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1. DIAGNOSTIC indicator Welding selector mode R C net 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 Polarity inverter two way switch 26 07 04 M60GB I 1988 90 S0 c L euoIzezziojne ens ezues Gilet e O JEOIUNWOD O OJINpo du ip OJSIAIP uoo ouBesip ejueseud ep eyeudoud eebe Ip IULIIS e BAISSLI IS YSON EI USE N esejoda7 Sd 009 dsa T jJ esou mmw dy Bed P V J uBiseq euuoen ebeqo ATVLIHIW O9VSNI 06007 1ojeu6 sid BUIYIDEIA LO v 0LL sunuad euibu3 5 3o oid uoneuiuioueq i wol4 Beg eq 0yebold UOIZeUILIOUEG UOREOLIPON EOIJIDON DSP 600 PS PSX I I I I I I I I I I TU MEE I I I SL g LF D 1 i R I ll p TTT Kl LL Va OL C lt zH09 0S lt e Adee SCO LeO Lao 9I oo 9 O a Juu 3 G umm gt O Bei O a LL cO O LO T e o S Z E e e ua o 2 DSP 600 PS 400T230M110M Esa G umm gt O ud O a DI cO e LO T e o s Z E ae lt e ua o 2 a ae ens ezues ES e SE o olunpoidi Ip o IAIp uoo ouB sip ejueseud ep eyeudoud e 26e Ip tuua
2. conforme con quanto previsto dalle Direttive Comunitarie e relative modifiche est en conformit avec ce qui est pr vu 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 98 37 CE 73 23 CE 89 336 CE 2000 14 CE per la verifica sono state considerate le seguenti norme armonizzate Norme nazionali e internazionali pour la v rification de la conformit ont t consult es les normes harmonis es suivantes normes nationales et internationales to check the conformity the following harmonized norms national and international norms have been consulted zur Pr fung hat man die folgenden Gbereinstimmenden nationalen und internationalen Normen herangezogen ter verificatie van de overeenkomst zijn de volgende geharmoniseerde normen nationaal en internationaal geconsulteerd para su verification se han tenido en cuenta las Normas armonizadas Normas nacionales e internacionales Norme armonizzate normes harmonis es harmonized norms bereinstimmende Normen geharmoniseerde normen Normas armonizadas EN 292 1 EN 292 2 EN 60204 1 EN 50199 EN 60974 1 Solo per modelli Seulement pour les mod les Only for mo
3. A00F IA8Y YYOL lat LL Ly VL qe z Ca c gt ES LE CS r e L co o LO P ce T e la 4 2s D w ES o E G 2 Qa o V I LL988 90 50 31 guo 7077110 ne ens ezues Gilet e OLJesIUNUIO9 o OLNPOJd Ip OJSIAIP uoo ouB sip ejueseuJd ap eyeudoud ej 9663 Ip IULIIS e BAISSII IS WSOW 27 USE i N esejoda7 Sd 009 dsa ESOU MAAT Cu Bed Eil eubiseg uuoen obego ATVLI IN O9DVSNI 0600Z euo0jeuBesiq euiuooelN 2 rentre gt VS UJjO Lu abed 3oefoJd uoneuiuioueg jebeg Wo4 AU ID ubed 0 jebold auoizeuiwoueg bed eq ddy UODSCOHIDO addy S i H DSP 600 PS PSX O 92 WWOY OL OLN Ot si Ch x a n EE x 4 OH x ii x 9 T a da E a SS e nmm Ll e e H cO o LO F e la EK D ES E G 2 Qa o V DSP 600 PS PSX a Ba S a EI e nmm Sum is e eo H cO o LO F e la 4 2s D Y ES o E 2 Qua o V euoizezzuojne ens ezues Gilet e ojreoiunujoo o ounpoaudu Ip ojeiup uoo OUBaSIP ejueseud ep eyeudoud e a6Ba ip iuiuue e euesu IS WSOW 27 ER U Jo mai OVO S LL988 9002 090 N a9eioda7 Sd 009 dsqQ lt J esou MMM dju u FM ejeq Joubisag t9uluoBN obed oL ATVLI IIN ODWSND 06002 U SIG 2ed 1oje
4. e LE ight Air filter Belt for preheatin de Duce blockage breakage Users Information Various manual news Overspeed Control unit QEA temperature Electronic Voltage regulator Voltmeter phase selector Frequency Ammeter meter Compound Switch Isolation monitoring Socket 48V EEC Battery charger Engine booster F E D m CC CV selector ET Contact starting Costant voltage Costant current Polarity inverter n Central lifting eye Maintenance Time Minus 15 06 98 M2 4GB CD LISA amp INSTALLATION AND ADVICE BEFORE USE GE MS TS OMOSA 1 0 06 00 CF A The installation and the general advice concerning the operations are finalized to the correct use of the machine in the place where it is Used as generator group and or welder Stop engine when fueling Do not touch electric devices if you Do not smoke avoid flames sparks or electric tools when fueling are barefoot or with wet clothes Unscrew the cap slowly to let out the fuel vapours Always keep off leaning surfaces d Slowly unscrew the cooling liquid tap if the liquid must be topped up uring work operations The vapor and the heated cooling liquid under pressure can burn face eyes skin Static electricity can demage the p arts on the circuit Do not fill tank completely Wipe up spilled fuel before starting engine hut off fuel of tank when moving machine where it is assembled An electr
5. D IMI IE Es A G REQUEST FOR ORDER SPARE PARTS MOSA 1 0 04 97 CF Dear Customer Ou can send us the request for order of MOSA original spare parts filling in this form with the new spare parts tables as well as with the old ones by FAX or mail Request mA lee ife rz TE Please send use us following sapre parts for the machine below MOSA SPARE PARTS model Ivpe nennen ess LAA Ett TT NEW TABLES OLD TABLES ENGINE SPARE PARTS engine model SYNCHRONOUS ALTERNATOR SPARE PARTS alternator model J alternator serial nr eee enn nnne 8 04 97 R1 1 E i A RE Au l e I c Ic X ac a O es c iL u Ioa c CEN VAM O A A VAL EN SM iu
6. Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine SYMBOLS AND SAFETY PRECAUTIONS GE_ MS TS SAFETY PRECAUTIONS AN 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 AN CAUTION To this advice can appear a danger for persons as well as for things for which can appear situations bringing mate rial damage to things AN IMPORTANT A AN ATTENTION These headings refer to information which will assis you in the correct use of the machine and or accessories NOTE 26 11 99 M2GB O OSA 1 1 04 03 CF SYMBOLS for all MOSA models MOSA STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE l 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 gt P E O gt FIRE Danger of flame or fire I
7. GS synchronous alternator h hour meter symbol H Hatz engine H Honda engine HI hydraulic central Hz frequency I single phase auxiliary generation symbol 1 MOSA MOSA GE MS_ TS_ IP protection grads for electric devices against acess to dangerous parts according to the IEC 529 norm Internal Protection kg kilogram mass K welding cables set kVA kilovolt ampere kW kilowatt engine power kWh kilowatt hour energy I liters capacity L Lombardini engine Lwa maximum acoustic power level according to the regulations in force mm millimeter length measure m meter length mA milliampere MS MSG MOSA engine driven welder with high frequency alternator MT magnetothermic switch MT grounding kit MTD magnetothermic switch GFI OH heater engine oil for generating sets P plus PAC power electric frame PAR device for double PB battery holder PL pipe line welding PS exhaust pipe extension PW welder for polyethylene and propylene pipes QEA automatic electric panel QEM manual electric panel R Ruggerini engine RVT voltage electronic regulator S symbol of EN 60974 1 S Suzuki mengineotore SKID unit assembled on a base with no protection no fairing S SC silenced faired silenced compact faired SX SXC supersilenced faired and sound prof supersilenced compact faired and super sound prof T thermic switch TC TCM TCPL remote
8. SPARE PARTS LIST SPARE PARTS 12 05 06 88611 GB CD M D SA D Copyright 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 We advise you to pay attention to the pages concerning the security see page M1 1 MOSA 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 m 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 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_
9. della Norma ISO 9001 2000 requirements Data di scadenza Expiring date 05 03 2009 DE 30 05 1 994 Emissione corrente Current issue 06 03 2006 ICIM S p A PIAZZA DIAZ 2 20123 MILANO The advantages for MOSA clients are e Constant quality of products and services at the high level which the client expects e Continuous efforts to improve the products and their performance at competitive conditions e Competent support in the solution of problems e Information and training in the correct application and use of the products to assure the security of the operator and protect the environment e Regular inspections by ICIM to confirm that the requirements of the company s quality system and ISO 9001 are being respected All these advantages are guaranteed by the CERTIFICATE OF QUALITY SYSTEM No 0192 issued by ICIM S p A Milano Italy www icim it 10 10 02 M01 GB DSP 600 PS PSX QUALITY SYSTEM COPYRIGHT NOTES CE MARK SYMBOLS AND SAFETY PRECAUTIONS ABBREVIATIONS LEGEND INSTALLATION AND ADVICE BEFORE USE INSTALLATION AND ADVICE UNPACKING TRANSPORT AND DISPLACEMENTS COVERED UNITS ASSEMBLY CTL PREPARING THE UNIT START UP SHUTTING DOWN THE MOTOR CONTROLS USE AS A WELDER WELDER DSP USE USING THE GENERATOR REMOTE CONTROL ENGINE PROTECTIONE EP5 TROUBLESHOOTING MAINTENANCE STORAGE CUST OFF TECHNICAL DATA TECHNICAL DATA ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM
10. 2 Aux power voltage value 15V too high or too low P4 Blinking red LED O 1 The chopper thermic protection is intervening 2 Temperature sensor situated on chopper NTC resistor short circuited or open 3 WDC defective P5 Red LED always on 1 WDC defective O 2 Chopper defective 3 Current sensor defective P6 PHG1 remote does not operate 1 Remote control or cable defective 2 WDC defective P7 The welding current WDC is always at Max or always at minimum 1 Potentiometer defective 2 WDC defective 3 Welding current defective on sensor P8 No voltage at the welding sockets in CV mode 1 Defective wire feeder cable 2 Defective wire feeder 3 Defective WDC P9 No welding or generation output 1 Short circuit of chopper 2 Short circuit of generation unit 3 Alternator defective 1 Adjust the position of the WDC regulation knob on the potentiometer spindle so that the potentiometer is not completely at the end of its travel when the knob reaches its minimum position Idem for the RC1 remote control knob 1 Replace the WDC 1 Connector P3 not inserted or defective see drawing 5 2 Check the aux trasformer see drawing 1 1 The output is inhibited automatically let the motor continue to run to cool down the chopper and after a few minutes the LED will automatically switch off and there will be current voltage once again at the welding sockets 2 Check
11. 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 avoid inconveniences due to negligence mistakes or incorrect maintenance The manual is for qualified personnel who knows the rules about safety and health installation and use of sets movable as well as fixed You must remember that in case you have difficulties for use or installation or others our Technical Service is always at your disposal for explanations or interventions The manual for Use Maintenance and Spare Parts is an integrant part of the product I
12. central b electri C 5 V d c us potentiometer RC1 terminal C INN short circuit with contact C E To switch Polarity Inverter F 5 V d c Close for negative polarity G Return from switch on CV welding gun 1 phase 44 48V a c H welding ground Welding ground for d c voltmeter on wire feeder 44 48V a c J 44 48V a c Voltage supply for wire feeder 11 10 04 M33_WDC_GB IM EI Es A use AS A GENERATOR MOSA 1 0 04 02 It is strictly forbidden to connect the group to the public mains and or to any other source of electric power GENERATION IN AC ALTERNATING CURRENT Make certain of the efficiency of the ground connection 12 See page M20 Position the G F l switch to ON c Voltage is now immediately available to the AC sockets Verify that the voltmeter displays the nominal voltage value 10 Connect the electric devices to be powered to the AC sockets using suitable plugs and cables in good condition c Verify that the electrical characteristics voltage frequency power of the device being powered are compatible with those of the generator Low frequency and or voltage can irreparably damage some electrical devices Verify that the ground lead of the electrical appliance tool to be powered is correctly connected to the terminal of the plug r For double insulation devices with the symbol the plug s ground terminal does not need
13. 06 00 CF GE_ MS TS_ 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 15 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 compression 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 recharge 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 fir
14. Netherlands KFQ Korea MSZT Hungary Nemko Certification Norway NSAI Ireland OQS Austria PCBC Poland PSB Certification Singapore QMI Canada RR Russia SAI Global Australia SFS Finland SII Israel SIQ Slovenia SOS Switzerland SRAC Romania TEST St Petersburg Russia YUQS Serbia and Montenegro IQNet is represented in the USA by the Following partners AFAQ AIB Vingotte International CISQ DQS KEMA NSAI QMI and SAI Global The list of IQNet partners is valid at the time of issue of this certificate Updated information is available under www iqnet certification com UNI EN ISO 9001 2000 gme ISO 9001 2000 Cert 0192 3 MOSA has certified its quality system according to UNI EN ISO 9001 2000 to ensure a constant high quality of its products This certification covers the design production and servicing of engine driven welders and generating sets The certifying institute ICIM which is a member of the International Certification Network IONet awarded the official approval to MOSA after an examination of its operations at the head office and plant in Cusago MI Italy This certification is not a point of arrival but a pledge on the part of the entire company to maintain a level of quality of both its products and services which will continue to satisfy the needs of its clients as well as to improve the transparency and the communications regarding all the company s actives in accordance with the official procedures and in harmony wi
15. chopper connector drawing 2 from pin 1 2 The resistor must be bigger than 1800 Q and less than 25 KO otherwise the led blinking Replace the chopper In the meantime you can work cutting the wire which arrives to pin 1 pin 2 and put on it one resistor 10 KQ In this case the thermic protection don t work but you can use the machine 3 Replace the WDC 1 Switch off the machine and start it up again if the LED remains off try to weld verifying that the welding is regular if the LED lights up again Replace the WDC 2 Check the chopper as shown on drawing 2 3 Replace the sensor 1 Check the remote control as drawing 4 2 Replace the WDC 1 Check from pin 1 12 connector P4 pin 1 ground see drawing 3 2 Replace the WDC 3 Replace the current sensor 1 Check the connections pin to pin of the wire 2 Check the wire feeder 3 Without wire feeder cable put the pin in short circuit with G on remote control connector the led ON must be light WDC ok otherwise change WDC 1 Disconnect the chopper and re start the machine if there is now an output present replace the chopper 2 Disconnect the auxiliary output circuit and re start the machine if there is now an output present there is a short circuit in the auxiliary output circuit or in one of the components 3 Disconnect all outputs on the alternator welding and 12 05 05 M40DSP EP5 GB CD GB GB TROUBLE SHOOTING 1 1 11 05 PROBLEM
16. control TS welder with asynchronous alternator V Volt Y Yanmar engine Y three phase auxiliary generation symbol 3 14 06 99 M2 3GB D MOSA symsois 1 1 04 05 CE C Elu S Y Conformity EN 60974 1 Triphase Ser n conformity conformity 3 Equipment and optional lob Air Water cooling cooling es er ers Engine Engine Engine protection protection protection e eN el Battery Fuel level Low fuel charger ae ae indicator indicator 69 Asynchronous Synchronous Generator Voltmeter alternator alternator high frequency wo ur D T poen oe Circuit Ground fault Thermal round fault breaker interrupter shut off interrupter Ei O O e CEE 1 CEE 1 Schuko T I Socket Socket Socket ZU 400 230V 280 110 48V 230V EEC EEC Schuko Arc Welding with Welding cur Bas current control covered rent electr I diode bridge electrode regulation A Hour Readv for Ground Emergency counter T connection stop button Bl Standard equipment Diesel engine Gasoline engine Engine protection C9 gt Oil level indicator Engine alarms Various Options on request boy e Welding cables Optionals Trolley Site tow Remote control GE_ MS_ TS DSP_ D Singlephase 1 B QU Manual Electric Battery recoil start 12 V ers tap Ea Engine Siren Engine shut Engine protection down oil speed x
17. e BAISSII IS YSOW 87 N e e1ode Sd 009 dSd y esourmmmw dpy lt AWLI II OOVSNI 0600Z ueuBiseq euluoew eBegd or e ojeuBesiq euiuooeWw Bed BIN Bid 1 984 LA 2X3 LOOL ZXWO0EZ LOOP nv me uoneuiuoueq Seg wou elo Zeg Dee euorzeuiuioueq uoneouipoyw EOUIPON H O D Vce ANO C V A00F Vc IAOLL I 1 1988 90 S0 cL I L E988 90 S0 cL euoizezziojne ens ezues IZJ8 e o reoiunuJoo o ounpoudu Ip OJSIAIP uoo ouBesip ejueseud ap eyeudoud eebe Ip ue e eAJesu IS YSOW 21 aid 020 S FPL98 9007 0 EL Neoeode Sd 009 S1 J _ wesouwwwydnu p JueuBiseq QUIYIEIN Ded oL ATVLI IW OSvSno 0600c j bed ellv e ojeubesiq euluo9en BidryL982 9 s LA exWoez Looy xnw gt gt Y D yo pu ged pelold uoneuiuoueq obey wol AU ID ubed 0Y9BOJd bed eq euoizeuiuioueg Iddy aje UOHedIIPO addy ad ee ESTESA DSP 600 PS 400T230Mx3 Q w 9 V9LAOg VCEINOET Vee A00r VOLIAOEE Ea 3 G umm gt O jud O a DUI cO O LO m T e o S Z e e ua o 2 I L L988 90 50 31 N e0e0de7 XSd 009 dSa lt H esou www dpnu euBiseq euryoew obego ATYLIIN O9vSN9 06007 ec eJojeubasid SOEN Ded env ls BidLoe8 LG W87 0XWO0EZ L00H xnv Vy ES 0 DI E W JE E EE DSP 600 PS 400T230Mx2 48M VCEINOEZ V
18. force in the place amp amp 89 6 9 amp 9 AA e Use suitable tools and clothes e Do not modify the components if not authorized HOT surface can hurt you ENGINE and ALTERNATOR PLEASE REFER TO THE SPECIFIC MANUALS PROVIDED 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 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 5 sulphur content do maintenance more frequently BATTERY WITHOUT MAINTENANCE DO NOT OPEN THE BATTERY The battery is charged automatically from the battery charger circuit suppplied with the engine Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced THE ENGINE PROTECTION NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHARGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 05 09 05 M43GB sere DO MOSA STORAGE 1 0
19. input 220 Vac Pin 1 2 output 18 Vac 25 Vac 10 Vac Pin 3 4 Pin 5 6 Pin 7 8 Pin 9 10 Pin 11 12 3 3 KQ 3 3 KQ Pin 13 14 3 3 KQ 3 3 KQ 3 3 KQ 3 3KQ 3 3 KQ 3 3KQ DSP 2x400 500 DSP 600 615 LO T lt T lt T Q 90 a DRAWING 1 DRAWING 2 Connector P4 on WDC How to check the potentiometer put on WDC 1 Start the welding without load at max RPM 2 Take the voltage from pin 1 pin 12 on connector P4 3 0000000000000 0000000000000 Position Voltage Knob from pin 1 pin 12 on P4 Minimum 0 Vdc Max 4 5 4 7 Vdc DRAWING 3 12 05 05 M40DSP EP5 GB CDD LISA GS TROUBLE SHOOTING DSP EP5 MOSA 1 0 05 05 O H A OG Ol BO OF OJ CO E D O P1 Supply connector P2 Chopper connector P3 Current sensor connector P4 P5 Free Put the knob on RC1 at minimum max put one ohmmeter from pin A B and measure the resistance Minimum 50 100 Q Max 4 5 4 7 KO DRAWING 4 DRAWING 5 12 05 05 M40DSP EP5 GB N WARNING 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 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 r
20. type diesel fuel for example For further details on the type of diesel fuel to use see the motor operating manual supplied Do not fill the tank completely leave a space of approx 10 mm between the fuel level and the wall of the tank to allow for expansion In rigid environmental temperature conditions use special winterized diesel fuels or specific additives in order to avoid the formation of paraffin leo 12 06 03 M20 R HO2 GB a D M I SA Set up for operation MOSA 1 0 06 03 CF AR COOLING LIQUID ATTENTION Do not remove the radiator tap with the gt motor in operation or still hot as the liquid BEN 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 diminished 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 GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a differential switch circuit breaker In these groups the generator star point is generally connected to the m
21. 06467109 PROTEZIONE TERMICA C B 11 873407107 DISGIUNTORE TERMICO 30A 250V 12 155307107 DISGIUNTORE TERMICO 15A 250V 13 307017240 PRESA 220V 16A 14 105111520 PRESA CEE 220V MONOF 2POLI T 15 105111510 PRESA CEE 380V TRIFASE 16 101131220 PRESA DINSE 17 105111530 PRESA CEE 32A 110V 2 POLI T 18 307047250 PRESA CEE 110V 16A 2 POLI T 19 765007111 PRESA DI SALDATURA NERA 20 786127020 PANNELLO FRONTALE superiore 21 765007305 AMPEROMETRO DI SALD 600A 90mV 22 765007300 VOLTMETRO DI SALD 100V F S DC 23 744507219 PULSANTE STOP D EMERGENZA 24 765107205 PANNELLO FRONTALE inferiore 25 306479199 RELE AVV ELETTRICO 26 282009869 TRASFORMATORE 27 208029104 DISTANZIALE ISOLANTE 28 105111830 MORSETTIERA 29 765107010 SCATOLA ELETTRICA 30 386005400 PONTE CHOPPER 31 786109890 SHUNT DI MISURA 32 282005091 STAFFA SUPPORTO CHOPPER 33 000078610A725 KIT FOR MAINS VRD Pos Rev Cod Descr Note 1 0000786107425 WDC Module 2 219937130 COVER GFI 3 305717300 VOLTMETER 4 305027105 GROUNDFAULT INTERRUPTOR GFI 5 219937036 BRACKET 6 105511810 HOURMETER 230V 50Hz IP65 7 325507210 FUEL LEVEL GAUGE 8 744509770 PCB ENGINE CONTROL EP5 9 873407107 CIRCUIT BREAKER 30A 250V 10 306467109 THERMOPROTECTION B C 11 873407107 THERMAL SWITCH 30A 250V 12 155307107 THERMAL SWITCH 15A 250V 13 307017240 EEC SOCKET 16A 220V 2P T 14 105111520 EEC SOCKET SINGLE PH 220V 2P 15 105111510 EEC SOCKET THREE PHASE 380V 16 101131220 SOCKET 17 10511
22. 1530 EEC SOCKET 32A 110V 2 POLES N 18 307047250 EEC SOCKET 110V 16A 2 POLES N 19 765007111 BLACK WELDING SOCKET 20 786127020 FRONY PANEL UP 21 765007305 WELDING AMMETER 600 A 90mV 22 765007300 WELDING VOLTMETER 100V DC RANGE BOTTOM 23 744507219 EMERGENCY PUSH BUTTON STOP 24 765107205 FRONT PANEL DOWN 25 306479199 RELAY ELECTRIC START 26 282009869 TRANSFORMER 27 208029104 SPACER 28 105111830 TERMINAL BOARD 29 765107010 ELECTRIC BOX 30 386005400 CHOPPER BRIDGE 31 786109890 SHUNT 32 282005091 BRACKET CHOPPER SUPPORT 33 000078610A725 KIT FOR MAINS VRD 12 05 06 8861 1 I LL N H OI lt Y a Y a e e O a Y c d Ar Z W J zj P AUST mL da NECE AA Tig Wa 1 D ASA H aut amp cd VE E CE Tabla de recambios D Ersatzteile 10 0606 CEO Pi ces de rechange D CD Ricambi MOSA GB Spare parts lt D O O I 11988 90 S0 cL Au RF KEN AV YA HA N A RAI 4 T AL T DA A 232 N z n CWN Se J L eT AMI MZ VA 17 Ci Ricambi GB Spare parts CD Ersatzteile CE Tabla de recambios 10 0606 Pi ces de rechange D MOSA MOSA Pos Rev Cod 1 740568065 2 209719882 3 764409150 4 400409154 5 386005107 6 342202026 7 765109863 8 740562147 9 105319880 10 740568164 11 107300180 12 740567015 13 740561100 1
23. 30V 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 lt gt o m m Q Z gt 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 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 01 Starter key R1 Starter motor S1 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 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 I resistor Q2 T E P engine protection R2 Solenoid control PCBT 92 Oil level trans
24. 4 766709041 15 740568290 16 740568239 17 786104100 Pos Rev Cod 1 740568065 2 209719882 3 764409150 4 400409154 5 386005107 6 342202026 7 765109863 8 740562147 9 105319880 10 740568164 11 107300180 12 740567015 13 740561100 14 766709041 15 740568290 16 740568239 17 786104100 Descr GRIGLIA USCITA ARIA COMPL STAFFA BOX CONDENSATORI BATTERIA 12V 100Ah SENZA MANU STAFFA FISSAGGIO BATTERIA SENSORE DI HALL 600A TAPPO SERBATOIO LAMIERA PROTEZ CONDENSATORI STAFFA FISS PRE FILTRO GASOLIO BOX CONDENSATORI BACINELLA RACCOLTA ACQUA CHIUSURA COMPL A LEVA COPERCHIO SCATOLA ELETTRICA ROLL BAR COMPLETO SBARRETTA BOX CONDENSATORI PARATIA SUPERIORE ALTERNATORE TRAVERSINO SUPP PARATIA ALTER REATTORE DI LIVELLO Descr OUT AIR GRATE CAPACITOR BOX BRACKET BATTERY BATTERY BRACKET HALL SENSOR CAP FUEL TANK CONDENSER PROTECTION FUEL FILTER FIXING BRACKET CAPACITOR BOX WATER TRAY LATCH ELECTRICAL BOX COVER ROLL BAR CAPACITOR BOX BRACKET ALTERNATOR TOP COVER ALTERNATOR RIGHT BRACKET LEVEL REACTOR DSP 600 PS PSX 12 05 06 8861 1 I I 11988 90 S0 cL DSP 600 PS PSX 2 Sj a e a e gt S 2 D Ni G hi LA 10 0606 CEO Pi ces de rechange D Ci Ricambi M D A GB Spare parts MOSA MOSA Pos O OO N D I QO N ND cl Go D o Pos O OO N D I QO N ND sech Go D o Ci R
25. DSP 600 PS PSX 886119003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG 12 05 06 88611M00 preparato da UPT approvato da DITE D M LI CA GB Quality system MOSA 1 2 05 03 CE a z HR URI THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE IQNet and its partner CISQ ICIM hereby certify that the organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 I 20081 Abbiategrasso MI BCS FERRARI PASQUALI Trade Marks Operative Units Via Valbrina 17 19 1 42045 Luzzara RE BCS FERRARI PASQUALI Trade Marks Viale Europa 59 I 20090 Cusago MI Mosa Trade Mark for the following field of activities Design production and servicing of tractors agricultural and green maintenance machines Design production and servicing of engine driven welders and generating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2000 Issued on 2006 03 06 Validity date 2009 03 05 Registration Number T 3722 Zaa ST og Gianrenzo Prati President of CISQ Fabio Roversi President of IQNet IQNet Partners AENOR Spain AFAQ France AIB Vingotte International Belgium ANCE Mexico APCER Portugal CISQ Italy CQC China COM China CSQ Czech Republic Cro Cert Croatia DQS Germany DS Denmark ELOT Greece FCAV Brazil FONDONORMA Venezuela HKQAA Hong Kong ICONTEC Colombia IMNC Mexico IRAM Argentina JQA Japan KEMA
26. O N OMNMNMNMNNMNMNMNMNMNMND 4 OOO N O O1 AS D O OO Y Do VN O Pos 0 N O 01 N IS 5 N N NS N N NS N amp a OOO N O O1 AS D O O 0 01 QN O Ci Ricambi GB Spare parts CD Ersatzteile CE Tabla de recambios 10 0606 CF Pi ces de rechange D Rev Rev Cod 107301390 765006020 307806010 765008222 765003010 386003020 6050050 1001050 366103030 842712200 765013012 765008224 307803101 740352070 343332038 740562050 305232071 308102023 308101262 105612060 740562212 105612070 764409975 740561050 740568125 JJ0062292 6095030 JJ0062025 740568066 784102069 Cod 107301390 765006020 307806010 765008222 765003010 386003020 6050050 1001050 366103030 842712200 765013012 765008224 307803101 740352070 343332038 740562050 305232071 308102023 308101262 105612060 740562212 105612070 764409975 740561050 740568125 JJ0062292 6095030 JJ0062025 740568066 784102069 Descr Note ANELLO VENTOLA PER GENERATORE CONVOGLIATORE GENERATORE COPERTURA ALTERNATORE CARCASSA PER STATORE STATORE AVV 400T230M110CTE 48M ANELLO SEEGER CUSCINETTO ALBERO CON ROTORE MOTORE PERKINS 1103A 33G1 DISCO ALBERO ROTORE STAFFA SUPPORTO COPERTURA ALT TRAVERSA ALTERNATORE TUBO DI SCARICO RONDELLA D12 5x48 SP3 SILENZIATORE SCARICO COMPL GUARNIZIONE PER FLANGIA GUARNIZIONE TAPPO SCARICO SERBAT
27. OFF Accelerator electronic control Actuator Pick up Warning light high temperature Commutator auxiliary power 24V diode bridge Y s commutator Emergency stop button Engine protection EP5 Pre heat push button Accelerator solenoid PCB Oil 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 PAC 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 heather indicator Battery charge indicator Transfer pump selector AUT 0 MAN Fuel transfer pump GECO generating set test Flooting with level switches Voltmeter regulator WELD AUX switch Reactor 3 phase Switch disconnector Solenoid stop timer VODIA connector F EDCA connector OFF ON DIAGN selector DIAGNOSTIC push button
28. OIO ANTIVIBRANTE 40x100 TUBO SCARICO OLIO ANTIVIBRANTE 40x50 SENSORE LIVELLO CARBURANTE L 225 BASAMENTO COPERCHIO ISPEZ DIODI ALTERN NIPPLO OLEODINAMICO 1 2 G TUBO GOMMA qm RUBINETTO M F 1 2 G CORNICE PER RADIATORE GUARNIZIONE SCARICO MOTORE Descr Note RING FIXING FAN ALTERNATOR FAN GENERATOR CONVEYOR ALTERNATOR COVER ALTERNATOR HOUSING STATOR RING SEEGER BEARING SHAFT WITH ROTOR ENGINE PRKINS 1103A 33G1 SHAFT WITH ROTOR DISC ALTERNATOR COVER SUPPORT ALTERNATOR BRACKET EXHAUST PIPE WASHER EXHAUST MUFFLER GASKET X FAN GASKET FUEL TANK CAP VIBRATION DAMPER 40x100 OIL EXHAUST PIPE VIBRATION DAMPER 40x50 FUEL LEVEL SENSOR BASE ALTERNATOR DIODE INSPECTION COVER OLEODYNAMIC NIPPLE PIPE qm COCK RADIATOR FRAME GASKET DSP 600 PS PSX 12 05 06 88611 l M H SA GB Spare parts MOSA Ci Ricambi CDD Ersatzteile CE Tabla de recambios 10 0606 CEO Pi ces de rechange D DSP 600 PS PSX 12 05 06 88611 l Ricambi CDD Ersatzteile MUSA GB Spare parts CE Tabla de recambios DSP 600 PS PSX MOSA 1006 6 CF Pi ces de rechange D Pos Rev Cod Descr Note 1 0000786107425 WDC 2 219937130 COPERCHIO INTERRUT DIFFERENZ 3 305717300 VOLTMETRO 4 305027105 INTERRUTTORE DIFFERENZIALE 5 219937036 STAFFA 6 105511810 CONTAORE 230V 50Hz IP65 7 325507210 INDICATORE LIVELLO CARBURANTE 8 744509770 UNITA CONTROLLO MOTORE 9 873407107 DISGIUNTORE TERMICO 30A 250V 10 3
29. S INSTALLATION AND ADVICE GE Me TS O MOSA 1 0 11 99 CF INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to GASOLINE ENGINES Cause a dangerous increase of the temperature m Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area DIESEL ENGINES u 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 OFTHE MACHINE rS At any move check that the engine is off that there are no connections with cables which impede the moves PLACE OF THE MACHINE In spots where it often rains and or there are flooded areas do not put the machine 49 u in the bad weather ane m in flooded places POSITION Place the machine on a level surface at a distance of at least 1 5 m from buildings or other plants Protect all the electric parts at risk because water infiltrations could cause short circuits with damages at persons and or things The protection degree of the machine is put on the data plate and in this manual at page Technical Data Maximum leaning of the machine in case of dislevel Li 20 max 10 26 11 99 M2 6GB MOSA MOSA 1 0 06 06 CD Installazione Luftzirkulation Installation In
30. S POSSIBLE CAUSE P10The welding tension after 3 sec isn t less enough plus in 12V dc P1 Voltmeter shows no voltage or low voltage but actual voltage at the sockets is OK P2 No three phase voltage present at the socket s P3 No single phase voltage one socket but voltmeter reading is normal and there is voltage on the other sockets P4 No voltage present See problem P9 P1 The engine does not start or stops immediately after startup P2 Engine stops due to intervention of EP5 ES P3 he battery is not charged P4 For other problems refer to the attached engine manual DSP EP5 WHAT TO DO generation unless the output going to the condensers and check the capacity of the condensers Restart the machine if there is still no output replace the alternator WELDING WITH V R D 1 Net R C defective or disconnected from or welding socket 2 WDC defective 1 Check the net R C Check the connections 2 Replace the WDC GENERETING 1 Voltmeter malfunction 1 Differential switch not inserted 2 Differential malfunction switch 1 Intervention of thermal switch due to excessive current 2 Thermal switch malfunction 1 Short circuit present on the generator outputs MOTOR 1 Low battery voltage battery dead or defective 2 Presence of air in the fuel supply circuit 3 Starting system switch thermal 4 Fuel injection pump thermal Switch 5 Engin
31. achine s earthing by employing the TN or TT distribution system the differential switch guarantees protection against indirect contacts In the case of powering complex installations requiring 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 TS_ DSP_ GE Water cooled systems leo 12 06 03 M20 R HO2 GB MOSA gt MOSA 1 0 11 05 ENGINE STARTING AND USE Check daily SS cB A NOTE Do not alter the factory adjustment of the engine and do not touch the sealed parts 1500 1800 RPM ENGINES These engines start their normal operating speed IGNITION KEY OFF The ingnition key is a part of the EP5 ON Om engine protection device and has three positions STARTING THE ENGINE Introduce the key Q1 turn it clockwise completely leaving it as soon as the engine starts NB for safety reason the key must be kept by qualified personel Let the engine run for some minutes before drawing the load ENGINE PROTECTION EP5 The EP5 device monitors the engine oil pressure the engine water temperature and the rpm of the engine If the oil pressure is too low the water temperature too high or the speed too high the device shuts down the engine For a few seconds after the engine is started the shut down f
32. antees protection against indirect contacts due to faulty ground currents When the G F l switch picks up a faulty ground current that is higher than 30mA it intervenes by immediately cutting off voltage to the AC sockets In case of intervention by this protection device reset the G F I switch by moving the lever to the ON position In case of another intervention verify that there are no faults in the tools connected or replace the G F I switch with another one of matching specifications and or contact the Service Department c Notes Verify the operation of the G F l switch atleastonce a month by pressing the TEST button The generator must be running and the G F l lever in the ON position SIMULTANEOUS USE The welder s alternator permits the simultaneous use of auxiliary power and welding current The auxiliary power available to the AC plugs 15 diminishes as the welding current drawn increases The table on page M52 TECHNICAL SPECIFICATIONS shows the amount of auxiliary power available as the welding current varies COMBINED USE The output available from the various auxiliary power sockets is limited not only by the declared output of the unit but also by the capacity of each individual socket 09 04 02 M37DSP GB MOSA lt MOSA 1 0 0402 GB RC1 REMOTE CONTROL POLARITY SWITCH 64A Is it possible to connect the RC1 to all DSP engine driven welders The remote control RC1 which regulates the we
33. arnings Avoid by appropriate means to have oil sprays over metallic hot surfaces or over electric ontacts switches plugs etc In case of oil sprinkling from pressure circuits keep in mind that the inflamability point is very low N WARNING THE MACHINE MUST NOT BE USED IN AREAS WITH WARNING EXPLOSIVE ATMOSPHERE 10 06 00 M2 5l CD LISA o PRECAUTION ENGINE DRIVEN WELDER GE MS TS 1 0 03 00 CF 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 O oct ER 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 in the operation area of the welder Make sure that other used devices are compatible If it is the case provide other additional measures of protection The daily duration of the welding t
34. ay arc TERMS 1 Short refers to the way of transferring the material wire to the work piece In this case each time a drop of molten material is formed at the tip of the wire assuming that the rod continues to advance the tip touches the molten weld pool and is combined with it provoking a very brief short circuit hence the term Short is commonly used 2 Spray refers to the transfer of material in the form of tiny molten droplets which by means of the arc itself pass into the molten weld pool as if they were sprayed by the arc Short arc welding requires a much lower arc voltage than spray arc on the order of 25 less The passage from short arc to spray arc occurs automatically by setting a higher operating voltage if using inert gases or a mixture of gases but not with pure CO With pure CO the spray arc occurs only in part and in any case over a wide area resulting in excessive splatter Short arc welding can be performed with low currents in relation to the diameter of the wire and is therefore especially suitable when working with thin material or in cases where the welding heat could create warping problems Spray arc welding requires higher arc voltages which also imply higher currents for an equal size of wire in respect to short arc and is used with medium high sheet thicknesses For high currents with thick materials it is preferr
35. dels nur fur die Modelle Alleen voor de modellen S lo para modelos TS EN 50081 2 EN 50082 2 Altre norme autres normes other norms andere Normen andere normen otras normas ISO 8528 Solo per modelli Seulement pour les mod les Only for models nur f r die Modelle Alleen voor de modellen S lo para modelos GE Ind Benso Marelli Cusago Direttore Generale MM 065 2 doc The CE mark European Community certifies that the product complies with the essential safety requirements provided by the applicable COMMUNITY DIRECTIVES In the Conformity Declaration are reported the HARMONIZED NORMS and not used for the checking 10 10 02 M1 4 GB O OSA 1 0 11 99 SYMBOLS IN THIS MANUAL MOSA 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 us N B The information contained in the manual can be 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 AN Situations of danger no harm to persons or things
36. e generator and therefore the battery recharging The visual signal will last without stopping the engine until the cause is eliminated FEEDING M5 6 The signal point out that the device is working c N B if the unit is used in hot climates and whit loads near to the maximum the protection can be triggered off please reduce the load of the engine In case of intervention of the device after having removed the cause of the problem it is sufficient to bring back the ignition key to the position OFF device not inserted them start again the new work cycle THE ENGINE PROTECTIONS OF THE EP TYPE DO NOT WORK WHEN OIL IS OF LOW QUALITY BECAUSE NOT CHANGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL M5 1 G Fuel stok COLORS M5 2 G Battery charge M5 3 R Overspeed G yellow M5 4 R High temperature V green M5 5 R Low oil pressure R red M5 6 V Feeding O 4 A OOOO M5 5 M5 4 M5 3 M5 6 18 07 97 M39GB D TROUBLE SHOOTING 1 0 05 05 OSA MOSA PROBLEM POSSIBLE CAUSE DSP EP5 WHAT TO DO WELDING P1 All functions performed 1 Position of regulation poten by the WDC are regular tiometer incorrect knob but there is no tension on the welding sockets P2 Malfunction in the selection of welding processes or in their confirmation on other functions performed by the WDC 1 WDC defective P3 Blinking ON LED 1 Current sensor connector P3
37. e solenoid 1 Engine temperature too high or insufficient oil pressure 2 High temperature sensor or oil pressure defective 3 EP5 ES protection defective 1 Battery charger alternator defective 2 Battery charger warning light defective 1 Replace the voltmeter 1 Turn on the switch 2 Replace the switch 1 Push in the thermal switch 2 Replace the thermal switch 1 Disconnect all outputs on the generator except for those on the condensers and re start machine check for voltage on condensers 1 Check the level of the electrolyte Fill or replace the battery 2 Carry out de aeration on the fuel system See engine operating manual 3 Push in the thermal switch In case the problem persists check the electrical circuit and eliminate the problem Call an authorised service centre 4 Push in the thermal switch In case the problem persists check the electrical circuit and eliminate the problem Call an authorised service centre 2 See engine manual 1 Check oil level 2 Replace the malfunctioning sensor 3 Replace the protection 1 Replace 2 Replace 18 11 05 M40DSP EP5 GB D TROUBLE SHOOTING DSP EP5 1 0 05 05 CHECK THE CHOPPER FROM THE CONNECTOR CHOPPER CONNECTOR CHECK MOSFET ON CHOPPER OUTPUT 48 Vca OUTPUT 10 Vea 18 Vca OUTPUT OUTPUT as vca FOR THE CHECK HOLD THE CONNECTOR AS SHOWED ABOVE WITH A TESTER CHECK THERE ARE Check the transformer in this way
38. e two lights winking and fixed the device will carry out a self control cycle To start the machine bring the ignition key to position c starting IGNITION KEY The ignition key has three operation positions a device not inserted OFF b device inserted C starting with automatic return STOP BUTTON It allows to stop the engine in any condition Push the button until the engine stops OVERSPEED M5 3 It signals the intervention of the overspeed device connected to the alternator frequency at 50 as well as at 60 Hz The optical and acoustic signal is activated and the engine stopped HIGHTEMPERATURE M5 4 It signals through the temperature sensors a high tem perature anomaly The optical and acoustic signal is activated and the engine stopped Check the air duct there must be no obstruction the cooling liquid if engine is water cooled the oil level etc LOW OIL PRESSURE M5 5 It signals through the pressure sensors a low oil pressure anomaly The optical and acoustic signal is activated and the engine stopped Check the oil level and if it is correct call the Assistance Service FUEL STOCK M5 1 It signals the fuel state inside the tank running out acoustically with the siren and optically without stopping the engine the signal lasts until the cause is eliminated EP5 ENGINE PROTECTION BATTERY CHARGE M5 2 It signals the failed exicitation of the battery charg
39. ed with respect to short arc Spray arc welding is ideal for welding aluminium or magnesium WELDING DIGITAL CONTROL 11 10 04 M33_WDC_GB z D MOSA use MOSA 1 0 10 04 CF WIRE FEEDER CONNECTION Model WF4 Connect the wire feeder to the welder with the welder turned off Welding cable between the machine s 9 welding plug and the wire feeder Welding cable between the machine s 10 welding plug and the piece to be welded Control oower cable between the machine s connector X1 and the corresponding connector on the wire feeder Start the machine welder The ON LED will be off and will turn on only when there is voltage at the welding plugs and therefore at the wire The voltage is only present when the welding torch button is pressed The setting of the welding voltage is done using the knob on the wire feeder The adjusting knob on the welder is automatically inhibited WELDING DIGITAL CONTROL CONTACT No STARTING TIG 1 STAND BY O Z gt eq gt gt 400A POLARITY INVERTER REMOTE CONTROL A OB 10 OC JO H GO FO WELDING DIGITAL CONTROL The connection of other brands of 42V AC wire feeders to the front panel connection can be done ONLY if wire feeder connector has the same configuration as showed below NAME OF CONTACT DESCRIPTION A electric ground ne potentiometer RC1 terminal a INN To potentiometer RC1
40. en in the a m directives These limits can be used to judge the sound level produced on site For example the sound power level of 100 LWA The sound pressure noise produced at 7 meters distance is about 75dBA the limit value less 25 To calculate the sound level at other distances use this formula dBA dBA 10 log c At 4 meters the noise level becomes 75 dBA 10 log E 80 dBA 12 05 06 88611 GB D MEIS A o DSP 600 PS OMOSA 1 0 05 06 TECHNICAL DATA C C WELDING Current Range 10 600A Welding current 600A 35 550 A 60 500A 100 Starting voltage 60V C V WELDING Welding current 550 A 60 500A 100 Welding voltage 16 44V _ N_ C C Noc STATIC CHARACTERISTIC c debe V 65 i _ C C TIG C CV 10 100 200 300 400 500 550 600 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 E I 7kVA 13KVA 17 kVA 21 KVA 24 kVA 30 kVA 12 05 06 88611 GB gt Dimensioni Abmessungen MOSA Dimensions Dimensiones DSP 600 PS PSX MOSA 10 0606 Dimensions QD DELP DIO CDN VENUE SUPER m Er ENCED Oe T D I r I V 1132 V 12 05 06 88611 l CD MESA o ELECTRICAL SYSTEM LEGENDE 1 4 02 06 Alternator Wire connection unit Capacitor G F I Welding PCB transformer Fuse 400V 3 phase socket 2
41. equiring their removal is complete MOVING 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 maintenance 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 maintenance 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 delivered as standard equipment any lifting system The periodic maintenance should be performed according 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
42. f the advice is not respected fires can happen HEAT Hot surfaces If the advice is not respected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not respected there can be explosions WATER Danger of shortcircuit If the advice is not respected fires or damage to persons can be caused SMOKING The cigarette can cause fire or explosion If the advice is not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosions with damage to persons or things WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons PRESSION Danger of burns caused by the expulsion of hot liquids under pressure gt gt gt P ACCES FORBIDDEN to non authorizadpeaple SYMBOLS AND SAFETY PRECAUTIONS GE MS TS_ PROHIBITIONS No harm for persons Use only with safety clothing Use only with safety clothing A It is compulsory to use the personal protection means given in equipment Use only with safety protections It is a must to use protection means suitable for the different welding works It is Compulsory to use the personal protection means given in equipment Use with only safety material It is prohibited to use water to quench fires on the electric machines Use only with non inserted vol
43. g electrode 1 for MIG MAG welding continuous wire The switch can also be set to stand by first position In this position there is no current at the welding connections led ON off The process can be selected either before or after starting the motor powered welder After selecting the mode the ON LED lights up except for the MIG MAG mode which can only be 6 selected when the button on the torch is pressed 11 10 04 M33 WDC WELDING DIGITAL CONTROL TIG MODE Contact starting TIG This position is specifically for TIG welding To cre ate the arc simply place the tip of the TIG electrode on the piece that requires welding then gently move the tip away The arc starts automatically and at the same time the welding current rises to the preset value first using the welding current adjustment knob which is on the lower part of the control panel The welding current can be adjusted continuously from a minimum of 10 A to a maximum which depends on the power of the machine 400 A 500 A 600 A For EP1 version it is compulsory to accelerate the engine manually STICK MODE Electrode Features C C Constant Current There are three stick modes which feature increasing arc forces so that the arc has different levels of penetration according to the electrode and or welding position MIG MAG MODE continuous wire Features C V Constant Voltage All wire type welding processes can be carried
44. ic shock can kill Avoid spilling fuel on hot engine Sparks may cause the explosion of battery vapours us FIRST AID In case the operator shold be sprayed by accident from corrosive liquids a o hot toxic gas or whatever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions CHECKING BOARD 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 n om to the hospital with the utmost urgency Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone ln hs person involved us 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 arbonate anhydride or carbon dioxyde powder foam nebulized water otto be used Avoid the use of water jets Other indications over eventual shedding not on fire with foam or sand use water jets to cool off the surfaces close to the fire articular protection ear an autorespiratory mask when heavy smoke is present Useful w
45. icambi GB Spare parts CD Ersatzteile CE Tabla de recambios DSP 600 PS PSX 10 0606 Pi ces de rechange D Rev Rev Cod 740568270 765007057 765008112 740568021 744508140 740568035 740568010 740561100 209718070 102042870 209718073 305718115 343339601 740568004 740568100 Cod 740568270 765007057 765008112 740568021 744508140 740568035 740568010 740561100 209718070 102042870 209718073 305718115 343339601 740568004 740568100 Descr PERNO PER CERNIERA CHIAVE PER SERRATURA SERRATURA COPERCHIO CARENATURA ANTERIORE CERNIERA PER FIANCATA CARENATURA POSTERIORE FIANCATA DX CARENAT ANTERIORE ROLL BAR COMPLETO COPERCHIETTO MOLLA TIRANTE PISTONE SOSTEGNO MANIGLIA FIANCATA SX CARENAT ANTERIORE COPERCHIO FRONTALE Descr HINGE PIN ELECTRIC BOX COVER KEY LATCH FOR ELECTRICAL BOX COVER COVER LATCH REAR COVER FRONT COVER RIGHT SIDE COVER COVER SPRING TIE ROD SUPPORT REAR COVER KNOB FRONT COVER LEFT SIDE FRONT COVER 12 05 06 8861 1 I CTL 35 740350140 I i L l il OEE Piddi OA PA De wm mm s sm m sm sm d n I nr gt e r C Rs n IE r i ub Zu NJ E Zu w 8 MAN AAA LA J AL dein CEA Ia Toe IR 225100141 GR TIMONE PIEDE X TRAINO LENTO KIT SITE TOW 305751150 TIMONE TOW BAR 740350142 GR ASSALE RUOTE TRAINO LENTO KITSITE TOW 305751160 ASSALE AXLE 325501170 RUOTA WHEEL 11 06 04 KA
46. ime N ATTENTION Make sure that the area is safe before starting any welding operation Im 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 III Do not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes n gt Insulate yourself from the work surface while welding Use carpets or other insulating materials to avoid physical contact with the work surface and the floor im Always wear dry insulating glovers without holes and body protection n gt Do not wind cables around the body m Use ear protections if the noise level is high in Keep flamable material away from the welding area n gt Do not weld on containers which contain flamable material n gt Do not weld near refuelling areas n Do not weld on easily flamable surfaces n gt Do not use the welder to defrost thaw pipes in Remove the electrode from the electrode holder when not welding gt Avoid inhaling fumes by providing a ventilation system or if not possible use an approved air breather in Do not work in closed areas where there is no fresh air flow m Protect face and eyes protective mask with suitable dark lens and side screens ears and body non flamable protective clothers 30 03 00 M2 5GB CD IMI IE Es A G
47. inflamable 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 MOSA is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization GE MS TS 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 30 03 00 M45GB D MEIS A o DSP 600 PS OMOSA 1 0 05 06 TECHNICAL DATA The DSP 600 engine driven welder ia a unit which ensures the function as a a current source for arc welding b a current source for the auxiliary power generation It is meant for industrial and professional use powered by an endothermic engine it is composed of various main parts such as engine alternator electric and electronic controls the fairing or a protective structure The assembling is made on a steel structu
48. is compulsory to disconnect or shut off any loads which are connected to the unit auxiliary outputs stop welding Turn the starter key to the off position 28 11 05 78412 GB CD EE Es A G CONTROLS LEGENDE 1 0 05 01 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 Space for remote control Remote control Space for E A S Space 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
49. lding current in the CC mode and the welding voltage in the CV mode is connected to the front panel by means of a multipole connector When the remote control is connected to the remote control connector 8 it is functional and automatically excludes the front panel regulation The remote control can also be connected to the connector on the wire feeder front panel but in this case it is necessary to switch the wire feeder commutator so it can operate The polarity inverter 64A if installed can be operated from the remote control Adjust the welding current control knob to the correct current for the diameter and type of electrode being welded WELDING DIGITAL CONTROL some N D v I N mes Q 4 n ON Jo OPTION POLARITY INVERTER PUSH AND SCREW TIGHT N ATTENTION When the RC1 is not used it is necessary to disconnect the multipole connector 09 04 02 M38GB MESA use or THE PROTECTION 1 0 07 97 The electronic device EP 5 M5 ensures the protection of the engine in case of low oil pressure engine high temperature battery charge fuel stock overspeed MOSA Located on the front panel of the machine the EP 5 device enters in operation turning on the ignition key b device inserted and will signal it is working through the warning light M5 6 The feeding is visualized by winking light and the activation by fixed light In the lapse of time between th
50. mitter 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 PT0 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 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
51. mum 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 2 n CTL 35 50 gt A COMANDS I i me jov For assembling the generating set on the trolley CTL 35 45 50 95 please keep to following instructions 1 Liftthr generating set by means of suitable hook 6 Assemble on the machine the towbar 5 complete of foot with the M10x20 screws nuts and washers 7 Assemble the axle 7 to the base of the machine with 5 the M10x20 screws and relative washers two per part so that their supports coincide CTL 45 95 8 Insert the wheel 9 on the axle then twist the selfblocking nut 8 9 Pump the tyre 9 bringing the pressure to 4 atms for the CTL 35 45 50 and 5 6 for the CTL 95 10 Lowerthe machine to the ground and place the parking foot definitively regulating at the best height ATTENTION Do not substituite the original tires with other types AO RI 30 03 04 M6GB a D M RP SA Set up for operation 1 1 09 05 MOSA We 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
52. ng 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 ts 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 GE_ MS TS EAS Tel 02 90352 1 LE CS Fax 02 90390466 2 Net y e mail info mosa it ici www mosa it Divisione della BCS S p A ISO 9001 2000 Cert 0192 3 V le Europa 59 20090 Cusago Mi Italia DICHIARAZIONE DI CONFORMITA D claration de Conformit Declaration of Conformity Konformitatserklarung Conformiteitsverklaring Declaraci n de Conformidad MOSA dichiara sotto la propria responsabilit che la macchina MOSA d clare sous sa propre responsabilit que la machine MOSA declares under its own responsibility that the machine MOSA erkl rt da die Aggregate MOSA verklaard onder haar eigen verantwoordelijkheid dat de machine MOSA declara bajo su responsabilidad que la maquina Modello Mod le Model Modell Model Modelo Codice Code Code Kode Code Codigo
53. ol unit EP6 Welding voltage voltmeter Polarity inverter control Oil pressure indicator Remote control switch Selection push button 30 l 1 PTO HI Battery voltmeter Remote control socket Button indicating light 20 I 1 PTO HI Commutator switch serial parallel Thermal magnetic circuit breaker Selection push button 20 l 1 PTO HI Water temperature indicator 10 05 01 M30 GB DSP 600 PS PSX D Bedienelemente QD D CI Comandi MOSA Controls 1 0 05 06 CE Commandes MOSA N MC M 2 T 86 CEE Version Option V Rs pum gt F 110 Version 48 Version I 1 1988 90 S0 cL A y SNA Co MN ee AN Y IAS z e A el m 1 2 Uz sp b Nasal d SI i NI J I c y Hi j e 1 OD lt a IM 6o Cl IMI E s A 0 use AS A WELDER O MOSA 1 0 04 02 CF ATTENTION Access to non qualified personnel is prohibited in proximity of these areas the control panel front end the engine exhaust fumes the welding process requirements for arc welding apparatus indicates that the engine driven welder is suitable for use in environments with an increased risk of electrical shock S This symbol regulation EN 60974 1 on safety WELDING CABLE CONNECTION Fully insert the welding cable plugs into the corresponding sockets turning them clockwise to lock them in position PUSH AND TWIST ce Make sure that
54. out naked or coated The voltage can be adjusted using the same knob which adjusts the current in STICK mode Adjustment is continuous and goes from a minimum of 15 V to a maximum of 36V 40 V Optional remote control The welding current can also be set from a distance using the optional remote control Once the remote control is connected to the connector X1 the current is controlled by the remote control To return to front panel control remove the connector Optional VRD program Voltage Reduction Device VRD When you choose the program stick or stick arc force the Open Circuit Voltage OCV go up bat only for about 3 than the OCV go down about 11V and stop there until the welder start welding When you make a short circuit with the stick the OCV immediately go up so you can start to welding VRD don t work with the program MIG MAG Inversion of polarity Optional available on request In order to invert polarity press the switch on the remote control unit By selecting inversion the ON LED switches off and the voltage at the welding socket becomes zero The power contactor is witched inside the electrical box and the voltage reappears at the welding sockets The ON LED switches back on at the same time The Invert polarity LED on the front panel near the welding current adjuster switches on You cannot invert polarity in MIG MAG mode PROTECTIONS The Welding Digital Control featu
55. re on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise Technical data DSP 600 PS GENERATOR Output three phase 30 KVA 400 V 57 8 A Output single phase 15 KVA 230 V 65 2 A Output single phase 5 KVA 48V 104 A Frequency 50 Hz Cos o 0 8 ALTERNATOR Self excited self regulated brushless Type three phase asynchronous Insulating class H ENGINE Mark PERKINS Model 1103A 33G Type 4 Stroke Displacement 3300 cm Cylinders 3 Output Stand by 30 4 kW 40 8 HP Output P R P 27 7 KW 37 1 HP Speed 1500 rpm Fuel consumption 211 g kWh Cooling system water Cooling system capacity 10 2 Engine oil capacity 7 91 Starter Electric Fuel Diesel GENERAL SPECIFICATIONS Battery 12V 100Ah Tankcapacity 65 Running time 16 h Protection IP 23 Dimensions Lxwxh mm 2050x850x1135 Dimensions with CTL 35 Lxwxh mm 2950x1300x1420 Weight 980 Kg Noise level 96 LWA 71 dB A 7 m OUTPUT Declared powers at the following ambient conditions temperature 20 C relative humidity 30 altitude 100 m above sea level In an approximative way one reduces of 1 every 100 m altitude and of 2 5 for every 5 C above 25 C For possible modifications or changes to be brought on the engines with climate conditions different from those above mentioned please call our Assistance Authorized Centers ACOUSTIC POWER LEVEL The machine respects the noise limits expressed in sound power giv
56. res 3 protections for the control and chopper 1 ON LED blinking O ON When the engine of the welder is started the control unit automatically goes to the stand by mode for few istants stand by LED on and performs a self diagnosis of the current sensor connector and power source voltage 15V than the last process is loaded on led turned ON In case of malfunction the ON LED blinks 2 Red LED blinking The chopper has a thermal protection O which intervenes in case the operating temperature exceeds 85 C If the protection intervenes the red LED begins to flash and the welding current voltage goes to zero In this case do not switch off the welder since the alternator fan will help cool down the chopper more quickly After a few minutes the LED will automatically switch itself off and the welding voltage current will once again be available at the plugs 3 Red LED continuously lit If an anomalous current is detected in Q the chopper the control blocks the conversion immediately the output welding current voltage goes to zero and the red LED lights up To reset everything it is necessary to switch off the machine If the protections 1 and 3 should intervene it is best to immediately contact the nearest authorised G Service Centre 11 10 04 M33_WDC D MOSA Gus MOSA 1 0 10 04 WIRE WELDING with constant voltage C V Wire welding can be performed in two modes short arc or spr
57. st aid and of fire prevention see page M2 5 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 es 30 00 00 M45GB ns Have qualified personnel disassemble the machine and dispose of the parts including the oil fuel etc in a correct manner when it is to be taken out of service As cust off we intend all operations to be made at utilizer s care at the end of the use of the machine This comprises the dismantling of the machine the subdivision of the several components for a further reutilization or for getting rid of them the eventual packing and transportation of the eliminated parts up to their delivery to the store or to the bureau encharged to the cust off or to the storage office etc The several operations concerning the cust off involve 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
58. stalacion Installation OC DSP 600 PS PSX 12 05 06 8861 1 I CD LISA 2 UNPACKING GE MS TS MOSA 1 1 02 04 AN NOTE rS Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conforms to local rules and regula tions When receiving the goods make sure that the prod uct 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 ab sence of parts envelopes manuals etc we ad vise you to inform immediately our Technical Ser vice For eliminating the packing materials the User must keep to the norms in force in his country mms s Gol 1 e 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 m C 2 O c O O c D CTL 35 45 50 95 LISA 0 ASSEMBLY MOSA 1 1 04 06 CE ATTENTION The CTL accessory cannot be removed from the machine and used separately actioned manually or following vehicles for the transport of loads or anyway for used different from the machine movements TRAILERS The machines provided for assembling the CTL accessory slow towing trolley can be towed up to a maxi
59. t 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 which was agreed when selling the machine MOSA excludes any responsibility for damages to the machine to the things or to persons in this case Our products are made in conformity with the safety norms in force for which it is advisable to use all these devices or information so that the use does not bring damage to persons or things While working it is advisable to keep to the personal safety norms in force in the countries to which the product is destined clothi
60. tage 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 Wi It is forbidden to weld in rooms containing Ww 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 fa It is advisable to use protections suitable for 4 the different welding works Use only with safety protections fe Itis advisable to use protections suitable for the different daily checking works Use only with safety protections EM is advisable to use all protections while A shifting the machine Use only with safety protections 74 It is advisable to use protections suitable for A the different daily checking works and or of A maintenance 26 11 99 M2 1GB D ABBREVIATIONS LEGEND 1 0 06 99 CF C temperature Celsius grades 10 10 kVA synchronous wording example 10000 10 kVA asynchronous wording example A Ampere A ADIM engine atm pressure B pretrol BAT battery BC base current C A c a alternating current C B battery charger C C c c direct current cc cm volume CE European norm conformity CF special for pipe welding CTL slow touring trolley CTM CTV fast touring trolle
61. th the MOSA Manual of Quality GE MS TS EAS CERTIFICATO n CERTIFICATE No 0192 4 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 marchi BCS FERRARI PASQUALI Unit Operative Via Valbrina 17 19 42045 Luzzara RE marchi BCS FERRARI PASQUALI Viale Europa 59 20090 Cusago MI marchio MOSA Italia E CONFORME ALLA NORMA IS IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2000 PER LE SEGUENTI ATTIVITA FOR THE FOLLOWING ACTIVITIES Ea 18 Progettazione produzione ed assistenza di trattori macchine per agricoltura e manutenzione del verde Progettazione produzione ed assistenza di motosaldatrici e gruppi elettrogeni Design production and servicing of tractors agricultural and green maintenance machines Design production and servicing of engine driven welders and generating sets Riferirsi al Manuale della Qualit per l applicabilit dei requisiti Refer to Quality Manual for details of application to ISO 9001 2000 Il presente certificato soggetto al rispetto del regolamento per la certificazione dei sistemi di gestione per la qualit delle aziende The use and the validity of this certificate shall satisfy the requirements of the rules for the certification of company quality management systems
62. 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 pos tion Pay attention to the two polarities of the welding circuit which must not come in electric contact between themselves 21 04 04 M32 DSP GB WELDING DIGITAL CONTROL WELDING DIGITAL CONTROL commer N De TIG STAND BY O REMOTE CONTROL GETTING STARTED 1 After having prepared the machine charged the battery put in oil and fuel the machine is ready for operation Before starting the engine please note the following The welder should only be operated by qualified personnel with experience in working with engine driven welders Check the oil level daily Fuel should be put in before starting the engine Before using the welder or the auxiliary power let the engine warm up and before stopping the engine let it run without load to cool down Refer to the following instructions regarding the function of the various controls on the front panel OFF 2 Start the engine of the welder 3 Turn the welding current voltage adjusting knob to the minimum setting POLARITY INVERTER SETTING THE WELDING PROCESS comer Ps STARTING TIG I STANDBY _t There is a manual switch for selecting the various welding processes on the welding control panel There are 5 processes to choose from 1 for TIG welding 3 for STICK weldin
63. to be grounded THERMAL PROTECTION The monophase outputs are protected against overloads by the thermal protection 59B When the rated current is exceeded the protection intervenes to cut off the voltage to the AC socket Note the intervention of the thermal protection is not instantaneous but reacts according to an overcurrent time characteristic whereby the greater the overcurrent the quicker the intervention In case of intervention by the protection device verify that the total power for the loads connected does not exceed the declared rating and decrease if necessary Disconnect the loads and wait a few minutes to allow the thermal protection to cool down IP wp E L1 In O CIRCUIT BREAKER WELDING DIGITAL CONTROL DSP Before resetting by pressing a the central button and then PUSH TO connect the load again RESET If the protection should Intervene again replace it with another one with matching intervention current specifications and or contact the Service Department Note do not forcibly hold the central button of the thermal protection device to prevent its intervention as this could irreparably damage the unit s alternator us Note the three phase output does not require any protection against overcurrents since it Uses a self protecting asynchronous type alternator GROUND FAULT INTERRUPTOR SWITCH The high sensitivity ground fault interruptor switch G F I 30mA D guar
64. u6 sid reulyooe Beg ely S Bud erogz ano BuipieM As 0 uoneuiuoueq ebe uuoJ4 u eBeg 00 01 pu Bed age euoizeuiuoueq Bea SO possess HESE 99 INIYUYNI 39NVH NMO E RT Tee s opo ep SUE qu YOLOANNOD TWWAS X3 TOW Nid 9 I L 1988 90 S0 cL CD LISA c SPARE PARTS LIST 1 0 03 00 CF 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 us The requested data are to be found on the data plate located on the machine structure quite visible and easy to consult Tel 3802 90352 1 fax 39 02 90390466 1 serial number he 2 model of welder and or generating set 3 amp n table 4 n position 5 quantity 12 RES 2 19 S 55 ee 21 22 23 i cvm 14 4 5 6 H ABBREVIATIONS AND SYMBOLS EV When ordering specify the engine type and the auxiliary voltage ER Engine with recoil starter only ES Engine with electric starter only VE E A S version only QM When ordering specify the length in meters VS Special version only SR By request only 22 03 00 R1GB M H SA GB Spare parts MOSA Ci Ricambi CDD Ersatzteile CE Tabla de recambios 10 0606 CEO Pi ces de rechange D DSP 600 PS PSX 12 05 06 88611 l MOSA MOSA Pos JO 01 Q
65. unction is inhibited to allow the engine to start DSP 2x400 PS DSP 600 PS PSX M5 1 yellow Fuel reserve M5 2 yellow Battery charge M5 3 red Overspeed M5 4 red High temperature M5 5 red Low oil pressure M5 6 green Protection unit on LOW OIL PRESSURE M5 5 In the event of low oil pressure the LED lights and the engine is shut down HIGH TEMPERATURE M5 4 If the water temperature is too high the LED lights and the engine is shut down OVERSPEED M5 3 If the engine speed goes over the preset value the LED lights and the engine is shutdown The nominal frequency 50 or 60 Hz is monitored FUEL RESERVE M5 1 If the fuel level reaches the reserve level the LED lights and the sirene sounds and the engine is shut down BATTERY CHARGE M5 2 It the battery is not being charged the LED light but the engine does not stop The visual signal will stay on until until the charging system is repaired STOP BUTTON The stop button can be used to stop the engine at any time Push and hold the button until the engine stops N CAUTION RUNNING IN During the first 50 hours of operation do not use more than 60 of the maximum output power of the unit and check the oil level frequently in any case please stick to the rules given in the engine use manual leee 28 11 05 78412 GB CD MOSA o DSP 2x400 PS MOSA 1 0 11 05 STOPPING THE ENGINE DSP 600 PS PSX Before stopping the engine it
66. warning light Display Wire connection unit Selector Setting confirmation Fuel valve Oil syringe Insulation monitoring Button indicating light 30 1 1 PTO HI Engine control unit EP2 E A S connector GE MS TS_ 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 Freguency meter Fuse Stop switch Warning light high temperature Arc Force selector Fuel level transmitter Voltage commutator Fuel electro pump 48V A C socket Welding scale switch Preheating indicator Y A switch Start Local Remote selector A C output indicator Emergency button Choke button Hour counter Warning level light Contactor Engine control unit EP5 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 contr
67. which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY SEA LUBRICANT RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products kel Agip 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 ATTENTION It is dangerous to fill the motor with too much oil as its combustion can provoke a sudden increase in rotation speed TS_ DSP_ GE Water cooled systems D 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 Hi FUEL A _ ATTENTION 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
68. y hand touring trolley D diesel D GFI D Deutz engine E electric start EAS automatic intervention panel for generating sets for connection to the mains EL electronic regulation allows to use welder and generating set simultaneausly EP1 automatic accelerator according to requestedpower engine protection low oil pressure high temperature with engine stop troble warning lights EP2 engine protection low oil pressure hight temperature with engine stop trouble warning lights EP4 engine protection low oil pressure high temperature with engine stop no battery charge belt broken low fuel level with engine stop trouble warning lights EP5 engine protection low oil pressure high temperature with engine stop no battery charge belt broken low fuel level with engine stop everspeed trouble warning lights EP6 Control and protection unit of generating sets lt has operating modes OFF MAN AUTO lt protects the engine for low oil pressure high temperature belt broken no battery charge and low fuel level over peed and under speed over and under voltage and no tarting t shows besides voltage frequency and current generator current battery voltage and battery charge engine rpm EP6 disposes of 29 programmable parameters ES oil temperature engine protection device EV electrovalve g kwh grams kilowatt hour engine consumption GA asynchronous alternator GE generating set GHF high frequency alternator

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