ts300 Mosa PDF
ts300 Mosa PDF
ts300 Mosa PDF
Codice
Code
373049003
TS 300 KS Codigo
Kodezahl
M A D E I N I T A L Y
M
DESCRIPTION OF THE MACHINE TS 300 KS-KSX 0
REV.0-04/14
WELDING CURRENT
REGULATION
CONNECTOR
E.P.1
FOR REMOTE
CONTROL
LOW
ENGINE
OK
PRESS.
HIGH
20
100%
ON
OFF
FILTER
BATTERY
MUFFLER
The engine driven welder has a base constructed in steel which includes the tank. A cover which is hinged
14/04/14 37304-GB
to the roll bar facilitates a rapid check for daily maintenance, while a central hook on the roll bar facilitates
the removal or the loading of the machine. The free maintenance battery reduces at minimum the checking
of its charge condition. The engine has a low oil and a hight temperature protection. Two knobs adjust the
welding current, one knob adjusts the effective current; the other one the arc force current.
M
INDEX 1
REV.3-04/14
M 01 QUALITY SYSTEM
M 1.01 COPYRIGHT
M 1.1 NOTES
M 1.4 CE MARK
M 1.4.1 DECLARATION OF CONFORMITY
M 1.5 TECHNICAL DATA
M 1.6 TECHNICAL DATA ENGINE DRIVEN WELDER
M 2 ADVICE
M 2.1 SYMBOLS AND SAFETY PRECAUTIONS
M 2.6 INSTALLATIONS AND ADVICE
M 2.7 INSTALLATION
M 2.7.1 DIMENSIONS
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 ENGINE)
M 25 SETTING-UP THE UNIT (GASOLINE ENGINE)
M 26 STARTING THE ENGINE (GASOLINE ENGINE)
M 27 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
M 39... USE OF THE ENGINE PROTECTION
M 40... TROUBLE SHOOTING
M 43... MAINTENANCE
M 45 STORAGE
M 46 CAST OFF
M 55 RECOMMENDED ELECTRODES
M 60 ELECTRICAL SYSTEM LEGENDE
M 61... ELECTRICAL SYSTEM
11/01/01 M1-GB
M
Quality system 01
REV.4-03/12
MOSA has certified its quality system according The advantages for MOSA clients are:
to UNI EN ISO 9001:2008 to ensure a constant, ·Constant quality of products and services at thehigh
highquality of its products. This certification covers level which the client expects;
thedesign, production and servicing of engine dri-
venwelders and generating sets. · Continuous efforts to improve the products andtheir
performance at competitive conditions;
The certifying institute, ICIM, which is a member
· Competent support in the solution of problems;
ofthe International Certification Network IQNet,
awarded the official approval to MOSA after an- · Information and training in the correct applicatio-
examination of its operations at the head office nand use of the products to assure the security
andplant in Cusago (MI), Italy. ofthe operator and protect the environment;
· Regular inspections by ICIM to confirm that the-
This certification is not a point of arrival but a
requirements of the company’s quality systemand
pledgeon the part of the entire company to maintain ISO 9001 are being respected.
a levelof quality of both its products and services
whichwill continue to satisfy the needs of its clients, All these advantages are guaranteed by the CER-
aswell as to improve the transparency and thecom- TIFICATE OF QUALITY SYSTEM No.0192 issued
munications regarding all the company’s activesin by ICIM S.p.A. - Milano (Italy ) - www.icim.it
accordance with the official procedures and inhar-
mony with the MOSA Manual of Quality.
10/10/02 M01-GB
M
Copyright 1.01
REV.0-10/02
! 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.
+The use of non original spare parts will cancel While working it is advisable to keep to the personal safety
immediately any guarantee and Technical Service norms in force in the countries to which the product is
obligation. destined (clothing, work tools, etc.).
NOTES ABOUT THE MANUAL Do not modify for any motive parts of the machine (faste-
Before actioning the machine please read this manual nings, holes, electric or mechanical devices, others..) if
attentively. Follow the instructions contained in it, in this not duly authorized in writing: the responsibility coming
way you will avoid inconveniences due to negligence, from any potential intervention will fall on the executioner
mistakes or incorrect maintenance. The manual is for as in fact he becomes maker of the machine.
qualified personnel, who knows the rules: about safety
and health, installation and use of sets movable as well
as fixed.
Any of our product is labelled with CE marking attesting its conformity to appliable directives and
also the fulfillment of safety requirements of the product itself; the list of these directives is part
of the declaration of conformity included in any machine standard equipment.
Here below the adopted symbol:
CE marking is clearly readable and unerasable and it can be either part of the data-plate.
TYPE
SERIAL N° Made in UE-ITALY
TYPE/N°
VOLTAGE(V)
POWER(W)
Hz KVA
P.F. V(V)
G I(A)
I.CL.
LTP POWER IN ACCORDANCE WITH ISO 8528
n RPM TEMP. °C IP
Pmax kW ALTIT. m Kg
Furthermore, on each model it is shown the noise level value; the symbol used is the following:
10/10/02 M1-4 GB
DICHIARAZIONE DI CONFORMITA'
Marchio / Brand :
Modello / Model :
ing. Benso Marelli - Consigliere Delegato / Managing Director ; V.le Europa 59, 20090 Cusago (MI) – Italy
_______________
Cusago, Ing. Benso Marelli
Consigliere Delegato
04/06/10 M1.4.1
Managing Director
MM 083.1
M
Technical data TS 300 KS - KSX 1.5
REV.0-04/14
The TS 300 engine driven welder ia a unit which ensures the function as:
a) a current source for arc welding
b) a current source for the auxiliary power generation
It is meant for industrial and professional use, powered by an endothermic engine; it is composed of
various main parts such as: engine, alternator, electric and electronic controls, the fairing or a protective structure.
The assembling is made on a steel structure, on which are provided elastic support which must damp the vibrations and also
eliminate sounds which would produce noise.
Technical data TS 300 KS TS 300 KSX
ALTERNATOR self-excited, self-regulated, brushless
Type Three-phase, asynchronous
Insulating class H
A.C. GENERATORA.
Three-phase generation 10 kVA / 400 V / 14.4 A
Single-phase generation 5 kVA / 230 V / 21.7 A
Single-phase generation 2.5 kVA / 110 V / 22.7 4
Single-phase generation 5 kVA / 48 V / 104 A
Frequency 50 Hz
ENGINE
Mark / Model KOHLER KD 477/2
Type / Cooling system Diesel 4-Stroke / Air
Cylinders / Displacement 2 / 954 cm3
Net output 14.9 kW (20.3 HP)
Speed 3000 rpm
Fuel consumption (welder 60%) 2.5 l/h
Engine oil capacity 3l
Starter Electric
GENERAL SPECIFICATIONS
Battery 12V - 45Ah
Tank capacity 23 l
Running time (welder 60%) 9.2 h
Protection IP 23
Dimensions / max. (Lxlxh in mm) 1320x790x750
Dimensions with CTM 1630x920x930
Dimensions with CTL 2050x980x990
Weight 350 Kg 370 Kg
Weight with CTM 370 Kg 390 Kg
Weight with CTL 410 Kg 440 Kg
Acoustic power LwA (pression LpA) 99 dB(A) (74 dB(A) @ 7m) -
Measured acoustic power LwA (pression LpA) - 96 dB(A)(71 dB(A) @ 7m)
Guaranteed acoustic power LwA (pression LpA) - 97 dB(A)(72 dB(A) @ 7m) 2000 / 14 / CE
POWER
Declared power according to ISO 3046-1 (temperature 25°C, 30% relative hummidity, altitude 100 m above sea level).
It’s admitted overload of 10% each hour every 12 h.
In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.
PLEASE NOTE: the symbol when with acoustic noise values, indicates that the device respects noise emission limits
2000 / 14 / CE
OUTPUT CARACTERISTIC
0 - 9*
The installation and general warnings regarding operations are aimed achieving correct use of the machine and/or
apparatus in the place where it is used as a genset and/or motor welder.
- Advice to the User about the safety:
+ NB: The information contained in the manual can be changed without notice.
Any damage caused in connection with the use of these instructions shall not be considered as they are only
indicative.
Remember that the non observance of the indications reported by us might cause damage to persons or
things. It is understood, that local dispositions and/or laws must be respected.
! IMPORTANT
These headings refer to information which will assis you
! NOTE in the correct use of the machine and/or accessories.
! ATTENTION
+ 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.
+ FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable to
cause severe wounds or death, follow the first aid as described by the ruling norms or local ones.
EXTINCTION MEANS
Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Not to be used Avoid the use of water jets
Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces close to the fire
Particular protection Wear an autorespiratory mask when heavy smoke is present
10/06/00 M2GB
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.
M
SYMBOLS AND SAFETY PRECAUTIONS 2-1
REV.2-06/10
Read and pay due attention Use only with safety clothing -
It is compulsory to use the personal protection
means given in equipment.
WRENCH - Use of the tools. If the advice is Use only with safety protections -
not respected damage can be caused to things It is advisable to use all protections while
and even to persons. shifting the machine.
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.
1. Telephonic wirings and/or of communication, check wirings and so on, in the immediate vicinity.
2. Radio and television receptors and transmettors.
3. Computer and other checking devices.
4. Critical devices for safety and/or for industrial checks.
5. Peapol who, for instance, use pace-maker, hearing-aid for deaf or something and else.
6. Devices used for rating and measuring.
7. 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.
8. The daily duration of the welding time.
! WARNING
Make sure that the area is safe before starting any welding operation.
àDo 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.
àDo not touch any electrical parts or the electrode while standing in water or with wet hands, feet or clothes.
àInsulate yourself from the work surface while welding. Use carpets or other insulating materials to avoid
physical contact with the work surface and the floor.
àAlways wear dry, insulating glovers, without holes, and body protection.
àDo not wind cables around the body.
àUse ear protections if the noise level is high.
àKeep flamable material away from the welding area.
àDo not weld on containers which contain flamable material.
àDo not weld near refuelling areas.
àDo not weld on easily flamable surfaces.
àDo not use the welder to defrost (thaw) pipes.
àRemove the electrode from the electrode holder, when not welding.
àAvoid inhaling fumes by providing a ventilation system or, if not possible, use an approved air breather.
àDo not work in closed areas where there is no fresh air flow.
30/03/00 M2-5GB
àProtect face and eyes (protective mask with suitable dark lens and side screens), ears and body (non-
flamable protective clothers).
M
INSTALLATION AND ADVICE 2.6
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.
1,5
DIESEL ENGINES 1,5
m
m
+ Use in open space, air swept or vent exhaust gases
far from the work area. 1,5
m
PUT
UICTO
TC AOR
DISS
SU
GHAA
EX
+ Make sure that the machine does not move during the
work: block it possibly with tools and/or devices made
to this purpose.
! ATTENTION
For a safer use from the operator DO NOT
fit the machine in locations with high risk
of flood.
POSITION Please do not use the machine in weather
Place the machine on a level surface at a distance of at conditions which are beyond IP protection
least 1,5 m from buildings or other plants. shown both in the data plate and on page
named "technical data" in this same manual.
10° 10°
= 20° max = 20° max
10° 10°
26/11/99 M2-6GB
Installazione D Luftzirkulation M
Installation E Instalación TS 300 KS-KSX 2.7
Installation NL TS 300 EP1
14/04/14 37304-I
Dimensioni D Abmessungen M
Dimensions E Dimensiones TS 300 KS-KSX 2.7.1
Dimensions NL
14/04/14 37304-I
M
UNPACKING 3
REV.1-02/04
! NOTE
+ 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.
2
30/03/00 M3GB
M
TRANSPORT AND DISPLACEMENTS COVERED UNITS 4
REV.1-06/10
! NOTE
Transportation must always take place with the engine off, electrical cables and starting battery disconnected and
fuel tank empty.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging,
and conform to local rules and regulations.
Only authorized persons involved in the transport of the machine should be in the area of movement.
DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION.
IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with
no CTL accessory).
If you did not keep to the instructions, you could damage the structure of the machine.
! NOTE
Transportation must always take place with the engine off, electrical cables and starting battery disconnected and
fuel tank empty.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging,
and conform to local rules and regulations.
Only authorized persons involved in the transport of the machine should be in the area of movement.
DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION.
IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with
no CTM accessory).
If you did not keep to the instructions, you could damage the structure of the machine.
! 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 accessory (slow towing trolley) can be towed up to a maximum speed
of 40 Kms/hour on asphalted surfaces.
Towing on public roads or turnpikes of any type IS EXCLUDED, because not in possesion of the requirements by
national and foreign traffic norms.
Nota: Lift the machine and assemble the parts as shown in the drawing
CTM300 CTL300
! ATTENTION
10/06/00 M6GB
8D
Do not substitute the original tires with other types.
M
Set-up for operation (Engine diesel) Air cooled systems 20
REV.1-09/05
Connect the cable + (positive) Fill the air filter using the same engine oil up to the
to the pole + (positive) of the level indicated on the filter.
battery (after having taken
away the protection), by FUEL
properly tightening the clamp.
Check the state of the battery
from the colour of the warning light which is in the ! ATTENTION
upper part.
Do not smoke or use open flames during
refuelling operations, in order to avoid
- Green colour: battery OK
explosions or fire hazards.
- Black colour: battery to be recharged
Fuel fumes are highly toxic; carry out
- White colour: battery to be replaced
operations outdoors only, or in a well-
DO NOT OPEN THE BATTERY. ventilated environment.
Avoid accidentally spilling fuel. Clean
LUBRICANT any eventual leaks before starting up
RECOMMENDED OIL motor.
MOSA recommends selecting AGIP engine oil.
Refer to the label on the motor for the recommended Refill the tank with good quality diesel fuel, such as
products. automobile type diesel fuel, for example.
Please refer to the motor operating manual for the In rigid environmental temperature conditions, use
recommended viscosity. special winterized diesel fuels or specific additives
in order to avoid the formation of paraffin.
NOTE
ON
Introduce the key (Q1), turn it clockwi-
! START
! CAUTION
If the engine fails to start, do not insist for at least
15 seconds.
Space the further operations waiting for at least
4 minutes.
! CAUTION
MACHINE WITH EMERGENCY BUTTON
Before starting the engine, make sure that the
! CAUTION
emergency button (32B) is off (turn the button RUNNING-IN
clockwise for this operation) During the first 50 hours of operation, do not use
14/06/99 M20-GB
Pull the stop lever (28) until the engine stops (where
it is assembled).
OFF
ON
(where it is assembled).
4A Hydraulic oil level light B4 Exclusion indicating light PTO HI W3 Selection push button 30 l/1' PTO HI
9 Welding socket ( + ) B5 Auxiliary current push button W5 Battery voltmeter
10 Welding socket ( - ) C2 Fuel level light X1 Remote control socket
12 Earth terminal C3 E.A.S. PCB Y3 Button indicating light 20 l/1' PTO HI
15 A.C. socket C6 Control unit for generating sets QEA Y5 Commutator/switch, serial/parallel
16 Accelerator lever D Ground fault interrupter ( 30 mA ) Z2 Thermal-magnetic circuit breaker
17 Feed pump D1 Engine control unit and economiser Z3 Selection push button 20 l/1' PTO HI
19 48V D.C. socket EP1 Z5 Water temperature indicator
22 Engine air filter D2 Ammeter
23 Oil level dipstick E2 Frequency meter
24 Engine oil reservoir cap E6 Frequency rpm regulator
24A Hydraulic oil reservoir cap E7 Voltmeter regulator
24B Water filling cap F Fuse
25 Fuel prefilter F3 Stop switch
26 Fuel tank cap F5 Warning light, high temperature
27 Muffler F6 Arc-Force selector
28 Stop control G1 Fuel level transmitter
29 Engine protection cover H2 Voltage commutator
30 Engine cooling/alternator fan belt H6 Fuel electro pump
31 Oil drain tap H8 Engine control unit EP7
31A Hydraulic oil drain tap I2 48V A.C. socket
31B Water drain tap I3 Welding scale switch
31C Exhaust tap for tank fuel I4 Preheating indicator
32 Button I5 Y/ switch
33 Start button I6 Start Local/Remote selector
34 Booster socket 12V I8 AUTOIDLE switch
34A Booster socket 24V L A.C. output indicator
35 Battery charge fuse L5 Emergency button
36 Space for remote control L6 Choke button
37 Remote control M Hour counter
42 Space for E.A.S. M1 Warning level light
42A Space for PAC M2 Contactor
47 Fuel pump M5 Engine control unit EP5
49 Electric start socket M6 CC/CV switch
54 Reset button PTO HI N Voltmeter
55 Quick coupling m. PTO HI N1 Battery charge warning light
55A Quick coupling f. PTO HI N2 Thermal-magnetic circuit breaker/
56 Hydraulic oil filter Ground fault interrupter
59 Battery charger thermal switch N5 Pre-heat push-button
59A Engine thermal switch N6 Connector - wire feader
59B Aux current thermal switch O1 Oil pressure warning light/Oil alert
59C Supply thermal switch wire feeder-42V O8 V/A digital instruments and led VRD PCB
59D Pre-heater (spark plug) thermal switch P Welding arc regulator
59E Supply thermal switch oil/water heather P8 Water in fuel
59F Electropump thermal switch Q1 Starter key
63 No load voltage control Q3 Derivation box
66 Choke control Q4 Battery charge sockets
67A Auxiliary / welding current control Q7 Welding selector mode
68 Cellulosic electrodes control R3 Siren
69A Voltmeter relay S Welding ammeter
70 Warning lights S1 Battery
71 Selecting knob S3 Engine control unit EP4
72 Load commut. push button S6 Wire feeder supply switch
73 Starting push button S7 Plug 230V singlephase
74 Operating mode selector T Welding current regulator
75 Power on warning light T4 Dirty air filter warning light/indicator
76 Display T5 Earth leakage relay
79 Wire connection unit T7 Analogic instrument V/Hz
86 Selector U Current trasformer
86A Setting confirmation U3 R.P.M. adjuster
87 Fuel valve U4 Polarity inverter remote control
88 Oil syringe U5 Relase coil
10/05/01 M30-GB
M
N
D
L
F
T
D1
E.P.1
LOW
ENGINE
OK
PRESS.
HIGH
M1 W1
20
100%
N1
ON
OFF
X1
Q1 P
10
28
15 16 9
15
14/04/14 37304-I
M
USE AS WELDER 34
REV.0-10/99
This symbol (Norm EN 60974-1 security +Make sure that the ground clamp ,whose cable
standards for arc welders ) signifies that the must be connected to the + or - terminal, de-
welder can be used in areas with increased pending on the type of electrode, makes a
risk of electrical shock. good connection and is near to the welding
position.
Pay attention to the two polarities of the welding
circuit, which must not come in electric contact
! ATTENTION between themselves.
When using the welder for air arc gouging connect
The sockets, after the machine is started (see the ground lead to the - socket and the gouging
pages M21-26), also with no cables, are anyway lead to the socket marked "only gouging" (if
under voltage. present).
MACHINES WITH E.V. PROTECTION
! ATTENTION Accelerate the engine at max. with the acce-
lerator lever (16).See page M 39.
The areas, access of which is forbiden to unqua-
lified personel, are:
- the control switchboard (front) - the exhaust of MACHINE WITH E.P.2 PROTECTION (B2)
the endothermic engine - the welding process. Accelerate the engine at max. with
the accelerator lever (16) (when
Check at the beginning of any work the electric assebled).
parameters and/or the control placed on the front. See page M 39
Make sure that the ground connection (12) is efficent MACHINE WITH E.P.1 PRO-
(keep to installation local rules and/or to national
laws), in order to integrate or ensure the working
of varius electric protection devices referring to the
several distribution system TT/TN/IT, operation un- ! ATTENTION
necessary for machine with isometer. To reduce the risk of electromagnetic interferen-
ces, use the minimum lenght of welding cables
Fully insert the welding cable plugs into the corre- and keep them near and down (ex. on the floor).
sponding sockets (“only gauging”, 9+/10-) turnning The welding operations must take place far from
them clockwise to lock them in position. any sensitive electronic device.Make sure that
the unit is earthed. (see M20 and/or M25). In
case the interference should last, adapt further
disposition,such as: move the unit, use screened
cables, line filters, screen the entire work area.
ONLY GOUGING In case the above mentioned operations are non
PUSH AND sufficient, please contact our Thechnical Assistan-
TWIST ce Service.
+ It is strictly forbidden to connect the group + N.B.:if the warning light does not flash, check
to the public mains a/o to another source of the accelerator which must bebat its ma-
electric power. ximum, or the fuse of the relevant socket.
(single-phase) or the thermoprotection.
Move the accelerator lever (16) and reach the engine If you overload the genset the thermoprotection will
maximum speed, except for the engines with con- automatically switch off.
stant rpm; the voltmeter (N) (where it is assembled) lf the thermoprotection is released, disconnect all
shows the single-phase voltage whether three or the connected loads.
single-phase current has to be drawn.
Connect up the machine, using proper plugs and Reset the thermoprotection pressing the central
cables in good condition to the AC socket (15) to pole.
draw single or three-phase power, or, by cables with When reset, connect the loads again.
adeguate section, to the terminal board, placed In case the protection should act furtherly, check: the
inside the derivation box (Q3). connections, the wires or others, and if necessary
call the Assistance Service.
AvoId to hold the central
pole of the thermopro-
PRESS TO tection pressed for a
RESET
long time.
Otherwise, in case of trouble, it will not click, dama-
ging the generating set.
16/06/99 M37-GB
ON
OFF
PUSH AND
SCREW TIGHT
07/05/01 M39GB
M
TROUBLE SHOOTING TS 40.1
REV.0-04/04
2) Problem with welding current control 2) Replace the welding current control PCB
PCB
No welding output and 1) Short circuit in wiring 1) Check the wiring inside the welder for
no auxiliary power a short circuit between cables or to
output ground.
2) Defective condenser 2) If the wiring is OK, short circuit the con-
denser to be sure that it is discharged,
disconnect all wires from condenser
and, using an ohmmeter, check that the
condenser is not short circuited.
3) Defective stator 3) If the condenser box is OK, disconnect
all leads from the stator except for those
going to the condenser box and check
the output from the alternator.
If there is no output from the welding
winding and the auxiliary winding,
replace the stator.
4) Short circuited diode bridge 4) If there is output from all windings
reconnect the diode bridge and check
if there is welding current. If not the
diode bridge is defective. If there is
welding current connect the auxiliary
power leads one at a time until there is
no output; at this point, the short circuit
is in that line.
06/04/04 M40-1-I
! WARNING
●● 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 at-
tention moving parts, hot parts (exhaust manifold and muffler, etc.)
electrical parts which may be unprotected when the machine is open.
●● Remove guards only when necessary to perform maintenance, and
replace them when the maintenance requiring their removal is complete.
●● Please wear the appropriate clothing and make use of the PPE (Per-
MOVING sonal Protective Equipment), according to the type of intervention HOT surface
PARTS (protective gloves, insulated gloves, glasses). can
●● Do not modify the components if not authorized.
can injure hurt you
- See pag. M1.1 -
Start the engine: lt will run until it stops due to the lack
of fuel. ! IMPORTANT
Drain the oil from the engine sump and fill it with new oil In the storage operations avoid that
(see page M25). polluting substances, liquids, exhausted
oils, etc. bring damage to people or
Pour about 10 cc of oil into the spark plug hole and things or can cause negative effects to
screw the spark plug, after having rotated the crankshaft surroindings, health or safety respecting
several times. completely the laws and/or dispositions
in force in the place.
Rotate the crankshaft slowly until you feel a certain com-
pression, then leave it.
Clean the covers and all the other parts of the machine
carefully.
DIESEL ENGINE
Clean the covers and all the other parts of the machine
carefully.
+ Have qualified personnel disassemble the In case of necessity for first aid and fire prevention,
machine and dispose of the parts, including the see page M2.5.
oil, fuel, etc., in a correct manner when it is to
be taken out of service.
! IMPORTANT
As cust off we intend all operations to be made, at In the cust-off operations avoid that
utilizer’s care, at the end of the use of the machine. polluting substances, liquids, exhausted
This comprises the dismantling of the machine, the oils, etc. bring damage to people or
subdivision of the several components for a further things or can cause negative effects to
reutilization or for getting rid of them, the eventual surroindings, health or safety respecting
packing and transportation of the eliminated parts completely the laws and/or dispositions
up to their delivery to the store, or to the bureau in force in the place.
encharged to the cust off or to the storage office, etc.
The information here below are to be intended only as indicative since the above norm is much larger.
For further details please see the specific norms and/or the manufacturers of the product to be used in the welding
process.
Basic electrrodes wels onlu in d.c. with inverse polarity (+ on the electrode holder) ; there are also types for a.c.
Suitable for impure carbon steels. Weld in all position.
The iron contained in the coating increases the quality of metal added. Good mechanical properties. Weld in all
position. Electrode holder at + (inverse polarity). Wld deposit of nice aspect, also vertical. Workable; high yield.
Suitable for steels with high contens of sulphur (impurities).
Cellulosic electrodes weld only in d.c. with polarity + electrode holder - ground clamp.
Special for steels run on pipes with R max 55 kg/mm2. Weld in all position. volatile slag.
2 for plane and verticl penetration if required, for flat position welding
3 for plane posotion only only for d.c. (- pole) and a.c.
Table 2 Table 3
I M
GB ELECTRICAL SYSTEM LEGENDE 60
F REV.10-05/13
A : Alternator E3 : Open circuit voltage switch I6 : Start Local/Remote selector N9 : UP/DOWN button mast
B : Wire connection unit F3 : Stop push-button L6 : Choke button O9 : Hydraulic unit solenoid valve
C : Capacitor G3 : Ignition coil M6 : Switch CC/CV P9 : Hydraulic unit engine
D : G.F.I. H3 : Spark plug N6 : Connector – wire feeder Q9 : Ignitor
E : Welding PCB transformer I3 : Range switch O6 : 420V/110V 3-phase transformer R9 : Lamp
F : Fuse L3 : Oil shut-down button P6 : Switch IDLE/RUN S9 : Power system
G : 400V 3-phase socket M3 : Battery charge diode Q6 : Hz/V/A analogic instrument T9 :
H : 230V 1phase socket N3 : Relay R6 : EMC filter U9 :
I : 110V 1-phase socket O3 : Resistor S6 : Wire feeder supply switch V9 :
L : Socket warning light P3 : Sparkler reactor T6 : Wire feeder socket Z9 :
M : Hour-counter Q3 : Output power unit U6 : DSP chopper PCB W9 :
N : Voltmeter R3 : Electric siren V6 : Power chopper supply PCB X9 :
P : Welding arc regulator S3 : E.P.4 engine protection Z6 : Switch and leds PCB Y9 :
Q : 230V 3-phase socket T3 : Engine control PCB W6 : Hall sensor
R : Welding control PCB U3 : R.P.M. electronic regulator X6 : Water heather indicator
S : Welding current ammeter V3 : PTO HI control PCB Y6 : Battery charge indicator
T : Welding current regulator Z3 : PTO HI 20 l/min push-button A7 : Transfer pump selector AUT-0-MAN
U : Current transformer W3 : PTO HI 30 l/min push-button B7 : Fuel transfer pump
V : Welding voltage voltmeter X3 : PTO HI reset push-button C7 : "GECO" generating set test
Z : Welding sockets Y3 : PTO HI 20 l/min indicator D7 : Flooting with level switches
X : Shunt A4 : PTO HI 30 l/min indicator E7 : Voltmeter regulator
W : D.C. inductor B4 : PTO HI reset indicator F7 : WELD/AUX switch
Y : Welding diode bridge C4 : PTO HI 20 l/min solenoid valve G7 : Reactor, 3-phase
A1 : Arc striking resistor D4 : PTO HI 30 l/ min solenoid valve H7 : Switch disconnector
B1 : Arc striking circuit E4 : Hydraulic oil pressure switch I7 : Solenoid stop timer
C1 : 110V D.C./48V D.C. diode bridge F4 : Hycraulic oil level gauge L7 : "VODIA" connector
D1 : E.P.1 engine protection G4 : Preheating glow plugs M7 : "F" EDC4 connector
E1 : Engine stop solenoid H4 : Preheating gearbox N7 : OFF-ON-DIAGN. selector
F1 : Acceleration solenoid I4 : Preheating indicator O7 : DIAGNOSTIC push-button
G1 : Fuel level transmitter L4 : R.C. filter P7 : DIAGNOSTIC indicator
H1 : Oil or water thermostat M4 : Heater with thermostat Q7 : Welding selector mode
I1 : 48V D.C. socket N4 : Choke solenoid R7 : VRD load
L1 : Oil pressure switch O4 : Step relay S7 : 230V 1-phase plug
M1 : Fuel warning light P4 : Circuit breaker T7 : V/Hz analogic instrument
N1 : Battery charge warning light Q4 : Battery charge sockets U7 : Engine protection EP6
O1 : Oil pressure warning light R4 : Sensor, cooling liquid temperature V7 : G.F.I. relay supply switch
P1 : Fuse S4 : Sensor, air filter clogging Z7 : Radio remote control receiver
Q1 : Starter key T4 : Warning light, air filter clogging W7 : Radio remote control trasnsmitter
R1 : Starter motor U4 : Polarity inverter remote control X7 : Isometer test push-button
S1 : Battery V4 : Polarity inverter switch Y7 : Remote start socket
T1 : Battery charge alternator Z4 : Transformer 230/48V A8 : Transfer fuel pump control
U1 : Battery charge voltage regulator W4 : Diode bridge, polarity change B8 : Ammeter selector switch
V1 : Solenoid valve control PCBT X4 : Base current diode bridge C8 : 400V/230V/115V commutator
Z1 : Solenoid valve Y4 : PCB control unit, polarity inverter D8 : 50/60 Hz switch
W1 : Remote control switch A5 : Base current switch E8 : Cold start advance with temp. switch
X1 : Remote control and/or wire feeder B5 : Auxiliary push-button ON/OFF F8 : START/STOP switch
socket C5 : Accelerator electronic control G8 : Polarity inverter two way switch
Y1 : Remote control plug D5 : Actuator H8 : Engine protection EP7
A2 : Remote control welding regulator E5 : Pick-up I8 : AUTOIDLE switch
B2 : E.P.2 engine protection F5 : Warning light, high temperature L8 : AUTOIDLE PCB
C2 : Fuel level gauge G5 : Commutator auxiliary power M8 : A4E2 ECM engine PCB
D2 : Ammeter H5 : 24V diode bridge N8 : Remote emergency stop connector
E2 : Frequency meter I5 : Y/s commutator O8 : V/A digital instruments and led VRD
F2 : Battery charge trasformer L5 : Emergency stop button PCB
G2 : Battery charge PCB M5 : Engine protection EP5 P8 : Water in fuel
H2 : Voltage selector switch N5 : Pre-heat push-button Q8 : Battery disconnect switch
I2 : 48V a.c. socket O5 : Accelerator solenoid PCB R8 : Inverter
L2 : Thermal relay P5 : Oil pressure switch S8 : Overload led
M2 : Contactor Q5 : Water temperature switch T8 : Main IT/TN selector
N2 : G.F.I. and circuit breaker R5 : Water heater U8 : NATO socket 12V
O2 : 42V EEC socket S5 : Engine connector 24 poles V8 : Diesel pressure switch
P2 : G.F.I. resistor T5 : Electronic GFI relais Z8 : Remote control PCB
Q2 : T.E.P. engine protection U5 : Release coil, circuit breaker W8 : Pressure turbo protection
R2 : Solenoid control PCBT V5 : Oil pressure indicator X8 : Water in fuel sender
S2 : Oil level transmitter Z5 : Water temperature indicator Y8 : EDC7-UC31 engine PCB
T2 : Engine stop push-button T.C.1 W5 : Battery voltmeter A9 : Low water level sender
U2 : Engine start push-buttonT.C.1 X5 : Contactor, polarity change B9 : Interface card
V2 : 24V c.a. socket Y5 : Commutator/switch, series/parallel C9 : Limit switch
Z2 : Thermal magnetic circuit breaker A6 : Commutator/switch D9 : Starter timing card
W2 : S.C.R. protection unit B6 : Key switch, on/off E9 : Luquid pouring level float
X2 : Remote control socket C6 : QEA control unit F9 : Under voltage coil
26/07/04 M60GB
Y2 : Remote control plug D6 : Connector, PAC G9 : Low water level warning light
A3 : Insulation moitoring E6 : Frequency rpm regulator H9 : Chopper driver PCB
B3 : E.A.S. connector F6 : Arc-Force selector I9 : Fuel filter heater
C3 : E.A.S. PCB G6 : Device starting motor L9 : Air heater
D3 : Booster socket H6 : Fuel electro pump 12V c.c. M9 : ON/OFF switch lamp
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.1
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.2
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.3
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.4
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.5
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.6
Piéces de rechange NL
14/04/14 37304-I
Ricambi D Ersatzteile M
Spare parts E Tabla de recambios TS 300 KS-KSX 61.7
Piéces de rechange NL
14/04/14 37304-I
WWW.MOSA.IT
MOSA div. della BCS S.p.A.
Stabilimento di Viale Europa, 59
20090 Cusago (MI) Italia
Tel. + 39 - 0290352.1
Fax + 39 - 0290390466