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TS 400 PS

1. _iddy sq wed E JOH LNOO 31038 TS 400 PS BC TS 500 PS BC O A c O vv go 5 ES UY QD CD Schema elettrico Electric diagram REV 0 04 05 CF Schemas electriques MOSA MOSA 0779 SO VO CV euoizezzuojne ens ezues 219 e o OJINPoO IdL Ip uoo ouBesip ejueseud Ip e IS WSOW 7 eoeJode ld Sd00rPSL J esoUrMWwWJ dyu leuBiseq ebeqo ATVLI IN OOYSNI 06007 eojeubesiq Bed gt Ads ebeg ou Ip ed F 3 L0OW3H TS 400 PS PL TS 500 PS PL BL OZ K 2 Y 5 7 19002 E o dy c O A ge 5 ES lt UY LL QD CD Schema elettrico Electric diagram OL LL REV 0 04 05 Schemas electriques MOSA MOSA 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 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 sp
2. 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 ny DS Denmari k vela HKQAA Hong Ko ng Chin 1 ICONTEC C 6 nbi ia IMNC Mexico JQA Japar cee MSZT Hungary Nemko AS No NSAI Ireland sia SII Israel SIQ Slovenia SIRIM RAS Internatic al Ma si ia 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 onal Belgiu CISQ Italy CQC China CQM China COS Czech i din ELOT Greece Brazil OR A Ver Inspecta Certification Finland IRAM Arg PCBC Poland Quality Austria Austria RR Rus IQNet is The list of IQNet partner amp m w E2Net ICIM I ISO 9001 2008 Cert 0192 UNI EN ISO 90
3. E A S connector Exclusion indicating light PTO HI Auxiliary current push button Fuel level light E A S PCB Control unit for generating sets QEA Ground fault interrupter 30 mA Engine control unit and economiser EP1 Ammeter Frequency meter Fuse Stop switch Warning light high temperature Arc Force selector Fuel level transmitter Voltage commutator Fuel electro pump Engine control unit EP7 48V A C socket Welding scale switch Preheating indicator Y A switch Start Local Remote selector AUTOIDLE switch A C output indicator Emergency button Choke button Hour counter Warning level light Contactor Engine control unit 5 CC CV switch Voltmeter Battery charge warning light Thermal magnetic circuit breaker Ground fault interrupter Pre heat push button Connector wire feader Oil pressure warning light Oil alert Welding arc regulator Starter key Derivation box Battery charge sockets Welding selector mode Siren Welding ammeter Battery Engine control unit EP4 Wire feeder supply switch Plug 230V singlephase Welding current regulator Dirty air filter warning light indicator Earth leakage relay Analogic instrument V Hz Current trasformer R P M adjuster Polarity inverter remote control Relase coil Engine control unit EP6 Welding voltage voltmeter Polarity inverter control Oil pressure indicator Remote control switch Selection push button 30 1 1 PTO HI Battery vo
4. qm Note Up to REV 0 04 05 Del 90 08 08 05 08 From REV 1 06 08 Del 90 08 08 05 08 Up to REV 0 04 05 Del 90 08 08 05 08 From REV 1 06 08 Del 90 08 08 05 08 qm qm 12 04 05 76440 Ricambi Ersatzteile M O SA GB Spare parts CE Tabla de recambios TS 400 PS OMOSA REV0 0405 CF Pi ces de rechange TS 500 PS 10 31 PL Version 31a 30 13 PL Version 29 14 20 PL Version 28a 15 27 16 50Hz 16a 60Hz 26 25 24 23 22 21 20 19 14 17 PL Version 34 35 36 37 38 42 50Hz 42 60Hz 12 04 05 76440 MOSA O MOSA Pos Rev Cod 00 CON O M107509702 M836709715 M0000836709701 M219937130 M105111540 M219937036 M325507210 M1302040 M1302500 M352007109 107517032 307017240 101131220 764407020 873407107 1302080 1302510 M105511810 M205187330 M155307107 M1243020 307047250 105111530 105111520 105111510 105111550 282009741 282009962 307759045 1291250 76440 042 M76446C042 M317809911 M102042740 M102013290 M107509902 M1241010 M764407205 M102301310 M102044400 M764407010 M744507219 M107509041 M209719882 M107509870 M700409860 M307809880 M105319880 M105111830 M209719850 M282009807 866707220 208019800 M0000866817420 MED0109870 M366609690 M307709800 M317807212 CD Ricambi Spare parts REV 1 06 08 Pieces de rechange CD Ersatzteile CE Tabla de recambios TS 40
5. 4c 0 YN YN For CD Schema elettrico Electric diagram REV 0 04 05 CF Schemas electriques AINO MOSA MOSA 0779 SO VO Cl ads ens ezues IZI9 e uoo ejueseJd ejyeudoud ip e IS WSOW 7 e e1ode Id Sd 007 SL esourwww dnu seubiseg SUIYIEN sS o ATV I IW OSVSnO 0600Z Bed eJoyeubesi JOMOd MES o uoneuriuuoueg Te oU IP_ U E euoizeuiuoueq Bea eq addy ised ejeq TS 400 PS PL TS 500 PS PL O E de c O A go 5 ES UY LL QD TOY o Y DX CD Schema elettrico Electric diagram REV 0 04 05 CF Schemas electriques MOSA MOSA 90 70 21 euorzezzuojne ens ezues 210 e o ojunpoidu uoo ouBesip ejueseud eyeudoud Ip IS VSON 81 0 70 5 07792 0020 5 esejoda7 98 Sd 00 SL esourwww dpnu Bug Jeubiseq ebed oL AWLIIW OSVSND 06002 eJojeuDesiq Beg ei e S sr 75 0 3oefoJd ou Ip euoizeuiwoueg eq Iddy se oye
6. M SA Installation OMOSA REVO 06 08 CF Installation CDD Luftzirkulation Instalaci n QD TS 400 PS TS 500 PS 12 04 05 76440 CD 68 GD UNPACKING 0204 CF 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 TE 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 B the plates fixed on the machine the data plate A e O I e CD E TRANSPORT AND DISPLACEMENTS COVERED UNITS REV 1 06 10 A NOTE Transportation must always take place with the engine off electrical cables and starting battery disconnected and 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
7. M6050050 M1001050 M764403030 M773713012 M764402200 M764412200 M764422200 M764432200 M841562212 M364108224 M307803101 M107509005 M105112270 M764408066 Cod M107301390 M765006020 M307806010 M282008222 M764403010 M764403020 M764423020 M6050050 M1001050 M764403030 M773713012 M764402200 M764412200 M764422200 M764422200 M841562212 M364108224 M307803101 M107509005 M105112270 M764408066 ANELLO VENTOLA PER GENERATORE CONVOGLIATORE GENERATORE COPERTURA ALTERNATORE CARCASSA STATORE STATORE AVV 400T230M110M CTE 50Hz STATORE AVV 400T230M110M CTE 60Hz ANELLO SEEGER CUSCINETTO ALBERO ROTORE DISCO ALBERO ROTORE MOTORE PERKINS 404C 22G 50Hz MOTORE PERKINS 404D 22G 50Hz MOTORE PERKINS 404C 22G 60Hz MOTORE PERKINS 404D 22G 60Hz TUBO SCARICO OLIO STAFFA TRAVERSA ALTERNATORE GUARNIZIONE GUARNIZIONE L MT 1 CORNICE RADIATORE Descr RING FIXING FAN ALTERNATOR FAN GENERATOR CONVEYOR COVER ALTERNATOR HOUSING STATOR STATOR 400T230M110M CTE 50Hz STATOR 400T230M110M CTE 60Hz RING SEEGER BEARING SHAFT WITH ROTOR SHAFT WITH ROTOR DISC PERKINS ENGINE 404C 22G 50Hz PERKINS ENGINE 404D 22G 50Hz PERKINS ENGINE 404C 22G 60Hz PERKINS ENGINE 404D 22G 60Hz OIL EXHAUST TUBE BRACKET ALTERNATOR BRACKET GASKET STRIP SEALING L MT 1 RADIATOR FRAME Fino a REV 0 04 05 Del 90 08 08 05 08 Da REV 1 06 08 Del 90 08 08 05 08 Fino a REV 0 04 05 Del 90 08 08 05 08 Da REV 1 06 08 Del 90 08 08 05 08 qm
8. MOSA CONTROLS LEGENDE REV 1 10 07 CF Hydraulic oil level light Welding socket Welding socket Earth terminal A C socket Accelerator lever Feed pump 48V D C socket Engine air filter Oil level dipstick Engine oil reservoir cap Hydraulic oil reservoir cap Water filling cap Fuel prefilter Fuel tank cap Muffler Stop control Engine protection cover Engine cooling alternator fan belt Oil drain tap Hydraulic oil drain tap Water drain tap Exhaust tap for tank fuel Button Start button Booster socket 12V Booster socket 24V Battery charge fuse opace for remote control Remote control opace for E A S opace for PAC Fuel pump Electric start socket Reset button PTO HI Quick coupling m PTO HI Quick coupling f PTO HI Hydraulic oil filter Battery charger thermal switch Engine thermal switch Aux current thermal switch Supply thermal switch wire feeder 42V Pre heater spark plug thermal switch Supply thermal switch oil water heather Electropump thermal switch No load voltage control Choke control Auxiliary welding current control Cellulosic electrodes control Voltmeter relay Warning lights Selecting knob Load commut push button Starting push button Operating mode selector Power on warning light Display Wire connection unit Selector Setting confirmation Fuel valve Oil syringe Insulation monitoring Button indicating light 30 I 1 PTO HI Engine control unit EP2
9. V OUTPUT CARACTERISTIC 80 75 BC ARC FORCE WITH BASE CURRENT 50 100 150 200 250 300 350 400 450 SIMULTANEOUS UTILIZATION FACTORS In case Welding and Generation can be used simultaneously however the engine cannot be overloaded The table below gives the maximum limits to be respected WELDING CURRENT gt 250 200A 150A 100A 24 AUXILIARY POWER 2 4kVA 7 5kVA 10 kVA 16 kVA 19 05 05 76440 GB CD MOSA 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 respected 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 us
10. C2 Fuel level gauge D2 Ammeter E2 Frequency meter F2 Battery charge trasformer G2 Battery charge PCB H2 Voltage selector switch 12 48V a c socket L2 Thermal relay M2 Contactor N2 G F l and circuit breaker 02 42V EEC socket P2 G F l resistor Q2 T E P engine protection R2 Solenoid control PCBT 92 Oil level transmitter T2 Engine stop push button T C 1 U2 Engine start push buttonT C 1 V2 24V c a socket Z2 Thermal magnetic circuit breaker W2 S C R protection unit X2 Remote control socket Y2 Remote control plug X5 Y5 Insulation moitoring E A S connector E A S PCB Booster 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 l 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 c
11. GASKET ENGINE EXHAUST 403C 15G 10 M764402070 EXHAUST TUBE 11 M305232071 GASKET X FAN 12 M764402050 EXHAUST MUFFLER 13 M764412050 EXHAUST SILENCER FOR SPARK ARRESTOR Spark arrestor version 14 M764412093 ARREST BRACKET EXHAUST PIPE Spark arrestor version 15 M764412078 CONNECTOR EXHAUST PIPE SILENCER Spark arrestor version 16 M366105091 RECTIFIER ASSY BRACKET 17 M309014013 SPACER 18 M309015043 WASHER 19 M766704010 POWER RESISTANCE 20 M317805100 DIODE BRIDGE 21 M873769895 WIRED RESISTOR PL Version 22 M366104118 REACTANCE BRACKET 29 366104110 REACTANCE SUPPORT BRACKET 24 M364124100 REACTANCE 12 04 05 76440 0779 S0 70 lt L TS 400 PS TS 500 PS 8 qm 5 4 ey EAA Y im Nm o 10 qm Y A CS M A NO x MES T A 55 DNA L O QNS Y s E NO CW x ND DS 4 CN 2 Wi gt WK a LIN EN LANNY V V TOS AL ANNAN GV AAT 2 N 2 PIA W S ED SDN x a 9 MX d o gt e x bp CT IIS Sq CD Ersatzteile d 11 CED Tabla de recambios A N YV ES ihe gt Sa Spare parts REV 1 09 10 CE Pieces de rechange CD Ricambi lt lt c gt Ricambi CD Ersatzteile M O CA Spare parts CED Tabla de recambios TS 400 PS OMOSA REV1 09 10 CF Pi ces de rechange WD TS 500 PS Pos Rev Cod Des
12. 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 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 L
13. 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 amp INSTALLATION AND ADVICE BEFORE USE GE MS TS p COGN AN MOSA 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 tools 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 O Static electricity can dema
14. current If not the diode bridge is defective If there is welding current connect the auxiliary power leads one ata time until there is no output at this point the short circuit is in that line GENERETING P1 Voltmeter shows no voltage or low 1 Voltmeter malfunction 1 Replace the voltmeter voltage but actual voltage at the sockets is OK P2 No three phase voltage present 1 Differential switch not inserted 1 Turn on the differential switch at the socket s but voltmeter 2 Differential switch malfunction 2 Replace the differential switch reading is normal and there is voltage on the other sockets No single phase voltage one sok 1 Intervention of thermal switch due 1 Push in the thermal switch ket but voltmeter reading is normal to excessive current and there is voltage on the other 2 Thermal switch malfunction 2 Replace the thermal switch sockets P4 No voltage present 1 Short circuit present on the genera 1 Disconnect all outputs on the generator except for those on the tor outputs condensers and re start machine check for voltage on conden Sers 19 05 05 76440 GB CD LISA Trouble shooting TS 400 500 600 PS REV 2 12 11 Solution P1 The engine does not start or stops 1 Low battery voltage battery dead 1 Check the warning light state of the battery Green colour immediately after startup or defective battery OK Black colour battery to be recharged White
15. 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 instructions contained in it in this way you will av
16. gt 9 10 SPARK ARRESTOR Q 12 04 05 76440 15 1114 13 11 Ricambi Ersatzteile M O CA 68 Spare parts CED Tabla de recambios TS 400 PS MOSA 0 0405 rechange QD TS 500 PS Pos Rev Cod Descr Note 1 M105612070 ANTIVIBRANTE 40x50 2 M764409975 SENSORE LIVELLO CARBURANTE 3 M308101262 TAPPO SCARICO SERBATOIO 4 M308102023 GUARNIZIONE 5 M317801035 ANTIVIBRANTE D 70x45 F M12 6 M342202026 TAPPO SERBATOIO 7 107509890 SHUNT DI MISURA 8 M366105090 PONTE DI BASE 9 M841562071 GUARN SCARICO MOTORE 403C 15G 10 M764402070 TUBO DI SCARICO 11 M305232071 GUARNIZIONE PER FLANGIA 12 M764402050 SILENZIATORE SCARICO 13 M764412050 SIL SCARICO PER PARASCINTILLE Spark arrestor version 14 M764412093 SQUADRETTA BLOCC TUBO SCARICO Spark arrestor version 15 764412078 RACCORDO TUBO SILENZ SCARICO Spark arrestor version 16 M366105091 STAFFA 17 M309014013 DISTANZIALE 18 M309015043 RONDELLA 19 M766704010 RESISTORE DI POTENZA 20 M317805100 PONTE DIODI 21 M873769895 RESISTENZA CABLATA PL Version 22 366104118 SQUADRETTA FISSAGGIO REATTORE 23 366104110 STAFFA SUPPORTO REATTORE 24 364124100 REATTORE DI LIVELLO Pos Rev Cod Descr Note 1 M105612070 VIBRATION DAMPER 40x50 2 M764409975 FUEL LEVEL SENSOR 3 M308101262 FUEL TANK CAP 4 M308102023 GASKET 5 317801035 VIBRANTION DAMPER D 70x45 F M12 6 M342202026 CAP FUEL TANK 7 107509890 5 8 M366105090 BASE CURRENT BRIDGE 9 M841562071
17. 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 S p A Milano Italy www icim it 10 10 02 M01 GB lt O Q gt O lt N lt lt lt IS IN DUI M 2 7 M 3 4 6 3 M 20 21 31 32 34 37 40 43 44 1 45 M 46 M 53 M 55 M 60 M 61 R 1 FO TS 400 PS TS 500 PS QUALITY SYSTEM COPYRIGHT NOTES CE MA
18. uoneuiuoue Ulp ubed euoizeuluuoue Jd aye O s wd O VDO HY 7 98002206 CECO TS 500 PS 92 ce I I I I I Fr i E I Lon 1 2 8 9 L Z00vYNL o SD 5 5 000 YN Gn e D 5 L o 5 o 4 i ES 1 E CE 1 of 2 o E o qu o 9 o 9 vis v Y 104 OV 6L ZL O I 000 y I I I 440 I I e cdl cicli 6 DI LI LL 10 y O MOSA MOSA 92 SO VO CV euorzezzuojne ens ezues 129 e o ojunpoudu ojeiup uoo ouBesip ejueseud eyeudoud Ip e IS VSON 87 ae OZO S OPr9 4 0020 5 e0e10de7 98 Sd 007 SLI esotu www diu aaide euuoew ebeqo ATYLIIN OOYSNI 06007 U SI eJojeuBesiq euigooew Bed 2x3L9011 W0 z 1001 xnv N Y E 0 W euopeuluoued Bed ed Iddy Ise eje UOneoyipo a sd ee Ed TS 400 PS TS 500 PS 4007230 110 9 E n 086 V A00F VZ N0LL o dy lt O A go 5 ES UY LL QD CD Schema elettrico Electric diagram REV 0 04 05 Schemas el
19. with the warning light of high temperature or low oil pressure In case of low oil pressure check the level and if it is correct call the Service Station In case of high temperature make sure that there are no leaves and or pieces of material obstructing the air ducts rs N B if the unit is used as a generator in hot climates and with loads near to the maximum the protection device can be triggered off please reduce the load of the engine Once the cause of the problem is removed to reset the protection it is enough to report the ignition key Q1 on OFF position and start the engine again J M k lai High temperature 4 SZ Low oil pressure THE ENGINE PROTECTIONS DO NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHANGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 07 05 01 M39GB Trouble shooting TS 400 500 600 PS Solution WELDING P1 No welding current but auxiliary 1 Position of remote control switch 1 Check that it is in OFF position if there is no remote control or in output is OK ON position with remote control inserted 2 Potentiometer defect in welding 2 Check the continuity of the welding potentiometer and relative current control connections 3 Welding current signal interrupter 3 Check that cables from shunt to card are in perfect state 4 Defect card 4 Replace card 5 Defect in di
20. 0 PS QD TS 500 PS Descr Note MANOPOLA REG CORRENTE SALDAT KNOB WELDING CURRENT REGULAT GR POTENZIOMETRO WELDING CURRENT REGULATOR GR POTENZIOMETRO COMPL WELDING CURRENT REGULATOR COMPL COPERCHIO INTERRUT DIFFERENZ COVER GFI Vedi Cod See part no 219937105 STAFFA BRACKET INDICATORE LIVELLO CARBURANTE FUEL LEVEL GAUGE SPIA ROSSA RED WARNING LIGHT 12V SPIA ROSSA RED WARNING LIGHT 12V PROTEZIONE TERMICA THERMOPROTECTION 5A Fino a REV 0 04 05 Del 57 08 10 03 08 Da REV 1 06 08 Del 57 08 10 03 08 COPERCHIO PRESE BLIND PLATE SOCKETS 48V 400T230M48M Version PRESA EEC SOCKET 16A 220V 2P T 400T230M48M Version PRESA DINSE SOCKET 400T230M48M Version PANNELLO FRONTALE sup FRONT PANEL DISGIUNTORE TERMICO CIRCUIT BREAKER 30A 250V SPIA PER WARNING LIGHT FOR 48V SPIA PER WARNING LIGHT FOR 48V CONTAORE HOURMETER 230 50Hz IP65 CONTAORE HOURMETER 60HZ DISGIUNTORE TERMICO THERMAL SWITCH 15A 250V GUIDA PER MORSETTIERA TERMINAL GUIDE PRESA CEE EEC SOCKET 110V 16A2 P T PRESA CEE EEC SOCKET 32A 110V 2 P T PRESA CEE EEC SOCKET 220V MONOF SINGLE PH 2 T PRESA CEE EEC SOCKET 380V TRIFASE THREE PH VOLTMETRO VOLTMETER FS 500V INTERRUTTORE UNIPOLARE 15A UNIPOLAR SWITCH CAPPUCCIO ISOLANTE x INTERRUT CAP PORTAFUSIBILE FUSE HOLDER FUSIBILE FUSE GR CAVI SEGNALI COMANDI SALD CABLE SET SIGNALS AND CONTROLS GR CAVI SEGNALI COMANDI SALD CABLE SET SI
21. 01 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 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 PERL 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 20081 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
22. 1800 RPM must be approx 230V 10 Push upwards the lever of Ground Fault Interrupter GROUND FAULT INTERRUPTER SWITCH 4 Turn on the safety switch D by pushing it upwards in the event of a malfunction In this case the switch disconnects the three and single phase circuit when in any part of the electric connections a current lea kage of more than 30 mA occurs 19 05 05 76440 GB CD Es o accessory USE MOSA 1 1 06 05 Y a 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 TC2 TC2 50 move the switch 7 located above the multipole connector 8 to ON position Position welding current adjusting T knob at the necessary current value for the diameter and type of electrode See page M51 REMOTE CONTROL TC2 TC2 50 PUSH AND SCREW TIGHT 09 11 99 M38GB ENGINE PROTECTION ES EV ENGINE PROTECTION ES EV The devices ES or EV ensure the protection of the engine in case of low oil pressure or engine high temperature The system consist of electronic card of control and check and of an engine stop device solenoid ElettroStop electrovalve ElettroValvola The device enter in operation when the engine starts and in case of low oil pressure and high temperature will stop the machine and show the cause of the stop
23. GNALS AND CONTROLS PL Version Fino a REV 0 04 05 Del 57 08 10 03 08 Da REV 1 06 08 Del 57 08 10 03 08 400T230M110M Version 400T230M110M Version CAPPUCCIO CAP PL Version CAPPUCCIO CAP COMMUTATORE COMMUTATOR COMMUTATORE TRIPOLARE TRIPOLES SWITCH PL Version PIASTRINA PLATE PANNELLO FRONTALE inferiore FRONT PANEL PRESA DI SALDATURA WELDING SOCKET PRESA DI SALDATURA WELDING SOCKET SCATOLA ELETTRICA ELECTRIC BOX PULSANTE STOP D EMERGENZA EMERGENCY PUSH BUTTON STOP SBARRETTA BOX CONDENSATORI CONNECTING PLATE CAPACITOR BOX STAFFA BOX CONDENSATORI CAPACITOR BOX BRACKET TRASFORMATORE AUXILIARY TRANSFORMER UNITA FILTRO ANTIDISTURBI ANTIJAMMING FILTER BOX CONDENSATORI CAPACITOR BOX 3X80 UF 50 Hz BOX CONDENSATORI CAPACITOR BOX 60 Hz MORSETTIERA TERMINAL BOARD SCHEDA EV ES DISTANZ ISOLANTE PER SCHEDE SPACER TELERUTTORE CONTACTOR 40A SCHEDA DI CONTROLLO SALDATURA PCB WELDING CONTROL TELERUT INVERSIONE POLARITA COMPL PLARITY CHANGE CONTACTOR PL Version TRASFORMATORE AUSILIARIA AUXILIARY TRANSFORMER PL Version SCHEDA COMANDO INVERT POLARITA PCB POLARITY INVERTER PL Version UNITA CONTROLLO SALDATURA WELDING CONTROL UNIT PIASTRINA DI PARALLELO PLATE 12 04 05 76440 Ricambi CD Ersatzteile M O SA GB Spare parts CE Tabla de recambios TS 400 PS 9MOSA REV0 0405 CF Pi ces de rechange QD TS 500 PS PL Version 21 20 19 18
24. OW QUALITY BECAUSE NOT CHARGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 05 09 05 M43GB CD O CA Periodical maintenance TS 400 PS REV 0 0505 CF TS 500 PS A B C D E F HOW IT WORKS e Check the level of the coolant le Check the concentration of the coolant 1 le Check the tension and the state of the driving belt Replace the control belt of the alternator e Drain the water from the prefilter if assembled jel Replace the cartridge of the fuel filter Check the efficiency of the injectors 2 Check the level of the lubricating oil DENEN Change the lubricating oil of the engine fill slowly make shure the right quantity is used 3 Replace the engine oil filter Clean the air filter and empty the dust gathering cup of the air filter in very dusty condi tions DENEN Clean the air filter and empty the dust gathering cup of the air filter in very dusty condi tions Clean the housing of the rotor in the turboblower and the housing of the compressor in the turboblower 2 Check the valve clearance of the engine and set it up if necessary 2 j Check all hoses and connectors Replace the engine breather pipe Check the alternator the starting motor 2 Inspect the electrical plant to see that the wires are well firm and not worm out _ je Check and repair any loss or damage the engine PROGRAMS The i
25. RK TECHNICAL DATA TECHNICAL DATA SYMBOLS SYMBOLS INSTALLATION AND ADVICE BEFORE USE INSTALLATION AND ADVICE INSTALLATION UNPACKING TRANSPORT AND DISPLACEMENTS ASSEMBLY CTL22 SET UP FOR OPERATION STARTING AND STOPPING THE ENGINE CONTROLS USE ASA WELDER USE AS WELDER USE ASA GENERATOR TROUBLE SHOOTING MAINTENANCE PERIODICAL MAINTENANCE STORAGE CUST OFF DIMENSIONS RECOMMENDED ELECTRODES ELECTRICAL SYSTEM LEGEND ELECTRICAL SYSTEM SPARE PARTS LIST SPARE PARTS 19 05 05 76440 GB 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 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 and the rights connected to the creation and
26. STAZIONAMENTO 305751150 TIMONE 305201150 TIMONE 0000305600142 GR ASSALE RUOTE x TRAINO LENTO 305751160 ASSALE 105612030 RUOTA 305751062 MANIGLIA BLOCC PIEDE STAZION KIT SITE TOW KIT SITE TOW PARKING STAND PARKING STAND TOW BAR TOW BAR KIT SITE TOW AXLE WHEEL FIXING HANDLE PARKING STAND CTL 22 305200140 L_z Da from REV 1 02 07 Del 09 del 26 01 07 Fino a up to REV 0 12 02 Del 09 del 26 01 07 Da from REV 1 02 07 Del 09 del 26 01 07 Fino a up to REV 0 12 02 Del 09 del 26 01 07 Da from REV 1 02 07 Del 09 del 26 01 07 Fino a up to REV 0 12 02 Del 09 del 26 01 07 era 305600142 10 12 02 Da from REV 1 02 07 Del 09 del 26 01 07 11 12 02 KA MOSA CD 68 REV 1 07 07 TC 2 TC2 50 209510018 930600000 70 1 N N Vs 180 NN Ng 1 E ON Y ES 1 7 1 V Z 100 P d atte 1 SELETTORE CORRENTE q 1 RANGE b y Ire AN n ri y 100 130 L Y T Sa LO 0 1 V Y Y iene Ya 1 2X x I ANA ps I IN Mal TEAD I la py Z ila IP b l OIM Tes 2 4444 I 16 I N 27 lt ey y 7 5 7 s 5 7 9 8 4 TC 2 11 TC 2 4A TC 2 50 11A TC 2 50 Des
27. TS 400 PS BC PL 50Hz TS 500 PS BC PL 60 Hz 764409003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG 19 05 05 76440 00 approvato da DITE Es DESCRIPTION OF THE MACHINE TS 400 PS MOSA REV 1 09 10 TS 500 PS Main Characteristics of the unit e Maximum welding current 400A TS400PS 500A TS500PS e Three phase power genaration 16 kVA single phase 12 kVA e Diesel engine PERKINS 404 D 22G e Noise level at 7m 67 dBA e Dimensions weight 1720x980x1100 780 Kg WELDING CURRENT BATTERY REGULATION FILTER m UN un LA CT LO ee I CONNECTOR FOR REMOTE CONTROL EMERGENCY STOP The engine driven welder has a base constructed in steel which includes the tank A cover which is hinged to the roll bar facilitates a rapid check for daily maintenance while a central hook on the roll bar facilitates the removal or the loading of the machine The free maintenance battery reduces at minimum the checking of its charge condition The engine has a low oil and a hight temperature protection rT MOSA Quality system MOSA REV 3 02 09 THE INTERNATIONAL 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 Operative Units Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 1 20090 Cusago
28. 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 P b Pb P P P P J AY 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 fires on the electric machines with non 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
29. 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 LIFT ONLY THE MACHINE DO NOT LIFT THE MACHINE AND TRAILER DANGER LIFTING EYE IS NOT DESIGNED TO SUPPORT ADDED WEIGHT OF ROAD TOW TRAILER AOSO 30 03 00 M4GB ASSEMBLY ATTENZIONE 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 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 GE 22 TS 415 TS 400 P To assemble the generating set on the tr
30. are parts it is recom mended to indicate O MIDA 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 4 n position En quantity 3 n table 5 MES TWOLARICANBI SPARE PARTS PIECES DE RECHANGE ERSATZTEILE au T EA 3 4 1 3 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 request only 14 12 986Q16M31 22 03 00 R1GB MOSA CD Ricambi M SA Spare parts REV 0 04 05 CE Pieces de rechange CD Ersatzteile Tabla de recambios ND 6 50Hz TS 400 PS TS 500 PS 11 50Hz 11a 60Hz 12 04 05 76440 CD Ricambi M CA Spare parts CD Ersatzteile Tabla de recambios OMOSA REV1 0608 CF Pi ces de rechange WD Pos Rev Cod TS 400 PS TS 500 PS Descr Note O ON DOD I WIN gt LL A lI lI cl Cr 1 l3 2 NOOB WN Pos O ON O O O WN gt LL lI lA lI cl 1 l3 YO Oc N AO Rev M107301390 M765006020 M307806010 M282008222 M764403010 M764403020 M764423020
31. cal data TS 400 PS TS 500 PS A C GENERATOR Three phase generation 16 400 V 1 23 1 A Single phase generation 12 kVA 230 V 52 1 A Single phase generation 6 110 V 54 4 Single phase generation 5 48 V 104 A Frequency 50 Hz 60 Hz ALTERNATOR self excited self regulated brushless Type three phase asynchronous Insulating class H ENGINE Mark Model PERKINS 404 D 22G Type Cooling system Diesel 4 stroke Liquid Cylinders Displacement 412216 cm Net output 20 3 kW 27 6 HP 22 6 kW 30 7 HP Speed 1500 rpm 1800 rpm Fuel consumption welder 60 3 8 l h 4 2 1 h Cooling system capacity 7 Engine oil capacity 8 5 Starter Electric GENERAL SPECIFICATIONS Battery 12V 100Ah Tank capacity 60 Running time welder 60 16h Protection IP 23 Dimensions max Lxwxh mm 1720x980x1110 Weight 780 Kg Measured acoustic power LwA pressure LpA Guaranteed acoustic power LwA pressure LpA 92 dB A 67 dB A 7m Acoustic power LwA pressure LpA 94 dB A 69 dB A 7m Dimensions and weight are inclusive of all parts without wheels and towbar 91 dB A 66 dB A 7m POWER Declared power according to ISO 3046 1 temperature 25 30 relative humidity altitude 100 m above sea level Its admitted overload of 10 each hour every 12 h In approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 C ACOUSTIC POWER LEVEL ATTENTION The concrete risk due to
32. clearly readable and unerasable and it can be either part of the data plate A or placed as a sticker near the data plate B O gt Wee Europe 59 20090 CUSAGO M ITALY 5 0 CS LA tel 39 02903521 fax 39 0290390466 Europa 59 20090 CUSAGO MI ITALY III Ill lU http e mai infoemosa it 38 02903521 fax 39 0290390466 tel 48 in VESTALY TYPE C http www mosait e mail infoemosa it i N Uo Emi TTA Ed n L IRM n PC ____ __ ____ 9 Furthermore on each model it is shown the noise level value the symbol used is the following yy 2 6 28 db Say Sal 10 10 02 M1 4 GB The indication is shown in a clear readable and indeleble way on a sticker 6D MO S A technical data MOSA REV 2 09 10 TS 400 PS TS 500 PS The TS 400 500 engine driven welder ia a unit which ensures the function as 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 Techni
33. colour battery to be 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 circuit manual 3 Engine protection thermic fuse 3 Replace In case the problem persists check the electrical circuit blown and eliminate the problem Call an authorised service centre P2 Engine stop due to intervention of 1 Engine temperature too high or 1 Check oil level engine protection insufficient oil pressure 2 High temperature sensor or oil 2 Replace the malfunctioning sensor pressure defective 3 Engine protection defective 3 Replace the protection 4 Stop device defective 4 Replace P3 The battery is not charged 1 Battery charger alternator de 1 Replace fective 2 Battery charger alternator not exci 2 Check the excitation system of battery charger ted P4 For other problems refer to the attached engine manual 19 05 05 76440 GB CD MAINTENANCE REV 0 06 10 Have qualified personnel do maintenance and troubleshooting work e the engine before doing any work inside the machine If 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 i
34. cr 209519904 CONNETTORE COMPLETO DI CAVI CONNECTOR WITH CABLES _ TC2 vers 930609904 CONNETTORE CON CAVI CONNECTORS WITH CABLES TC2 50 vers 107509702 MANOPOLA REG CORRENTE SALDAT KNOB WELDING CURRENT REGULAT 107509700 POTENZIOMETRO WELDING CURRENT REGULATOR Fino a Up to REV 10 99 Del 129 06 04 09 07 836709715 POTENZIOMETRO WELDING CURRENT REGULATOR Da From REV 07 07 Del 129 06 04 09 07 107509900 SCATOLA CASE BOTTOM HALF 209519901 COPERCHIO CD COVER 209510018 TC2 COMANDO DISTANZA STD TC2 STD REMOTE CONTROL 930600018 102 50 COMANDO DISTANZA STD TC2 50 STD REMOTE CONTROL 18 10 99 KD
35. cr Note 1 M400409154 STAFFA FISSAGGIO BATTERIA 2 M764409150 BATTERIA 12V 105Ah SENZA MANU 3 M105112270 GUARNIZIONE L MT 1 4 M764407015 COPERCHIO SCATOLA ELETTRICA 5 M764408290 PARATIA SUPERIORE ALTERNATORE 6 M764401100 ROLL BAR 7 M256602228 FILTRO GASOLIO Fino a REV 0 04 05 Del 21 09 03 03 09 7 M841562228 FILTRO SEPARATORE ACQUA Da REV 1 09 10 Del 21 09 03 03 09 8 M308102207 GOMMA L MT 1 qm 9 M107301890 TUBO SFIATO L MT 1 qm 10 M307402208 TUBO GOMMA L MT 1 qm 11 M764408239 TRAVERSINO SUPP PARATIA ALT 12 M764402241 STAFFA SUPP FILTRO CARBURANTE Da REV 1 09 10 Del 21 09 03 03 09 Pos Rev Cod Descr Note 1 M400409154 BATTERY BRACKET 2 M764409150 BATTERY 12V 105Ah WITHOUT MAINENANCE 3 M105112270 STRIP SEALING L MT 1 4 M764407015 ELECTRICAL BOX COVER 5 764408290 ALTERNATOR BULKHEAD 6 M764401100 ROLL BAR 7 M256602228 FUEL FILTER Up to REV 0 04 05 Del 21 09 03 03 09 7 841562228 FUEL PRE FILTER From REV 1 09 10 Del 21 09 03 03 09 8 M308102207 PIPE qm 9 M107301890 PIPE BREATHER L MT 1 qm 10 M307402208 PIPE qm 11 M764408239 ALTERNATOR SUPPORT BRACKET BULKHEAD 12 M764402241 SUPPORT FUEL FILTER From REV 1 09 10 Del 21 09 03 03 09 12 04 05 76440 0779 S0 70 CL TS 400 PS TS 500 PS ac We EEA AR eR AN Y QO o 2 a E O D E 3 49 c dy N o LLI CD Ricambi Spare parts REV 0 04 05 CE Pieces de rechange MOSA MOSA n R
36. ectriques MOSA MOSA 0779 90 70 21 euoIZezzuojne ens ezues 1210 e o ip OJSIAIP uoo ejueseud eyeudoud Ip IULIIS e IS VSON 7 ae 0020 67 7797 so0ZvO LO 98 Sd 00 SLI yesourmmwy dyy J U JeuBiseq 01 AWLIIN OSVSND 06002 10 SI eJojeuBesiq Beg ely Wer eXWOEZ LOO xnV TUR V y S 0 N Mo fused a AY O PON TS 400 PS 400T230M48M 6 066 VZ N00y Vr0L A8p O dy lt O A go 5 ES UY LL QD Electric diagram REV 0 04 05 Schemas electriques CD Schema elettrico MOSA MOSA 92 SO VO CV euorzezzuojne ens ezues 129 e o Ip uoo ejueseud eyeudoud e669 ip iuiuue e Is WSOW 21 AC UN 020 5 0 92 00z 0L SL N eoejode7 29 007 SLI yresourmmmy diyy n euuoew OOYSNI 06007 Bed gt do ugt UIp E euoizeuiuoueq Ded eq d med UPON _ TS 400 PS BC TS 500 PS BC o i O H o E dy c O A ge 5 ES UY QD
37. ed 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 MOSA REV 2 06 10 o lt 00 o STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE lf 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 implies 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
38. ed on the front Make sure the unit is properly grounded 12 where itis assembled the voltmeter N shows the single phase voltage whether three or single phase current has to be drawn Nominal voltage no load voltage 110V 0 10 230V 0 10 230V 0 10 400V 0 10 Connect up the machine using proper plugs and cables in good condition to the AC socket 15 to draw single or three phase power Using several sockets at tha same time the maxi mum power possible is that indicated on the data plate To draw power simultaneously see page M52 The max continuous power of the generating set or theload current must not be exceeded TS 400 PS TS 500 PS THERMOPROTECTION If you overload the genset the thermoprotection will automatically switch off If the thermoprotection is released disconnect all the connected loads gt CLOSED OPEN Ci CIRCUIT BREAKER Reset the thermoprotec tion pressing the central pole When reset connect the me PRESS TO RESET loads again In case the protection should act furtherly check the connections the wires or others and if necessary call the Assistance Service Avold to hold the central pole of the thermoprotection pressed for a long time Otherwise in case of trouble it will not click dama ging the generating set TS PL VERSION otart the machine The voltmeter will show the auxiliary voltage which for machines at 1500
39. er indicator Battery charge indicator Transfer pump selector AUT 0 MAN Fuel transfer pump GECO generating set test Hooting with level switches Voltmeter regulator WELD AUX switch Reactor 3 phase Switch disconnector Solenoid stop timer VODIA connector F EDCA 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 F I relay supply switch Radio remote control receiver Radio remote control trasnsmitter Isometer test push button Remote start socket Transfer fuel pump control Ammeter selector switch 400V 230V 115V commutator 90 60 Hz switch Cold start advance with temp switch SIART STOP switch Polarity inverter two way switch Engine protection EP AUTOIDLE switch AUTOIDLE PCB A4E2 ECM engine PCB Remote emergency stop connector V A digital instruments and led VRD PCB Water in fuel 26 07 04 M60GB 0779 SO VO ClI uozezziio ne ens ezues 1219 e ojjeoiunujoo o ojinpoudu Ip uoo ouBesip e3uesaud jap eyeuudoud Ip tuwa e eaS IS WSOIN 21 1 v oLO S Orr 9Z v00ZOLSL N 95e10de1 98 Sd 00 SL l esouu www dnu m ds sad EN AWLI IIN ODVSNI 0600Z USI aopeubasig euitooe A z 922 aUo u abed 409014
40. ge 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 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 EXTINCTION MEANS Appropriated Carbonate anhydride or carbon dioxyde powder foam nebulized water Not to be used Avoid the use of water jets Other indications C
41. generating group O1 Oil pressure warning light If on during the F6 Arc Force selector In ON position it inserts group s operation indicates a malfunction in the the BC circuit base current motor s oil circuit ARC FORCE _ F5 High temperature warning light For groups A V4 Polarity inverter control Positioned on with water cooled motor indicates a malfunction Polarity it inverts the polarity at the welding sockets PL in the cooling circuit a switc Version N1 Battery charge warning light If on during the group s operation indicates a malfunction W1 Remote control switch In ON position in the motor s battery charge circuit it qualifies the remote control to regulate the welding current M1 Low fuel warning light If on indicates the fuel in the tank has reached the low level X1 Remote control socket connector Multi point pole connector for remote control C2 Fuel level indicator Indicates the percen tage of fuel in the fuel tank F Fuse Protect the electronic welding card l4 Preheating pilot light If on indicates the in case of short circuited remote control activation of the preheating circuit 100mA 250V 5x20 mm L5 Emergency stop button Allows for the group s immediate stop in case of danger and prevents start up until it is released D Differential switch Generally with a current of 30 mA this is the safety device against indirect contacts 59B T
42. hanical properties Weld in all position Electrode holder at inverse polarity Wid deposit of nice aspect also vertical Workable high yield Suitable for steels with high contens of sulphur impurities CELLULOSIC ELECTRODES E 6010 Cellulosic electrodes weld only in d c with polarity electrode holder ground clamp Special for steels run on pipes with R max 55 kg mm Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS 2 digits type of coating and electric power conditions see table 3 1 digits welding positions see table 2 Li Descrizione 2 3 digits tesile strenght of g 9 Cellulose electrodes for d c the weld deposit see table 1 Cellulose electrodes for a c symbol for Rutile electrode for d c Coated Rutile electrode for a c electrode High yield rutile electrodes T 60 000 70 000 Basic electrodes for d c Basic electrodes for c a High yield basic electrodes for d c inverse polarity Acid electrodes for flat or front position welding for d c pole and for a c High yield rutile electrodes for flat or front plane position welding for d c and a c High yield acid electrodes for flat or front plane position welding for d c pole and a c High yield basic electrodes for flat or front plane Table 1 position welding for d c inverse polarity Extra high yield acid electrodes extra high penetration if required for flat position we
43. harge 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 EPS Pre heat push button Accelerator solenoid PCB Oil pressure switch Water temperature switch Water heater Engine connector 24 poles Electronic GFI 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 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 EMC filter Wire feeder supply switch Wire feeder socket DSP chopper PCB Power chopper supply PCB Switch and leds PCB Hall sensor Water heath
44. hermal protection for inputs c a rotects individual sockets generally the mono phase inputs from overloads N Line voltmeter The presence of line voltage indicates power can be drawn from the sockets c a 12 Grounding terminal PE terminal for the group s earthing connection to a grounding installation 19 05 05 76440 GB CD USE AS WELDER This symbol Norm EN 60974 1 security standards for arc welders signifies that the welder can be used in areas with increased risk of electrical shock OSA REV 0 05 05 N ATTENTION The welding sockets after the machine is started also with no cables are anyway under voltage Check at the beginning of any work the electric parameters and or the control placed on the front Make sure that the ground connection 12 is efficent keep to installation local rules and or to national laws in order to integrate or ensure the working of varius electric protection devices referring to the several distribution system TT TN IT operation unnecessary for machine with isometer Fully insert the welding cable plugs into the corre sponding sockets only gauging 9 10 turning them clockwise to lock them in position 0 0 ONLY GOUGING PUSH AND TWIST di Latin ie 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 posit
45. hich 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 CD o ce mark MOSA REv 4 10 07 CF Any of our product is labelled with CE marking attesting its conformity to appliable directives and also the fulfillment of safety requirements of the product itself the list of these directives is part of the declaration of conformity included in any machine standard equipment Here below the adopted symbol CE marking is
46. icambi CD Ersatzteile M O CA G Spare parts CED Tabla de recambios MOSA REV 0 04 05 Pi ces de rechange ND Pos Rev Cod Descr 1 M343338270 PERNO PER CERNIERA 2 M765008112 SERRATURA 3 M765007057 CHIAVE PER SERRATURA 4 M841508021 COPERCHIO CARENATURA ANTERIORE 5 744508140 CERNIERA PER FIANCATA 6 M105112270 GUARNIZIONE L MT 1 7 764408035 POSTERIORE 8 102302280 GUARNIZIONE L MT 1 9 M764408010 FIANCATA dx CARENATURA ANT 10 M305718115 PISTONE SOSTEGNO 11 M107300180 CHIUSURA COMPL A LEVA 12 M343339601 MANIGLIA 13 M764401050 BASAMENTO 14 M764408015 FIANCATA sx CARENATURA ANT 15 M102042870 MOLLA 16 M343338100 COPERCHIO FRONTALE Pos Rev Cod Descr 1 M343338270 HINGE PIN 2 M765008112 LATCH FOR ELECTRICAL BOX COVER 3 M765007057 ELECTRIC BOX COVER KEY 4 M841508021 FRONT HOUSING COVER 5 M744508140 LATCH 6 M105112270 STRIP SEALING L MT 1 7 764408035 COVER REAR 8 M102302280 GASKET L MT 1 9 M764408010 FRONT COVER RIGHT SIDE 10 M305718115 SUPPORT REAR COVER 11 M107300180 LATCH 12 M343339601 KNOB 13 M764401050 BASE 14 764408015 FRONT COVER LEFT SIDE 15 M102042870 SPRING 16 M343338100 FRONT COVER TS 400 PS TS 500 PS Note qm qm Note qm qm 12 04 05 76440 MOSA a CD 68 REV 1 02 07 CF I I 0000225100141 GR TIMONE PIEDE x TRAINO LENTO 0000305200141 GR TIMONE PIEDE xTRAINO LENTO 342231051 PIEDE DI STAZIONAMENTO 102351750 PIEDE DI
47. ion Pay attention to the two polarities of the welding circuit which must not come in electric contact between themselves When using the welder for air arc gouging connect the ground lead to the socket and the gouging lead to the socket marked only gouging if present REMOTE CONTROL TC oee page M 38 TS 400 PS TS 500 PS WELDING CURRENT REGULATION KNOB Position knob T in correspondance of the chosen current value so as to obtain the necessary amperage taking into acount the diameter and the type of the electrode For technical data see page 1 6 N ATTENTION To reduce the risk of electromagnetic interferences use the minimum lenght of welding cables and keep them near and down ex on the floor The welding operations must take place far from any sensitive electronic device Make sure that the unit is earthed see M20 and or M25 In case the interference should last adapt further disposition such as move the unit use screened cables line filters screen the entire work area In case the above mentioned operations are non sufficient please contact our Technical Assistance Service With a welding cable length up to 20 m is suggested a section of 35 mm with longer cables a bigger section is required A 19 05 05 76440 GB CD CISA use As WELDER REV 0 05 05 TS 400 PS TS 500 PS REDUCTION SCALE 100 For small electrodes up 0 3 25 130A and 4 200 it is rec
48. lding only for d c pole and a c 80 000 90 000 100 000 110 000 120 000 for all positions for plane and verticl for plane posotion only Table 2 Table 3 10 10 03 M55GB CD MOS A o ELECTRICAL SYSTEM LEGENDE REV 6 06 08 CF Alternator Wire connection unit Capacitor Welding transformer Fuse 400V 3 phase socket 230V 1phase socket 110V 1 phase socket Socket warning light Hour counter Voltmeter Welding arc regulator 230V 3 phase socket Welding control PCB Welding current ammeter Welding current regulator Current transformer Welding voltage voltmeter Welding sockets shunt D C inductor Welding diode bridge MOSA lt gt x lt m m Q Z gt 1 Arc striking resistor B1 Arc striking circuit C1 110V D C 48V D C diode bridge D1 E P 1 engine protection E1 Engine stop solenoid F1 Acceleration solenoid G1 Fuel level transmitter H1 Oil or water thermostat 11 48V D C socket L1 Oil pressure switch M1 Fuel warning light N1 Battery charge warning light 01 Oil pressure warning light P1 Fuse Q1 Starter key R1 Starter motor 51 Battery T1 Battery charge alternator U1 Battery charge voltage regulator V1 Solenoid valve control PCBT Z1 Solenoid valve W1 Remote control switch X1 Remote control and or wire feeder socket Y1 Remote control plug A2 Remote control welding regulator B2 E P 2 engine protection
49. letely 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 9030 12 06 03 M20 R HO2 GB sa a M CA Set up for operation MOSA 1 0 06 03 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 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 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
50. ltmeter Remote control socket Button indicating light 20 I 1 PTO HI Commutator switch serial parallel Thermal magnetic circuit breaker Selection push button 20 1 1 PTO HI Water temperature indicator 10 05 01 M30 GB Comandi D M MOSA 0 controls Mandos TS 400 PS 31 OMOSA REVO0405 Commandes TS 500 PS 400T230M48M 400T230M110M VERSION VERSION T D NM C2 F5 M1 59A V X1 F F6 12 15 598 14 O1 59D V4 15 99B 12 04 05 76440 a M O CA Front panel components TS 400 PS OMOSA REV 0 05 05 TS 500 PS 9 c c welding sockets Connection otor protection Motor control circuit with au 10 c c welding sockets sockets for omatic shutdown for low oil pressure and hig wu 9 Socket only gouging welding ca emperature Outlet used only for cutting ples Q1 Start up key Control unit for start up shu works Bi tdown and preheating operations T Welding current regulator allows the regula tion of the welding current 59A Motor thermic protection Protects the battery circuit auxiliary devices pilot lights I3 Switch for welding scale reduction Placed on relays instruments sensors etc from power 200A it limits the maximum value of the welding overloads and short circuits current regulator T at 200A so permitting a M Hours counter Indicates effective operating more accurate regulation of the welding current hours for the electricity
51. n 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 DUPLI 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 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 protec
52. nterventions listed below must be effected at the intervals hours and months in the chronologie order A every day or every 8 hours D every 1000 hours B every 250 hours or every 6 months E every 2000 hours C every 500 hours or every 12 months F every 3000 hours 1 Replace the antifreeze every 2 years If instead of antifreeze anticorrosive is used in the coolant replace it every 6 months Make sure you use the right quantity 2 By well trained staff 3 The interval for changing oil must be modified if the load factor of the engine is above 40 or if a specifically wrong oil is used If you are not sure how to calculate the load factor for said application please turn to the Assistance Centre 19 05 05 76440 GB a STORAGE REV 0 06 07 In case the machine should not be used 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 t Have qualified personnel prepare the machine for storage GASOLINE ENGINE Start the engine It 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 pressi
53. ode bridge 5 Check the diode or the controlled diodes P2 There is welding but non penetra 1 Connnection of base current control 1 Check that the a c 48V arrives to the contactor of the base current tion are open 2 Defect in the base current contactor 2 Check that the contacts and the contactor shut are good conditions Defect in welding high and discon 1 Defect in connections between 1 Check the continuity and the state of different connections which tinued sparks shunt and potentiometer go to the card from the shunt as well as from the potentiometer 2 Defect in diode bridge 2 Check the diodes and SCR 3 Defect in card 3 Replace the card P4 No welding output and no auxiliary 1 Short circuit in wiring 1 Check the wiring inside the welder for a short circuit between power output cables or to ground 2 Defective condenser 2 If the wiring is OK short circuit the condenser to be sure that it is discharged disconnect all wires from condenser and using an ohmmeter check that the condenser is not short circuited 3 Defective stator 3 If the condenser box is OK disconnect all leads from the stator except for those going to the condenser box and check the output from the alternator If there is no output from the welding winding and the auxiliary winding replace the stator 4 Short circuited diode bridge 4 If there is output from all windings reconnect the diode bridge and check if there is welding
54. oid 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 which could happen or anyway from that w
55. olley CTL 22 please keep to following instructions 1 Liftthe generating set by means of a suitable hook 2 Slightly fix the jaw 3 of the parking foot to the bar with the screws AV the nuts and the washers and tighten all parts 3 Open the jaw so as to let the foot sprag 45 go through 4 Introduce into the jaw 3 the upper part 45 of the foot and block momentaneously with the lever 4L the whole foot 6 Assemble on the machine the towbar 5 complete of foot with the screws nuts and washers 7 Assemble the axle 7 to the base of the machine with the 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 Pump the tyre 9 fixing the pressure to four atms 10 Lower the machine to the ground and place the parking foot definitively regulating at the suitable height e N ATTENTION Do not substitute the original tires with other types 10 06 00 M6GB sa a M SA Set up for operation MOSA 1 1 09 05 CF 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 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 colou
56. ommended to use the O reduction scale switch 13 allowing a more accurate regulation of the welding current max lever position at 130 A and or 2004 When using electrodes of a diameter greater than 3 25 and or 4 set the welding scale knob to 100 and or max position Protection fuse he fuse protects the electronic welding PCB in case the remote control is short circuited POLARITY INVERTER PL VERSION It permits to have atthe electrode holder the positive or negative polarity of the welding Polarity diode bridge itch ice Itis used above all in the first run with cellulosic electrodes to lower the bath temperature and so doing ease up the welding on pipes of small thickness BASIC CURRENT BC Positioning the switch on is obtained a low voltage welding current which keeps always the lit arc necessary for some types of cellulosic electrodes or when a high penetration is wanted 19 05 05 76440 GB yi Es Gs use As GENERATOR REV 0 05 05 CE IS It is strictly forbidden to connect the group to the public mains a o to another source of electric power Sockets are not self locked tension is avaible immediately after starting also with no plug The areas access of which is forbidden to un qualified personel are the control switchboard front the exhaust of the endothermic engine ie At the beginning of every work check the electric parameters and or the controls plac
57. on 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 IMPORTANT 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 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 subdivisi
58. on 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 The 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 opera
59. over 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 G 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 is 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 so 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 i
60. r 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 automobile 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 comp
61. s 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 mechanical 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
62. s up at its operating speed 1500 or 1800 rpm After start up allow the motor to run for a few minutes before powering on the utilities oee table lt 20 to 20 C from 10 C to 10 C from 5 C gt 5 5 start up low temperatures The motor will normally start up without problems down to temperatures of 10 C 15 C In case of starting difficulty it is possible to repe at the starting preheating for a max time of 10 TS 400 PS TS 500 PS seconds For start up and use at lower tempe ratures please see the engine manual or turn to our Technical Assistance Center is In case of unsuccessful start up do not insist for longer than 5 seconds Wait 10 15 se conds before attempting another start up STOP For shutdown under normal conditions proceed as follows 1 Break the welding process in course 3 Letthe engine run with no load for a few minutes 4 Turn the start key Q1 to the OFF position OFF EN START EMERGENCY SHUTDOWN To stop the group in a dangerous situation press the emergency stop button L5 or turn the start key Q1 to the OFF position To reset the knob turn it clockwise 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 en 19 05 05 76440 MOSA
63. 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 Water cooled systems 9030 12 06 03 M20 R HO2 GB L cs STARTING AND STOPPING THE ENGINE a REV 0 05 05 Check daily FE 33 5 Do not alter the primary conditions of regulation and do not touch the sealed parts START UP 1 By start up of the generator the welding circuit is immediately operative i e under voltage Make sure that there are no unwished electrical contacts between the components of the outside welding circuit electrode electrode holder gun workpiece etc 2 Check that at the start up the a c auxiliary ge neration sockets do not feed any load Open the D of the generator or disconnect the plugs of the loads from the sockets 3 turn the start key Q1 to the preheat position identified by a picture of a spark plug Keep the on key in this position for about 5 seconds SS sm the action is shown by the preheating light on I4 Turn the start key to the ON position and then on START After the start up of the motor release the key which will automatically place itself in the ON position OFF 4 the motor start
64. 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 I 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 a4 meters 95 dB A 20 dB A 75 dB A Lp a 7 meters 95 dB A 25 dB A 70 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 2000 14 CE directive 19 05 05 76440 GB T T MOSA Technical data TS 400 PS O REV 1 02 09 CF TS 500 PS D C WELDING TS 400 PS 50 Hz TS 500 PS 60 Hz Welding current electronic 20 200 20 400A 20 200 20 400A regulation on two scales Service 400 A 60 350 A 100 500 A 35 450 A 60 400 A 100 Striking voltage 1001 V
65. tions 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 A 9 OI 04 06 07 M45GB Dimensioni CD Abmessungen M CA Dimensions Dimensiones TS 400 PS OMOSA REVOOU05 CE Dimensions WD TS 500 PS o oe SILENCED 205 1300 1720 980 gt I st st cO N LO st N vr DL M O SA RECOMMENDED ELECTRODES in accordance with A W S Standard MOSA 1 0 10 03 CE The information here below are to be intended only as indicative since the above norm is much larger For further details please see the specific norms and or the manufacturers of the product to be used in the welding process RUTILE ELECTRODES E 6013 Easily removable fluid slag suitable foe welding in all position Rutile electrodes weld in d c with both polarities electrode holder at or and in a c Suitable for soft steels R 38 45 kg mm Also for soft steels of lower quality BASIC ELECTRODES E 7015 Basic electrrodes wels onlu in d c with inverse polarity on the electrode holder there are also types for a c Suitable for impure carbon steels Weld in all position HIGH YIELD BASIC ELECTRODES E 7018 The iron contained in the coating increases the quality of metal added Good mec
66. tive mask with suitable dark lens and side screens ears and body non flamable protective clothers Mn 30 03 00 M2 5GB CD INSTALLATION AND ADVICE REV 1 06 07 CF MOSA MOSA INSTALLATION AND ADVICE BEFORE USE GASOLINE ENGINES B Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area DIESEL ENGINES m Use in open space air swept or vent exhaust gases far from the work area POSITION Place the machine on a level surface at a distance of at least 1 5 m from buildings or other plants X Maximum leaning of the machine in case of dislevel A 20 max 10 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 gt Make sure that the machine does move during the work block it possibly with tools and or devices made to this purpose MOVES OF THE MACHINE 157 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 of flood Please do not use the machine in weather conditions which are beyond IP protection shown both in the data plate and on page named technical data in this same manual 26 11 99 M2 6GB gt Installazione

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