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TS 600 PS-BC

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1. harm for persons Use only with safety clothing ng It is compulsory to use the personal Man protection means given in equip ment Use only with safety clothing 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 with inserted voltage It is prohibited to make interventions before having disinserted the voltage No smoking It is prohibited to smoke while filling the tank with fuel No welding It is forbidden to weld rooms containing explosive gases ADVICE No harm for persons and things Use only with safety tools adapted to the specific use It is advisable to use tools adapted to the various maintenance works Use only with safety protections specifically suitable 229 It is 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
2. 2 model of welder and or generating set 4 n position a 3 table quantity 9 TAVOLA RICAMBI SPARE PARTS PIECES DE RECHANGE ERSATZTEILE 13 18 17 16 20 21 22 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 _ pl P V2 Cat HR D ll eli 13 12 11 76605 1 Ricambi CD Ersatzteile Spare parts CE Tabla de recambios CF Pi ces de rechanges QD Pos Cod Descr Note 1 M107301390 ANELLO RING FIXING FAN 2 M765006020 VENTOLA PER GENERATORE ALTERNATOR FAN 3 M307806010 CONVOGLIATORE GENERATORE GENERATOR CONVEYOR 4 M765008222 COPERTURA ALTERNATORE ALTERNATOR COVER 5 M765003010 CARCASSA PER STATORE ALTERNATOR HOUSING 6 M766053020 STATORE STATOR 7 M6050050 ANELLO SEEGER RING SEEGER 8 M1001050 CUSCINETTO BEARING 9 M366103030 ALBERO CON ROTORE SHAFT WITH ROTOR 10 M765013012 DISCO ALBERO ROTORE DISK 11 M740552200 MOTORE PERKINS 1103A 33TG1 PERKINS ENGINE 1103A 33TG1 12 M740562212 TUBO SCARICO OLIO EXHAUST OIL PIPE 13 M765008224 STAFFA SUPPORTO COPERTURA ALTERNATOR COVER SUPPORT 14 M307803101 TRAVERSA ALTERNATOR
3. 0192 6 CERTIFICATE No SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITA DI WE HEREBY CERTIFY THAT THE QUALITY MANAGEMENT SYSTEM OPERATED BY BCS S p A UNITA OPERATIVE OPERATIVE UNITS Sede e Unit Operativa Viale Mazzini 161 20081 Abbiategrasso MI Unit Operative Via Valbrina 17 19 42045 Luzzara RE Viale Europa 59 20090 Cusago MI Italia E CONFORME ALLA NORMA IS IN COMPLIANCE WITH THE STANDARD UNI EN ISO 9001 2008 PER LE SEGUENTI ATTIVITA FOR THE FOLLOWING ACTIVITIES EA 18 Progettazione produzione ed assistenza di trattori macchine per agricoltura e manutenzione del verde motosaldatrici e gruppi elettrogeni Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets Riferirsi al Manu Portes Cana pec LA applicabilit dei requisiti della norma di riferimento Refer to Quality Manual for of application to reference ys Il presente certificato soggetto al rispetto EECH sistemi di gestione per la qualit delle aziende The use and the validity of this certificate shall sa E a AC AYMAN pil e Data emissione Emissione corrente First issue Current issue 30 05 1994 06 03 2012 Data di scadenza Expiring date 05 03 2015 D S p A Piazza Don Enrico 75 20099 Sesto San Giov ACCREDIA The advantages for MOSA clients are Constant quality of products and services at thehigh leve
4. C 06 Y 0 P N CO O O d N WON O P ND gt Cod M0000836709701 M219937130 M305717300 M305027105 M219937036 M744527190 M744527192 M786130094 M325507210 M265509770 M352007109 M873407107 M105511810 M155307107 M766057020 M307047250 M105111530 M105111520 M105111510 M765007305 M765007300 M765000166 M282009962 M765009911 M102042740 M107509702 M836709715 M282009741 M102013290 M765009910 M765007111 M765107205 M744507219 M372959860 M265507237 M282009807 M208019800 M866707220 M218019874 M306479199 M105111830 M107509870 M317807212 M1241010 M1243020 M765107010 CD Ersatzteile CE Tabla de recambios Descr Note POTENZIOMETRO WELDING CURRENT REGULATOR COPERCHIO INTERRUT DIFFERENZ COVER VOLTMETRO VOLTMETER INTERRUTTORE DIFFERENZIALE GROUNDFAULT INTERRUPTOR GFI STAFFA BRACKET INDICATORE PRESSIONE OLIO OIL PRESSURE INDICATOR SR INDICATORE TEMPERATURA ACQUA WATER TEMPERATURE INDICATOR SR MG7 KIT TERMO MANOMETRO MG7 GAUGE KIT SR INDICATORE LIVELLO CARBURANTE FUEL LEVEL GAUGE UNITACONTROLLO MOTORE ENGINE CONTROL UNIT EP7 PROTEZIONE TERMICA 5A THERMOPROTECTION DISGIUNTORE TERMICO 30 250 CIRCUIT BREAKER 30A 250V CONTAORE 230V 50Hz IP65 HOURMETER 230V 50Hz IP65 DISGIUNTORE TERMICO 15A 250V THERMAL SWITCH 15A 250V PANNELLO FRONTALE FRONT PANEL PRESA CEE 110V 16A 2P T EEC SOCKET 110V 16A 2P N PRESA CEE 32A 110V
5. isa aje sd ed E REV 0 04 05 TS 400 PS BC 500 PS BC 600 PS BC Eee NL X L EE 1 O fe E gt 5 YN LLI CD Stromlaufplan tO IOO 0 0 0 GE ONIONO9 AINO CF Schemas electriques D Schema elettrico Electric diagram 1890994 LL CL EL 070 6099 LLOz LL LZ roonpreg lt F Jeufiseq o eJojeubesiq Bed 9 s 61090992 E gt A0 u afed 30014 ubed onaboug euoizeuiuoue bed eq 100 eie OW 212 REV 0 12 11 ALOWSY TS 600 PS BC fe E gt 5 YN LLI CD Stromlaufplan LL OL 6 CF Schemas electriques D Schema elettrico Electric diagram D SPARE PARTS LIST 1 0 03 00 manufacturer guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement spare parts 15 required always ask for genuine parts only UI 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
6. weight inclusive of parts without wheels towbar POWER Declared power according to ISO 3046 1 temperature 25 30 relative humidity altitude 100 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 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 a 4 meters 95 dB A 20 dB A 75 dB A Lp a 10 meters 95 dB A 28 dB A 67 dB A PLEASE NOTE the symbol when with acoustic noise values indicates that the device respects noise emission
7. 26 11 99 M2 1GB D INSTALLATION AND ADVICE BEFORE USE REV 0 06 00 A The installation and the general advice concerning the operations are finalized to the correct use of the ma chine the place where 1 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 static electricity demage Do not fill tank completely the parts on the circuit Wipe up spilled fuel before starting engine si gens An electric shock can kill CHECKIN Shut off fuel of tank when moving machine where it is assembled Avoid spilling fuel on hot engine Sparks may cause the explosion of battery vapours or whatever event which may cause serious injuries or death predispose the first aid in accordance a FIRST AID In case the operator shold be sprayed by accident from corrosive liquids hot toxic gas with the ruling labour accident standards or of local instructions Skin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist
8. Italia V le Europa 59 Tel 39 02 903521 Via Marradi 1 20123 Milano Italia Fax 39 02 90390466 50 9001 2000 Cert 0192 Sede legale DICHIARAZIONE DI CONFORMITA D claration de Conformit Declaration of Conformity Konformitatserklarung Conformiteitsverklaring Declaraci n de Conformidad BCS S p A dichiara sotto la propria responsabilita che la macchina BCS S p A d clare sous sa propre responsabilit que la machine BCS S p A declares under its own responsibility that the machine BCS S p A erklart die Aggregate BCS S p A verklaard onder haar eigen verantwoordelijkheid dat de machine BCS S p A declara bajo su responsabilidad que la m quina GRUPPO ELETTROGENO DI SALDATURA WELDING GENERATOR H GRUPPO ELETTROGENO POWER GENERATOR Marchio Brand Modello Model Matricola Serial number e conforme con qua est en conformit a conforms with the C mit den Vorschriften di lt in overeenkomst is m t deinboud gemeenschapsrichtliinemen gerelateerde modificaties comple con los requisitos de la Directiva Comunitaria y sus anexos 2006 42 2006 95 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 Ausf llung der technischen Akten ermach
9. 16 13 Ae ed rat ZZ A Sm N se n E d r V EA l A AS 2 E ZA A Essa m mp 7 e o 8 QA nu 2 7 2 4 2 LA 2 4 e 10 N 18 CE Tabla de recambios 19 QD CD Ersatzteile 20 O c O um po Y O Q Ricambi Spare parts 600 PS BC 32 1 Ricambi CD Ersatzteile EF Spare parts CE Tabla de recambios CF Pi ces de rechanges QD REV 0 12 11 Pos Cod Descr Note 1 M740568065 GRIGLIA USCITA ARIA COMPL 2 M740561100 ROLL BAR 3 M400409154 STAFFA FISSAGGIO BATTERIA 4 M764409150 BATTERIA 5 M740568290 PARATIA SUPERIORE ALTERNATORE 6 M740568239 TRAVERSINO SUPP PARATIA ALTER 7 M342202026 SERBATOIO 8 M740568164 BACINELLA RACCOLTA ACQUA 9 M740562147 STAFFAFISS PRE FILTRO GASOLIO 10 765109863 LAMIERA PROTEZ CONDENSATORI 11 M841562228 FILTRO SEPARATORE ACQUA Fornito con motore 12 M740567015 COPERCHIO SCATOLA ELETTRICA 13 766709041 SBARRETTA BOX CONDENSATORI 14 M105319880 BOX CONDENSATORI 15 M209719882 STAFFA BOX CONDENSATORI 16 M766704010 RESISTORE DI POTENZA 17 309015043 RONDELLA 18 M309014013 DISTANZIALE 19 266155300 GRUPPO RADDRIZZATORI 20 M366105091 STAFFA 21 766019890 SHUNT DI MISURA 22 M766054110 STAFFA SUPP REATTANZA 23 M364124100 REATTORE DI LIVELLO Pos Cod Descr Note 1 74056806
10. 2P T EEC SOCKET 32A 110V 2 P N PRESA CEE 220V MONOF 2P T EEC SOCKET SINGLE PH 220V 2P N PRESA CEE 380V TRIFASE EEC SOCKET THREE PHASE 380V AMPEROMETRO AMPEROMETER SR VOLTMETRO VOLTMETER SR AV1 KIT AMPEROMETRO VOLTMETRO AV1 KIT AMPEROMETER VOLTMETER SR CAPPUCCIO ISOLANTE CAP CAPPUCCIO X CONNETTORE CONNECTOR CAPPUCCIO CAP MANOPOLA REG CORRENTE SALDAT KNOB WELDING CURRENT REGULAT POTENZIOMETRO COMPL POTENTIOMETER INTERRUTTORE UNIPOLARE SWITCH COMMUTATORE COMMUTATOR CONNETTORE CONNECTOR PRESA DI SALDATURA NERA BLACK WELDING SOCKET PANNELLO FRONTALE inferiore FRONT PANEL PULSANTE STOP D EMERGENZA EMERGENCY PUSH BUTTON STOP SCHEDA FILTRO ANTIDISTURBI ANTIJAMMING FILTER CONTATTO NORMALMENTE APERTO CONTACT N O DISTANZIALE ISOLANTE SPACER SCHEDA DI CONTROLLO SALDATURA PCB WELDING CONTROL TELERUTTORE 40A CONTACTOR 40A STAFFA BRACKET RELE AVV ELETTRICO RELAY ELECTRIC START MORSETTIERA TERMINAL BOARD TRASFORMATORE AUXILIARY TRANSFORMER PIASTRINA DI PARALLELO PLATE PIASTRINA SMALL PLATE GUIDA MORSETTIERA TERMINAL GUIDE SCATOLA ELETTRICA ELECTRIC BOX TS 600 PS BC EF 31 1 REV 0 12 11 13 12 11 76605 1 4099 LL CL EL LL N 2 oc TS 600 PS BC 7 ZANNI IAN d 1 P AY a 14 13 5 1 11 0 l Ve 17
11. DIAGRAM ELECTRIQUE SCHEMA ELEKTRISCHES SCHEMA Cod De scr Descr Pos Descr e Meseroosza scaron M0000KD0259904 CAVO COMANDO DISTANZA REMOTE CONTROL CABLE 9 20904 CAVO COMANDO DISTANZA REMOTE CONTROL CABLE M936840555 COMANDO RC2 SENZA CAVO RC2 REMOTE CONTROL
12. Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor Suction of liquids from If you suppose that vomit has entered the lungs as in case of spontaneous vomit take the subject to the lungs hospital with the utmost urgency Inhalation In case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved r gt FIRE PREVENTION In case the working zone for whatsoever cause goes on fire with flames liable to cause severe wounds or death follow the first aid as described by the ruling norms or local ones EXTINCTION MEANS Appropriated Carbonate anhydride or carbon dioxyde powder foam nebulized water Not to be used Avoid the use of water jets Other indications Cover eventual shedding not on fire with foam or sand use water jets to cool off the surfaces close to the fire Particular protection Wear an autorespiratory mask when heavy smoke 15 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 D PRECAUTION ENGINE DRIVEN WELDER REV 0 06 07 INSTALLATION AND ADVICE BEFORE USE The operator of the welder 15 responsible for the security of the people who work wit
13. connection 12 is efficent when this connection is present being necessary See page M20 CONNECT WELDING CABLES Insert the welding cable plugs completely in the sockets turning clockwise to lock them in place oe ONLY GOUGING P PUSH AND TWIST Connect the earth clamp to the negative pole and the electrode holder to the positive rispecting in all cases the welding polarity required by the type of electrode used When using the welder for air arc gouging connect the ground lead to the socket and the gouging lead to the socket marked only gouging if present iz Pay attention to the two polarities on the welding circuit which must not come into electrical contact with each other Carefully tighten the output cables to the bu shings if loose they can cause problems of overheating and damage the bushings cables etc Make certain the grounding pincer is connected as near as possible to the work station ADJUSTING THE WELDING CURRENT For every welding current chosen the machine shall run at its nominal speed M 600 PS BC 34 REV 0 12 11 Do not modify the regulation of the engine rpm Speeds different from the rated one can worsen the performances and even the reliability of the machine The welding current is regulated by turning knob T continuously set to the minimum turned fully in an anticlockwise direction it provi des a current of approximately 30 A if s
14. operating manual Replace the tap ensuring it is perfectly closed After refilling operations allow the motor to run for a brief time and check the level as it may have di minished due to air bubbles present in the cooling circuit restore the level with water To replace the liquid coolant follow the operations described in the motor operating manual ATTENTION The engine cooling system 15 originally filled with coolant type AGIP ANTIFREEZE EXTRA During the engine life it is strongly recommended to use the same coolant type This is because a coolant change would require a careful cleaning of the cooling system which is not an easy job A lack in tacking these precautions would result in the mix of different additives used in different coolants which would originate gelatinous substances capable of obstructing the cooling system Water cooled systems GROUNDING CONNECTION The grounding connection to an earthed installation is obligatory for all models equipped with a diffe rential switch circuit breaker In these groups the generator star point is generally connected to the machine s earthing by employing the TN or TT di stribution system the differential switch guarantees protection against indirect contacts In 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 groundi
15. starting alert will intervene the two LEDs Engine running and glow plug will flash alternately see motor protection description At any time it is possible to stop the engine by turning the key in an anti clockwise direction OFF position In case of engine anomaly due to low oil pres sure high temperature broken transmission belt low fuel level or emergency the will automatically stop the engine M DSP 600 TS 600 PS BC 21 REV 0 12 11 4 The engine starts up at its operating speed 1500 or 1800 rpm After start up allow the engine to run for a few minutes before powering on the utilities See table Temperature lt 20 C to 20 C from 10 to 10 C from 5 29 C 5 Start up at low temperatures The engine has e good start up to temperatures of 10 C For start up at low temperatures is necessary to use the glow plugs You can adjust the preheating phase turning the trimmer an the back of the For start up and use at temperature lower then 20 C please contact our Technical Assistance gt In case of unsuccessful start up do not in sist for longer than 5 seconds Wait 10 15 seconds before attempting another start up 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 CD M S
16. 5 OUTAIR GRATE 2 740561100 ROLL BAR 3 400409154 4 764409150 5 M740568290 ALTERNATOR TOP COVER 6 740568239 s ALTERNATOR RIGHT BRACKET 7 M342202026 CAP FUEL TANK 8 M740568164 WATER TRAY 9 M740562147 FUEL FILTER FIXING BRACKET 10 M765109863 CONDENSER PROTECTION 11 M841562228 FUEL PRE FILTER Fornito con motore 12 740567015 ELECTRICAL BOX COVER 13 766709041 CAPACITOR BOX BRACKET 14 M105319880 CAPACITOR BOX 15 209719882 CAPACITOR BOX BRACKET 16 M766704010 POWER RESISTANCE 17 309015043 WASHER 18 309014013 SPACER 19 266155300 RECTIFIER ASSY 20 M366105091 RECTIFIER ASSY BRACKET 21 M766019890 SHUNT 22 766054110 REACTANCE SUPPORT BRACKET 23 M364124100 REACTANCE 13 12 11 76605 1 9099 LL CL EL 0 12 11 5 600 5 ZANI C us 2 qm o 2 2 CD Ersatzteile CF Pi ces de rechanges 16 15 14 4 13 12 11 10 Spare parts Ricambi CD Ersatzteile EF Spare parts CE Tabla de recambios TS 600 PS BC 33 1 CF Pi ces de rechanges QD REV 0 12 11 Pos Cod Descr Note 1 M765007057 CHIAVE PER SERRATURA 2 M105112270 GUARNIZIONE L MT 1 qm M766708070 COPERCHIO TAPPO RADIATORE 4 M102042870 MOLLA 5 209718073 TIRANTE 6 M740568035 CARENATURA POSTERIORE 7 M744508140 CERNIERA PER FIANCATA 8 740568010 FIANCATA DX CARENAT ANTERIORE 9 M305718115 PISTON
17. 766059003 GB USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG O MOSA 13 12 11 76605 00 preparato da UPT approvato da DITE D M DESCRIPTION OF THE MACHINE TS 600 PS BC 0 REV 0 12 11 The TS 600 engine driven welder is a unit which ensures the function as a a current source for welding b a current source for the auxiliary generation The welding generator set is a source of DC electric power driven by an internal combustion engine which allows to perform arc welding processes with different types of electrodes Besides the generation set can provide ac 50 Hz auxiliary power both three phase and single phase usable for the various needs associated with the welding The engine which drives the generator set is a three cylinder diesel type water cooled while the alternator is an asynchronous three phase type The welding current control is performed by means of a semi controlled thyristor rectifier SCR while the regulation board is implemen ted with analogue technology From a mechanical viewpoint the machine is composed of a bunded basement and a roll bar which support the engine alternator assembly The canopy includes a protection cover for the front panel and one rear cover intended to allow the routine maintenance operations On the front panel there are the engine protection unit which includes the start key and a few indicator lights which monitor the engine status welding devices and the adju
18. D Remote potentiometer cursor Dunes E Porty change command 06 ATTENTION To reduce the risk of electromagnetic interferences use the minimum lenght of welding cables and keep them near and down ex on the floor The welding operations must take place far from any sensitive electronic device Make sure that the unit is earthed see M20 et or 25 In case the interference should last adapt further disposition such as move the unit use screened cables line filters screen the entire work area In case the above mentioned operations are non sufficient please contact our Technical Assistance Service CD ACCESSORY USE TS SERIES REV 0 12 11 PUSH AND SCREW TIGHT The remote control device for regulating the welding current is connected to the front panel by means of a multipole connector To regulate the current from the RC2 move the switch 7 located above the multipole connector 8 to ON position Position welding current adjusting T knob at the necessary current value for the diameter and type of electrode REMOTE CONTROL RC2 PL Version RC2 90 PL Version PUSH AND SCREW TIGHT 09 04 02 M38GB CD USE AS A GENERATOR DANGEROUS It is strictly forbidden to connect the machine to the ublic mains a o to another source of electric power Access forbidden to area adjacent to 8 electricity generating set for all authorized personn
19. E CHARGER ALTERNATOR 08 02 08 M39GB CD Comandi CD Bedienelemente M Controls CE Mandos TS 600 PS BC 31 Commandes QD REV 0 12 11 Kit MG7 SR 9 T F6 D Z5 V5 C2 H8 y a Presa di saldatura Presa di saldatura Presa di messa a terra Presa di corrente in c a Filtro aria motore Asta livello olio motore Tappo caricamento olio motore Tappo caric liquido di raffredd Prefiltro combustibile Tappo serbatoio Silenziatore di scarico Tappo scarico olio motore Tappo scarico combustibile serbatoio Protezione termica motore Protezione termica corrente aux Indicatore livello combustibile Interruttore differenziale 30mA Selettore Arc Force Trasmettitore livello carburante Unit controllo motore Commut riduz scala saldatura Pulsante stop emergenza Contaore Voltmetro Amperometro di saldatura Batteria Regolatore corrente di saldatura Voltmetro tensione saldatura Indicatore pressione olio Indicatore temperatura acqua Presa per comando a distanza Interruttore comando a distanza a gt TR 12 15 59B L5 Welding socket Welding socket Earth terminal A C socket Engine air filter Oil level dipstick Engine oil reservoir cap Water filling cap Fuel prefilter Fuel tank cap Muffler Oil drain tap Exhaust tap for tank fuel Engine thermal switch Aux current thermal switch Fuel level light G F l Arc Force sele
20. E ALTERNATOR BRACKET 15 M107509005 GUARNIZIONE GASKET qm 16 M764409975 SENSORE LIVELLO CARBURANTE FUEL LEVEL SENSOR 17 M308101262 TAPPO SCARICO SERBATOIO FUEL TANK CAP 18 308102023 GUARNIZIONE GASKET 19 M6095030 TUBO GOMMA PIPE 20 MJJ0062292 NIPPLO OLEODINAMICO 1 2 G NIPPLE 21 MJJ0062025 RUBINETTO M F 1 2 G OIL TAP 22 M784102069 GUARNIZIONE SCARICO MOTORE GASKET 23 M740560566 KIT TUBO SCARICO PIPE KIT 24 M740562050 SILENZIATORE SCARICO COMPL EXHAUST MUFFLER 25 M305232071 GUARNIZIONE GASKET 26 M105612070 ANTIVIBRANTE 40x50 VIBRATION DAMPER 40x50 27 M766051038 PIASTRA ANT CHIUSURA BASAM BASE FRONTAL LOCKING 28 M740561050 BASAMENTO BASE 29 M105612060 ANTIVIBRANTE 40x100 VIBRATION DAMPER 40x100 30 105112270 GUARNIZIONE L MT 1 STRIP SEALING L MT 1 qm gt M740568066 CORNICE PER RADIATORE RADIATOR FRAME TS 600 PS BC EF 30 1 REV 0 12 11 13 12 11 76605 1 CD Ricambi CD Ersatzteile EF Spare parts CE Tabla de recambios TS 600 PS BC 31 CE Pi ces de QD REV 0 12 11 7 MG7 Kit SR m a 24 ORR SI ad 12 24 lt 13 14 23 21 20 12 19 18 17 16 15 22 1 Kit SR 13 12 11 76605 1 Ricambi Spare parts CF Pi ces de rechanges QD Pos cO OO N SD ND R As BR A A O 9 9 9 WW W a N N N N N N N N N N gt a 2 O
21. E SOSTEGNO 10 107300180 CHIUSURA COMPL A LEVA 11 343339601 MANIGLIA 12 102302280 GUARNIZIONE L MT 1 qm 13 M740568004 FIANCATA SX CARENAT ANTERIORE 14 766058100 COPERCHIO FRONTALE 15 766058021 COPERCHIO CARENATURA ANTERIORE 16 M765008112 SERRATURA Pos Cod Descr Note 1 M765007057 ELECTRIC BOX COVER KEY 2 M105112270 STRIP SEALING L MT 1 qm M766708070 RADIATOR COVER CAP 4 M102042870 SPRING 5 209718073 TIE ROD 6 M740568035 COVER REAR 7 M744508140 LATCH 8 740568010 FRONT COVER RIGHT SIDE 9 M305718115 SUPPORT REAR COVER 10 107300180 LATCH 11 343339601 KNOB 12 102302280 GASKET L MT 1 qm 13 M740568004 FRONT COVER LEFT SIDE 14 766058100 FRONT COVER 15 M766058021 FRONT HOUSING COVER 16 765008112 LATCH FOR ELECTRICAL BOX COVER 13 12 11 76605 1 CTL 35 740350140 17 0 05 06 IP L l d hod dh A as d nr ie et Rs n le Au N Eu gt P 9 M Ad dA M225100141 GR TIMONE PIEDE X TRAINO LENTO KIT SITE TOW M740350142 GR ASSALE RUOTE TRAINO LENTO KIT SITE TOW M305751160 ASSALE AXLE m Iess _ _ _ NE wsessonro 11 06 04 KA RC2 M936840000 BC version KD RC2 90 M936850000 BC version 13 REV 0 09 10 RC2 RC2 90 1 O SCHEMA ELETTRICO ELECTRICAL
22. IEOLL eues supuieg 199 005 o gt w O e 02 63 Se ka 0 TEE sese 9 2 O 9 o O A cJ ma A 4 1 1 ul Jam L L J N 48 228 dois Hed IWNOILdO 7 1 0 L 0 09 E X A O LUVIS 09 752 4 SL e S i 85 too LE 0 G o o5 5 5 o o I LL988 90 60 61 Cla V OZO S EL982 90027070 asejoda7 panoidd u Bug SUTUIPN 03 294 H STA ezed 5971984 ESE AH Tp u beg euorzeuruoueg addy 1590 9160 d MEA HY TN 80020102 ZG LS Jed eo y REV 1 11 08 DSP 600 PS 600 PS BC QO VCcElNOE 0 3 boo Ses o 5 5 5 5 oou 0779 50 70 01 060507797 v00ZOL SL N lt Fz ATE Jaubisag OL eJojeuBesi Beg BIM S v 62907794 gt u abed 3oefoJgd uoneuiuouegq wos AH ID Lu bed beg eq ddy
23. O NOT LIFT THE MACHINE AND TRAILER DANGER LIFTING EYE IS NOT DESIGNED TO SUPPORT casi ADDED WEIGHT OF ROAD TOW TRAILER A 30 03 00 M4GB D CTL 35 45 50 95 M ASSEMBLY 6 8 REV 1 03 06 N ATTENTION The CTL accessory cannot be removed from the machine and used separately actioned manually or following vehicles for the transport of loads or anyway for used different from the machine movements TRAILERS The machines provided for assembling the CTL accessory slow towing trolley can be towed up to a 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 CTL 35 50 a x l COMANDI p CTL 45 M N M w w w w o IL 17 For assembling the generating set on the trolley CTL 35 45 50 95 please keep to following instructions 1 Lift thr generating set by means of suitable hook 6 Assemble on the machine the towbar 5 complete offoot with the M10x20 screws nuts and washers 5 7 Assemble the axle 7 to the base of the machine CTL 45 95 withthe M10x20 screws and relative washers two perpart so that their supports coincide 8 Insert the wheel 9 on the axle then twist the
24. TOPPING THE ENGINE DSP 500 PS 22 15 600 PS BC REV 0 09 07 STOP For shutdown under normal conditions proceed as follows 1 Break the welding process in course 3 Letthe engine run with no load for a few minutes 4 Turn the start key on the EP7 to the OFF position OFF N START EMERGENCY SHUTDOWN To stop the engine in a dangerous situation press the emergency stop button L5 or turn the start key to the OFF position To reset the emergency stop button turn it clockwise 21 09 07 78510 D PROTECTIONS REV 0 02 08 Description The EP7 includes the basic safeguards to protect an DIESEL engine features 7 LEDs Static Outputs and a 30A Key Switch The EP7 monitors an Oil Pressure switch Temperature switch Fuel Level switch Charger Alternator Voltage and an Emergency switch PREHEAT yellow LED This indicator illuminates during the Pre Glow cycle 10 secs to 60 secs EMERGENCY red LED This LED illuminates continuously when a shut down has been caused by the Emergency switch ALTERNATOR FAILURE red LED This LED illuminates before engine starting or if a Belt Break shut down occurs than 20 secs OIL PRESSURE red LED This LED illuminates before engine starting or if an Oil Pressure shut down occurs FUEL LEVEL red LED This LED blinks when a low fuel condition occurs This LED illuminates continuously to indicate a shut down if the swit
25. al must also given to him Do not damage it do not take parts away do not tear pages and keep it in places protected from dampness and heat You must take into account that some figures contained in it want only to identify the described parts and therefore might not correspond to the machine in your possession INFORMATION OF GENERAL TYPE In the envelope given together with the machine and or set you will find the manual for Use Maintenance and opare 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 ONE INDICATED relieves the manufacturer from the risks which could happen or anyway from that which was agreed when selling the machine The manufacturer excludes any responsibility for damages to the machine to the things or to persons in this case Our products are made in conformity with the safety norms in force for which it is advisable to use all these devices or information so that the use does not bring damage to persons or things While working it is advisable to keep to the personal safety norms in force in the countries to which the product is destined clothing work tools etc Do not modify for any motive parts of the machine fastenings holes electric or mechanical d
26. ative since the above norm is much larger For further details please see the specific norms and or the manufacturers of the product to be used in the welding process RUTILE ELECTRODES E 6013 Easily removable fluid slag suitable foe welding in all position Rutile electrodes weld in d c with both polarities electrode holder at or and in a c Suitable for soft steels R 38 45 kg mm Also for soft steels of lower quality BASIC ELECTRODES E 7015 Basic electrrodes wels onlu in d c with inverse polarity on the electrode holder there are also types for a c Suitable for impure carbon steels Weld in all position HIGH YIELD BASIC ELECTRODES E 7018 The iron contained in the coating increases the quality of metal added Good mechanical properties Weld in all position Electrode holder at inverse polarity Wld deposit of nice aspect also vertical Workable high yield Suitable for steels with high contens of sulphur impurities CELLULOSIC ELECTRODES E 6010 Cellulosic electrodes weld only in d c with polarity electrode holder ground clamp Special for steels run on pipes with R max 55 kg mm Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS 2 digits type of coating and electric power con ditions see table 3 1 digits welding positions see table 2 the weld deposit see table 1 Cellulose electrodes for d c symbol
27. attery Green colour immediately after startup or defective battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY 2 Presence of air in the fuel supply 2 Carry out de aeration on the fuel system See engine operating circuit manual 3 Engine protection thermic fuse 3 Replace In case the problem persists check the electrical circuit blown and eliminate the problem Call an authorised service centre P2 Engine stop due to intervention of 1 Engine temperature too high or 1 Check oil level engine protection insufficient oil pressure 2 High temperature sensor or oil 2 Replace the malfunctioning sensor pressure defective 3 Engine protection defective 3 Replace the protection 4 Stop device defective 4 Replace P3 The battery is not charged 1 Battery charger alternator de 1 Replace fective 2 Battery charger alternator not exci 2 Check the excitation system of battery charger ted P4 For other problems refer to the attached engine manual 19 05 05 76440 GB D MAINTENANCE M 43 0 06 10 qualified personnel do maintenance and troubleshooting work e Stop the engine before doing any work inside the machine If for any re ason the machine must be operated while working inside pay attention moving parts hot parts exhaust manifold and muffler etc electrical parts which be unprotected when the
28. ause injuries or wounds must be made wearing heavy gloves and using suitable tools The getting rid of the various components of the machine must be made accordingly to rules in force of law a o local rules Particular attention must be paid when getting rid of lubricating oils battery electrolyte and infla mable liquids such as fuel cooling liquid The machine user is responsible for the observance of the norms concerning the environment conditions with regard to the elimination of the machine being cust off and of all its components In case the machine should be cust off without any previous disassembly it is however compulsory to remove tank fuel engine lubricating oil cooling liquid from the engine battery NOTE BCS is involved with custing off the machine only for the second hand ones when not reparable This of course after authorization M 46 REV 0 06 07 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 04 06 07 M45GB CD M RECOMMENDED ELECTRODES In accordance with A W S Standard 55 1 0 10 03 information here below to be intended only as indic
29. ch has been closed for more than 5 minutes TEMPERATURE red LED This LED illuminates when an High Temperature shut down occurs AUXILIARY OUTPUT STARTER 12 24V 36 4 EP7 ENGINE PROTECTION Specification DC Supply Battery Plant 8V up to 36 Vdc Static Outputs short circuit proof 200 mAdc Key Switch Rating 30 A 30 secs 80 5 secs Dimensions DIN 96 Size 72 72 55 ex switch key Weight 300 gr Operating Temperature 30 70 Operating Humidity 96 non condensing ENGINE RUNNING green LED This LED blinks for 15 seconds indicating that the EP7 15 ready to start the engine you have to turn the key to start If the engine does not run within 15 seconds the Starting Failure alarm will take place This LED illuminates continuously if the engine runs KEY SWITCH OFF position KEY SWITCH Pre Heat position KEY SWITCH START position Engine protection STARTING FAILURE ALARM indication Z s These 2 LEDs blink alternatevely slowly to indicate a starting failure alarm OPTIONAL ALARM indication T FC These 2 LEDs blink alternatevely L3 quickly to indicate the intervention of the alarm ALARM OUTPUT anticlockwise y E 1007 67 Gl setting 1 STOP SOLENOID STOP SOLENOID clockwise Ki Ki OR REGULATOR 6 lt IN PREHEAT yA FUEL LEVEL EMERGENCY TEMPERATURE OIL PRESSUR
30. cooled systems AIR FILTER Y Check that the dry air filter is correctly installed and that there are no leaks around the filter which could lead to infiltrations of non filtered air to the inside of the motor Hy FUEL Do not smoke or use open flames during refuelling operations in order to avoid explosions or fire hazards Fuel fumes are highly toxic carry out operations outdoors only or in a well ventilated environment Avoid accidentally spilling fuel Clean any eventual leaks before starting up motor Refill the tank with good quality diesel fuel such as automobile type diesel fuel for example For further details on the type of diesel fuel to use see the motor operating manual supplied Do not fill the tank 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 9 o 12 06 03 M20 R HO2 GB CD Set up for operation REV 1 02 11 a COOLING LIQUID N ATTENTION Do not remove the radiator tap with the motor in operation or still hot as the liquid coolant may spurt out and cause serious burns Remove the tap very carefully Remove the tap and pour the liquid coolant into the radiator the quantity and composition of the liquid coolant are indicated in the motor
31. ctor Fuel level transmitter Engine control unit 7 Welding scale switch Emergency button Hour counter Voltmeter Welding ammeter Battery Welding current regulator Welding voltage voltmeter Oil pressure indicator Water temperature indicator Remote control socket Remote control switch 23 24 27 Referenalst Prise de soudage Prise de soudage Prise de mise a terre Prises de courant en c a Filtre air moteur Jauge niveau huile moteur Bouchon remplissage huile moteur Bouchon remplissage liquide de refroidiss Pr filtre carburant Bouchon r servoir Silencieux d chappement Bouchon d charge huile moteur Bouchon vidange carburant reservoir Protection thermique moteur Protection thermique courant aux Indicateur niveau carburant Interrupteur differential Selecteur Arc Force Niveau carburant Protection moteur 7 Commutateur chelle soudage Bouton d urgence Compte heures Voltmetre de soudage Batterie R gulateur courant soudage Voltmetre tension soudage Indicateur pression huile Indicateur temperature eau Prise pour telecommande Commutateur telecommande 25 26 61 31C SchweiBbuchse SchweiBbuchse Erdanschluss Steckdose AC Luftfilter Motor Oelmess Stab F llverschluf Motor l F llverschluf K hlwasser Kraftstoffvorfilter F llverschluf Kraftstofftank Auspufftopf AblaRoffnung Motor l AblaRoffnung Kraftstoff T
32. e and maintenance manual is an important part of the machines in question The assistance and maintenance personel must keep said manual at disposal as well as that for the engine and alternator if the machine is synchronous and all other documentation about the machine We advise you to pay attention to the pages concerning the security see page M1 1 All rights are reserved to said Company It is a property logo of MOSA division of B C S S p A All other possible logos contained in the documen tation are registered by the respective owners E gt gt The reproduction and total or partial use in any form and or with any means of the documen tation is allowed to nobody without a written permission by MOSA division of B C S S p A To this aim is reminded the protection of the author s 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 10 10 02 M1 01 GB lt Notes REV 0 10 02 INFORMATION Dear Customer We wish to thank you for havin
33. e protection against indirect contacts caused by faulty currents towards ground When the divice notes a faulty current at the ground superior to 30 mA it breaks the feeding at the a c sockets In case of intervention check that there is no isolation fault in the plant of union cables sockets and plugs inserted tools Before each work session check the GFI device efficiency pressing the test key The generating set must be working and the lever in ON position M 600 PS BC 37 REV 0 12 11 The GFI does not work correctly without grounding of the unit Before use dispose an efficient grounding system using the PE terminal 12 and keeping to rules and laws in force concerning safety and electric plant PLUGS and CABLES Before inserting a load into the machine check that the cable is in good condition its section fit for the drawn current and the plug inserted correctly VOLTMETER The presence of the voltage means that is possible to draw power from a c sockets THERMIC PROTECTION Generally present to protect against overloads on an individual power socket 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 tha
34. een colour battery OK Black colour battery to be recharged White colour battery to be replaced THE ENGINE PROTECTION NOT WORK WHEN THE OIL IS OF LOW QUALITY BECAUSE NOT CHARGED REGULARLY AT INTERVALS AS PRESCRIBED IN THE OWNER S ENGINE MANUAL 05 09 05 MA3GB In case the machine should not be used for more than 30 days make sure that the room in which it is stored presents a suitable shelter from heat sources weather changes or anything which can cause rust corrosion or damages to the machine Have qualified personnel prepare the machine for storage GASOLINE ENGINE Start the engine lt 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 25 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 15 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 l
35. eheating glow plugs M7 F EDCA connector E P 1 engine protection H4 Preheating gearbox N7 OFF ON DIAGN selector Engine stop solenoid 14 Preheating indicator O7 DIAGNOSTIC push button Acceleration solenoid L4 R C filter P7 DIAGNOSTIC indicator Fuel level transmitter M4 Heater with thermostat Q7 Welding selector mode Oil or water thermostat NA Choke solenoid R7 VRD load 48V D C socket 04 Step relay S7 230V 1 phase plug Oil pressure switch P4 Circuit breaker T7 VlHz analogic instrument Fuel warning light Q4 Battery charge sockets U7 Engine protection EP6 Battery charge warning light R4 Sensor cooling liquid temperature V7 GEI relay supply switch Oil pressure warning light 54 Sensor air filter clogging 27 Radio remote control receiver Fuse T4 Warning light air filter clogging W7 Radio remote control trasnsmitter Starter key U4 Polarity inverter remote control Isometer test push button Starter motor V4 Polarity inverter switch Remote start socket Battery Z4 Transformer 230 48V A8 Transfer fuel pump control Battery charge alternator W4 Diode bridge polarity change 8 Ammeter selector switch Battery charge voltage regulator X4 Base current diode bridge C8 400V 230V 115V commutator Solenoid valve control PCBT YA PCB control unit polarity inverter 08 50 60 Hz switch Solenoid valve 5 Base current switch E8 Cold start ad
36. el The generating set 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 discharge gases heat etc RPM VOLTAGE FREQUECY The engine speed determines the values of voltage and frequency of the auxiliary generation system Check the proper engine operation at its nominal speed before each usage Do not modify the regulation of the engine rpm Speeds different from the rated one can worsen the performan ces and even the reliability of the machine With no load the values of voltage and frequency are usually superior to their rated values about 10 for vol tage and 5 for frequency When the power increases with inserted loads the voltage and frequency values decrease at full power the voltage can be reduced of 10 and the frequncy of 3 Before the use 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 installations requirements The D at higt sensitiveness 30 mA guarantees th
37. eration of the machine as well as potential hazards and dangers for persons and things IMPORTANT ADVICE Advice to the User about the safety i 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 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 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 A ATTENTION NOTE These headings refer
38. et to the maximum turned fully in a clockwise direction it gives a maximum current of approximately 600A F SWITCH REDUCTION SCALE A For small electrodes up to 2 3 25 130A and 4 200 it is recommended 200 A to use the reduction scale switch 13 allowing a more accurate regulation of the welding current lever position at 200A When using electrodes of a diameter greater than 3 25 and or 4 set the welding scale knob to max position SWITCH ARC FORCE BASE CURRENT Positioning the switch on ON is obtained a low ON voltage welding current which keeps always the lit arc necessary for some OFF types of cellulosic basic electrodes or when a high penetration is wanted For electrodes of rutile type position the switch on OFF RECOMMENDED ELECTRODES All the electrodes on the market can be used SWITCH POLARITY INVERTER It permits to have at the electrode holder the positive or negative welding polarity It is used above all in the first run with cellulosic elec trodes to lower the bath temperature olarity switch and so doing ease up the welding on pipes of small thickness Note the welder is provided with polarity inverter only on request 7000 CD M USE AS WELDER TS 600 PS BC 34 1 REV 0 12 11 REMOTE CONTROL RC The welding current can also be set from a distance using the optional remote control SCREW TIGHT OB 16 60 OC JO FO
39. evices others if not duly authorized in writing the responsibility coming from any potential intervention will fall on the executioner as in fact he becomes maker of the machine vs Notice this manual does not engage the manufacturer who keeps the faculty apart the essential characteristics of the model here described and illustrated to bring betterments and modifications to parts and accessories without putting this manual uptodate immediately 10 10 02 M 1 1 NEUTRO CD CE MARK REV 5 03 11 Any of our product is 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 1 part of the declaration of conformity included in any machine standard equipment Here below the adopted symbol marking is clearly readable and unerasable and it can be either part of the data plate Uo UM Hz 1 PF vw e vm 100 m 25 Furthermore each model it is shown the noise level value the symbol used is the following we indication is shown a clear readable and indeleble way on a sticker 10 10 02 M1 4 GB C1 Dichiarazione conformit Konformitatserklarung 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
40. for Cellulose electrodes for a c Coated Rutile electrode for d c electrode Rutile electrode for a c High yield rutile electrodes Basic electrodes for d c Basic electrodes for c a High yield basic electrodes for d c inverse polarity Acid electrodes for flat or front position welding for d c pole and for a c High yield rutile electrodes for flat or front plane position welding for d c and a c High yield acid electrodes for flat or front plane position welding for d c pole and a c High yield basic electrodes for flat or front plane position welding for d c inverse polarity Extra high yield acid electrodes extra high penetration if required for flat position welding only for d c pole and a c Number 60 000 70 000 80 000 90 000 100 000 110 000 120 000 Table 1 1 for all positions 2 for plane and verticl 3 for plane posotion only Table 2 Table 3 10 10 03 M55GB lt X IN lt C AA G Z O T O O U gt ELECTRICAL SYSTEM LEGENDE 60 REV 9 06 11 Alternator F3 Stop push button L6 Choke button Wire connection unit G3 lonition coil M6 Switch CC CV Capacitor Spark plug N6 Connector wire feeder G F 13 Range switch 420 110 3 phase transformer Welding PCB transformer L3 Oil shut down button P6 Switch IDLE RUN Fuse M3 Battery charge diode Q6 Hz V A analogic instrument 400V 3
41. g bought a high quality set Our sections for Technical Service and Spare Parts will work at best to help you if it were necessary To this purpose we advise you for all control and overhaul operations to turn to the nearest authorized Service Centre where you will obtain a prompt and specialized intervention c n case you do not profit on these Services and some arts are replaced please ask and be sure that are used exclusively original parts this to guarantee that the performances and the initial safety prescribed by the norms in force are re established gt use of non original spare parts will cancel immediately any guarantee and Technical Service obligation NOTES ABOUT THE MANUAL Before actioning the machine please read this manual attentively Follow the instructions contained in it in this way you will avoid 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 manu
42. gary Nemko AS Norway NSAI Ireland PCBC Poland Quality Austria Austria RR Russia SII Israel SIQ Slovenia SIRIM QAS International Malaysia SQS Switzerland SRAC Romania TEST St Petersburg Russia TSE Turkey YUQS Serbia IQNet is represented in the USA by AFNOR Certification CISQ DQS Holding GmbH and NSAI Inc The list of IQNet partners is valid at the time of issue of this certificate Updated information is available under www iqnet certification com Gianrenzo Prati 1 150 9001 2008 Cert 0192 UNI EN ISO 9001 2008 MOSA has certified its quality system according to UNI EN ISO 9001 2008 to ensure a constant highquality of its products This certification covers thedesign production and servicing of engine dri venwelders and generating sets The certifying institute ICIM which is a member ofthe International Certification Network IQNet awarded the official approval to MOSA after an examination of its operations at the head office andplant in Cusago MI Italy This certification is not a point of arrival but a pledgeon the part of the entire company to maintain a levelof quality of both its products and services whichwill continue to satisfy the needs of its clients aswell as to improve the transparency and thecom munications regarding all the company s activesin accordance with the official procedures and inhar mony with the MOSA Manual of Quality M 01 REV 4 03 12 www icim it CERTIFICATO n
43. h the welder and for those in the vicinity The security measures must satisfy the rules and regulations for engine driven welders The information given below is in addition to the local security norms Estimate possible electromagnetic problems in the work area taking into account the following indications Telephonic wirings and or of communication check wirings and so on in the immediate vicinity Radio and television receptors and transmettors Computer and other checking devices Critical devices for safety and or for industrial checks Peapol who for instance use pace maker hearing aid for deaf or something and else Devices used for rating and measuring The immunity of other devices 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 DU ge DN ATTENTION Make sure that the area 15 safe before starting any welding operation Do not touch any bare wires leads or contacts as they 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 Do not touch any electrical parts or the electrode while standing in water or with wet hands feet or clothes Insulate yourself from the work surface while welding Use carpets or other insulating materials t
44. hermoschutz Motor Thermoschutz Hilfsstrom Anzeige Kraftstoffpegel Fl Schalter GFI Schalter Arc Force Fullstandsgeber Kraftstoff Motorschutz 7 Bereichsschalter SchweiBstrom Notschalter Stundenzahler Voltmeter Amperemeter Schweilsstrom Batterie Schweifsstromregler Voltmeter Schweifspannung Anzeige Oldruck Anzeige Wassertemperatur Steckdose Fernbedienung Umschalter Fernbedienung 13 12 11 76605 1 CD Front panel components Connection sockets for 9 c c welding sockets 10 c c welding sockets 0 9 9 c c socket only gouging Out welding cables ONLY GOUGING ARC FORCE CR gr let used only for cutting works 13 Switch for welding scale reduction Placed on 200A it limits the maximum value of the welding current regulator T at 200A so permitting a more accurate regulation of the welding current F6 Arc Force selector The ON position powe red the BC circuit base current W1 Remote control switch The ON position enables the remote control to adjust the welding current X1 Remote control socket connector Multipole connector for remote control D Differential switch Generally with a current of 30 mA this is the safety device against indirect contacts 59B Thermal protection for inputs c a Protects individual sockets generally the mono phase inputs from overloads N Line voltmeter The presence of line voltage means that is possible to draw powe
45. ing current signal interrupter 3 Check that cables from shunt to card are in perfect state 4 Defect card 4 Replace card 5 Defect in diode bridge 5 Check the diode or the controlled diodes P2 There is welding but non penetra 1 Connnection of base current control 1 Check that the a c 48V arrives to the contactor of the base current tion are open 2 Defect in the base current contactor 2 Check that the contacts and the contactor shut are in good conditions Defect in welding high and discon 1 Defect in connections between 1 Check the continuity and the state of different connections which tinued sparks shunt and potentiometer go to the card from the shunt as well as from the potentiometer 2 Defect in diode bridge 2 Check the diodes and SCR 3 Defect in card 3 Replace the card P4 No welding output and no auxiliary 1 Short circuit in wiring 1 Check the wiring inside the welder for a short circuit between power output cables or to ground 2 Defective condenser 2 If the wiring is OK short circuit the condenser to be sure that it is discharged disconnect all wires from condenser and using an ohmmeter check that the condenser is not short circuited 3 Defective stator 3 If the condenser box is OK disconnect all leads from the stator except for those going to the condenser box and check the output from the alternator If there is no output from the welding winding and the auxiliary winding replace the sta
46. l which the client expects Continuous efforts to improve the products andtheir performance at competitive conditions Competent support in the solution of problems Information and training in the correct applicatio nand use of the products to assure the security ofthe operator and protect the environment Regular inspections by ICIM to confirm that the requirements of the company s quality systemand ISO 9001 are being respected All these advantages are guaranteed by the CER TIFICATE OF QUALITY SYSTEM No 0192 issued by S p A Milano Italy www icim it 10 10 02 MO1 GB 600 PS BC DESCRIPTION OF THE MACHINE QUALITY SYSTEM COPYRIGHT NOTES CE MARK DECLARATION OF CONFORMITY TECHNICAL DATA WELDING TECHNICAL DATA SYMBOLS AND SAFETY PRECAUTIONS INSTALLATION AND ADVICE BEFORE USE INSTALLATION AND ADVICE INSTALLATION AND DIMENSIONS UNPACKING TRANSPORT AND DISPLACEMENTS ASSEMBLY CTL PREPARING THE UNIT STARTING THE ENGINE SPOPPING THE ENGINE USE OF THE ENGINE PROTECTION CONTROLS COMPONENTS OF FRONTAL PANEL USE AS A WELDER REMOTE CONTROL RC2 REMOTE CONTROL TC7 USING THE GENERATOR TROUBLESHOOTING MAINTENANCE STORAGE CUST OFF RECOMMENDED ELECTRODES ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM SPARE PARTS LIST SPARE PARTS SPARE PARTS LIST SPARE PARTS M 1 REV 0 12 11 19 01 11 37312 CD M Copyright 1 01 REV 0 10 02 N ATTENTION This us
47. limits according to 2000 14 CE directive 19 01 11 37312 D M Technical data 1 6 TS 600 PS BC REV 0 12 11 Technical data D C WELDING Welding current electronic regulation on 2 scales 20 200 20 600 Service 600A 35 550A 60 500 100 Striking voltage 75V C C STATIC CHARACTERISTICS U2 V ATT HUNT HHH Att A TUL THUN HUOILL 111111 11111111 LLN 1 8 1 8 1 E 0 IL UE TL 8 2 ANTE NE 50 100 150 200 250 300 350 400 450 500 550 600 650 700 4 Le sas p L wai E E 2 1 EA KE E p ng p p Eu d ES EA sas p I p Ess E L L LJ T _ J W J J A j 1 I j H d _ i 1 d i i 1 H SIMULTANEOUS UTILISATION LIMITS 200A 250A 300A 3504 24004 40 31 A 25 5 kva rS vA SIVA 6 kva ease enn tov A7 kv akva Cerva skva Tiv SS A ss kva akva OWA D SYMBOLS AND SAFETY PRECAUTIONS REV 0 11 99 SYMBOLS IN THIS MANUAL The symbols used in this manual are designed to call your attention to important aspects of the op
48. machine 1 open eRemove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete eUse suitable tools and clothes MOVING PARTS can injure See pag M1 1 NOTE By maintenance at care of the utilizer we intend all the operatios concerning the verification of mechanical parts electrical parts and of the fluids subject to use or consumption during the normal operation of the machine For what concerns the fluids we must consider as main tenance even the periodical change and or the refills eventually necessary Maintenance operations also include machine cleaning operations when carried out on a periodic basis outside of the normal work cycle The repairs cannot be considered among the mainte nance activities i e 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 manufacturer The replacement of tires for machines equipped with trolleys must be considered as repair since it is not de livered as standard equipment any lifting system The periodic maintenance should be performed accor ding to the schedule shown in the engine manual An optional hour counter M is available to simplify the determination of the working hours IMPORTANT In the maintenance operations avoid that polluting substances liquids exhaus
49. ng connection use the terminal 12 comply to local and or current regulations in force for electrical installations and safety 10030 12 06 03 M20 R HO2 GB D STARTING THE ENGINE Check daily FE 412 Do not alter the primary conditions of regulation and do not touch the sealed parts ATTENTION By start up of the generator the welding circuit is immediately operative 1 under voltage Make sure that there are no unwished electrical contacts between the components of the outside welding circuit electrode electrode holder gun workpiece etc N Check that at the start up the a c auxiliary ge neration sockets do not feed any load Open the electric protection interrupter of the generator or disconnect the plugs of the loads from the sockets 3 START UP Starting is actuated using the key which is an integral part of the EP7 post on the front panel Turn the key in a clockwise direction until all the LED lights are illuminated B Wait until the OIL PRESSURE and BATTERY VOLTAGE LEDs remain illuminated If the timer lamp is used the yellow PREHEAT LED co mes on for the set time of the imposed settings C As soon as the green ENGINE RUNNING LED starts to flash actuate the key switch in a clockwise direction momentarily in the position then with return to rest until obtaining starting of the engine If the engine does not start within 15 seconds the non
50. ng the work block it possibly with tools and or devices made to this purpose MOVES OF THE MACHINE t At any move check that the engine is off that there are no connections with cables which impede the moves PLACE OF THE MACHINE N ATTENTION For a safer use from the operator DO NOT fit the machine in locations with high risk 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 9 conditions which are beyond IP protection least 1 5 m from buildings or other plants shown both in the data plate and on page named technical data in this same manual Maximum leaning of the machine in case of dislevel O CD Installazione e dimensioni Luftzirkulation und abmessungen Installation and dimensions Instalaci n y dimensiones CF Installation et dimensions D Q13n 4fori TS 600 PS BC ke A ii Ra 2 7 REV 0 12 11 13 12 11 76605 1 D UNPACKING REV 1 02 04 t Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s pack aging and conforms to local rules and regulations When receiving the goods make sure that the product has not suffered damage during the transport that there has not been rough handling or taking away of parts contained inside the packing or in the set In case you find damage
51. o avoid physical contact with the work surface and the floor Always wear dry insulating glovers without holes and body protection Do not wind cables around the body Use ear protections if the noise level is high Keep flamable material away from the welding area Do weld on containers which contain flamable material Do not weld near refuelling areas Do not weld on easily flamable surfaces Do not use the welder to defrost thaw pipes Remove the electrode from the electrode holder when not welding Avoid inhaling fumes by providing a ventilation system or if not possible use an approved air breather Do not work in closed areas where there is no fresh air flow Protect face and eyes protective mask with suitable dark lens and side screens ears and body non flamable protective clothers 04 06 07 M2 5GB D 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 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 duri
52. ong periods of inactivity turn to the after soles service of the engine manufacturer Clean the covers and all the other parts of the machine carefully Protect the machine with a plastic hood and store it in a dry place 45 0 06 07 In case of necessity for first aid and of fire prevention see page 2 5 IMPORTANT In the storage operations avoid that polluting substances liquids exhausted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place G ss 04 06 07 M45GB CD CUST OFF CED gt 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 c
53. or Y8 EDC7 UC31 engine PCB Oil level transmitter Z5 Water temperature indicator A9 Low water level sender Engine stop push button T C 1 W5 Battery voltmeter B9 Interface card Engine start push buttonT C 1 X5 Contactor polarity change C9 Limit switch 24V c a socket Y5 Commutator switch series parallel D9 Starter timing card Thermal magnetic circuit breaker A6 Commutator switch E9 Luquid pouring level float S C R protection unit B6 Key switch on off F9 Under voltage coil Remote control socket C6 QEA control unit G9 Low water level warning light Remote control plug 06 Connector H9 Chopper driver PCB Insulation moitoring Ep Frequency rpm regulator 9 E A S connector F6 selector L9 E A S PCB G6 starting motor Booster socket H6 Fuelelectro pump 12V c c Open circuit voltage switch 6 StartLocal Remote selector 26 07 04 M60GB I LL988 90 60 61 N 5 010 578198 80020 02 Z hi 99 u ejeq JeuDiseq ol ojeAoJddy ue eq auoyeuBbasiq Bed LOLEE VEOLL subu d 8Ul6u3 D onebolg euoizeuiuoue bed eq gt lt e SCH TNI 8002 OL Oc 011 seues sunJeg JO o J 10211126 OP
54. phase socket N3 Relay R6 EMC filter 230V 1phase socket O3 Resistor S6 Wire feeder supply switch 110V 1 phase socket P3 Sparkler reactor T6 Wire feeder socket Socket warning light Q3 Output power unit U6 DSP chopper PCB Hour counter R3 Electric siren V6 Power chopper supply PCB Voltmeter 53 EPA engine protection Z6 Switch and leds PCB Welding arc regulator T3 Engine control PCB 6 Hall sensor 230V 3 phase socket U3 R P M electronic regulator X6 Water heather indicator Welding control PCB V3 control PCB Y6 Battery charge indicator Welding current ammeter Z3 20 l min push button A7 Transfer pump selector AUT 0 MAN Welding current regulator W3 PTOHI 30 l min push button B7 Fueltransfer pump Current transformer X3 PTOHI reset push button C7 GECO generating set test Welding voltage voltmeter PTOHI 20 l min indicator D7 Flooting with level switches Welding sockets A4 PTOHI 30 l min indicator Voltmeter regulator Shunt B4 PTOHI reset indicator F7 WELD AUX switch D C inductor C4 PTOHI 20 l min solenoid valve G7 3 phase Welding diode bridge 04 PTOHI 30 min solenoid valve H7 Switch disconnector Arc striking resistor E4 Hydraulic oil pressure switch I7 Solenoid stop timer Arc striking circuit FA Hycraulic oil level gauge L7 VODIA connector 110V D C 48V D C diode bridge G4 Pr
55. r from a c sockets 12 Grounding terminal PE terminal for the generator s earthing connection to a grounding installation M TS 600 PS BC 32 REV 0 12 11 8 EP7 engine protection Control and pro tection device for engine that includes the start stop key 59A Engine thermic protection They protects the battery circuit auxiliary devices pilot lights relays instruments sensors etc from power overloads and short circuits M Hours meter Indicates effective operating hours of the generator C2 Fuel level indicator Indicates the percen tage of fuel in the fuel tank L5 Emergency stop button Allows for the generators s immediate stop in case of danger and prevents start up until it is released OPTIONAL Z5 SR Engine coolant indicator Indicates the engine coolant temperature V5 SR Engine pressure oil indicator Indicates the engine oil pression operating CD GB GB USE AS WELDER This symbol Norm EN 60974 1 security 5 standards for arc welders signifies that the welder can be used in areas with increased risk of electrical shock ATTENTION The welding sockets after the machine 1 started also with no cables are anyway under voltage Access forbidden to area adjacent to elec tricity generating set for all non authorized personnel Check at the beginning of any work the electric parameters and or the control placed on the front Make sure that the ground
56. s rough handling or absence of parts envelopes manuals etc we advise you to inform immediately our Technical Service i iE 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 D TRANSPORT AND DISPLACEMENTS COVERED UNITS REV 1 06 10 AN 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 LIFT ONLY THE MACHINE D
57. selfblo cking nut 8 9 Pump the tyre 9 bringing the pressure to 4 atms forthe CTL 35 45 50 and 5 6 for the CTL 95 10 Lower the machine to the ground and place the par kingfoot definitively regulating at the best height ATTENTION Do not substituite the original tyres with other types 10 06 00 M6GB CD Set up for operation REV 1 09 05 a PW BATTERY WITHOUT MAINTENANCE Connect the cable positive to the pole positive of the battery after having taken away the protection by properly tightening the clamp Check the state of the battery from the colour of the warning light which is in the upper part Green colour battery OK Black colour battery to be recharged White colour battery to be replaced DO NOT OPEN THE BATTERY LUBRICANT RECOMMENDED OIL The manufacturer recommends selecting 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 Water
58. stment knob of welding current the auxiliary power sockets and the welding sockets FRONT PANEL ENGINE CANOPY ROLL BAR 4 IN By N EN die 4 VIBRATION DAMPER D Quality system Net THE INTERNATIONAL CERTIFICATION NETWORK CERTIFICATE CISQ ICIM hereby certify that the organization BCS S p A Head Office Operative Unit Viale Mazzini 161 1 20081 Abbiategrasso MI Operative Units Via Valbrina 17 19 1 42045 Luzzara RE Viale Europa 59 1 20090 Cusago MI for the following field of activities Design production and servicing of tractors agricultural and green maintenance machines engine driven welders and generating sets has implemented and maintains a Quality Management System which fulfills the requirements of the following standard ISO 9001 2008 Issued on 2012 03 06 Validity date 2015 03 05 Registration Number T 3722 KNet ZZ lt lt TO Michael Drechsel President of IONET President of CISQ IQNet Partners AENOR Spain AFNOR Certification France AIB Vingotte International Belgium ANCE Mexico APCER Portugal CCC Cyprus CISQ Italy CQC China China CQS Czech Republic Cro Cert Croatia DOS Holding GmbH Germany DS Denmark ELOT Greece Brazil FONDONORMA Venezuela ICONTEC Colombia IMNC Mexico INNORPI Tunisia Inspecta Certification Finland IRAM Argentina JQA Japan KFQ Korea MSZT Hun
59. t the current absorbed by the load does not exceed the protection s nominal operating current Allow the protection to cool off for a few minutes before resetting by pressing the central pole m n gt 2 Do not keep the central pole on the thermic protection forcefully pressed to prevent its intervention DELIVERED POWER For each auxiliary voltage it is possible to draw the rated power declared on the data plate Delivering rated power for a definite auxiliary voltage it is not possible to draw further power from other output Drawing power from different output their sum cannot go over the maximum power declared on data plate generally the three phase power SIMULTANEOUS USE welder permits the simultaneous use of auxiliary power and welding current The auxiliary power available to the AC plugs 15 decreases as the welding current drawn increases The table on page M1 6 TECHNICAL SPECIFICATIONS shows the amount of auxiliary power available as the welding current varies D Trouble shooting TS 400 500 600 PS REV 1 12 11 Solution WELDING welding current but auxiliary 1 Position of remote control switch 1 Check that it is in OFF position if there is no remote control or in output is OK position with remote control inserted 2 Potentiometer defect in welding 2 Check the continuity of the welding potentiometer and relative current control connections 3 Weld
60. ted oils etc bring damage to people or things or can cause negative effects to surroindings health or safety respecting completely the laws and or dispositions in force in the place ENGINE and ALTERNATOR PLEASE REFER TO THE SPECIFIC MANUALS PROVIDED Every engine and alternator manufacturer has 000099 A A eDo not modify the components if not authorized HOT surface can hurt you maintenance intervals and specific checks for each model it is necessary to consult the specific engine or alternator USER AND MAINTENANCE manual VENTILATION Make certain there are no obstructions rags leaves or other in the air inlet and outlet openings on the machine alternator and motor ELECTRICAL PANELS Check condition of cables and connections daily Clean periodically using a vacuum cleaner DO NOT USE COMPRESSED AIR DECALS AND LABELS warning and decals should be checked once a year and replaced if missing or unreadable STRENUOUS OPERATING CONDITIONS Under extreme operating conditions frequent stops and starts dusty environment cold weather extended periods of no load operation fuel with over 0 596 sulphur content do maintenance more frequently BATTERY WITHOUT MAINTENANCE DO NOT OPEN THE BATTERY The battery is charged automatically from the battery charger circuit suppplied with the engine Check the state of the battery from the colour of the warning light which is in the upper part Gr
61. tigten Person Persoon bevoegd om het technische document en bedrijf gegevens in te vullen Nombre y direcci n de la persona autorizada a componer el expediente t cnico ing Benso Marelli Amministratore Delegato CEO V le Europa 59 20090 Cusago MI Italy Cusago li g Benso Marelli Amministratore Delegato CEO MM 083 0 04 06 10 M1 4 1 CD M Technical data TS 600 PS BC 1 5 REV 0 12 11 Technical data TS 600 PS BC DC WELDING Duty cycle 600A 35 550 60 500 100 Welding current regulation scale 20 600A Welding voltage 75V GENERATOR Three phase generation 40 kVA 400 V 57 7 A Single phase generation 15 230 V 165 2 A Single phase generation 8 kVA 110 V 72 7 A Single phase generation 5 48 104 Frequency 50 Hz Cos 0 8 ALTERNATOR Self excited self regulated Type three phase asynchronous Insulating class H ENGINE Mark Model Perkins 1103A 33TG1 Type Cooling system Diesel 4 stroke water Cylinders Displacement 3 3300 cm Output 45 6 kW 62 HP Speed 1500 rpm Fuel consumption welding 60 6 l h Engine oil capacity 7 8 Starter Electric GENERAL SPECIFICATIONS Tank capacity 65 Running time welding 60 10 5h Protection 29 Dimensions Lxwxh mm 2030x870x1130 Weight 1025 Kg Measured acoustic power LwA pressure LpA 96 dB A 71 dB A 7 Guaranteed acoustic power LwA pressure LpA 97 dB A 72 4 7 T Dimensions
62. to information which will assis you in the correct use of the machine and or accessories 26 11 99 M2GB D SYMBOLS AND SAFETY PRECAUTIONS REV 2 06 10 a o 00 O STOP Read absolutely and be duly attentive Read and pay due attention GENERAL ADVICE lf the advice is not respected damage can happen to persons or things HIGH VOLTAGE Attention High Voltage There can be parts in voltage dangerous to touch The non observance of the advice implies life danger FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces the advice is 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 the advice is not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosions with damage to persons or things WRENCH Use of the tools If the advice is not respected damage can be caused to things and even to persons PRESSION Danger of burns caused by the expulsion of hot liquids under pressure P P P P P P J AY ACCES FORBIDDEN to non authorizad peaple PROHIBITIONS
63. tor 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 GENERETING P1 Voltmeter shows no voltage or low 1 Voltmeter malfunction 1 Replace the voltmeter voltage but actual voltage at the sockets is OK P2 No three phase voltage present 1 Differential switch not inserted 1 Turn on the differential switch at the socket s but voltmeter 2 Differential switch malfunction 2 Replace the differential switch reading is normal and there is voltage on the other sockets P3 No single phase voltage one sok 1 Intervention of thermal switch due 1 Push in the thermal switch ket but voltmeter reading is normal to excessive current and there is voltage on the other 2 Thermal switch malfunction 2 Replace the thermal switch sockets P4 No voltage present 1 Short circuit present on the genera 1 Disconnect all outputs on the generator except for those on the tor outputs condensers and re start machine check for voltage on conden Sers 19 05 05 76440 GB CD Trouble shooting TS 400 500 600 PS REV 2 12 11 Solution P1 The engine does not start or stops 1 Low battery voltage battery dead 1 Check the warning light state of the b
64. vance with temp switch Remote control switch B5 push button ON OFF F8 START STOP switch Remote control and or wire feeder socket C5 Accelerator electronic control G8 Polarity inverter two way switch Remote control plug 05 Actuator H8 Engine protection Remote control welding regulator E5 Pick up 18 AUTOIDLE switch 2 engine protection F5 Warning light high temperature L8 AUTOIDLE PCB Fuel level gauge G5 Commutator auxiliary power M8 A4E2 ECM engine PCB Ammeter H5 24 diode bridge N8 Remote emergency stop connector Frequency meter 5 YLA commutator O8 digital instruments and led VRD PCB Battery charge trasformer 5 Emergency stop button P8 Water in fuel Battery charge PCB M5 Engine protection EP5 Q8 Battery disconnect switch Voltage selector switch N5 Pre heat push button R8 Inverter 48V a c socket O5 Accelerator solenoid PCB S8 Overload led Thermal relay P5 Oil pressure switch T8 Main selector Contactor Q5 Water temperature switch U8 NATO socket 12V G F I and circuit breaker R5 Water heater V8 Diesel pressure switch 42V EEC socket S5 Engine connector 24 poles Z8 Remote control PCB G F I resistor T5 Electronic GFI relais Pressure turbo protection T E P engine protection U5 Release coil circuit breaker X8 Water in fuel sender Solenoid control PCBT V5 Oil pressure indicat

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