death N WARNING This heading warns of situations which could result in injury for persons or damage to things N CAUTION To this advice can appear a danger for persons as well as for things for which can appear situations bringing material damage to things N IMPORTANT NOTE N ATTENTION These headings refer to information which will assis you in the correct use of the machine and or accessories 26 11 99 M2GB CD MOSA REV 2 06 10 60 lt 00 60 STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE f the advice is not respected damage can happen to persons or things HIGH VOLTAGE Attention High Voltage There can be parts in voltage dangerous to touch The non observance of the advice impl
32. d for more than 30 days make sure that the room in which it is stored presents a suitable shelter from heat sources weather changes or anything which can cause rust corrosion or damages to the machine r gt Have qualified personnel prepare the machine for storage GASOLINE ENGINE Start the engine lt will run until it stops due to the lack of fuel Drain the oil from the engine sump and fill it with new oil see page M25 Pour about 10 cc of oil into the spark plug hole and screw the spark plug after having rotated the crankshaft several times Rotate the crankshaft slowly until you feel a certain com pression then leave it In case the battery for the electric start is assembled disconnect it Clean the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in o dry place DIESEL ENGINE For short periods of time it is advisable about every 10 days to make the machine work with load for 15 30 minutes for a correct distribution of the lubricant to re charge the battery and to prevent any possible bloking of the injection system For long periods of inactivity turn to the after soles service of the engine manufacturer Clean the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in a dry place In case of necessity for first aid and of fire prevention see page M2 5 N IMPORTA
33. ding current control knob to the cor rect current for the diameter and type of electrode being welded N ATTENTION REMOTE CONTROL RC2 PL Version RC2 90 PL Version ri 0 1 RANGE POLARITY T CURRENT CC INVERTER il rl O O MAX e hi 1 III III e n ri 1 50 PUSH AND SCREW TIGHT When the RC is not used it is necessary to disconnect the multipole connector 09 04 02 M38GB TROUBLE SHOOTING DSP 5 PROBLEM POSSIBLE CAUSE WHAT TO DO WELDING P1 All functions performed by 1 Position of regulation poten 1 Adjust the position of the WDC regulation knob on the potentiometer the WDC are regular but tiometer incorrect knob spindle so that the potentiometer is not completely at the end of its there is no tension on the travel when the knob reaches its minimum position Idem for the RC1 welding sockets remote control knob P2 Malfunction in the selec 1 WDC defective 1 Replace the WDC tion of welding processes or in their confirmation on other functions performed by the WDC P3 Blinking ON LED 1 Current sensor connector P3 1 Connector P3 not inserted or defective see drawing 5 2 Aux power voltage value 15V too high or too low 2 Check the aux trasformer see drawing 1 P4 Blinking red LED 1 The chopper thermic protection is 1 The outputis inhibited automatically let the motor continue to run to cool O
34. e declared rating and decrease if necessary Disconnect the loads and wait a few IP wp mE Ci In O CIRCUIT BREAKER WELDING DIGITAL CONTROL minutes to allow the thermal Ea protection to cool down Ad Before resetting by pressing the central button and then connect the load again If the protection should intervene again replace it with another one with matching intervention current specifications and or contact the Service Depart ment Note do not forcibly hold the central button of the thermal protection device to prevent its interven tion as this could irreparably damage the unit s alternator Note the three phase output does not require any protection against overcurrents since it uses a self protecting asynchronous type alternator GROUND FAULT INTERRUPTOR SWITCH The high sensitivity ground fault interruptor switch G F I 30mA D guarantees protection against indirect contacts due to faulty ground currents When the G F l switch picks up a faulty ground current that is higher than 30mA it inter venes by immediately cutting off voltage to the AC sockets In case of intervention by this protection device reset the switch by moving the lever to the ON position In case of another intervention verify that there are no faults in the tools connected or replace the G F l switch with another one of matching specifications and or contact the Service Department rs Notes Verify the ope
35. e 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 EXTINCTION MEANS 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 THE MACHINE MUST NOT BE USED IN AREAS WITH EX PLOSIVE ATMOSPHERE 10 06 00 M2 51 CD MOS amp PRECAUTION ENGINE DRIVEN WELDER GE_ MS_ TS_ AAA 1 0 03 00 INSTALLATION AND ADVICE BEFORE USE 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 15 in addition to the local security norms Estimate possible electromagnetic problems in the work area taking into account the following indications Telephonic wirings and or of communication check wirings and s
36. eight are inclusive of all parts without wheels and towbar POWER Declared power according to ISO 3046 1 temperature 25 C 30 relative humidity altitude 100 m above sea level It s admitted overload of 10 each hour every 12 h In an approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 ACOUSTIC POWER LEVEL ATTENTION The concrete risk due to the machine depends on the conditions in which it is used Therefore it is up to the end user and under his direct responsibility to make a correct evaluation of the same risk and to adopt specific precautions for instance adopting a 1 P D Individual Protection Device Acoustic Noise Level LWA Measure Unit dB A it stands for acoustic noise released in a certain delay of time This is not submitted to the distance of measurement Acoustic Pressure Lp Measure Unit dB A it measures the pressure originated by sound waves emission Its value changes in proportion to the distance of measurement The here below table shows examples of acoustic pressure Lp at different distances from a machine with Acoustic Noise Level LWA of 95 dB A Lp a 1 meter 95 dB A 8 dB A 87 dB A Lp a 7 meters 95 dB A 25 dB A 70 dB A Lp a 4 meters 95 dB A 20 dB A 75 dB A Lp a 10 meters 95 dB A 28 dB A 67 dB A PLEASE NOTE the symbol when with acoustic noise values indicates that the device respects noise emission limits according to 2
37. ement between pins 1 GND and 12 of connector P4 3 Turn the knob completely AKW and check thet the voltage is lt 0 5V 4 Turn the knob gradually KW and check that the voltage increases up to a value gt 4 5V at rotation stop the voltage shall increase in a regular way with the rotation 12 05 05 M40DSP EP5 ES_GB CDD G TROUBLE SHOOTING DSP EP5 EP7 ES REV 0 05 05 O H OG Ol BO OF CO 0 Put the on RC1 at minimum max put onmmeter from pin A B and measure the resistance Minimum 50 1000 Max 4 5 4 7 KO DRAWING 4 P1 Supply connector P2 Chopper connector P3 Current sensor connector P4 P5 Free DRAWING 5 12 05 05 MAODSP EP5 ES GB CD MAINTENANCE REV 0 06 10 Have qualified personnel do maintenance troubleshooting work e Stop the engine before doing any work inside the machine for any reason the machine must be operated while working inside pay attention moving parts hot parts exhaust manifold and muffler etc electrical parts which may be unprotected when the machine is open e Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete MOVING e Use suitable tools and clothes PARTS can injure See pag M1 1 NOTE By maintenance at care of the utilizer we intend all the operatios concerning the verification of mech
38. f the welding voltage is done using the knob on the wire feeder The adjusting knob on the welder is automatically inhibited POLARITY CURRENT CC INVERTER MAX REMOTE CONTROL A OB 10 OC JO H GO FO WELDING DIGITAL CONTROL A WARNING You can use the wire feeder only by respecting the pin configuration as shown on the below mentioned table WIRE FEEDER connected without remote control connector Welding voltage is always present on welding sockets and also VRD is active Welding cable between the machine s 9 welding plug and the wire feeder Welding cable between the machine s 10 welding plug and the piece to be welded The setting of the welding voltage is done by using the knob on the front panel NAME OF D CONTACT ESCRIPTION A electric ground ne potentiometer RC1 terminal a To potentiometer RC1 central b C 5 V d c To potentiometer RC1 terminal c C short circuit with contact E To switch Polarity Inverter F 5 V d c Close for negative polarity G Return from switch on CV welding gun 1 phase 44 48V a c H welding ground Welding ground for d c voltmeter on wire feeder 44 48V a c J 44 48V a c Voltage supply for wire feeder 11 10 04 M33_WDC_GB USE AS A GENERATOR It is strictly forbidden to connect the group to the public mains and or to any other source of electric power
39. ficient oil pressure ES 2 High temperature sensor or oil 1 Check oil level 2 Replace the malfunctioning sensor pressure defective 3 EP5 EP7 ES protection defective 3 Replace the protection P3 The battery is not 1 Battery charger alternator defecti 1 Replace charged ve 2 Battery charger warning light de 2 Replace fective P4 Forother problems refer to the attached engine manual 18 11 05 MA0DSP EP5 ES GB TROUBLE SHOOTING DSP 5 TEST CHECK THE FOLLOWING RESISTIVE VALUES OUTPUT 4g TPUT 10 Vca OUTPUT 46 Vea OUTPUT OUTPUT 25 vca ON THE CHOPPER CONNECTOR WIEW FROM INSERTION SIDE Check the resistive values between the following pairs of pins by means of an onmmeter Check the transformer in this way input 220 Vac output 18 Vac 25 Vac 10 Vac DRAWING 1 Connector P4 on WDC 0000000000000 0000000000000 DRAWING 3 DSP 400 CT 350 DSP 2x400 DSP 600 DSP 500 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 5 3 33 KO 5 1 8 25 5 In funzione della temperatura DRAWING 2 POTENTIOMETER TEST To check if the potentiometer of the WDC works correctly perform the following test 1 Start the welding machine and let it run at nominal r p m 2 Connect a multimeter set for VDC mea sur
40. he machine user is responsible for the observance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its components In case the machine should be cust off without any previous disassembly it is however compulsory to remove tank fuel engine lubricating oil cooling liquid from the engine battery NOTE BCS is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization In case of necessity for first aid and fire prevention see page M2 5 N IMPORTANT In the cust off operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place 04 06 07 M45GB MOSA REV 0 11 05 1300 CD Dimensioni CD Abmessungen Dimension 2490 2260 DSP 2x400 PSX 93 n 4 fori 216 18 11 05 88412 MOSA lt x N lt lt lt m O 7 m m 9 O gt gt CD CISA o ELECTRICAL SYSTEM LEGENDE 7 10 09 CF Alternator Wire connection unit Capacitor El Welding PCB transformer Fuse 400V 3 phase socket 230V 1phase socket 110V 1 phase socket Socket warning light Hour counter Voltmeter Welding arc regulator 230V 3 pha
41. ies life danger FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces If the advice is not respected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not respected there can be explosions WATER Danger of shortcircuit If the advice is not respected fires or damage to persons can be caused SMOKING The cigarette can cause fire or explosion If the advice is not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosions with damage to persons or things WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons PRESSION Danger of burns caused by the expulsion of hot liquids under pressure gt gt P gt A ACCES FORBIDDEN to non authorizad peaple SYMBOLS AND SAFETY PRECAUTIONS PROHIBITIONS harm for persons Use only with safety clothing ng It is compulsory to use the personal Man protection means given in equip ment Use only with safety clothing A It is compulsory to use the personal protection means given in equipment Use only with safety protections Itis a mustto use protection means suitable for the different welding works e with only safety material It is prohibited to use water to quench fire
42. ing instructions regarding the function of the various controls on the front panel OFF OS 2 Start the engine of the welder 3 Turn the welding current voltage adjusting knob to the minimum setting ARC FORCE CELLULOSE 1 CURRENT CC WELDING DIGITAL CONTROL CC STICK CELLULOSE 2 400A POLARITY INVERTER RANGE MAX E 50 SETTING THE WELDING PROCESS comer Ps STARTING TIG 1 sTAND BY There is a manual switch for selecting the various welding processes on the welding control panel There are 5 processes to choose from 1 for TIG welding 3 for STICK welding electrode 1 for MIG MAG welding continuous wire The switch can also be set to stand by first position In this position there is no current at the welding connections led ON off The process can be selected either before or after starting the motor powered welder After selecting the mode the ON LED lights up If the wirefeeder connector is connected on remote O control connector the ON LED lights only when Q the button torch is pressed 11 10 04 M33 W CD GB MOSA REV 1 01 08 CF TIG MODE Contact starting TIG This position is specifically for TIG welding To cre ate the arc simply place the tip of the TIG electrode on the piece that requires welding then gently move the tip away The arc starts automatically and at the same time the welding current rises to the
43. ipment Here below the adopted symbol CE marking 15 clearly readable and unerasable and it can be either part of the data plate A placed as a sticker near the data plate B Vle Europa 59 20090 CUSAGO ITALY e XJ JS SAN 0 ES LA tel 39 02903521 fax 39 0290390466 Vle Europa 59 20090 CUSAGO ITALY E http www mosait e mail infoemosait 0 ES AN t a 39 02903521 fax 39 0290390466 Made n UEATALY TYPE WwWw mosait e mail infoemosa it fie me NUO n ____ n JRPM nj RPM Pia ____ ___ Furthermore on each model it is shown the noise level value the symbol used is the following RIG es dB The indication is shown in a clear readable and indeleble way on a sticker 10 10 02 M1 4 GB Dichiarazione conformit D gt Konformitatserklarung SA GB Declaration of conformity E gt Declaraci n de conformidad REV 0 06 10 CF D claration de conformit ND BCS S p A Stabilimento di Cusago 20090 MI Italia V le Europa 59 Tel 39 02 903521 Via Marradi 1 20123 Milano Italia Fax 39 02 90390466 ISO 9001 2000 Cert 0192 Sede legale DICHIARAZIONE DI CONFORMITA D claration de Conformit Declaration of Conformity Konformitatserklarung Conformiteitsverklaring Declaraci n de Conformidad BCS S p A dichiara sotto la propria responsabilit che la macchina BCS S p A d cla
44. mable 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 clothers Mn 30 03 00 M2 5GB CD MOS A INSTALLATION AND ADVICE AA 2 2224 MOSA REV 1 06 07 INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature GASOLINE ENGINES Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area DIESEL ENGINES t Use in open space air swept or vent exhaust gases far from the work area t Make sure that the machine does not move during the work block it possibly with tools and or devices made to this purpose MOVES OF THE MACHINE t At any move check that the engine is off that there are no connections with cables which impede the moves PLACE OF THE MACHINE N ATTENTION For a safer use from the operator DO NOT fit the machine in locations with high risk E re gt of flood POSITION 4 Please do not use the machine i
45. mobile type diesel fuel for example For further details on the type of diesel fuel to use see the motor operating manual supplied Do not fill the tank completely leave a space of approx 10 mm between the fuel level and the wall of the tank to allow for expansion In rigid environmental temperature conditions use special winterized diesel fuels or specific additives in order to avoid the formation of paraffin 90 30 12 06 03 M20 R HO2 GB MOSA REV 1 02 11 CD Set up for operation COOLING LIQUID N ATTENTION Do not remove the radiator tap with the motor in operation or still hot as the liquid coolant may spurt out and cause serious burns Remove the tap very carefully A Remove the tap and pour the liquid coolant into the radiator the quantity and composition of the liquid coolant are indicated in the motor operating manual Replace the tap ensuring it is perfectly closed After refilling operations allow the motor to run for a brief time and check the level as it may have di minished due to air bubbles present in the cooling circuit restore the level with water To replace the liquid coolant follow the operations described in the motor operating manual ATTENTION The engine cooling system is originally filled with coolant type AGIP ANTIFREEZE EXTRA During the engine life it is strongly recommended to use the same coolant type This is because a coolant change would require
46. n weather Place the machine on a level surface at a distance of at 0 sti 9 conditions which are beyond IP protection least 1 5 m from buildings or other plants shown both in the data plate and on page named technical data in this same manual Maximum leaning of the machine in case of dislevel 10 A 20 max 10 26 11 99 M2 6GB I 21188 50 11 81 M1 4 A DSP 2x400 PSX n o S 5 lt N 2 c N amp I 0 O 9 o 27 O 65 o MOSA REV 1 09 08 CD 68 68 UNPACKING 0204 t Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s pack aging and conforms to local rules and regulations When receiving the goods make sure that the product has not suffered damage during the transport that there has not been rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or absence of parts envelopes manuals etc we advise you to inform immediately our Technical Service i iE THE For eliminating the packing materials the User must keep to the norms in force in his country 1 Take the machine C out of the shipment packing Take out of the envelope A the user s manual B 2 Read the user s manual
47. nd the rights connected to the creation and design for communication as provided by the laws in force in the matter In no case MOSA division of B C S S p A will be held responsible for any damaga direct or indirect in relation with the use of the given information MOSA division of B C S S p A does not take any responsibility about the shown information on firms or individuals but keeps the right to refuse services or information publication which it judges discutible unright or illegal GE MS TS EAS 10 10 02 M1 01 GB GE_ MS_ TS_ EAS INFORMATION Dear Customer We wish to thank you for having bought from MOSA a high quality set Our sections for Technical Service and Spare Parts will work at best to help you if it were necessary To this purpose we advise you for all control and overhaul operations to turn to the nearest authorized Service Centre where you will obtain a prompt and specialized intervention rs In case you do not profit on these Services and some parts are replaced please ask and be sure that are used exclusively original MOSA parts this to guarantee that the performances and the initial safety prescribed by the norms in force are re established ts The use of non original spare parts will cancel immediately any guarantee and Technical Ser vice obligation from MOSA NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively Follow the instructio
48. ns contained in it in this way you will avoid inconveniences due to negligence mistakes or incorrect maintenance The manual is for qualified personnel who knows the rules about safety and health installation and use of sets movable as well as fixed You must remember that in case you have difficulties for use or installation or others our Technical Service is always at your disposal for explanations or interventions The manual for Use Maintenance and Spare Parts is an integrant part of the product It must be kept with care during all the life of the product In case the machine and or the set should be yielded to another user this manual must also given to him Do not damage it do not take parts away do not tear pages and keep it in places protected from dampness and heat You must take into account that some figures contained in it want only to identify the described parts and therefore might not correspond to the machine in your possession INFORMATION OF GENERAL TYPE In the envelope given together with the machine and or set you will find the manual for Use Maintenance and Spare Parts the manual for use of the engine and the tools if included in the equipment the guarantee in the countries where itis prescribed by law Our products have been designed for the use of generation for welding electric and hydraulic system ANY OTHER DIFFERENT USE NOT INCLUDED IN THE ONE INDICATED relieves MOSA from the risks
49. o a Up to Del 52 09 20 04 09 2 M784135400 PONTE CHOPPER CHOPPER BRIDGE Da From Del 52 09 20 04 09 Fino a Up to REV 1 11 06 Del 118 10 27 09 10 2 M884125400 PONTE CHOPPER CHOPPER BRIDGE Da From REV 2 02 11 Del 118 10 27 09 10 3 M78610A725 RETE R C VRD RICAMBI R C NET VRD Solo versione VRD Only VRD version 4 M766708160 CASSONETTO INT ASPIRAZ COMPL INTAKE CASE COMPLETE 5 M744507219 PULSANTE STOP D EMERGENZA EMERGENCY PUSH BUTTON STOP 6 M784008005 CARENATURA ANTERIORE COMPL FRONT COVER COMPL 7 M784005091 STAFFA SUPPORTO PONTE DIODI SUPPORT BRACKET DIODE BRIDGE 8 M784007102 STAFFA SUPP SCATOLA ELETTRICA SUPPPORT BRACKET ELECTRIC BOX 9 M766707004 SCATOLA SUPP APPARECC ELETTR ELECTRICAL DEVICES HOLDING BOX 10 M840768091 CARENATURA SUPERIORE TOP COVER 11 M766708426 FIANCATA LATO STRUMEN COMPL INSTRUMENTS SIDE 12 M744508090 SQUADR FISS SCHERMO PORTELLA FIXING BRACKET DOOR SCREEN 13 M766708220 CASSONETTO ASPIRAZIONE ARIA AIR INTAKE BOX 14 M744508089 SCHERMO PER PORTELLA GLASS COVER 15 M744508426 FIANCATA LATO STRUMENTI COVER COMMANDS SIDE 16 M744508136 MANIGLIA A PULSANTE HANDLE 17 M744508428 FIANCATA INTERMEDIA MIDDLE COVER 18 M744508140 CERNIERA PER FIANCATA LATCH 19 M325252069 GUARNIZIONE GASKET 20 M840752050 SILENZIATORE DI SCARICO EXHAUST MUFFLER 21 M841658360 COPERCHIO ERMETICO RADIATOR COVER CAP Era was 766708070 22 M841659357 TIRANTE TIE ROD Era was
50. o on in the immediate vicinity Radio and television receptors and transmettors Computer and other checking devices Critical devices for safety and or for industrial checks Peapol who for instance use pace maker hearing aid for deaf or something and else Devices used for rating and measuring The immunity of other devices in the operation area of the welder Make sure that other used devices are compatible If it is the case provide other additional measures of protection The daily duration of the welding time IM po 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 not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes nsulate 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 glovers 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 refuelling areas Do not weld on easily fla
51. ools when fueling clothes Unscrew the cap slowly to let out the fuel vapours Always keep off leaning sur Slowly unscrew the cooling liquid tap if the liquid must be topped up faces during work operations BOARD The vapor and the heated cooling liquid under pressure can burn face eyes skin Static electricity can demage Do not fill tank completely the parts on the circuit Wipe up spilled fuel before starting engine Mi gens An electric shock can kill CHECKIN Shut off fuel of tank when moving machine where it is assembled Avoid spilling fuel on hot engine Sparks may cause the explosion of battery vapours or whatever event which may cause serious injuries or death predispose the first aid in accordance a FIRST AID In case the operator shold be sprayed by accident from corrosive liquids hot toxic gas 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 Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor Suction of liquids from If you suppose that vomit has entered the lungs as in case of spontaneous vomit take the subject to the lungs 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 r gt FIRE PREVENTION In case th
52. oster socket Open circuit voltage switch Stop push button Ignition coil Spark plug Range switch Oil shut down button Battery charge diode Relay Resistor Sparkler reactor Output power unit Electric siren E P 4 engine protection Engine control PCB R P M electronic regulator PTO HI control PCB PTO HI 20 l min push button PTO HI 30 l min push button PTO HI reset push button PTO HI 20 l min indicator PTO HI 30 l min indicator PTO HI reset indicator PTO HI 20 l min solenoid valve PTO HI 30 1 min solenoid valve Hydraulic oil pressure switch Hycraulic oil level gauge Preheating glow plugs Preheating gearbox Preheating indicator R C filter Heater with thermostat Choke solenoid Step relay Circuit breaker Battery charge sockets Sensor cooling liquid temperature Sensor air filter clogging Warning light air filter clogging Polarity inverter remote control Polarity inverter switch Transformer 230 48V Diode bridge polarity change Base current diode bridge PCB control unit polarity inverter Base current switch Auxiliary push button ON OFF Accelerator electronic control Actuator Pick up Warning light high temperature Commutator auxiliary power 24V diode bridge Y s commutator Emergency stop button Engine protection EP5 Pre heat push button Accelerator solenoid PCB Oil
53. preset value first using the welding current adjustment knob which is on the lower part of the control panel The welding current can be adjusted continuously from a minimum of 10 A to a maximum which depends on the power of the machine 400 A 500 A 600 A Ax WARNING For EP1 version it is compulsory to accelerate the engine manually STICK MODE Electrode Features C C Constant Current There are three stick modes which feature increasing arc forces so that the arc has different levels of penetration according to the electrode and or welding position MIG MAG MODE continuous wire Features C V Constant Voltage All wire type welding processes can be carried out naked or coated The voltage can be adjusted using the same knob which adjusts the current in STICK mode Adjustment is continuous and goes from a minimum of 15 V to a maximum of 36V 40 V Optional remote control The welding current can also be set from a distance using the optional remote control Once the remote control is connected to the connector X1 the current is controlled by the remote control To return to front panel control remove the connector Optional VRD program Voltage Reduction Device VRD When you choose the program stick or stick arc force the Open Circuit Voltage OCV go up red light switch ON and green light switch OFF bat only for about 3 than the OCV go down green light switch ON and red light switch OFF abo
54. pressure switch Water temperature switch Water heater Engine connector 24 poles Electronic 611 relais Release coil circuit breaker Oil pressure indicator Water temperature indicator Battery voltmeter Contactor polarity change Commutator switch series parallel Commutator switch Key switch on off QEA control unit Connector PAG Frequency rpm regulator Arc Force selector Device starting motor Fuel electro pump 12V c c Start Local Remote selector Choke button Switch CC CV Connector wire feeder 420V 110V 3 phase transformer Switch IDLE RUN Hz V A analogic instrument filter Wire feeder supply switch Wire feeder socket DSP chopper PCB Power chopper supply PCB Switch and leds PCB Hall sensor Water heather indicator Battery charge indicator Transfer pump selector AUT 0 MAN Fuel transfer pump GECO generating set test Flooting with level switches Voltmeter regulator WELD AUX switch Reactor 3 phase Switch disconnector Solenoid stop timer VODIA connector F EDC4 connector OFF ON DIAGN selector DIAGNOSTIC push button DIAGNOSTIC indicator Welding selector mode VRD load 230V 1 phase plug V Hz analogic instrument Engine protection EP6 G EI relay supply switch Radio remote control receiver Radio remote control trasnsmitter Isometer test push button
55. ration of the G F l switch atleast once a month by pressing the TEST button The generator must be running and the G F I lever in the ON position SIMULTANEOUS USE The welder s alternator permits the simultaneous use of auxiliary power and welding current The auxiliary power available to the AC plugs 15 di minishes as the welding current drawn increases The table on page M1 6 TECHNICAL SPECIFI CATIONS shows the amount of auxiliary power available as the welding current varies COMBINED USE The output available from the various auxiliary power sockets is limited not only by the declared output of the unit but also by the capacity of each individual socket m 09 04 02 M37DSP G MOS A o accessory USE REV 2 09 10 oo DEN n 1 RANGE POLARITY III 1 CURRENTCC INVERTER MAX 2T d o PUSH AND SCREW TIGHT The remote control RC which regulates the welding current in the CC STICK welding mode and the welding voltage in the CV MIG MAG welding is connected to the front panel by means of a multipole connector When the remote control is connected to the remote control connector 8 it is functional and automati cally excludes the front panel regulation The remote control can also be connected to the connector on the wire feeder front panel but in this case it is ne cessary to switch the wire feeder commutator so it can operate Adjust the wel
56. re sous sa propre responsabilit que la machine BCS S p A declares under its own responsibility that the machine BCS S p A erklart die Aggregate BCS S p A verklaard onder haar eigen verantwoordelijkheid dat de machine BCS S p A declara bajo su responsabilidad que la m quina GRUPPO ELETTROGENO DI SALDATURA WELDING GENERATOR GRUPPO ELETTROGENO POWER GENERATOR Marchio Brand Modello Model Matricola Serial number e conforme con qua est en conformit a conforms with the C mit den Vorschriften di in overeenkomst is m t de nhoud van gemeenschapsrichtliinemen gerelateerde modificaties comple con los requisitos de la Directiva Comunitaria y sus anexos 2006 42 CE 2006 95 CE 2004 108 CE Nome e indirizzo della persona autorizzata a costituire il fascicolo tecnico Nom et adresse de la personne autoris e composer le Dossier Technique Person authorized to compile the technical file and address Name und Adresse der zur Ausf llung der technischen Akten ermachtigten Person Persoon bevoegd om het technische document en bedrijf gegevens in te vullen Nombre y direcci n de la persona autorizada a componer el expediente t cnico ing Benso Marelli Amministratore Delegato CEO V le Europa 59 20090 Cusago MI Italy Cusago g Benso Marelli Amministratore Delegato CEO MM 083 0 04 06 10 M1 4 1 CD MOSA o DSP 2x400 PSX REV 3 02 11 TECHNICAL
57. rn it clockwise completely leaving it as soon as the engine starts NB forsafety reason the key must be kept by qualified personel Let the engine run for some minutes before drawing the load ENGINE PROTECTION EP5 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 tem perature 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 DSP 2x400 PSX DSP 600 PS PSX M5 1 yellow Fuel reserve M5 2 yellow Battery charge M5 3 red Overspe ed M5 4 red High tem perature M5 5 red Low oil pressure M5 6 green Protec tion unit on LOW OIL PRESSURE M5 5 In the event of low oil pressure the LED lights and the engine is shut down HIGH TEMPERATURE M5 4 If the water temperature is too high the LED lights and the engine is shut down OVERSPEED M5 3 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 FUEL RESERVE M5 1 If the fuel level reaches the reserve level the LED lights and the sirene sounds and the engine is shut down BATTERY CHARGE M5 2 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 i
58. s on the electric machines with inserted voltage It is prohibited to make interventions before having disinserted the voltage No smoking It is prohibited to smoke while filling the tank with fuel No welding It is forbidden to weld in rooms containing explosive gases ADVICE No harm for persons and things Use only with safety tools adapted to the specific use It is advisable to use tools adapted to the various maintenance works Use only with safety protections specifically suitable P Itis advisable to use protections suitable for the different welding works Use only with safety protections ws Itis advisable to use protections suitable for the different daily checking works Use only with safety protections it is advisable to use all protections while A shifting the machine Use only with safety protections It is advisable to use protections suitable for the different daily checking works and or of maintenance 26 11 99 M2 1GB CD MOS amp INSTALLATION AND ADVICE BEFORE USE GE MS TS A AAA AN 1 0 06 00 A The installation and the general advice concerning the operations are finalized to the correct use of the ma chine in the place where it is used as generator group and or welder Stop engine when fueling Do not touch electric devices if you are barefoot or with wet Do not smoke avoid flames sparks or electric t
59. s repaired STOP BUTTON The stop button can be used to stop the engine at any time Push and hold the button until the engine stops A CAUTION RUNNING IN During the first 50 hours of operation do not use more than 60 of the maximum output power of the unit and check the oil level frequently in any case please stick to the rules given in the engine use manual 10600 28 11 05 88412 GB MOSA REV 0 11 05 STOPPING THE ENGINE DSP 2x400 PSX DSP 600 PS PSX Before stopping the engine it is compulsory to disconnect or shut off any loads which are connec ted to the unit auxiliary outputs stop welding To stop the engine OFF NE ON N START Turn the starter key to the off position 28 11 05 88412 GB 71 Comandi 2 Bedienelemente 0 contos O DSP 2x400 PSX REV O 11 05 Commandes 0 OPTION V S 59C 86 V4 Descrizione Description Referenzliste Presa di saldatura Welding socket Prise de soudage Schweifsbuchse Presa di saldatura Welding socket Prise de soudage SchweiBbuchse Presa di messa a terra Earth terminal de mise terre Erdanschlu amp Presa di corrente in c a A C socket Prises de courant en c a Steckdose AC Protezione termica motore Engine thermal switch Protection thermique moteur Thermoschutz Motor Protezione termica corrente aux Aux current thermal switch Protection thermique courant aux Thermo
60. schutz Hilfsstrom Prot termica alim 42V trainafilo Supply thermal switch wire feeder Protection thermique alimenta Thermoschutz 42V Drahtvorschub 42V tion 42V fil Protezione termica elettropompa Fuel injection pump thermal Protection thermique lectro pompe Thermoschutz elektropumpe switch Indicatore livello combustibile Fuel level light Indicateur niveau carburant Anzeige Kraftstoffpegel Interruttore differenziale 30mA G F l Interrupteur diff rentiel Fl Schalter GFI Presa di corrente 48V c a 48V A C socket Prise de soudage 48V c a Steckdose 48V AC Contaore Hour counter Compte heures Stundenzahler Unit controllo motore EP5 Engine control unit 5 Protection moteur EP5 Motorschutz EP5 Voltmetro Voltmete Voltm tre Voltmeter Selettore modalit saldatura Welding selector mode S lecteur madalit soudage Schweissschalter Amperometro di saldatura Welding ammeter Amp rom tre de soudage Amperemeter SchweiBstrom Regolatore corrente di saldatura Welding current regulator R gulateur courant soudage Schweifsstromregler Voltmetro tensione saldatura Welding voltage voltmeter Voltm tre tension soudage Voltmeter Schwei amp spannung Comando invertitore di polarita Polarity inverter control Commande inverseur polarit Polwendeschalter Presa per comando a distanza Remote control socket Prise pour t l commande Steckdose Fernbedienung 18 11 05 88412 MOS o use As WELDER O MOSA 1 0 04 02 CF N ATTENT
61. se socket Welding control PCB Welding current ammeter Welding current regulator Current transformer Welding voltage voltmeter Welding sockets Shunt D C inductor Welding diode bridge Arc striking resistor Arc striking circuit 110V D C 48V D C diode bridge E P 1 engine protection Engine stop solenoid Acceleration solenoid Fuel level transmitter Oil or water thermostat 48V D C socket Oil pressure switch Fuel warning light Battery charge warning light Oil pressure warning light Fuse Starter key Starter motor Battery Battery charge alternator Battery charge voltage regulator Solenoid valve control PCBT Solenoid valve Remote control switch Remote control and or wire feeder socket Remote control plug Remote control welding regulator E P 2 engine protection Fuel level gauge Ammeter Frequency meter Battery charge trasformer Battery charge PCB Voltage selector switch 48V a c socket Thermal relay Contactor G EI and circuit breaker 42V EEC socket G FI resistor TE P engine protection Solenoid control PCBT Oil level transmitter Engine stop push button T C 1 Engine start push buttonT C 1 24V c a socket Thermal magnetic circuit breaker S C R protection unit Remote control socket Remote control plug Insulation moitoring E A S connector E A S PCB Bo
62. st only 14 12 986Q16M31 22 03 00 R1GB MOSA REV 1 02 11 CD Ricambi Spare parts Pieces de rechanges Ersatzteile Tabla de recambios 60 DSP 2x400 PSX E E lt 5 18 11 05 88412 DSP 2x400 PSX Note Fino a REV 04 08 Del 5 08 16 01 08 Da REV 09 08 Del 5 08 16 01 08 Fino a REV 04 08 Del 252 07 14 11 07 Da REV 04 08 Del 252 07 14 11 07 Era 282004100 Note Up to REV 04 08 Del 5 08 16 01 08 From REV 09 08 Del 5 08 16 01 08 Up to REV 04 08 Del 252 07 14 11 07 From REV 04 08 Del 252 07 14 11 07 Tavola ricambi D Ersatzteile O CA Spare parts table Tabla de recambios REV 3 02 11 Table pi ces de rechange QD Pos Rev Cod Descr 1 M107301390 ANELLO 2 M107601470 VENTOLA COMPLETA 3 M308306010 CONVOGLIATORE ARIA ALTERNATORE 4 M784008222 COPERTURA ALTERNATORE 5 766703010 CARCASSA PER STATORE 6 M784003020 STATORE 7 6050050 ANELLO SEEGER 8 M1001050 CUSCINETTO 9 M766703030 ALBERO CON ROTORE COMPLETO 10 M740552200 MOTORE PERKINS 1103A 33TG1 10 M840562200 MOTORE PERKINS 1103C 33TG3 11 M765008224 STAFFA SUPPORTO COPERTURA ALT 12 M323003101 TRAVERSA ALTERNATORE COMPL 12 M884123101 TRAVERSA ALTERNATORE COMPL 13 M744508430 TRAVERSA UNIONE FIANCATE 14 M744501060 TRAVERSA DI SOLLEVAMENTO 15 M840768215 PARETE SCARICO ARIA MOTORE 16 M784104126 LAMIERA PORTA REATTORE 22 M209719882 STAFFA BOX CONDENSATORI 23 M107509041 SBARRETTA BOX CONDENSATORI
63. the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY LUBRICANT RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products Please refer to the motor operating manual for the recommended viscosity REFUELLING AND CONTROL Carry out refuelling and controls with motor at level position 1 Remove the oil fill tap 24 2 Pour oil and replace the tap 3 Check the oil level using the dipstick 23 the oil level must be comprised between the minimum and maximum indicators N ATTENTION It is dangerous to fill the motor with too much oil as its combustion can provoke a sudden increase in rotation speed Water cooled systems AIR FILTER Y Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered air to the inside of the motor Hy FUEL Do not smoke or use open flames during refuelling operations in order to avoid explosions or fire hazards Fuel fumes are highly toxic carry out operations outdoors only or in a well ventilated environment Avoid accidentally spilling fuel Clean any eventual leaks before starting up motor Refill the tank with good quality diesel fuel such as auto
64. the connections pin to pin of the wire sockets in CV mode 2 Defective wire feeder 2 Check the wire feeder 3 Defective WDC 3 Without wire feeder cable put the pin in short circuit with G on remote control connector the led ON must be light WDC ok otherwise change WDC P9 No welding or generation 1 Short circuit of chopper 1 Disconnect the chopper and re start the machine if there is now an output output present replace the chopper 2 Short circuit of generation unit 2 Disconnect the auxiliary output circuit and re start the machine if there is now an output present there is a short circuit in the auxiliary output circuit or in one of the components 3 Alternator defective 3 Disconnect all outputs on the alternator welding and generation unless the output going to the condensers and check the capacity of the condensers Restart the machine if there is still no output replace the alternator 12 05 05 4005 5 GB TROUBLE SHOOTING DSP 5 PROBLEM POSSIBLE CAUSE WHAT TO DO WELDING WITH V R D P10 The welding tension after 1 Net R C defective or disconnected 1 Check the net R C Check the connections 3 sec isn t less enough from or welding socket plus in 12V dc 2 WDC defective 2 Replace the WDC GENERETING P1 Voltmeter shows no volta 1 Voltmeter malfunction 1 Replace the voltmeter ge or low voltage but ac tual voltage at the sockets is OK P2
65. ut 11V and stop there until the welder start welding When you make a short circuit with the stick the OCV immediately go up so you can start to welding WELDING DIGITAL CONTROL Inversion of polarity Optional available on request In order to invert polarity press the switch on the remote control unit By selecting inversion the ON LED switches off and the voltage at the welding socket becomes zero The power contactor is witched inside the electrical box and the voltage reappears at the welding sockets The ON LED switches back on at the same time The Invert polarity LED on the front panel near the welding current adjuster switches on You cannot invert polarity in MIG MAG mode PROTECTIONS The Welding Digital Control features 3 protections for the control and chopper 1 ON LED blinking Q ON When the engine of the welder is started the control unit automatically goes to the stand by mode for few istants stand by LED on and performs a self diagnosis of the current sensor connector and power source voltage 15V than the last process is loaded on led turned ON In case of malfunction the ON LED blinks 2 Red LED blinking The chopper has a thermal protection Q which intervenes in case the operating temperature exceeds 85 C If the protection intervenes the red LED begins to flash and the welding current voltage goes to zero In this case do not switch off the welder since the alternator

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