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1. eeng jasa s un RONDELLA s uo jco ewseur o moms Romn weg 12 12 13 14 PB3 M256020040 Z Pos Go pe fosse no 2 m2020 emcoreRcMOcowETo COMPLETE COVER s 256020168 CESTELLO PORTABATTERIA BATTERYHOLDER 256020160 CESTEILOPBATT CoPeRCHO serremvmounenwmicaeg 21 04 97 KA MUSA GRUPPI ELETTROGENI MOTOSALDATRICI WWW MOSA IT MOSA div della BCS S p A Stabilimento di Viale Europa 59 20090 Cusago Italia Tel 39 0290352 1 Fax 39 0290390466 a ISO 9001 2008 Cert 0192
2. 33a 230 110 Vers 33 230M Vers 33a 230M110M Vers 33 230M Vers 33b 400T230M Vers 38 KA A ITA VASO N 4 8 Y PS Ricambi Spare parts CD Ersatzteile CE Tabla de recambios CF Pi ces derechanges QD Cod Descr M272702200 MOTORE YANMAR L100AE DG M256752200 MOTORE YANMAR L100N M256862200 MOTORE YANMAR L100AE DEG Pos 30 30 30a 30a 30b 30b 30b 31 32 33 33a 33b 34 35 37 38 39 Pos 30 30 30a 30a 30b 30b 30b 31 32 33 33a 33b 34 35 37 38 39 M256762200 MOTORE YANMAR L100N M272612200 MOTORE HONDA GX 390 1 VXB M256702200 MOTORE HONDA GX390 VXB9 M256712200 MOTORE HONDA UT2 M102041250 ANTIVIBRANTE M256703101 SUPP ALTERNATORE M356403100 ALTERNATORE M356413100 ALTERNATORE M356453100 ALTERNATORE M222401035 ANTIVIBRANTE M272502035 TRAVERSA SUPPORTO MOTORE M306202038 RONDELLA D9x35 SP5 256708222 COPERTURA ALTERNATORE M372802038 RONDELLA DI BLOCCAGGIO Cod Descr M272702200 YANMAR ENGINE L100AE DG M256752200 YANMAR ENGINE L100N M256862200 YANMAR ENGINE L100AE DEG 256762200 YANMAR ENGINE L100N M272612200 HONDA ENGINE GX 390 K1 VXB M256702200 HONDA ENGINE GX390 VXB9 M256712200 HONDA ENGINE UT2 M102041250 VIBRATION DAMPER M256703101 ALTERNATOR SUPPORT M356403100 ALTERNATOR M356413100 ALTERNATOR M356453100 ALTERNATOR M222401035 VIBRATION DAMPER M27250
3. CD Stromlaufplan YALYVLsS 110938 IVNNVIN OddVdals V OLN3IAVIAAV S3NION3 VONOH VONOH INOLON CF Schema electriques CD Schema elettrico Electric diagram I 0 9Sc t0 L0 SL a9ejoda7 lt TT 408 LU Jaubiseq GUIDE ol ojeno1ddy eJojeufesiq Beg e 3991019 uoneuiuoua abe Ulp euoizeuiuoue Bed eq Idd ge UONBOIIIPO d Fa SIS So TN 90026062 eueyeq eoueo IP ojajduos o onu uoo V REV 1 02 09 92 e 92 e LO cO cO LLI e UO 00l 3 DE c 5 OO GN xL c o O Mm 2 E 5 E ES 2 L NM AAA 00 W I 0 AID YALYEVLS I I I Y Y LYVLS a I CF Schema electriques D QD Schema elettrico Electric diagram I 029Sc VO LO SL 020 5 0 962 lt 00201772 N aoejoda7 1eubrseq SUTUIPN SU ST BUTUDIRN 40 962 LING zxWoez xny DT EAFA 32e o1d uorqeuruou q AJ39 0 19149 u p u beg 4 euorzeuruoueq iir E EEN addy sta eyed POTITPON 3N19 N19 TN 9002 6062 eueyeq eoueo V JONVYO SNOIO
4. Particular attention must be paid when getting rid of lubricating oils battery electrolyte and infla mable liquids such as fuel cooling liquid The machine user is responsible for the observance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its components In case the machine should be cust off without any previous disassembly it is however compulsory to remove tank fuel engine lubricating oil cooling liquid from the engine battery NOTE BCS is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization In case of necessity for first aid and fire prevention see page 2 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 Legenda schema elettrico A Alternatore C Condensatore D Interruttore differenziale G Presa 400V trifase H Presa 230V monofase Presa 110V monofase M Contaore N Voltmetro N1 Spia carica batteria O1 Spia pressostato Q1 Chiave avviamento R1 Motorino avviamento 91 Batteria U1 Regolatore tensione batteria S2 Trasmettitore livello olio Z2
5. PN e lt 9 N E lt S3 E Bs 5 sss ss z z z 5 Sa la lt lt co N ss ss 2 lt X 5 5 do gt a ES a coo eu ze 15 01 04 25670 R SPARE PARTS LIST 1 0 03 00 The manufacturer guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement spare parts is required always ask for genuine parts only 55 The requested data are to be found on the data plate located on the machine structure quite visible and easy to consult When ordering the spare parts it is recom mended to indicate 1 serial number 2 model of welder and or generating set 4 n position im 3 n table quantity 5 TAVOLA RICAMBI SPARE PARTS PIECES DE RECHANGE ERSATZTEILE G 13 18 17 16 20 21 22 O 2 21 22 23 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 14 12 986Q16M31 22 03 00 R1GB I 029Sc VO LO SL Ae N _ ASA aN S gt MES gr 20 30a 30b HONDA CINC G n
6. PRP STAND BY POWER established by ISO 8528 1 and 3046 1 Norms and their definitions are listed in the manual s TECHNICAL SPECIFICATIONS page x During the use of the electricity generating group NE VER EXCEED the power indications paying careful at tention when several loads are powered simultaneously VOLTAGE GENERATORS WITH COMPOUND SETTING THREEPHASE GENERATORS WITH CONDENSER SETTING SINGLEPHASE In these types of generators the no load voltage is generally greater than 3 5 with respect to its nominal value f e for nominal voltage threephase 400Vac or singlephase 230Vac the no load voltage can be comprised between 410 420V threephase and 235 245V singlephase The precision of the load voltage is maintained within 5 with balanced loads and with a rotation speed variation of 496 Particularly with resistive loads cos o 1 a voltage over elevation occurs which with the machine cold and at full load can even attain 10 9o a value which any case is halved after the first 10 15 minutes of operation The insertion and release of the full load under constant rotation speed provokes a transitory voltage variation that is less than 1096 the voltage returns to its nominal value within 0 1 seconds GENERATORS WITH ELECTRONIC SETTING A V R In these types of generators the voltage precision is maintained within 1 5 with speed variations comprised from 10 to 30 and with balanced loads The volt
7. REDUCTION FOR SOCKET 32A 16A Note 230M Version 230M 230M 110M Version 230M 400T 230M Version 400T 230M Version 400T 230M Version 230M 230M 110M Version 230M Version 230M 230M 110M Version 230M 230M 110M Version 230M 110M Version 230M 110M Version 230M 110M Version 230M 110M Version 400T 230M Version 400T 230M Version 400T 230M Version qm 230M 110M Version 230M 400T 230M Version 230M 400T 230M Version 230M 400T 230M Version 230M 110M Version 230M 110M Version 230M 110M Version 400T 230M Version DES Version DES Version Fino a REV 1 09 04 Del 10 08 16 01 08 DES Version Da REV 2 01 09 Del 10 08 16 01 08 Schuko Version Note 230M Version 230M 230M 110M Version 230M 400T 230M Version 400T 230M Version 400T 230M Version 230M 230M 110M Version 230M Version 230M 230M 110M Version 230M 230M 110M Version 230M 110M Version 230M 110M Version 230M 110M Version 230M 110M Version 400T 230M Version 400T 230M Version 400T 230M Version qm 230M 110M Version 230M 400T 230M Version 230M 400T 230M Version 230M 400T 230M Version 230M 110M Version 230M 110M Version 230M 110M Version 400T 230M Version DES Version DES Version Up to REV 1 09 04 Del 10 08 16 01 08 DES Version From REV 2 01 09 Del 10 08 16 01 08 Schuko Version 15 01 04 25670 l I 029Sc VO LO SL SN gt gt WAI A Gs a ee U 75 al h Ul Q La
8. TS_ SAFETY PRECAUTIONS N DANGEROUS This heading warns of an immediate danger for persons as well for things Not following the advice can result in serious injury or death N WARNING This heading warns of situations which could result in injury for persons or damage to things N CAUTION To this advice can appear a danger for persons as well as for things for which can appear situations bringing material damage to things N IMPORTANT NOTE N ATTENTION These headings refer to information which will assis you in the correct use of the machine and or accessories 26 11 99 M2GB D MOSA REV 2 06 10 o lt 00 O o STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE lf the advice is not respected damage can happen to persons or things HIGH VOLTAGE Attention High Voltage There can be parts in voltage dangerous to touch The non observance of the advice implies life danger FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces If the advice is not respected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not respected there can be explosions 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 i
9. agricultural and green maintenance machines engine driven welders and generating sets Data Emissione corrente Data di scadenza Current issue Expiring date 19 10 2010 05 03 2012 E r First issue 30 05 1994 S ACCREDIA S The advantages for MOSA clients are Constant quality of products and services at thehigh level which the client expects Continuous efforts to improve the products andtheir performance at competitive conditions Competent support in the solution of problems Information and training in the correct applicatio nand use of the products to assure the security ofthe operator and protect the environment Regular inspections by ICIM to confirm that the requirements of the company s quality systemand ISO 9001 are being respected All these advantages are guaranteed by the CER TIFICATE OF QUALITY SYSTEM No 0192 issued by ICIM S p A Milano Italy www icim it 10 10 02 M01 GB CD INDEX GE 5 TS EAS REV 1 10 07 CE M 01 QUALITY SYSTEM M 1 01 COPYRIGHT M 1 1 NOTES M 1 4 CE MARK M 1 5 TECHNICAL DATA M 1 6 TECHNICAL DATA ENGINE DRIVEN WELDER M 2 2 1 SYMBOLS AND SAFETY PRECAUTIONS M 2 5 INSTALLATION AND ADVICE BEFORE USE M 2 6 INSTALLATIONS AND ADVICE M 2 7 INSTALLATION M3 PACKING M 4 TRANSPORT AND DISPLACEMENTS M 6 ASSEMBLY CT M 20 SETTING UP THE UNIT DIESEL ENGINE M 21 ENGINE STARTING AND USE DIESEL ENGINE M 22 STOPPING THE ENGINE DIESEL EN
10. least 1 5 m from buildings or other plants shown both in the data plate and on page named technical data in this same manual Maximum leaning of the machine in case of dislevel 10 20 max 10 O rA000000 I 029Sc VO LO SL SITO GE 7000 7500 BS GS GE 6000 6500 DS DES GS CD Dimensioni D Abmessungen M Dimensions GE 7000 7500 BS GS 2 7 1 CF Dimensions WD GE 6000 6500 DS DES GS REV 1 02 12 GE 7000 7500 BS GS GE 6000 6500 DS DES GS 15 01 04 25670 D GB GD UNPACKING REV 1 02104 CF t Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s pack aging and conforms to local rules and regulations When receiving the goods make sure that the product has not suffered damage during the transport that there has not been rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or absence of parts envelopes manuals etc we advise you to inform immediately our Technical Service i iE TE For eliminating the packing materials the User must keep to the norms in force in his country 1 Take the machine C out of the shipment packing Take out of the envelope A the user s manual B 2 Read the user s manual B the plates fixed on the machine the data plate 000 30 03 00 M3GB CD M TRAN
11. production and servicing of engine dri venwelders and generating sets The certifying institute ICIM which is a member ofthe International Certification Network IQNet awarded the official approval to MOSA after an examination of its operations at the head office andplant in Cusago Italy This certification is not a point of arrival but a pledgeon the part of the entire company to maintain a levelof quality of both its products and services whichwill continue to satisfy the needs of its clients aswell as to improve the transparency and thecom munications regarding all the company s activesin accordance with the official procedures and inhar mony with the MOSA Manual of Quality CISQ is a member of ICIM CERTIFICATO n 0192 5 CERTIFICATE No SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER L ALITA DI WE HEREBY CERTIFY THAT THE QUALITY MANAGEMENT SY ST TEM OPERATED BY BCS S p A UNITA OPERATIVE OPERATIVE UNITS Sede e Unita Operativa Viale Mazzini 161 20081 Abbiategrasso MI Unit Operative Via Valbrina 17 19 42045 Luzzara RE Viale Europa 59 20090 Cusago MI Italia E CONFORME ALLA NORMA IS IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2008 PER LE SEGUENTI ATTIVITA FOR THE FOLLOWING AC TIVITIES EA 18 Progettazione produzione ed assistenza di trattori macchine per agricoltura e manutenzione del verde motosaldatrici e gruppi elettrogeni Design production and servicing of tractors
12. 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 MOSSA G INSTALLATION AND ADVICE BEFORE USE GE MS TS p COGN AN MOSA 1 0 06 00 A The installation and the general advice concerning the operations are finalized to the correct use of the ma chine in the place where it is used as generator group and or welder Stop engine when fueling Do not touch electric devices if you are barefoot or with wet Do not smoke avoid flames sparks or electric tools when fueling clothes Unscrew the cap slowly to let out the fuel vapours Always keep off leaning sur Slowly unscrew the cooling liquid tap if the liquid must be topped up faces during work operations BOARD The vapor and the heated cooling liquid under pressure can burn face eyes skin O Static electricity can demage Do not fill tank completely the parts on the circuit Wipe up spilled fuel before starting engine EE 9 909 electric shock kill CHECKIN Shut off fuel of tank when
13. 10 07 CF Hydraulic oil level light Welding socket Welding socket Earth terminal A C socket Accelerator lever Feed pump 48V D C socket Engine air filter Oil level dipstick Engine oil reservoir cap Hydraulic oil reservoir cap Water filling cap Fuel prefilter Fuel tank cap Muffler Stop control Engine protection cover Engine cooling alternator fan belt Oil drain tap Hydraulic oil drain tap Water drain tap Exhaust tap for tank fuel Button Start button Booster socket 12V Booster socket 24V Battery charge fuse Space for remote control Remote control Space for 5 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 warning light Display Wire connection unit Selector Setting confirmation Fuel valve Oil syringe Insulation monitoring Button indicating light 30 I 1 PTO HI Engine control unit EP2 E A S connector Exclusion i
14. 306467107 16 256557325 17 105111540 18 1243020 19 356317330 20 307017240 21 105511810 22 256407010 23 256127325 24 256417315 25 256417010 26 305907270 28 107302460 29 1302040 29 1302500 31 259107241 32 M734517032 Descr PIASTRINA CHIUSURA FORO DISGIUNTORE TERMICO VOLTMETRO PANNELLO FRONTALE INTERRUTTORE MAGNETOTERMICO VOLTMETRO FS 500V CAPPUCCIO PROTEZIONE 1 D Vedi Cod 256007105 INT MAGNETOTERMICO 2POLI 25A GUIDA PRESA CEE 220V MONOFASE PRESA CEE 32A 110V PRESA 110V 16A FRONTALE PROTEZIONE TERMICA AUX INTERRUTTORE MAGNETOTERMICO Vedi Cod 219937105 GUIDA PER MORSETTIERA CONTAORE QUADRATO 110V 50Hz PRESA 220V 16A CONTAORE SCATOLA ELETTRICA INT MAGNETOTERMICO COMMUTATORE DI LINEA 25A 2P SCATOLA ELETTRICA PRESA CEE 16A 400V 3P N T STARTER A CHIAVE SPIA 12V SPIA 12V PRESA SCHUKO 16A 230V 2P T PIASTRA ADATTAMENTO Descr HOLE CLOSING PLATE THERMAL SWITCH VOLTMETER FRONT PANEL CIRCUIT BREAKER VOLTMETER FS 500V CAP See Part n 256007105 GFI 25 25A FIXING GUIDE EEC SOCKET SINGLE PHASE 220V SOCKET EEC 32A 110V SOCKET 110V 16A FRONT PANEL THERMOPROTECTION AUX CIRCUIT BREAKER See part no 219937105 TERMINAL GUIDE HOURMETER 110V 50HZ EEC SOCKET 16A 220V 2P T HOURMETER ELECTRICAL BOX CIRCUIT BREAKER COMMUTATOR SWITCH 25A 2P ELECTRICAL BOX EEC SOCKET 16A 400V 3P N T STARTER KEY WARNING LIGHT 12V WARNING LIGHT 12V SOCKET SCHUKO 16A 230V 2P T
15. ALTERNATOR PLEASE REFER TO THE SPECIFIC MANUALS PROVIDED Every engine and alternator manufacturer has 0800099 A A e Do not modify the components if not authorized HOT surface can hurt you maintenance intervals and specific checks for each model it is necessary to consult the specific engine or alternator USER AND MAINTENANCE manual VENTILATION Make certain there are no obstructions rags leaves or other in the air inlet and outlet openings on the machine alternator and motor ELECTRICAL PANELS Check condition of cables and connections daily Clean periodically using a vacuum cleaner DO NOT USE COMPRESSED AIR DECALS AND LABELS 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 IN
16. according to ISO 8528 1 temperature 25 C 30 relative humidity altitude 100 m above sea level Stand by maximum available power for use at variable loads for a yearly number of hours limited at 500 h No overload is admitted Prime power PRP maximum available power for use at variable loads for a yearly illimited number of hours The average power to be taken during a period of 24 h must not be over 80 of the PRP 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 C 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 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
17. moving machine where it is assembled Avoid spilling fuel on hot engine Sparks may cause the explosion of battery vapours or whatever event which may cause serious injuries or death predispose the first aid in accordance a FIRST AID In case the operator shold be sprayed by accident from corrosive liquids hot toxic gas with the ruling labour accident standards or of local instructions Skin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor Suction of liquids from If you suppose that vomit has entered the lungs as in case of spontaneous vomit take the subject to the lungs hospital with the utmost urgency Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved 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
18. 0M Version DS DES Version REV 3 02 12 15 01 04 25670 I 029Sc VO LO SL D A N gt oc 14 UTA 7500 BS GS 110M 16A 13 GE 6000 6500 DS DES GS GE 7000 O co N a E lt CN 2 gt 0 XI gt c o 8 D 5 2 ER e WE Ey D puc A4 gt a 908 Z E al I d VE o ce gt o c O 5 3 ETA co T Ch N e co O a o o Vv Ricambi CD Ersatzteile GQ GE 6000 6500 DS DES GS 16 1 GE7000 7500 BS GS REV 2 02 09 CE Tabla de recambios CD Ricambi Spare parts Pi ces derechanges 4 Pos Cod 1 M357017027 2 M155307107 3 M103011310 4 M256707020 5 M734507325 6 M105111550 7 M232027130 8 M220237105 9 256707325 10 232027036 11 105111520 12 105111530 13 307047250 14 256417020 15 306467107 16 256557325 17 105111540 18 1243020 19 356317330 20 307017240 21 105511810 22 256407010 23 256127325 24 256417315 25 256417010 26 305907270 28 107302460 29 1302040 29 1302500 31 259107241 32 734517032 Pos Cod 1 357017027 2 155307107 3 103011310 4 256707020 5 734507325 6 105111550 7 232027130 8 220237105 9 256707325 10 232027036 11 105111520 12 105111530 13 307047250 14 256417020 15
19. 2035 ENGINE SUPPORT BRACKET M306202038 WASHER D9x35 SP5 M256708222 ALTERNATOR COVER M372802038 STOP WASHER GQ GE 6000 6500 DS DES GS 15 1 GE 7000 500 BS GS Note DS Version Fino a REV 1 09 04 Del 12 09 Da REV 2 02 09 Del 12 09 DES Version era 272722200 Del 169 06 20 10 06 Fino a REV 1 09 04 Del 261 07 03 12 07 Del 285 07 11 01 08 Da REV 2 02 09 Del 261 07 03 12 07 Del 285 07 11 01 08 BS Version Fino a REV 1 09 04 Del 216 08 12 12 08 Da REV 2 02 09 Del 216 08 12 12 08 Fino a REV 2 02 09 Del 115 11 28 11 11 Da REV 3 02 12 Del 115 11 28 11 11 230M Version era 256703100 Del 169 06 20 10 06 230M 110M Version era 256713100 Del 169 06 20 10 06 400T 230M Version era 256803100 Del 169 06 20 10 06 DS DES Version era 256651035 17 01 05 BS Version BS Version 230M 230M 110M Version DS DES Version Note DS Version From REV 2 02 09 Del 12 09 DES Version Was 272722200 Del 169 06 20 10 06 Up to REV 1 09 04 Del 261 07 03 12 07 Del 285 07 11 01 08 From REV 2 02 09 Del 261 07 03 12 07 Del 285 07 11 01 08 BS Version Up to REV 1 09 04 Del 216 08 12 12 08 From REV 2 02 09 Del 216 08 12 12 08 Up to REV 2 02 09 Del 115 11 28 11 11 From REV 3 02 12 Del 115 11 28 11 11 230M Version Was 256703100 Del 169 06 20 01 06 230M 110M Version Was 256713100 Del 169 06 20 10 06 400T 230M Version Was 256803100 Del 169 06 20 10 06 DS DES Version was 256651035 17 01 05 BS Version BS Version 230M 230M 11
20. GE 7000 7500 BS GS GE 6000 6500 DS DES GS 0212 256709003 GB CID GE 7000 7500 BS GS M DESCRIPTION OF THE MACHINE GE 6000 6500 DS DES GS 0 CF REV 1 02 12 The generating sets are units which transform the mechanical energy generated by endothermic engine into electric energy through an alternator They are meant for industrial and professional use powered by an endothermic engine they are composed of various main parts such as engine alternator electric and electronic controls the fairing or a protective structure The assembling is made on a steel structure on which are provided elastic support which must damp the vibrations and also eliminate sounds which would produce noise GE 7000 7500 BS GS ENGINE CANOPY FRAME VIBRATION p DAMPER FRONT ALTERNATOR PANEL CANOPY ENGINE GE 6000 6500 DS DES GS FRAME A 15 ALTERNATOR VIBRATION DAMPER sara A LL MOSA Quality system MOSA REV 3 02 09 CF THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE IQNet and its partner hereby SRAGIM organization BCS S p A Head Office and Operative Unit Viale Mazzini 161 20081 Abbiategrasso Ml Operative Units Via Valbrina 17 19 42045 Luzzara RE Viale Europa 59 1 20090 Cusago for the following field of activities WC Design production and servicing of tractors agricultural green maintenance machines engine driven welders and ge
21. GENERATOR Three phase generation Stand by 7 5 KVA 6 kW 400 V 10 8 A Three phase generation PRP 6 5 kVA 5 2 kW 400 V 9 4 A Single phase generation Stand by 6 7 kVA 6 kW 230 V 29 1 A 4 230 V 17 4 A Single phase generation PRP 5 5 KVA 5 kW 230 V 23 9 A Single phase generation Stand by 6 7 KVA 6 kW 115 V 58 2 A Single phase generation PRP 5 5 KVA 5 kW 115 V 47 8 A Power factor Cos oi 0 9 0 8 Frequency 50 Hz 50 Hz ALTERNATOR Self excited self regulated brushless Self excited self regulated Type single phase synchronous three phase synchronous Insulating class H H ENGINE Mark Model Honda GX 390 Type Cooling system Gasoline 4 Stroke air Net power Stand by 8 2 kW 11 1 HP Net power PRP 6 4 kW 8 7 Hp Speed 3000 rpm Cylinders Displacement 11389 cm Fuel consumption 75 of PRP 2 4 I h Engine oil capacit 1 11 GENERAL SPECIFICATIONS Tank capacity 6 5 Running time 75 of PRP 3h Grade of protection IP IP 23 Dimensions max Lxwxh mm 910x525x613 Weight 81 kg 91 kg Measured acoustic power LWA LpA pression 97 dB A 72 dB A 7 m Guaranteed acoustic power LwA LpA pression 97 dB A 72 dB A 7 m Dimensions and weight are inclusive of all parts without wheels and towbar OUTPUT Declared power according to ISO 8528 1 temperature 25 C 30 relative humidity altitude 100 m above sea level Stand by maximum available power for use at variable loads f
22. GINE M25 SETTING UP THE UNIT GASOLINE ENGINE M 26 STARTING THE ENGINE GASOLINE ENGINE M27 STOPPING THE ENGINE GASOLINE ENGINE M 30 CONTROLS LEGEND M 31 CONTROLS M 34 USE AS A WELDER M 35 USE AS AN ENGINE STARTER M 36 USE AS A BATTERY CHARGE M 37 USE AS A GENERATOR M 38 USE OF THE REMOTE CONTROL 39 USE OF THE ENGINE PROTECTION M 40 TROUBLE SHOOTING M 43 MAINTENANCE M 45 STORAGE M 46 CAST OFF M53 DIMENSIONS M55 RECOMMENDED ELECTRODES M 60 ELECTRICAL SYSTEM LEGENDE M61 ELECTRICAL SYSTEM R 1 SPARE PARTS LIST SPARE PARTS ACCESSORIES 11 01 01 M1 GB MOSA MOSA 1 0 10 02 N ATTENTION This use and maintenance manual is an important part of the machines in question The assistance and maintenance personel must keep said manual at disposal as well as that for the engine and alternator if the machine is synchronous and all other documentation about the machine GB Copyright We advise you to pay attention to the pages concerning the security see page M1 1 MUSA All rights are reserved to said Company It is a property logo of MOSA division of B C S S p A All other possible logos contained in the documentation are registered by the respective owners The reproduction and total or partial use in any form and or with any means of the documentation is allowed to nobody without a written permission by MOSA division of B C S S p A To this aim is remind
23. Interruttore magnetotermico Pulsante stop G3 Bobina accensione H3 Candela accensione P4 Protezione termica Y5 Commutatore Serie Parallelo Stromlaufplan Referenzliste A Generator C Kondensatorbox D FI Schalter GFI Steckdose 400V 3 phasig H X Steckdose 230V 1 phasig Steckdose 110V 1 phasig M Stundenzahler Voltmeter N1 Warnleuchte Batterieladung O1 Warnleuchte ldruck Q1 Z ndschloss R1 Anlasser 51 Batterie U1 Laderegler Batterie S2 Olstandssensor 22 Thermomagnetschalter Si Automat F3 Taste Stopp G3 ZUndspule H3 Z ndkerze P4 Thermosicherung Y5 Anzeige Wassertemperatur Electrical system legende A Alternator C Capacitor D GEI G 400V 3 phase socket H 230 1phase socket 110V 1 phase socket Hour counter N Voltmeter N1 Battery charge warning light 01 Oil pressure warning light Q1 Starter key R1 Starter motor S1 Battery U1 Battery charge voltage regulator 92 Oil level transmitter Z2 Thermal magnetic circuit breaker F3 Stop push button G3 Ignition coil H3 Spark plug P4 Circuit breaker Y5 Commutator switch series parallel Leyenda esquema el ctrico A Alternador C Condensador D Interruptor diferencial G 400V trif sica H 230V monofasica Toma 110V monof sica M Cuentahoras N Voltimetro N1 Piloto carga bater a O1 Piloto presostato Q1 Llave arranque R1 Motor arranque 91 B
24. NVYY YO REV 1 02 09 MOVIG ONAN 8 d3Y 0SSOY HO lOO AJA IHO 102 VIN3931 GE 7000 BS GS GE 7000 LDES GS GE 6000 DS DES GS VOLINOSZ WZEINOEZ 97 18 fe G 3 YN YN X Stromlaufplan CD Schema elettrico Electric diagram I 029Sc VO LO SL N zeubtseq SUTUIPN 03ea01dd BUTUDION LING zxa190LL WOE2 ny gt FEES 3UHWOONVIS m e ma a AOS D TN 90026062 elleyeq eses ojeutuJl 3 V INMOSS 3NOMHMWVIN amame MOVIS OH3N Q3N OSSOH y YO 109 IHO 109 VaNao93l REV 1 02 09 MOTI3A OTIVIO eDeg 24 230M 110 M x 2 CTE NOILISOd NOILISOd EE VCE AOtC VOL AOLL 5 Es dy O D o LLI o dI O 2 O CD Stromlaufplan CD Schema elettrico Electric diagram CD Schema elettrico D Stromlaufplan GE 7500 BS GS M Electric diagram CE Esquema el ctrique GE 7500 LDES GS 61 5 CF Schema electriques ND GE 6500 DS DES GS 1 02 09 35645 prg 23 02 2006 35645 5 020 Leporace 400V 16A Disegnatore esigner Desi I
25. 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 clothing work tools Do not modify for any motive parts of the machine fastenings holes electric or mechanical devices others if not duly authorized in writing by MOSA the responsibility coming from any potential intervention will fall on the executioner as in fact he becomes maker of the machine t Notice this manual does not engage MOSA who keeps the faculty apart the essential characteristics of the model here described and illustrated to bring betterments and modifications to parts and accessories without putting this manual uptodate immediately 10 10 02 M 1 1 GB l MOSA G ce mark EN REV 5 03 11 Any of our product 15 labelled with CE marking attesting its conformity to appliable directives also the fulfillment of safety requirements of the product itself the list of these directives is part of the declaration of conformity in
26. PARTS can injure See pag M1 1 NOTE By maintenance at care of the utilizer we intend all the operatios concerning the verification of mechanical parts electrical parts and of the fluids subject to use or consumption during the normal operation of the machine For what concerns the fluids we must consider as main tenance even the periodical change and or the refills eventually necessary Maintenance operations also include machine cleaning operations when carried out on a periodic basis outside of the normal work cycle The repairs cannot be considered among the main tenance activities i e the replacement of parts subject to occasional damages and the replacement of electric and mechanic components consumed in normal use by the Assistance Authorized Center as well as by MOSA The replacement of tires for machines equipped with trolleys must be considered as repair since it is not de livered as standard equipment any lifting system The periodic maintenance should be performed accor ding to the schedule shown in the engine manual An optional hour counter M is available to simplify the determination of the working hours N IMPORTANT In the maintenance operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place ENGINE and
27. SPORT 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 fuel tank empty Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conform to local rules and regulations Only authorized persons involved in the transport of the machine should be in the area of movement DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION 5 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 M4GB PB3 6 1 REV 0 11 11 CD ASSEMBLY CTM 6 2 ATTENTION 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 Note Lift the machine and assemble the parts as shown in the drawing AO ORI 10 06 00 M6GB AAA CD D r D ERA Set up for operation Engine diesel MOSA 1 1 09 05 BATTERY WITHOUT MAINTENANCE Connect the cable positive to the pole positive of the battery after having taken away the protection by properly tightening the clam
28. TERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 05 09 05 M43GB LI MOSSA STORAGE REV 0 06 07 case the machine should not be used for more than 30 days make sure that the room in which it is stored presents a suitable shelter from heat sources weather changes or anything which can cause rust corrosion or damages to the machine t Have qualified personnel prepare the machine for storage GASOLINE ENGINE Start the engine It will run until it stops due to the lack of fuel Drain the oil from the engine sump and fill it with new oil see page M25 Pour about 10 cc of oil into the spark plug hole and screw the spark plug after having rotated the crankshaft several times Rotate the crankshaft slowly until you feel a certain com 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 Pro
29. age is the same both with no load and with load the insertion and release of the full load provokes a transitory voltage variation that is less than 1596 the voltage returns to its nominal value within 0 2 0 3 seconds FREQUENCY The frequency is a parameter that is directly dependento on the motor s rotation speed Depending on the type ofS alternator 2 or 4 pole we will have a frequency of 50 602 Hz with a rotation speed of 3000 3600 or 1500 1800 revolutions per minute AOO Start up the electricity generating group positioning the thermal magnetic switch Z2 and differential switch D to ON input lever in upward position Before powering on the utilities check that the voltmeter N and frequency meter E2 indicate nominal values in addition check on the voltmeter change over switch H2 where it is assembled that the three line voltages 12 06 03 M37GB_ REV 1 09 05 sarir a LL M SA Using the generator The frequency and therefore the number of motor revolutions is maintained constant by the motor s speed regulation system Generally this regulator is of a mechanical type and presents a droop from no load to nominal load which is less than 5 static or droop while under static conditions precision is maintained within 1 Therefore for generators at 50Hz the no load frequency can be 52 52 5 Hz while for generators at 60Hz the no load frequency can be 62 5 63Hz some motors or for
30. ater a U1 Regulador tensi n bater a 92 Captador nivel aceite Z2 Interruptor magnetot rmico F3 Pulsador stop G3 Bobina encendido H3 Buj a encendido P4 Protecci n t rmica Y5 Contactor Serie Paralelo GE 7000 7500 BS GS M GE 6000 6500 DS DES GS 60 Legende des schemas electriques Alternateur Condensateurs Interrupteur diff rentiel Prise 400V triphas Prise 230V monophas Prise 110V monophas Compte heures Voltm tre Voyant charge batterie Voyant pressostat Cl de d marrage Moteur de d marrage Batterie Regulateur tension batterie Transmetteur niveau huile Interrupteur magn tothermique Bouton stop Bobine allumage Bougie allumage Protection thermique Commutateur S rie Parall le REV 0 01 04 15 01 04 25670 I I 0 9Sc 0 10 9 4 loonpyjeg lt Jeubisaq 910 8 69810 Bed z Bd oorsz uere 0 8 058 zLN 027 Xo epuoH euibu3 gt 0 u abed 091044 1011 ubed oyefold euoizeuiuoue Bed eq 2 0 OM SI cea Eoo REV 0 01 04 MOTISAOTWIO A 8 0550 AIM RYO 109 GE 7000 7500 BS GS GE 7554 HBS L GE 7554 HBS 5 dy c 5 LLI 8
31. ccidentally 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 additives in order to avoid the formation of paraffin e GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a diffe rential switch circuit breaker In these groups the generator star point is generally connected to the machine 5 earthing by employing the TN or TT di stribution system the differential switch guarantees protection against indirect contacts In the case of powering complex installations re quiring or employing additional electrical protection devices the coordination between the protection devices must be verified For the grounding connection use the terminal 12 comply to local and or current regulations in force for electrical installations and safety SOS 16 07 03 M20 R A GB CD M Engine starting GE 6000 6500 DS DES GS 21 CF REV 0 01 04 check daily rh 7 push the decompression le ver down and release Do not alter the p
32. cluded 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 Vle Europa 59 20090 CUSAGO MI ITALY ASTE Ve Ergo 5920000 MI TY mpre mosat MOEA tel 39 02903521 fax 39 0290390466 Made n http www mosait e mail infoemosait C 1 Ir vm iOO m 25 n i 7 CLE Furthermore on each model it is shown the noise level value the symbol used is the following we ys dB 10 10 02 M1 4 GB The indication is shown in a clear readable and indeleble way on a sticker Dichiarazione conformit Konformitatserklarung M CA GB Declaration of conformity E gt Declaraci n de conformidad REV 0 06 10 CF D claration de conformit ND BCS S p A Stabilimento di Cusago 20090 MI Italia V le Europa 59 Tel 39 02 903521 Via Marradi 1 20123 Milano Italia Fax 39 02 90390466 ISO 9001 2000 Cert 0192 Sede legale DICHIARAZIONE DI CONFORMITA Declaration de Conformite Declaration of Conformity Konformitatserklarung Conformiteitsverklaring Declaracion de Conformidad BCS 5 dichiara sotto la propria responsabilita che la macchina BCS S p A d clare sous sa propre responsabilit que la machine BCS S p A
33. conds Space the further operations waiting for at least 4 minutes 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 14 06 99 M25 GB CD LI Es A G STOPPING THE ENGINE GASOLINE ENGINE GE MS TS MOSA REV 0 06 99 CF ts Before stopping the engine it is compulsory to effect the following operations stop to draw three single phase current from the auxiliary sockets stop to draw power from the welding sockets only for TS models ENGINES WITH ELECTRIC START us Make sure that the machine is not under load Wait for a few minutes to allow the engine to cool down anyway follow the instructions contained in the engine manual Shut the gasoline cock ap DC Take out the key Q1 turning it counter yw clockwise when assembled pressing the stop button 32 until the engine stops cs NB for safety reason the key must be kept by qualified personel ENGINES WITHOUT ELECTRIC START ms Make sure that the machine is not under load Wait for a few minutes to allow the engine to cool down take however into consideration the prescriptions given in the engine use manual Shut the gasoline cock Set the engine switch 32 to the OFF position 14 06 99 M25 GB MOSA MOSA CONTROLS LEGENDE REV 1
34. current In The start up current must not exceed the alternator s admissible overload current for brief periods generally in the order of 250 300 for 10 15 seconds To avoid a group oversize we recommend following these precautionary measures inthe case of a start up of several motors subdivide the motors into groups and set up their start up at intervals of 30 60 seconds when the operating machine coupled to the motor allows it see to a start up with reduced voltage star point triangle start up or with autotransformer or use a soft start system In all cases when the user circuit requires the start up of an asynchronous motor it is necessary to check that there are no utilities inserted into the installation which in the case of a voltage droop can cause more or less serious disservices opening of contact points temporary lack of power to control and command systems etc SINGLE PHASE LOADS Power to monophase utilities by means of three phase enerators requires some operating limitations In single phase operation the declared voltage tolerance can no longer be maintained by the regulator compound or electronic regulator since the system becomes highly unbalanced The voltage variation on the phases not affected by the power can prove dangerous we recommend sectioning the other loads eventually connected The maximum power which can be drawn between Neutral and Phase start connection is generally 1 3 o
35. dB A 25 dB A 70 dB A Lp a4 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 15 01 04 25670 GB D MOSA MOSA 1 0 11 99 SYMBOLS IN THIS MANUAL The symbols used in this manual are designed to call your attention to important aspects of the operation of the machine as well as potential hazards and dangers for persons and things IMPORTANT ADVICE Advice to the User about the safety r gt N B The information contained in the manual can 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 Situations of danger no harm to persons or things Do not use without protective devices provided Removing or disabling protective devices on the machine is prohibited Do not use the machine if it is not in good technical condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine SYMBOLS AND SAFETY PRECAUTIONS GE MS_
36. declares under its own responsibility that the machine BCS S p A erkl rt da die Aggregate BCS S p A verklaard onder haar eigen verantwoordelijkheid dat de machine BCS S p A declara bajo su responsabilidad que la maquina GRUPPO ELETTROGENO DI SALDATURA WELDING GENERATOR GRUPPO ELETTROGENO POWER GENERATOR Marchio Brand Modello Model Matricola Serial number conforme con est en conformite a conforms with the C mit den Vorschriften di in overeenkomst is m t de nhoud van gemeenschapsrichtliinemen gerelateerde modificaties comple con los requisitos de la Directiva Comunitaria y sus anexos 2006 42 CE 2006 95 CE 2004 108 CE Nome e indirizzo della persona autorizzata a costituire il fascicolo tecnico Nom et adresse de la personne autoris e a composer le Dossier Technique Person authorized to compile the technical file and address Name und Adresse der zur Ausfullung der technischen Akten ermachtigten Person Persoon bevoegd om het technische document en bedrijf gegevens in te vullen Nombre y direccion de la persona autorizada a componer el expediente tecnico ing Benso Marelli Amministratore Delegato CEO V le Europa 59 20090 Cusago Ml Italy Cusago II g Benso Marelli Amministratore Delegato CEO MM 083 0 04 06 10 M1 4 1 Technical data GE 7000 7500 BS GS 1 5 CF REV 2 02 12 Technical data GE 7000 BS GS GE 7500 BS GS
37. e isolation monitor A3 see page M37 Check the battery connection with the respective terminals Open the gosoline cock use the starter if the engine is cold and the temperature is low Introduce the key Q1 turn it clockwise completely leaving it as soon as the engine starts and or the push button 32 models without key leaving it as soon as the engine starts OFF N START GG NB for safety reason the key must be kept by qualified personel Once the engine is started with the starter off let it turn for a few minutes before drawing the load Accelerate the machine by means of the right lever 16 when it is assembled ENGINE WITH NO ELECTRIC START Insert the electric protection device D Z2 N2 lever towards above and where mounted check the isolation monitor A3 see page M37 Open the gasoline cock use the starter if the engine is cold and the temperature is low Y Hold the starting handle firmly GE_ MS_ TS_ Pull the rope hard and fast Pull it all the way out Use two hands if Once the engine is started with the starter off let it turn for a few minutes before drawing the load Accelerate the machine by means of the right lever 16 when it is assembled EMERGENCY START with rope In the versions with electric start in case of need it is possible to start the engine with the rope If the engine fails to start do not insist for at least 15 se
38. ed 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_ EAS 10 10 02 M1 01 GB 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 GG 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 GG 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 F
39. erating current Allow the protection to cool off for a few minutes before resetting by pressing the central pole T3 OFF ih Do not keep the central pole on the thermic protection forcefully pressed to prevent its intervention USAGE WITH EAS AUTOMATIC START UP PANEL The electricity generating group in combination with the EAS automatic start up panel forms a unit for distributing electrical energy within a few seconds of a power failure from the commercial electrical power line Below is some general operating information refer to the automatic panels specific manual for details on installation command control and signalling operations L Perform connections on the installation in safety conditions Position the automatic panel in RESET or LOCKED mode 1 Carry out the first start up in MANUAL mode Check that the generator s LOCAL START REMOTE START switch 16 is in the REMOTE position Check that the generator switches are enabled input lever in upward position Position the EAS panel in manual mode by pressing MAN key and only after having checked that there are no dangerous situations press the START key to start the electricity generating group 41 During the operation of the generator all controls and signals from both the automatic panel and group are enabled it is therefore possible to control its operation from both positions In case of an alarm with a shutdown of the motor low
40. et Button indicating light 20 I 1 PTO HI Commutator switch serial parallel Thermal magnetic circuit breaker Selection push button 20 I 1 PTO HI Water temperature indicator 10 05 01 M30 GB i Solo versione DES Version DES only 77 gt E 4 Wa lt 2 7 2 San i d O Ra SESS d gt 6 N Sse RH E ti 16 a 16 28 87 YP 23 24 73 S 15 01 04 25670 Using the generator It is absolutely forbidden to connect the unit to the public mains and or another electrical power source US Access forbidden to area adjacent to electricity generating group for all non authorized personnel For the canopy generator sets provided with doors the following instruction shall be observed During the normal operation the doors of the engine compartment and or the electrical box shall be kept closed locked up if possible as they must be considered in all respects as protection barriers The access to the internal parts shall occur for maintenance purposes only by qualified personnel and in any case when the engine is stopped The electricity generating groups are to be considered electrical energy producing stations The dangers of electrical energy must be considered together with those related to the presence of chemical substances fuels oils etc rotating parts and waste products fumes discha
41. f the nominal three phase power some types of alternators even allow for 40 Between two Phases triangle connection the maximum power cannot exceed 2 3 of the declared three phase power In electricity generating groups equipped with monophase sockets use these sockets for connecting the loads In other cases always use the R phase and Neutral ELECTRIC PROTECTIONS THERMAL MAGNETIC SWITCH The electricity generating group is protected against short circuits and against overloads by a thermal magnetic switch Z2 situated upstream from the installation Operating currents both thermic and magnetic can be fixed or adjustable in relation to the switch model In models with adjustable ope rating current do not modify the settings since doing so can com promise the installation s protection or the electricity generating group s output characteristics For eventual variations contact our Technical Service Department The intervention of the protection feature against overloads is not instantaneous but follows a current overload time outline the greater the overload the less the intervention Furthermore keep in mind that the nominal operating current refers to an operating temperature of 30 C so that each variation of 10 C roughly corresponds to a variation of 5 on the value of nominal current In case of an intervention on the part of the thermal magnetic protection device check that the total abso
42. gas y A ch 7 f iy gt 5 I V UYU NA fs GE 7000 7500 BS GS GE 6000 6500 DS DES GS CD Ricambi CD Ersatzteile GQ Spare parts CE Tabla de recambios GE 6000 6500 DS DES GS 17 1 Pi ces de rechanges amp D GE 7000 7500 BS GS REV 2 02 09 Pos Rev Cod Descr Note 40 M272707015 COPERCHIO SCATOLA ELETTRICA 41 M272501050 BARELLA BS Version 42 M272708205 SCATOLA DI BASE 43 M256408005 CARENATURA 44 M272708235 GRIGLIA DI ASPIRAZIONE 45 M256022275 REGOLATORE DI TENSIONE DES Version Fino a REV 1 09 04 Del 169 06 20 10 06 46 272701050 BARELLA DS DES Version Pos Rev Cod Descr Note 40 M272707015 COVER ELECTRICAL BOX 41 M272501050 FRAME BS Version 42 M272708205 CASE BOTTOM HALF 43 M256408005 COVER 44 M272708235 INTAKE GRATE 45 M256022275 VOLTAGE REGULATOR DES Version Up to REV 1 09 04 Del 169 06 20 10 06 46 M272701050 PROTECTIVE FRAME DS DES Version 15 01 04 25670 CTM 6 2 KA M212029080 3 REV 1 10 05 ZT N 10 r um wasa jus Deeg JAssae s un RONDELLA s uo jco O fio moms Rum CTM 200 M232120130 t wem 2a Deene waweua rave
43. going to the condenser boxlf there is no output from the auxiliary leads check the condenser box If it is OK replace the stator Remove the load and insert the circuit breaker Reconnect the load If it activates again check the rating of the load and the wiring between load and generator Remove the load and reset Isometer or GFI Check without the load If they activate there is an isolation fault or leakage to ground in the generator or internal wiring If not reconnect the load If they are activated with the load attached there is an isolation fault or leakage to ground in the load or related cables Check the fuses of the single phase sockets Disconnect the load and see if the voltage is normal If there is not output replace the alternator Chek the condition of the brushes if mounted and their position Worn out brushes can damage the brush holder and or collector 08 07 98 M40 2 GB MAINTENANCE Have qualified personnel do maintenance and troubleshooting work 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 requiring their removal is complete MOVING e Use suitable tools and clothes
44. ith attached ENGINE WITH OIL ALERT DEVICE If during the filling of the tank some gasoline is accidentally spilled around the engine chassis clean it immediately before starting up the engine The OILALERT device will stop the engine in case of no oil or insufficient amount of oil in the engine In case one tries to start the engine with oil below the minimum level the warning light when assembled will light and the device will not allow starting CLEANING OF DRY 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 e GROUND CONNECTION is ltis obligatory to connect the ground connec tion point 12 by means of a sure efficient cable please follow the installation local rules and or regulations in force in order to integrate or ensure the working of various electric protec tion devices referring to the several distribution systems TN The unit can be started only when the above ope rations have been correctly performed 17 05 01 M25 GB MOSSA STARTING THE ENGINE GASOLINE ENGINES REV 0 06 99 CF MOSA Check daily ERE Do not alter the primary conditions of regulation and do not touch the sealed parts ENGINES WITH ELECTRIC START Ilnsert the electric protection device D Z2 N2 lever towards above and where mounted check th
45. ndicating 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 Ammeter Frequency meter Fuse Stop switch Warning light high temperature Arc Force selector Fuel level transmitter Voltage commutator Fuel electro pump Engine control unit 48V A C socket Welding scale switch Preheating indicator Y A switch Start Local Remote selector AUTOIDLE switch A C output indicator Emergency button Choke button Hour counter Warning level light Contactor Engine control unit 5 CC CV switch Voltmeter Battery charge warning light Thermal magnetic circuit breaker Ground fault interrupter Pre heat push button Connector wire feader Oil pressure warning light Oil alert Welding arc regulator Starter key Derivation box Battery charge sockets Welding selector mode Siren Welding ammeter Battery Engine control unit EP4 Wire feeder supply switch Plug 230V singlephase Welding current regulator Dirty air filter warning light indicator Earth leakage relay Analogic instrument V Hz Current trasformer R P M adjuster Polarity inverter remote control Relase coil Engine control unit EP6 Welding voltage voltmeter Polarity inverter control Oil pressure indicator Remote control switch Selection push button 30 I 1 PTO HI Battery voltmeter Remote control sock
46. nerating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2008 Issued on 2010 10 19 Validity date 2012 03 05 Registration Number IT 3722 Gianrenzo Prati President of CISQ ANCE Mex APCER Po CCC Cyprus ublic Cro Cert Croatic DOS Holding GmbH Ge ny DS Denmari k vela HKQAA Hong Ko ng Chin a ICONTEC C 6 nbi ia IMNC Mexico JOA Japar MSZT Hungary Nemko AS No NSAI Ireland sia SII Israel SIQ Slovenia SIRIM RAS Internatic sl 1 SOS Switzerland SRAC Romania TEST Russia TSE Turkey YUQS Ser sented in the U SA by AFNOR Ce ortific ation CISQ DOS Holding G sen and NSAI Inc alid at the time of issue of this certificate Updated information is available under www ignet certification co K3Net Michael Drechsel President of IONET IQNet Partners AENOR Spain AFNOR Certification France AIB Vingotte Internatio onal Belgiu CISQ Italy CQC China CQM China COS Czech i Kr ELOT Greece FCAV Brazil FONDANTE A Ver Inspecta Certification Finland IRAM Arg PCBC Poland Quality Austria Austria RR Rus IQNet is The list of IQNet partner mi gt w H E2Net ICIM I ISO 9001 2008 Cert 0192 UNI EN ISO 9001 2008 MOSA has certified its quality system according to UNI EN ISO 9001 2008 to ensure a constant highquality of its products This certification covers thedesign
47. ollow 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 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 GE_ MS_ TS_ EAS_ 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 Our products have been designed for the use of generation for welding electric and hydraulic system ANY OTHER DIFFERENT USE NOT INCLUDED IN THE
48. or a yearly number of hours limited at 500 h No overload is admitted Prime power P R P maximum available power for use at variable loads for a yearly illimited number of hours The average power to be taken during a period of 24 h must not be over 80 of the P R P 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 C 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 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 a4 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 ac
49. oustic noise values indicates that the device respects noise emission limits according to 2000 14 CE directive 15 01 04 25670 GB CD M Technical data GE 6000 6500 DS DES GS 1 5 1 CF REV 2 02 12 Technical data GE 6000 DS DES GS GE 6500 DS DES GS GENERATOR Stand by three phase power 6 5 kVA 5 2 kW 400 V 9 4 A three phase power 5 7 KVA 4 6 kW 400 V 8 2A Stand by single phase power 5 7 KVA 5 1 KW 230 V 24 8 A 4kVA 230V 17 4A PRP single phase power 5 KVA 4 5 kW 230 V 21 7 Stand by single phase power 5 7 KVA 6 kW 115 V 49 6A _ PRP single phase power 5 KVA 5 kW 115 V 43 5A Cos o 0 9 0 8 Frequency 90 Hz 90 Hz ALTERNATOR Self excited self regulated brushless Self excited self regulated Type single phase synchronous three phase synchronous Insulating class H H ENGINE Mark Model Yanmar L100N Type Cooling system Diesel 4 Stroke air Net power Stand by 6 5 kW 8 8 HP Net power PRP 5 KW 7 7 HP Speed 3000 rpm Cylinders Displacement 1 435 cm Fuel consumption 75 of PRP 1 2 1 h Engine oil capacity 1 61 GENERAL SPECIFICATIONS Tank capacity 9 9 Running time 75 of PRP 4 6h Grade of protection IP 5 20 Dimensions Lxwxh mm 900x550x620 Weight DS 99 Kg 105 Kg Weight DES 105 Kg 108 Kg Acoustic power LwA LpA pression 99 dB A 74 dB A 7 m Dimensions and weight are inclusive of all parts without wheels and towbar OUTPUT Declared power
50. p 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 DO NOT OPEN THE BATTERY E LUBRICANT RECOMMENDED OIL MOSA recommends selecting AGIP engine oil Refer to the label on the motor for the recommended products Please refer to the motor operating manual for the recommended viscosity REFUELLING AND CONTROL Carry out refuelling and controls with motor at level position 1 Remove the oil fill tap 24 2 Pour oil and replace the tap 3 Check the oil level using the dipstick 23 the oil level must be comprised between the minimum and maximum indicators ATTENTION It is dangerous to fill the motor with too much oil as its combustion can provoke a sudden increase in rotation speed Y Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered air to the inside of the motor DRY AIR FILTER Air cooled systems 2 OIL BATH AIR FILTER Fill the air filter using the same engine oil up to the level indicated on the filter i FUEL Do not smoke or use open flames during refuelling operations in order to avoid explosions or fire hazards Fuel fumes are highly toxic carry out operations outdoors only or in a well ventilated environment Avoid a
51. present Useful warnings Avoid by appropriate means to have oil sprays over metallic hot surfaces or over electric contacts switches plugs etc In case of oil sprinkling from pressure circuits keep in mind that the inflamability point is very low THE MACHINE MUST NOT BE USED IN AREAS WITH Ex PLOSIVE ATMOSPHERE 10 06 00 M2 51 CD MOSSA INSTALLATION AND ADVICE crude 22 2 A zj MOSA REV 1 06 07 INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot air sent out does not come back inside the set so as to cause a dangerous increase of the temperature GASOLINE ENGINES Use in open space air swept or vent exhaust gases which contain the deathly carbone oxyde far from the work area DIESEL ENGINES t Use in open space air swept or vent exhaust gases far from the work area t Make sure that the machine does not move during the work block it possibly with tools and or devices made to this purpose MOVES OF THE MACHINE t At any move check that the engine is off that there are no connections with cables which impede the moves PLACE OF THE MACHINE ATTENTION For a safer use from the operator DO NOT fit the machine in locations with high risk E re gt of flood POSITION 4 Please do not use the machine in weather Place the machine on a level surface at a distance of at 0 sti 9 conditions which are beyond IP protection
52. pressure high temperature etc the automatic panel will indicate the malfunction that has caused the stoppage while the generator s front panel will be disabled and will no longer supply any information 12 06 03 M37GB 1500G GE D TROUBLE SHOOTING MOSA ewen 1 0 07 98 CF PROBLEM POSSIBLE CAUSE ASYNCHRONOUS ALTERNATORS No output 1 GFI or Isometer if installed have been activated 2 Thermal protection activated or fuse burned out 3 Overload 4 Bad condenser or stator burned out SYNCHRONOUS ALTERNATORS No outputMechanical 1 Overload circuit breaker activated damage 2 GFI or Isometer if installed have been activated 3 Fuse burned out 4 Stator burned out 5 Carbon brushes worn out Mechanical damage 6 Carbon brushes worn out A I9 e e 9 WHAT TO DO Reset GFI or Isometer If they are activated again check the cables and tools attached to the auxiliary sockets for short circuits or grounded leads Reset the thermal protection and check the fuses of the single phase sockets Disconnect the load and see if the voltage is normal If so the load caused the generator to lose its excitation This can occur when the kWatt of the load is larger than that of the generator or in the case of inductive loads motors when the device has a high starting current In both cases the solution is a larger genset Disconnect all leads from the stator except for those
53. r to the STOP position Electric starting version sum Remove the key Q1 turning it counter clockwise OFF position then take it out Shut the fuel cock i NB for safety reason the key must be kept by qualified personel GE 6000 6500 DS DES GS 22 REV 0 01 04 15 01 04 25670 GB D A BATTERY WITHOUT MAINTENANCE Connect the cable positive to the pole positive of the battery after having taken away the protection by properly tightening the clamp Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY LUBRICANT Check the level of the engine oil using the appropriate oil dipstick the level should be between the minimum and maximum marks lf necessary add more oil through the appropriate inlet OIL RECOMMENDED MOSA advises to choose AGIP for the type of oil Please keep to the label put on the engine for the recommended products i NOTE before starting and switching off see instructions in the engine owner s manual he rewith attached SETTING UP THE UNIT GASOLINE ENGINES d FUEL Check the level of fuel in the tank and if necessary add unleaded gasoline For further information regarding the fuel which has to be used see instructions in the engine owner s manual herew
54. rge gases heat etc GENERATION IN AC ALTERNATING CURRENT Before each work session check the efficiency of the ground connection for the electricity generating group if the distribution system adopted requires it such as for example the TT and TN systems Check that the electrical specifications for the units to be powered voltage power frequency are compatible with those of the generator Values that are too high or too low for voltage and frequency can damage electrical equipment irreparably In some cases for the powering of three phase loads it is necessary to ensure that the cyclic direction of the phases corresponds to the installation s requirements Connect the electric devices to be powered to the AC sockets using suitable plugs and cables in prime condition Before starting up the group make certain no dangerous situations exist on the installation to be powered Check that the thermal magnetic switch Z2 is in the OFF position input lever in downward position are the same In the absence of a load the values for voltage and frequency can be greater than their nominal values See sections on VOLTAGE and FREQUENCY OPERATING CONDITIONS POWER The electrical power expressed in kVA on an electricity generating group is the available output power to the reference environmental conditions and nominal values for voltage frequency power factors cos o There are various types of power PRIME POWER
55. rimary conditions of regulation and do ot touch the sealed parts 8 hold the starting handle firmly MANUAL RECOIL VERSION 9 pull the rope hard and fast Pull it all the way out Use two hands if necessary 1 Open the fuel coc ELECTRIC STARTING VERSION Effect the operations 1 2 and 7 as reported in the para Recoil starter OFF ES ON s Turn the starting key Q1 completely p2 Accelerator lever must be in y mls vie ao the START position clockwise until the motor starts Let the engine run for some minutes before drawing the load AL s n case of unsuccessful start up do not insist pen for longer than 5 seconds Wait 10 seconds before attempting another start up Emergency recoil start Turn the starting key 1 in position 4 pull the starting handle slow repeat the process of recoil starting battery is not connected disconnect voltage regulator to prevent damage 5 until feel resist until you feel resistance A CAUTION RUNNING IN During the first 50 hours do not use the unit at more than 60 of full load Check the oil level a regularly Sd 6 then return it slowly 1009 15 01 04 25670 GB O GB Stopping the engine rs Before stopping the engine it is compulsory shut off any loads which are connected to the unit auxiliary outputs To stop the engine Move the engine speed leve
56. rption does not exceed the electricity generating group s nominal current AOO 12 06 03 M37GB_1500G_G Using the generator DIFFERENTIAL SWITCH The differential switch or differential relay guarantee protection against indirect contacts due to malfunction currents towards the ground When the device detects a malfunction current that is higher than the nominal current or the set current it intervenes RESET LAGO Abou tx by cutting off power to the circuit connected In the case of an intervention by the differential switch check that there are no sheathing defects in the installation connection cables sockets and plugs utilities connected rs Before each work session check the operation of the differential protection device by pressing the test key The electricity generating group must be in operation and the lever on the differential switch must be in the ON position THERMIC PROTECTION Generally present to protect against overloads on an individual power socket c a When the nominal operating current has been exceeded the protection device intervenes by cutting off power to the socket The intervention of the protection device against overloads is not instantaneous but follows a current overload time outline the greater the overload the less the intervention In case of an intervention check that the current absorbed by the load does not exceed the protection s nominal op
57. s not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosions with damage to persons or things WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons PRESSION Danger of burns caused by the expulsion of hot liquids under pressure P b P P P loose AY ACCES FORBIDDEN to non authorizad peaple SYMBOLS AND SAFETY PRECAUTIONS PROHIBITIONS No harm for persons Use only with safety clothing a It is compulsory to use the personal Mun protection means given in equip ment Use only with safety clothing 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 e with only safety material It is prohibited to use water to quench fires on the electric machines O 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 Mr 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
58. special requirements the speed regulator is electronic in these cases precision under static operating conditions attains 0 25 and the frequency is maintained constant in operation from no load to load isochronal operation POWER FACTOR COS The power factor is a value which depends on the load s electrical specifications it indicates the ratio between the Active Power kW and Apparent Power kVA The apparent power is the total power necessary for the load achieved from the sum of the active power supplied by the motor after the alternator has transformed the mechanical power into electrical power and the Reactive Power KVAR supplied by the alternator The nominal value for the power factor is cos 0 8 for different values comprised between 0 8 and 1 it is important during usage not to exceed the declared active power kW so as to not overload the electricity generating group motor the apparent power kVA will diminish proportionally to the increase of cos q For cos values of less than 0 8 the alternator must be downgraded since at equal apparent power the alternator should supply a greater reactive power For reduction coefficients contact the Technical Service Department START UP OF ASYNCHRONOUS MOTORS The start up of asynchronous motors from an electricity generating group can prove critical because of high start up currents the asynchronous motor requires start up up to 8 times the nominal
59. tect the machine with a plastic hood and store it ina dry place In case of necessity for first aid and of fire prevention see page M2 5 N IMPORTANT In the storage operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place AO 04 06 07 M45GB Have qualified personnel disassemble the machine and dispose of the parts including the oil fuel etc in a correct manner when it is to be taken out of service As cust off we intend all operations to be made at utilizer s care at the end of the use of the machine This comprises the dismantling of the machine the 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

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