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1. MOSA 1 0 05 04 CE ARC WELDING HAZARDS Electric shock from welding electrode or wiring can kill Wear dry hole free insulating gloves and body protection Do not touch electrode with bare hand Do not wear wet or damaged gloves Do not touch live electrical parts Wet or confined spaces or if their is una danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Magnetic fields can affect pace makers Pace maker wearers keep away from arc welding and cutting operations and equipment Wearers should consult their doctor before going near arc welding gouging arc cutting or spot welding operations Protect yourself from electric shock by insulating yourself from work and ground Use non flammable dry insulating material if possible or use dry rubber amts dry wood or plywood or other dry insulating material big enough to cover your full area of contract with the work or ground and watch for fire Breathing welding fumes can be hazardous to your health Keep your out of the fumes Do not breathe the fumes Use enought ventilation exhaust atthe arc or both to keep fumes and gases from your breathing zone and the general area Use enought forced ventilation or local exhaust forced suction at the arc to remove the fumes from your breathing area Use a ventilating fan to remove fumes from the breathing
2. 243 5 CD Luftzirkulation Instalaci n I ES en Em ETE L Ha ly m Mollo Wu SS SS 338 422 5 MAGIC WELD 200 YD YDE 4 gt P E mal lala DO lo o o Zl Jg C Je m z TA z Nl WW RA M 2 7 1 REV 0 02 14 20 02 14 22270 l UNPACKING 3 CE REV 1 02 04 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 000 30 03 00 M3GB CD M TRANSPORT AND DISPLACEMENTS COVERED UNITS 4 1 REV 2 09 11 Transportation must always take place with the engine off electrical cables and starting battery disconnected and fue
3. Number 60 000 70 000 80 000 90 000 100 000 110 000 120 000 Table 1 1 for all positions 2 for plane and verticl 3 for plane posotion only Table 2 Table 3 10 10 03 M55GB CD ELECTRICAL SYSTEM LEGENDE 60 REV 10 05 13 Alternator Wire connection unit Capacitor GE 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 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 A1 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 I1 48V D C socket L1 Oil pressure switch M1 Fuel warning light N1 Battery charge warning light O1 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 P2 engine protection C2
4. Power system Hz V A analogic instrument 19 4 EMC filter U9 Wire feeder supply switch V9 Wire feeder socket Z9 DSP chopper PCB W9 Power chopper supply PCB X9 Switch and leds PCB Y9 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 EDC4 connector OFF ON DIAGN selector DIAGNOSTIC push button DIAGNOSTIC indicator Welding selector mode VRD load 230V 1 phase plug VIHz 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 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 VIA 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 Wa
5. battery NOTE The manufacturer is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization M 46 REV 0 06 07 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 A 9 OI 04 06 07 M45GB CD M RECOMMENDED ELECTRODES In accordance with A WS Standard 55 REV 0 10 03 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
6. Ask for intervention of Service Department Check the sensor and electrical circuit 20 02 14 22270 GB CD Trouble shooting No current under no load 1 conditions in weld mode Irregular or inconsistent wel ding current Engine always at idle speed Engine always at maximum speed AUXILIARY POWER GENERATION CIRCUIT No current under no load 1 conditions in auxiliary power 2 3 WELDING CIRCUIT Faulty welding control board Faulty Hall sensor Faulty welding control board Faulty Hall sensor Chopper bridge short circuit Faulty welding control board Fault to the Auto Idle Economizer system Auxiliary power diode bridge broken Faulty inverter Faulty alternator 1 M 40 1 REV 0 02 14 MAGIC WELD 200 YD YDE With a voltmeter check that between pins A and B of the circular connector on the front panel there is 5 Vdc Ask for intervention of Service Depart ment to replace the board Ask for intervention of Service Depart ment to replace the Hall sensor With a voltmeter check that between pins A and B of the circular connector on the front panel there is 5 Vdc Ask for intervention of Service Department to replace the board Ask for intervention of Service Department to replace the Hall sensor Ask for intervention of Service Department to replace the Chopper Bridge With a voltmeter check that between pins A and B of the circular connector on
7. Use as a generator N ATTENTION It is absolutely forbidden to connect the unit to the public mains and or another electrical power source ATTENTION It is prohibited for any unauthorized per sons to access areas adjacent to engine driven welder AUXILIARY GENERATION IN AC 230V 50Hz The auxiliary output is drawn by means of a 3 pole socket the two poles are live phase and neutral plus the earth for the machine The single phase generation of the machine was designed to supply small power tools grinders drills etc to assist the welding operations with a quick safe connection without the need to connect to earth In addition supplying only one tool at a time the protection against indirect contact is assured by electrical separation Therefore the machine MUST NOT be intentionally connected to earth attaching cables must be of 3 wires and the electrical equipment on which it being used must have an extension length limited to 100 200 metres This limitation of circuit extension length is fundamental for safety The cables must be SUITED to the environment in which they are to be used Bear in mind that at temperatures below 5 C PVC cables become rigid and the PVC insulation tends to split at the first crease Using double insulated equipment is advisable this is identifiable by the symbol for having no earth facility If the machine is designed to supply circuits which are particularl
8. CD GB STOPPING Before stopping the engine it is compulsory to stop the load stop welding i shut off any loads which are connected to the unit auxiliary outputs RECOIL VERSION ME Let the motor run at no load for several minutes to allow for cooling and then move the accelerator control into the STOP position ELECTRIC STARTING op OT Wait for the motor to automatically go to e the minimum RPM 6 7 seconds after load release leave the motor running under the se conditions for several minutes in order to allow for cooling then turn the starting key to the OFF position A ATTENTION To switch off the motor in case of emergency either move the accelerator control to the STOP position immediately or move the starter key to the OFF position Shut the fuel cock IS NB for safety purposes remove the starter key from the machine at the end of every work session MAGIC WELD 200 YD YDE M 22 REV 0 02 14 20 02 14 22270 GB CD Comandi O M Controls Mandos MAGIC WELD 200 YD YDE 31 Commandes REV 0 02 14 N1 73 O1 Q1 31 10 X1 58 SCHUKO YDE VERS vers Pos Descrizione Description Description Descripci n _ appo serbatoio Muffler Presa di corrente in a c socket Prises de courant en c a Toma de corriente en c a omando manuale avviamento Starting push button Commande manuelle d marrage Mando manual
9. 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 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 2000 14 CE directive 20 02 14 22270 GB CD M GB Technical data MAGIC WELD 200 YD YDE 1 6 O REV 0 02 14 D C WELDING Current range continuous 20 200A Open circuit voltage 65V Duty cycle 200 A 60 OUTPUT CARACTERISTIC U2 V 70 60 50 40 l min 30 20 MAX 10 0 0 50 100 150 200 250 I2 A 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 resp
10. 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 AS of flood POSITION amp Please do not use the machine in weather Place the machine on a level surface at a distance of at sti 40 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 m O rA000000 CD Installazione Luftzirkulation Installation Instalaci n Installation MAGIC WELD 200 YD YDE M1 4 LL M 2 7 REV 0 02 14 VERS 20 02 14 22270 l CD Installazione Installation CF Installation 338
11. arranque Comando acceleratore Accelerator control Commande acc l rateur Mando de aceleraci n Filtro aria motore Engine air filter Filtre air moteur Filtro aire motor indi S Oil drain tap 5 N1 pia carica batteria Battery charge warning light Voyant charge batterie Piloto carga bateria O1 Spia bassa pressione olio 20 02 14 22270 l USE AS WELDER This symbol Norm EN 60974 1 security standards for arc welders signifes that the welders can be used in areas with increa sed risk of electrical shock N ATTENTION ES It is prohibited for any unauthorized per E J sons to access areas adjacent to the en gine driven welder or the welding process N ATTENTION To reduce the risk of electromagnetic interfe ren ce keep the welding cable length short and keep them on or near the ground If possible welding operations should not be done near sensitive elec tronic devices If interference continues to occur adopt additional measures shift the group use shielded cables line flters shield the entire work area If the above solutions do not suffice consult our Technical Servicing Department N ATTENTION With a welding cable length up to 10 m is suggested a section of 35 mm with longer cables a bigger section is required CONNECT WELDING CABLES Fully insert the welding cable plugs into the corresponding sockets turning them clockwise to lock them in posit
12. in UE ITALY TYPEN FAA L Kies L CL Made in UE ITALY IP 60974 1 Kg LCL n RPM nij RPM o QU JE b O Pimx w Pr JT IT LTP POWER IN ACCORDANCE WITH ISO 8528 2 RPM TEM jec P kw amj m Furthermore on each model it is shown the noise level value the symbol used is the following WS x tsar dD The indication is shown in a clear readable and indeleble way on a sticker 10 10 02 M1 4 GB Dichiarazione conformit Konformitatserklarung M GB Declaration of conformity E gt Declaraci n de conformidad 1 4 1 CF D claration de conformit ED Declara o de conformidade REV 2 10 13 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 2008 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 clare sous sa propre responsabilit que la machine BCS S p A declares under its own responsibility that the machine BCS S p A erkl rt dal 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
13. liability for any damage to persons animals or property 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 faste nings holes electric or mechanical devices others if not duly authorized in writing the responsibility coming from any potential intervention will fall on the executioner as in fact he becomes maker of the machine t Notice the manufacturer 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 M1 1 GB REV 1 D M CE MARK 14 REV 7 02 14 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 clearly readable and unerasable and it can be either part of the data plate ALTIT OO m TEMP L2S C Ce Ce N Made
14. metal added Good mechanical properties Weld in all position Electrode holder at inverse polarity Wld 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 con ditions see table 3 1 digits welding positions see table 2 M the weld deposit Ne DESEnzione see table 1 Cellulose electrodes for d c symbol for Cellulose electrodes for a c Coated Rutile electrode for d c electrode Rutile electrode for a c High yield rutile electrodes 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 position welding for d c inverse polarity Extra high yield acid electrodes extra high penetration if required for flat position welding only for d c pole and a c
15. only or in a ld 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 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 ad ditives in order to avoid the formation of paraffin e GROUNDING CONNECTION See section Use as a generator page M37 20 02 14 22270 GB CD GB STARTING Check daily mear Do not alter the primary conditions of regulation and do not touch the sealed parts RECOIL VERSION 1 Open fuel cock 2 Accelerator lever must be in the START position 3 Grasp the starter handle as shown 4 Pull the starter rope until you feel resistance and let it return slowly to its original position 5 lower the decompression lever 6 pull the rope firmly as far as it will go If necessary use two hands M 21 REV 0 02 14 MAGIC WELD 200 YD YDE ELECTRIC STARTING 1 Carry out operations 1 and 5 as with pull start 2 Turn the starter key to the ON position the accelerator control solenoid will automatically move the D accelerato
16. zone and welding area If adequancy of ventilation or exhaust is uncertain have your exposure measured and compared to the T Welding can cause fire or explosion Do not weld near flammable material Move flammanles at least 10 m away or protect them with flame proof covers Do not weld on drums thanks or any closed containers unless a qualified person has tested it and declared it or prepared it to be safe Welding sparks can cause fires Have a fire extinguisher nearby and have a trained fire watcher ready to use it Arc rays can burn eyes and skin Use welding helmet with correct shade of filter Wear welders cap and safety glasses with side shields Use ear protection when welding out of position or in confined spaces Button shirt collar Wear complete body protection Wear oil free protective clothing such as leather gloves heavy shirt cuffless pants and hight boots 17 05 05 M2 2 TS DSP GB CD SIMBOLI E AVVERTENZE RELATIVE ALLA SICUREZZA MOSA MOSA 1 0 05 04 CE ENGINE HAZARDS Fuel can cause fire or explosion Engine fuel plus flames or sparks can cau se fire or explosion Do not weld near engine 29 fuel Do not spill fuel If fuel is spilled clean it up and do not start engine until fumes are by Engine exhaust gases can kill Vent exhaust outside and away from any x building air intakes D DO NOT fuel a hot engine Stop engine let it cool off before c
17. 03 05 Registration Number T 3722 KNet ZZ lt lt 0 Michael Drechsel President of IQNET President of CISQ IQNet Partners AENOR Spain AFNOR Certification France AIB Vingotte International Belgium ANCE Mexico APCER Portugal CCC Cyprus CISQ Italy CQC China China CQS Czech Republic Cro Cert Croatia DOS Holding GmbH Germany DS Denmark ELOT Greece FCAV Brazil FONDONORMA Venezuela ICONTEC Colombia IMNC Mexico INNORPI Tunisia Inspecta Certification Finland IRAM Argentina JQA Japan KFQ Korea MSZT Hungary Nemko AS Norway NSAI Ireland PCBC Poland Quality Austria Austria RR Russia SII Israel SIQ Slovenia SIRIM QAS International Malaysia SOS Switzerland SRAC Romania TEST St Petersburg Russia TSE Turkey YUQS Serbia IQNet is represented in the USA by AFNOR Certification CISQ DQS Holding GmbH and NSAI Inc The list of IQNet partners is valid at the time of issue of this certificate Updated information is available under www iqnet certification com Gianrenzo Prati SEE 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 operation
18. 200 YDE A C GENERATION 50 60 Hz Single phase output 230V max 3 3kVA 230V 14 3A Single phase output 230V continuous 230 V 13A Single phase output 115V max 2 1 kVA 110 V 18 3A Single phase output 115V continuous 1 8 KVA 110 V 16 4 A Cos y 0 8 ALTERNATOR Type permanent magnet self excited brushless Insulating class H ENGINE Mark Model YANMAR L70N Type Cooling system Diesel 4 stroke Air Cylinders Displacement 1 320 cm Net power 4 9 kW 6 7 HP Speed 3600 rpm Fuel consumption Welding 60 1 Wh Engine oil capacity 1 05 Starter recoil Electric GENERAL SPECIFICATIONS Tank capacity 9 91 Running time Welding 60 3 3 h Protection IP 23 Dimensions max on base Lxlxh 630x480x540 Weight dry 72 Kg 91 Kg Acoustic power LwA pressure LpA 103 dB A 78 dB A 7 m Dimensions and weight are inclusive of all parts POWER Declared power according to ISO 3046 1 temperature 25 C 30 relative hummidity altitude 100 m above sea level Its 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
19. CE MARK DECLARATION OF CONFORMITY TECHNICAL DATA TECHNICAL DATA ADVICE SYMBOLS SYMBOLS INSTALLATION AND ADVICE INSTALLATION UNPACKING AND TRANSPORT ASSEMBLING CTM MW 200 D ASSEMBLING TRM MW 200 D SET UP FOR OPERATION ENGINE STARTING STOPPING THE ENGINE CONTROLS USE ASAWELDER PARALLEL ENGINE DRIVEN WELDER USE AS A GENERATOR REMOTE CONTROL REMOTE CONTROL ENGINE PROTECTION TROUBLE SHOOTING MAINTENANCE SIORAGE CUST OFF RECOMMENDED ELECTRODES ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM M 1 REV 0 02 14 20 02 14 22270 GB CD M Copyright 1 01 REV 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 We advise you to pay attention to the pages concerning the security see page M1 1 All rights are reserved to said Company Itis a property logo of MOSA division of B C S S p A All other possible logos contained in the documen tation are registered by the respective owners E t The reproduction and total or partial use in any form and or with any means of the documen tation 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 ri
20. Fuel level gauge D2 Ammeter E2 Frequency meter F2 Battery charge trasformer G2 Battery charge PCB H2 Voltage selector switch I2 48V socket L2 Thermal relay M2 Contactor N2 G F l and circuit breaker O2 42V EEC socket P2 G F I 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 ca socket Z2 Thermal magnetic circuit breaker W2 S C R protection unit X2 Remote control socket Y2 Remote control plug Insulation moitoring B3 E A S connector E A S PCB D3 Booster socket lt X FN lt C AA G DO U Z TO T TI O gt 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 I min solenoid valve Hydraulic oil pressure switch Hycraulic oil level gauge Preheating glow plugs Preheating gearbox Preheating indicator R C filter He
21. PANELS Check condition of cables and connections daily Clean periodically using a vacuum cleaner DO NOT USE COMPRESSED AIR DECALS AND LABELS All 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 MA3GB 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 r gt 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
22. SALDATURA WELDING GENERATOR GRUPPO ELETTROGENO POWER GENERATOR TORRE FARO LIGHTING TOWER Marchio Brand Modello Model Matricola Serial conforme con quahtq Sto de Comunitarie e relative modifiche est en conformit aveclce Gul lest prevu par les Directives Communautaires et relatives modifications conforms with the Community Directives and related modifications mit den Vorschriften der Gemeinschaft und deren Erg nzungen bereinstimmt in overeenkomst is met de inhoud van gemeenschapsrichtlijnemen 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 erm chtigten 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 Consigliere Delegato Managing Director V le Europa 59 20090 Cusago MI Italy Cusago Ing Benso Marelli Consigliere Delegato Managing Director MM 083 1 04 06 10 M1 4 1 CD M Technical data MAGIC WELD 200 YD YDE 1 5 O REV 0 02 14 Technical data MAGIC WELD 200 YD MAGIC WELD
23. USE AND MAINTENANCE MANUAL MADE IN ITALY CD M DESCRIPTION OF THE MACHINE MAGIC WELD 200 YD YDE 0 CE REV 0 02 14 The MAGIC WELD engine driven welder is a unit which ensures the dual function as a a current source for are welding b current generator for generating auxiliary Unit meant for industrial and professional use Powered by an endothermic engine it is composed of va rious parts such as engine alternator electric and electronic controls the fairing at 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 CANOPY FRAME ENGINE BATTERY ALTERNATOR VIBRATION DAMPER 20 02 14 22270 GB CD Quality system LA Net THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE CISQ ICIM hereby certify that the organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 1 20081 Abbiategrasso MI Operative Units Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 1 20090 Cusago MI for the following field of activities Design production and servicing of tractors agricultural and 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 2012 03 06 Validity date 2015
24. V__ terminal CONTR Remote connection presence contact wire bridge towards C cabling side Non connected J AUTO IDLE Operation When the engine is switched on it immediately reaches a maximum speed of 3720 rpm for ap proximately 6 7 seconds for easy start up after which it automatically decreases and idles at 2650 rpm It remains at this speed until current is drawn when set to weld or auxiliary power When set to weld mode the machine reaches maximum engine speed as soon as there is minimum contact between the tip of the electrode and the piece to be welded and also when set to generation drawing a minimum of 250 300 W The machine returns to minimum 6 7 seconds later if power is not drawn during welding or generation 009 co 1 G 20 02 14 22270 CD M Parallel engine driven welder MAGIC WELD 200 34 3 CE MAGIC WELD 200 YD YDE REVO 11 08 How to put two machines in parallel from the front panels of the machines connect the two positives welding sockets between themselves and the two negative welding sockets bethween themselves To effect the connection ask for the accessory K2X150 ATTENTION use fit cables and tight at the connection point How to proceed start the machine putting the two welding handles T in the wanted position half of the total current put in parallel with the right cables proceed with welding So dal 18 11 08 22262 GB CD
25. ater 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 YLA commutator Emergency stop button Engine protection EP5 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 M Start Local Remote selector N9 UP DOWN button mast Choke button O9 Hydraulic unit solenoid valve Switch CC CV P9 Hydraulic unit engine Connector wire feeder Q9 Ignitor 420V 110V 3 phase transformer R9 Lamp Switch IDLE RUN S9
26. ces 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 M 1 1 REV 1 03 14 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 it is prescribed by law The Manufacturer shall not be liable for ANY USE OF THE PRODUCT OTHER THAN THAT PRECISELY SPECIFIED IN THIS MANUAL and is thus not liable for any risks which may occur as a result of IMPROPER USE The Company does not assume ary
27. e MARE Il presente certificato soggetto al rispetto EECH sistemi di gestione per la qualit delle aziende The use and the validity of this certificale shall sa rugs a AC AYMAN pil ali Data emissione Emissione corrente First issue Current issue 30 05 1994 06 03 2012 Data di scadenza Expiring date 05 03 2015 D ICIM S p A Piazza Don Enrico Mapelli 75 20099 Sesto San Giov ACCREDIA 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 M 01 M 1 01 M 1 1 M 1 4 M1 4 1 M 1 5 M 1 6 M 2 1 M 2 2 M 2 6 M 2 7 M 3 M 6 21 M 6 22 M 20 M 21 M 22 M 31 M 34 M 34 3 M 37 M 38 10 M 38 12 M 39 6 M 40 M 43 M 45 M 55 M 60 M 61 MAGIC WELD 200 YD YDE DESCRIPTION OF THE MACHINE QUALITY SYSTEM COPYRIGHT NOTES
28. e machine mo vements 10 06 00 M6GB CD GB Set up for operation E BATTERY WITHOUT MAINTENANCE where it is assembled The included battery must be activated To activate it fill the included acid please follow the instructions shown on the manual attached to the battery When battery is activated DON T add any other liquid LUBRICANT Please refer to the motor operating manual for the recommended viscosity RECOMMENDED OIL The manufacturer recommends selecting AGIP engine oil Refer to the label on the motor for the recom mended products 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 Don AIR FILTER 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 M MAGIC WELD 200 YD YDE 20 d FUEL Stop engine when fueling Do not smoke or use open flames during re fuelling operations in order to avoid explosions or fire hazards Fuel fumes are highly toxic carry P out operations outdoors
29. ected S3kVA POWER GENERATION 230 Vac OkVA O 8kVA 1 5 kVA 2 1 kVA 2 5 kVA 3kVA POWER GENERATION 115 Vac 0 5 1kVA 1 3 1 5 KVA 1 8 kVA 20 02 14 22270 GB CD M WARNINGS 2 REV 1 02 14 The installation and general warnings regarding operations are aimed achieving correct use of the machine and or apparatus in the place where it is used as a genset and or motor welder Advice to the User about the safety i NB The information contained in the manual can be changed without notice Any damage caused in connection with the use of these instructions shall not be considered as they 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 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 DANGEROUS This heading warns of situations which could result in injury for persons or damage to things To this advice can appear a danger for persons as well A CAUTION as for things for which can appear situations bringing material damage to things N IMPORTANT These headings refer to information which will assis you AN NOTE in the correct use of the machine and or accessories ATTENTION FIRST AID In case the operator shold be sprayed by acciden
30. ght and 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 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 10 10 02 M1 01 GB INFORMATION Dear Customer We wish to thank you for having bought 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 over haul operations to turn to the nearest authorized Service Centre where you will obtain a prompt and specialized intervention t In case you do not profit on these Services and some arts are replaced please ask and be sure that are used exclusively original parts this to guarantee that the performances and the initial safety prescribed by the norms in force are re established r gt The use of non original spare parts will cancel immediately any guarantee and Technical Service obligation NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively Follow the instructions contained in it in this way you will avoid inconvenien
31. he 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 manufacturer 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 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 0800099 A A T according to the type of intervention protective gloves insulated gloves glasses 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
32. hecking or adding fuel Use unit outside in open well ventilated areas Moving parts can cause injury Keep hands hair loose clothing and tools away from moving parts such as fans belts and rotors Keep all doors panels and guards closed and secured Battery explosion can blind Sparks can cause battery gases to explode Do not smoke and keep matches and flames away from battery Wear a face shield or safety glasses when working near or on a battery Bettery acid can burn skin and eyes Do not spill acid Wear rubber gloves and a face shield or safety glasses when working on a battery oteam and hot coolant can burn Check coolant level when engine is cold to avoid scalding If the engine is warm and checking is needed wear safety glassesand gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely removing cap Exhaust sparks can cause fire Use approved engine exhaust spark arrestor in required areas Keep exhaust and exhaust pipes away from flammables Do not locate unit near flammables Hot parts can cause severe burns Do not touch not welder with bare hand If handling is needed use proper tools and or wear heavy insulated welding gloves to prevent burns Allow cooling period before handing parts or working on gun or torch 17 05 05 M2 1 TS DSP GB CD M INSTALLATION AND ADVICE 2 6 REV 1 06 07 INSTALLATION AND ADVICE BEFORE
33. ion Ensure that ground clamp whose cable must be connec ted to the socket or the socket according to the type of electrode makes good contact and that if possible it is close to the welding position Pay attention to the two polarities of the welding circuit which must not come into electrical contact with each other PUSH AND TWIST ADJUSTING THE WELDING CURRENT The welding current is regulated by turning knob T continuously If so set to the minimum turned fully in an anticlockwise direction it provi des a current of approximately 30 Em A if set to the maximum turned fully in a clockwise direction it gives a maximum current of approximately 200A 20V M 34 REV 0 02 14 MAGIC WELD 200 YD YDE REMOTE CONTROL The welding machine is predisposed for connection to a remote control optional by means of the circu lar connector located on the front panel Once the connection to the remote control has been made the function of regulating the main potentiometer located on the front panel will be automatically switched to the remote control potentiometer be The following table describes the functions of each of the connector s contacts PUSH AND TWIST D E O CONTATTI DESCRIZIONE A electric To the RC TC potentiometer GND ground terminal To the RC TC potentiometer V terminal C To the RC TC potentiometer
34. l 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 CTM accessory If you did not keep to the instructions you could damage the structure of the machine Weight max per person 35 kg Total max weight 140 kg 15 01 01 MAGB Note Lift the machine and assemble the parts as shown in the drawing N ATTENTION The CTM 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 mo vements CD M ASSEMBLY CTM MW200 D 6 21 REV 0 02 14 AO ORI 10 06 00 M6GB CD M ASSEMBLY TRM MW200 D 6 22 REV 0 02 14 Note Lift the machine and assemble the parts as shown in the drawing n MY UM UM M M Mm TAN IW Ww 2 Wi WI MW 2 d 2 7 N ATTENTION The TRM 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 th
35. ole connector When the remote control is connected to the remote control connector 8 it is functional and automati cally excludes the front panel regulation Position welding current adjusting T knob at the necessary current value for the diameter and type of electrode REMOTE CONTROL PUSH AND SCREW TIGHT M 38 12 REV 0 06 10 09 11 99 M38GB CD ENGINE PROTECTIONS The engine is equipped with system protection stop in the event the oil pressure is too low In the event of a malfunction in the battery charging system the warning light will come on without stop ping the engine MAGIC WELD 200 YDE 47 39 6 REV 0 02 14 20 02 14 22270 GB CD Trouble shooting motor does start starts up then stops immediately MOTORE Lack of fuel in tank Air in the fuel circuit Incorrect position of accelerator control knob Battery low Battery cable terminals loose or corroded Start up motor defective Faulty starter key Faulty emergency stop of engine Malfunction on electrical power circuit 0 5 6 T 8 9 1 M MAGIC WELD 200 40 REV 0 02 14 Solution Rifornire il serbatoio Check power supply circuit Check position Recharge or replace Check the battery charge circuit Tighten and clean Replace if corroded Repair or replace Replace Replace Check and repair Malfunction on feed circuit defec
36. ons 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 M 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 rry MOSA
37. r lever into the START position 3 Turn the starter key to the ON position when the motor is running let the key reposition itself to ON 4 When the motor is started it will immediately reach the nominal RPM for approx 6 7 seconds after which time it will automatically go down to the minimum set by the solenoid which controls the accelerator lever 5 When welding power or auxiliary generation is required the motor will automatically go up to the nominal RPM necessary for the use of the machine EMERGENCY PULL START FOR ELECTRIC STARTER VERSIONS If all the above conditions have been met proceed as follows The pull start for electric starter versions is only possi ble if the all the conditions listed below have been met the starter battery must remain connected to the electrical circuit the starter battery must be able to power the accele rator control solenoid check this condition turning the starter key to the ON position unplug the pressure switch cable 1 Open fuel cock 2 Turn the starter key into the ON position check that the accelerator control solenoid moves the accelerator lever into the START position 3 Grasp the starter handle as shown 4 Pull the starter rope until you feel resistance and let it return slowly to its original position 5 lower the decompression lever 6 pull the rope firmly as far as it will go If necessary use two hands 10600 20 02 14 22270 GB
38. s 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 M 01 REV 4 03 12 ICIM www icim it CERTIFICATO n 0192 6 CERTIFICATE No SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITA DI WE HEREBY CERTIFY THAT THE QUALITY MANAGEMENT SYSTEM 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 ACTIVITIES 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 Riferirsi al Manu Portes preset applicabilit dei requisiti della norma di riferimento Refer to Quality Manual for of application to referenc
39. sure circuits keep in mind that the inflamability point is very low CO O N O CD SYMBOLS AND SAFETY PRECAUTIONS SYMBOLS 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 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 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 lt b P P P P P J AY ACCES FORBIDDEN to non authorized peaple M 2 1 REV 2 06 10 PROHIBITIONS harm for pers
40. t from corrosive liquids a o hot toxic gas or whatever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions ER 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 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 pres
41. ter in fuel sender EDC7 UC31 engine PCB Low water level sender Interface card Limit switch Starter timing card Luquid pouring level float Under voltage coil Low water level warning light Chopper driver PCB Fuel filter heater Air heater ON OFF switch lamp 26 07 04 M60GB 12 VL C0 07 4 ronpieg 1eubrseq euruoe azojeubastgq DEUIQOOPW 9N0 7 eurbu3 39e 01q uoi 033eb01g euolzeuruoueq beg eq UOTIPO TI TRON COTITPON REV 0 02 14 MAGIC WELD 200 YDE reco gt Lod D I oo is oto no A amp sg TT Lao I I I I I SIS 1N4007 1A O O 2 E o LLI CD Schema elettrico Electric diagram 14 vV co oc 090 S 07ccc t OcOVOV dloonpreg NMO38 3NOHsVvI 9 REV 0 02 14 gt ja ie i SEELEN e 62902222 webera Buum gt E E HRR D X worsAonwe LL PT ee HO 109 AIM VIN3931 VIL NOEC OLL e gt e gt o e LLI 2 e lt Conve vr waawo er waawnr 318V1 NOIL9313S LYVLS 19212 OOlINH LL3 13 OLN3IAVIAAV O lOS trico c Esquema CD Schema elettrico Electric diagram MOSA div della BCS S p A Viale Europa 59 20090 Cusago Milano Italy Tel 39 0290352 1 Fax 39 0290390466 www mosa it
42. the front panel there is 5 Vdc Ask for intervention of Service Department to replace the board Ask for intervention of Service Department Ask for intervention of Service Depart ment 20 02 14 22270 GB QD MAINTENANCE M 43 REV 1 01 13 e Have qualified personnel do maintenance and troubleshooting work e Stop the engine before doing any work inside the machine If for any reason the machine must be operated while working inside pay at tention 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 e Please wear the appropriate clothing and make use of the PPE Per MOVING sonal Protective Equipment 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 mainte nance activities i e t
43. tive pump 10 Ask for intervention of Service Department injector blocked 11 Clean or replace 11 Air filter or fuel filter clogged 12 Consult instruction and maintenance ma The motor does not accelerate Inconstant speed Black smoke White smoke Too little power provided by motor Low oil pressure 12 Other causes Air filter or fuel filter clogged Malfunction on feed circuit defective pump injector blocked Oil level too high Motor speed regulator defective Air filter clogged Overload Injectors defective Injection pump requires calibration Oil level too high Motor cold or in prolonged operation with little or no load Segments and or cylinders worn out Air filter clogged Insufficient fuel distribution impurities or water in feed circuit Injectors dirty or defective Oil level insufficient Air filter clogged Oil pump defective Alarm malfunction nual of the engine Clean or replace Ask for intervention of Service Department Eliminate excess oil Ask for intervention of Service Department Clean or replace Check the load connected and diminish Ask for intervention of Service Department Eliminate excess oil Insert load only with motor sufficiently hot Ask for intervention of Service Department Clean or replace Check the feed circuit clean and refill once again Ask for intervention of Service Department Reset level Check for leaks Replace filter
44. ts 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 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
45. 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 45 REV 0 06 07 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 CDD CUST OFF CED x Have qualified personnel disassemble the machine and dispose of the par
46. y complex or in an area with potential electrical risk it is required to interpose a complete electrical distribution panel equipped with all electrical protections required between the plug and loads For example you can use a distribution system TN S In this case one of the phases used as a neutral must be grounded a bipolar 30mA differential switch GFI must be mounted inside the electrical box before the sockets to which loads are connected the terminal in the frontal panel of the generating set near the socket is to be used as earth connection M MAGIC WELD 200 YD YDE 37 REV 0 02 14 wiring it to the ground of the electrical plant with which the machine is going to work WARNING bound the neutral to frame BEFORE the GFI 20 02 14 22270 GB CD ACCESSORY USE TS SERIES PUSH AND SCREW TIGHT 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 RC2 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 REMOTE CONTROL RC2 RC2 90 PUSH AND SCREW TIGHT M 38 10 REV 0 12 11 09 04 02 M38GB CD ACCESSORY USE The remote control device for regulating the welding current is connected to the front panel by means of a multip

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