USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG

TS 250 D

USE AND MAINTENANCE MANUALSPARE PARTS CATALOG

120299003 - GB1 1 0 6

05/07/95 12029M00preparato da UPTapprovato da DITE

Quality system GE_, MS_, TS_, EAS_M01

© MOSA 1.2-05/03

UNI EN ISO 9001 : 2000

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MOSA has certified its quality system according toUNI EN ISO 9001:2000 to ensure a constant, highquality of its products. This certification covers thedesign, production and servicing of engine drivenwelders and generating sets.

The certifying institute, ICIM, which is a member ofthe International Certification Network IQNet,awarded the official approval to MOSA after anexamination 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 thecommunications regarding all the company’s activesin accordance with the official procedures and inharmony with the MOSA Manual of Quality.

The advantages for MOSA clients are:

· Constant quality of products and services at thehigh level which the client expects;

· Continuous efforts to improve the products andtheir performance at competitive conditions;

· Competent support in the solution of problems;

· Information and training in the correct applicationand use of the products to assure the security ofthe operator and protect the environment;

· Regular inspections by ICIM to confirm that therequirements of the company’s quality systemand ISO 9001 are being respected.

All these advantages are guaranteed by theCERTIFICATE OF QUALITY SYSTEM No.0192issued by ICIM S.p.A. - Milano (Italy ) - www.icim.it

INDEX GE_, MS_, TS_, EAS_M1

© MOSA 1.0-01/01

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INDEX (for all MOSA models)

M 01 QUALITY SYSTEMM 1.01 COPYRIGHTM 1.1 NOTESM 1.4 NOTESM 2- ... SYMBOLS AND SAFETY PRECAUTIONSM 2.3 ABBREVIATIONS LEGENDM 2.4 SYMBOLSM 2.5... INSTALLATION AND ADVICE BEFORE USEM 2.6 INSTALLATIONS AND ADVICEM 2.7 INSTALLATIONM 3 PACKINGM 4 TRANSPORT AND DISPLACEMENTSM 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 LEGENDM 31 CONTROLSM 32 CONTROLS (FRONT PANEL)M 33 USE AS HYDRAULIC POWER TAKE-OFF only for TSM 34 USE AS A WELDER only for TSM 35 USE AS AN ENGINE STARTER only for TSM 36 USE AS A BATTERY CHARGEM 37 USE AS A GENERATORM 38 USE OF THE REMOTE CONTROLM 39 USE OF THE ENGINE PROTECTIONM 40 TROUBLE SHOOTINGM 43 MAINTENANCEM 44 PERIODIC MAINTENANCEM 45 STORAGEM 46 CAST OFFM 51 TECHNICAL DATAM 52 TECHNICAL DATA ENGINE DRIVEN WELDER only for TSM 53 DIMENSIONSM 55 RECOMMENDED ELECTRODES only for TSM 60 ELECTRICAL SYSTEM LEGENDEM 61 ELECTRICAL SYSTEMM 65 HYDRAULIC SYSTEM

R 1 SPARE PARTS LIST...... SPARE PARTS

K... ACCESSORIES

Copyright GE_, MS_, TS_, EASM

1.01© MOSA 1.0-10/02

ATTENTION

© 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 thedocumentation are registered by the respectiveowners.

➠ The reproduction and total or partial use, inany form and/or with any means, of thedocumentation is allowed to nobody without awritten permission by MOSA division of B.C.S.S.p.A.

To this aim is reminded the protection of the author’sright and the rights connected to the creation anddesign for communication, as provided by the lawsin force in the matter.

In no case MOSA division of B.C.S. S.p.A. will beheld 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 anyresponsibility about the shown information on firmsor individuals, but keeps the right to refuse servicesor information publication which it judges discutible,unright or illegal.

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This use and maintenance manual is an importantpart of the machines in question.The assistance and maintenance personel mustkeep said manual at disposal, as well as that forthe engine and alternator (if the machine issynchronous) and all other documentation about themachine.

We advise you to pay attention to the pagesconcerning the security (see page M1.1).

INFORMATION

Dear Customer,We wish to thank you for having bought fromMOSA a high quality set.

Our sections for Technical Service and SpareParts will work at best to help you if it werenecessary.

To this purpose we advise you, for all control andoverhaul operations, to turn to the nearestauthorized Service Centre, where you will obtaina prompt and specialized intervention.

☞ In case you do not profit on these Services andsome parts are replaced, please ask and besure that are used exclusively original MOSAparts; this to guarantee that the performancesand the initial safety prescribed by the norms inforce are re-established.

☞ The use of non original spare parts will cancelimmediately any guarantee and Technical Ser-vice obligation from MOSA.

NOTES ABOUT THE MANUALBefore actioning the machine please read thismanual attentively. Follow the instructionscontained in it, in this way you will avoidinconveniences due to negligence, mistakes orincorrect maintenance. The manual is for qualifiedpersonnel, who knows the rules: about safety andhealth, installation and use of sets movable aswell as fixed.

You must remember that, in case you havedifficulties for use or installation or others, ourTechnical Service is always at your disposal forexplanations or interventions.

The manual for Use Maintenance and Spare Partsis an integrant part of the product. It must be keptwith care during all the life of the product.In case the machine and/or the set should beyielded to another user, this manual must alsogiven to him.Do not damage it, do not take parts away, do nottear pages and keep it in places protected fromdampness and heat.

You must take into account that some figurescontained in it want only to identify the describedparts and therefore might not correspond to themachine in your possession.

INFORMATION OF GENERAL TYPE

In the envelope given together with the machineand/or set you will find: the manual for UseMaintenance and Spare Parts, the manual foruse of the engine and the tools (if included in theequipment), the guarantee (in the countries whereit is prescribed by law).

Our products have been designed for the use ofgeneration for welding, electric and hydraulicsystem; ANY OTHER DIFFERENT USE NOTINCLUDED IN THE ONE INDICATED, relievesMOSA from the risks which could happen or,anyway, from that which was agreed when sellingthe machine; MOSA excludes any responsibilityfor damages to the machine, to the things or topersons in this case.

Our products are made in conformity with thesafety norms in force, for which it is advisable touse all these devices or information so that theuse does not bring damage to persons or things.

While working it is advisable to keep to thepersonal safety norms in force in the countries towhich the product is destined (clothing, work tools,etc.).

Do not modify for any motive parts of the machine(fastenings, holes, electric or mechanical devices,others..) if not duly authorized in writing by MOSA:the responsibility coming from any potentialintervention will fall on the executioner as in facthe becomes maker of the machine.

Notes GE_, MS_, TS_, EAS_M

1-1© MOSA 1.0-10/02

☞ Notice: this manual does not engage MOSA,who keeps the faculty, apart the essentialcharacteristics of the model here described andillustrated, to bring betterments and modificationsto parts and accessories, without putting thismanual uptodate immediately.

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CE MARK GE_, MS_, TS_, EAS_M

1.4© MOSA 1.2-06/03

The CE mark (European Community) certifies that the product complies with the essentialsafety requirements provided by the applicable COMMUNITY DIRECTIVES. In the ConformityDeclaration are reported the HARMONIZED NORMS and not, used for the checking.

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SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_M2

© MOSA 1.0-11/99

SYMBOLS IN THIS MANUAL

- The symbols used in this manual are designed to callyour attention to important aspects of the operation ofthe machine as well as potential hazards and dangersfor persons and things.

IMPORTANT ADVICE

- Advice to the User about the safety:

☞ N.B.: The information contained in the manual canbe changed without notice.Potential damages caused in relation to the use ofthese instructions will not be considered becausethese are only indicative.Remember that the non observance of theindications reported by us might cause damage topersons or things.It is understood, that local dispositions and/or lawsmust be respected.

WARNING

Situations of danger - no harm to personsor things

Do not use without protective devices providedRemoving or disabling protective devices on themachine is prohibited.

Do not use the machine if it is not in good technicalconditionThe machine must be in good working order beforebeing used. Defects, especially those which regardthe safety of the machine, must be repaired beforeusing the machine.

SAFETY PRECAUTIONS

This heading warns of an immediate danger for personsas well for things. Not following the advice can result inserious injury or death.

This heading warns of situations which could result ininjury for persons or damage to things.

To this advice can appear a danger for persons as well asfor things, for which can appear situations bringing mate-rial damage to things.

These headings refer to information which will assis youin the correct use of the machine and/or accessories.

ATTENTION

NOTE

IMPORTANT

CAUTION

WARNING

DANGEROUS

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SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_M

2-1© MOSA 1.1-04/03

SYMBOLS (for all MOSA models)

STOP - Read absolutely and be duly attentive

Read and pay due attention

GENERAL ADVICE - If the advice is notrespected damage can happen to persons orthings.

HIGH VOLTAGE - Attention High Voltage.Therecan be parts in voltage, dangerous to touch.The non observance of the advice implies lifedanger.

FIRE - Danger of flame or fire. If the advice isnot respected fires can happen.

HEAT - Hot surfaces. If the advice is notrespected burns or damage to things can becaused.

EXPLOSION - Explosive material or danger ofexplosion. in general. If the advice is notrespected there can be explosions.

WATER - Danger of shortcircuit. If the adviceis not respected fires or damage to personscan be caused.

SMOKING - The cigarette can cause fire orexplosion. If the advice is not respected firesor explosions can be caused.

ACIDS - Danger of corrosion. If the advice isnot respected the acids can cause corrosionswith damage to persons or things.

WRENCH - Use of the tools. If the advice isnot respected damage can be caused to thingsand even to persons.

PRESSION - Danger of burns caused by theexpulsion of hot liquids under pressure.

PROHIBITIONS No harm for persons

Use only with safety clothing -It is compulsory to use the personalprotection means given in equipment.

Use only with safety clothing -It is compulsory to use the personal protectionmeans given in equipment.

Use only with safety protections -It is a must to use protection means suitable forthe different welding works.

Use with only safety material -It is prohibited to use water to quench fires onthe electric machines.

Use only with non inserted voltage -It is prohibited to make interventions beforehaving disinserted the voltage.

No smoking -It is prohibited to smoke while filling the tankwith fuel.

No welding -It is forbidden to weld in rooms containingexplosive gases.

ADVICE No harm for persons and things

Use only with safety tools, adapted to the specificuse -It is advisable to use tools adapted to the variousmaintenance works.

Use only with safety protections, specifically suitableIt is advisable to use protections suitable forthe different welding works.

Use only with safety protections -It is advisable to use protections suitablefor the different daily checking works.

Use only with safety protections -It is advisable to use all protections whileshifting the machine.

Use only with safety protections -It is advisable to use protections suitable forthe different daily checking works.and/or ofmaintenance.

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ACCES FORBIDDEN to non authorizad peaple.

INSTALLATION AND ADVICE BEFORE USE GE_, MS_, TS_M

2-5© MOSA 1.0-06/00

Stop engine when fueling

ENG

INE

CH

ECK

ING

BO

AR

D

Do not touch electric devices if youare barefoot or with wet clothes.

Always keep off leaning surfacesduring work operations

Static electricity can demage theparts on the circuit.

An electric shock can kill

The installation and the general advice concerning the operations, are finalized to the correct use of themachine, in the place where it is used as generator group and/or welder.

☞ FIRST AID. In case the operator shold be sprayed by accident, from corrosive liquids a/o hot toxic gasor whatever event which may cause serious injuries or death, predispose the first aid in accordance withthe ruling labour accident standards or of local instructions.

Skin contactEyes contactIngestionSuction of liquids fromlungsInhalation

Wash with water and soapIrrigate with plenty of water, if the irritation persists contact a specialistDo not induce vomit as to avoid the intake of vomit into the lungs, send for a doctorIf you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take thesubject to the hospital with the utmost urgencyIn case of exposure to high concentration of vapours take immediately to a non polluted zonethe person involved

☞ FIRE PREVENTION. In case the working zone,for whatsoever cause goes on fire with flames liable tocause severe wounds or death, follow the first aid as described by the ruling norms or local ones.

AppropriatedNot to be usedOther indications

Particular protectionUseful warnings

Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized waterAvoid the use of water jetsCover eventual shedding not on fire with foam or sand, use water jets to cool off thesurfaces close to the fireWear an autorespiratory mask when heavy smoke is presentAvoid, by appropriate means to have oil sprays over metallic hot surfaces or over electriccontacts (switches,plugs,etc.). In case of oil sprinkling from pressure circuits, keep inmind that the inflamability point is very low.

EXTINCTION MEANS

WARNING CAUTION

DANG

ERO

US

WARNINGTHE MACHINE MUST NOT BE USED IN AREAS WITH

EXPLOSIVE ATMOSPHERE

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Do not smoke, avoid flames, sparks or electric tools when fueling.

Unscrew the cap slowly to let out the fuel vapours.

Slowly unscrew the cooling liquid tap if the liquid must be topped up.

The vapor and the heated cooling liquid under pressure can burn face, eyes, skin.

Do not fill tank completely.Wipe up spilled fuel before starting engine.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

PRECAUTION (ENGINE DRIVEN WELDER) GE_, MS_, TS_M

2-5-1

© MOSA 1.0-03/00

INSTALLATION AND ADVICE BEFORE USE

The operator of the welder is responsible for the security of the people who work with the welder and for those in thevicinity.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.

ATTENTION

Make sure that the area is safe before starting any welding operation.

➠Do not touch any bare wires, leads or contacts as they may be live and there is danger of electric shockwhich can cause death or serious burns. The electrode and welding cables, etc. are live when the unit isoperating.

➠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 to 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 not 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).

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INSTALLATION AND ADVICE GE_, MS_, TS_M

2.6© MOSA 1.0-11/99

INSTALLATION AND ADVICE BEFORE USE

GASOLINE ENGINES■ Use in open space, air swept or vent exhaust gases,

which contain the deathly carbone oxyde, far fromthe work area.

DIESEL ENGINES■ Use in open space, air swept or vent exhaust gases

far from the work area.

POSITIONPlace the machine on a level surface at a distance of atleast 1,5 m from buildings or other plants.

Check that the air gets changed completely and the hotair sent out does not come back inside the set so as tocause a dangerous increase of the temperature.

☞ Make sure that the machine does not move duringthe work: block it possibly with tools and/or devicesmade to this purpose.

Protect all the electric parts at risk, because waterinfiltrations could cause short circuits with damagesat persons and/or things.

The protection degree of the machine is put on the dataplate and in this manual at page "Technical Data".

Maximum leaning of the machine (in case of dislevel)

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1,5m

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GASDI SCARIC

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EXHAUST OUTPUT

MOVES OF THE MACHINE☞ At any move check that the engine is off, that there

are no connections with cables which impede themoves.

PLACE OF THE MACHINE

In spots where it often rains and/or there areflooded areas, do not put the machine:■ in the bad weather■ in flooded places.

UNPACKING GE_, MS_, TS_M3

© MOSA 1.1-02/04

NOTE

☞ Be sure that the lifting devices are: correctly mounted,adequate for the weight of the machine with it’spackaging, and conforms to local rules and regula-tions.When receiving the goods make sure that the prod-uct has not suffered damage during the transport,that there has not been rough handling or takingaway of parts contained inside the packing or in theset.In case you find damages, rough handling or ab-sence of parts (envelopes, manuals, etc.), we ad-vise you to inform immediately our Technical Ser-vice.

For eliminating the packing materials, the Usermust 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 themachine, the data plate.

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TRANSPORT AND DISPLACEMENTS COVERED UNITS GE_, MS_, TS_M

4-1© MOSA 1.0-01/01

NOTEIn case you should transport or move the machine, keep to the instructions as per the figures.Make the transportation when the machine has no petrol in its tank, no oil in the engine and and electrolyte in thebattery.Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging, andconform 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 noCTM accessory).If you did not keep to the instructions, you could damage the structure of the machine.

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Weight max. per person: 35 kgTotal max. weight; 140 kg

ASSEMBLY CTM222© MOSA 1.0-06/00

M6.5

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Note: Lift the machine and assemble the parts as shown in the drawing

The CTM accessory cannot be removed from themachine and used separately (actioned manuallyor following vehicles) for the transport of loads oranyway for used different from the machine move-ments.

ATTENTION

GASOLINE ENGINE

DIESEL ENGINE

Set-up for operation (Engine diesel)TS_GEAir cooled systems

M20

© MOSA 1.1-09/05

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BATTERY WITHOUT MAINTENANCE

Connect the cable + (positive)to the pole + (positive) of thebattery (after having takenaway the protection), byproperly tightening the clamp.

Check the state of the batteryfrom the colour of the warning light which is in theupper part.

- Green colour: battery OK- Black colour: battery to be recharged- White colour: battery to be replacedDO NOT OPEN THE BATTERY.

RECOMMENDED OILMOSA recommends selecting AGIP engine oil.Refer to the label on the motor for the recommendedproducts.

LUBRICANT

Please refer to the motor operating manual for therecommended viscosity.

It is dangerous to fill the motor with too much oil,as its combustion can provoke a sudden increasein rotation speed.

ATTENTION

FUEL

Do not smoke or use open flames duringrefuelling operations, in order to avoidexplosions or fire hazards.Fuel fumes are highly toxic; carry outoperations outdoors only, or in a well-ventilated environment.Avoid accidentally spilling fuel. Cleanany eventual leaks before starting upmotor.

ATTENTION

Refill the tank with good quality diesel fuel, such asautomobile 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 ofapprox. 10 mm between the fuel level and the wallof the tank to allow for expansion.

In rigid environmental temperature conditions, usespecial winterized diesel fuels or specific additivesin order to avoid the formation of paraffin.

GROUNDING CONNECTION

The grounding connection to an earthed installationis obligatory for all models equipped with adifferential switch (circuit breaker). In these groupsthe generator star point is generally connected tothe machine’s earthing; by employing the TN or TTdistribution system, the differential switchguarantees protection against indirect contacts.In the case of powering complex installationsrequiring or employing additional electrical protectiondevices, the coordination between the protectiondevices must be verified.For the grounding connection, use the terminal(12); comply to local and/or current regulations inforce for electrical installations and safety.

REFUELLING AND CONTROL:Carry out refuelling and controls with motor at levelposition.1. Remove the oil-fill tap (24)2. Pour oil and replace the tap3. Check the oil level using the dipstick (23); the oil

level must be comprised between the minimumand maximum indicators.

DRY AIR FILTER

Check that the dry air filter is correctly installed andthat there are no leaks around the filter which couldlead to infiltrations of non-filtered air to the inside ofthe motor.

OIL BATH AIR FILTER

Fill the air filter using the same engine oil up to thelevel indicated on the filter.

ENGINE STARTING AND USE (DIESEL ENGINES) GE_, MS_, TS_M21

© MOSA 1.0-06/99

Do not alter the primary conditions of regulationand do not touch the sealed parts.

NOTE

Check daily

ENGINES WITH MANUAL RECOIL

OFFON

START

ENGINES WITHOUT ACCELERATOR LEVER

lnsert the electric protection device (D-Z2-N2) levertowards above and, where mounted, check theisolation monitor (A3) see page M37 –

Introduce the key (Q1), turn itclockwise completely, leaving it assoon as the engine starts.

NB.: for safety reason the key must be kept byqualified personel.

Let the engine run for some minutes before drawingthe load.

Open the fuel cock (where it is assembled).

OFFON

START

RUNNING-INDuring the first 50 hours of operation, do not usemore than 60% of the maximum output power ofthe unit and check the oil level frequently, in anycase please stick to the rules given in the engineuse manual.

CAUTION

The machines with E.P.1 engine protection device(D1), use the accelerator lever ONLY INEMERCENCY when the engine protection doesnot work. In this case turn immediately to ourAuthorized Assistance Centers.

NOTE

ENGINES WITH ACCELERATOR LEVER

Make sure that the accelerator lever or the switch(16) is at its minimum setting.

lnsert the electric protection device (D-Z2-N2) levertowards above and, where mounted, check theisolation monitor (A3) see page M37 –

Introduce the key (Q1), turn itclockwise completely, leaving it assoon as the engine starts and/or thepush button (32) (models without key)leaving it as soon as the engine starts.

☞ NB.: for safety reason the key must be keptby qualified personel.

Once the engine has started leave it running at areduced speed for some minutes.

Accelerate the engine at max., set lever on maximumposition and then take up load.

Hold the starting handle firmly.

Pull the rope hard and fast. Pull itall the way out. Use two hands ifnecessary.

Then returning it slowly.

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ENGINE STARTING AND USE (DIESEL ENGINES) GE_, MS_, TS_M

21.1© MOSA 1.0-06/99

ENGINE WITH PREHEATING GLOWPLUGS

Turn the starter key (Q1) on the position „preheatingglow plugs“ (the glow plugs light will be on I4), whenthe light is off, turn the starter key completelyclockwise until the engine begins to fire.Let the engine run for some minutes before drawingthe lood.

ENGINES WITH R.P.M. ELECTRONICADJUSTER (ONLY FOR GENERATING SET)

Turn the starter key (Q1) completely clockwiseuntil the engine begins to fire.

☞ Wait for the AUTOMATIC preheating time beforedrawing the load

OCCASIONAL USE OF THE ENGINEUsing the engine in special conditions which needan immediate intervention, such as emergencyplants, etc., use advise to use our EngineAssistance Centres for specific interventions orour Technical Assistance Service.

If the engine fails to start, do not insist for at least15 seconds.Space the further operations waiting for at least4 minutes.

CAUTION

RUNNING-INDuring the first 50 hours of operation, do not usemore than 60% of the maximum output power ofthe unit and check the oil level frequently, pleasefollow the instructions on the engine use andmaintenance manual..

CAUTIONMACHINE WITH EMERGENCY BUTTON

Before starting the engine, make sure that theemergency button (32B) is off (turn the buttonclockwise for this operation)

CAUTION

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STOPPING THE ENGINE (DIESEL ENGINE) GE_, MS_, TS_M22

© MOSA 1.0-10/00

☞ Before stopping the engine it is compulsory toeffect the following operations:

- stop to draw three/single-phase current from theauxiliary sockets.

- stop to draw power from the welding sockets(only for TS models).

ENGINES WITH ACCELERATOR LEVER

☞ Make sure that the unit ls not supplying anypower.

Disconnect the electrical protection device (D-Z2-N2) lever downward.

Set the accelerator lever or the switch (16) tominimum position and wait for a few minutes toallow the engine to cool, anyway follow theinstructions contained in the engine manual.

Pull the stop lever (28) until the engine stops (whereit is assembled).

Remove the key (Q1) turning it counterclockwise, OFF position, then take itout.

☞ NB.:for safety reason the key must be keptby qualified personel.

ENGINES WITHOUT ACCELERATOR LEVER

Make sure that the unit is not supplying any power.

Disconnect the electrical protection device (D-Z2-N2) lever downward.Let the engine idle for a few minutes.

Press the pushbutton (F3) until the engine stops

OFFON

START

(where it is assembled).

Shut the fuel cock (where it is assembled).


☞NB.: for safety reason the key must be keptby qualified personel.

ENGINES WITH R.P.M. ELECTRONICADJUSTER (ONLY FOR GENERATING SET)

Make sure that the unit is not supplying any power..Disconnect the electrical protection device (D-Z2-N2 lever downward.

Let the engine idle for a few minutes.

Press the pushbutton (F3) until the engine stops(where it is assembled).


☞ NB.: for safety reason the key must be keptby qualified personel.

OFFON

START

OFFON

START

MACHINE WITH EMERGENCY BUTTONPressing it, it allows to stop the engine in anycondition (32B) (when assembled).To re-establish it, see page M21...

CAUTION

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CONTROLS LEGENDE GE_, MS_, TS_M30

© MOSA 1.0-05/01

4A Hydraulic oil level light9 Welding socket ( + )10 Welding socket ( - )12 Earth terminal15 A.C. socket16 Accelerator lever17 Feed pump19 48V D.C. socket22 Engine air filter23 Oil level dipstick24 Engine oil reservoir cap24A Hydraulic oil reservoir cap24B Water filling cap25 Fuel prefilter26 Fuel tank cap27 Muffler28 Stop control29 Engine protection cover30 Engine cooling/alternator fan belt31 Oil drain tap31A Hydraulic oil drain tap31B Water drain tap31C Exhaust tap for tank fuel32 Button33 Start button34 Booster socket 12V34A Booster socket 24V35 Battery charge fuse36 Space for remote control37 Remote control42 Space for E.A.S.42A Space for PAC47 Fuel pump49 Electric start socket54 Reset button PTO HI55 Quick coupling m. PTO HI55A Quick coupling f. PTO HI56 Hydraulic oil filter59 Battery charger thermal switch59A Engine thermal switch59B Aux current thermal switch59C Supply thermal switch wire feeder-42V59D Pre-heater (spark plug) thermal switch59E Supply thermal switch oil/water heather59F Electropump thermal switch63 No load voltage control66 Choke control67A Auxiliary / welding current control68 Cellulosic electrodes control69A Voltmeter relay70 Warning lights71 Selecting knob72 Load commut. push button73 Starting push button74 Operating mode selector75 Power on warning light76 Display79 Wire connection unit86 Selector86A Setting confirmation87 Fuel valve88 Oil syringeA3 Insulation monitoringA4 Button indicating light 30 l/1' PTO HIB2 Engine control unit EP2B3 E.A.S. connector

B4 Exclusion indicating light PTO HIB5 Auxiliary current push buttonC2 Fuel level lightC3 E.A.S. PCBC6 Control unit for generating sets QEAD Ground fault interrupter ( 30 mA )D1 Engine control unit and economiser EP1D2 AmmeterE2 Frequency meterF FuseF3 Stop switchF5 Warning light, high temperatureF6 Arc-Force selectorG1 Fuel level transmitterH2 Voltage commutatorH6 Fuel electro pumpI2 48V A.C. socketI3 Welding scale switchI4 Preheating indicatorI5 Y/▲ switchI6 Start Local/Remote selectorL A.C. output indicatorL5 Emergency buttonL6 Choke buttonM Hour counterM1 Warning level lightM2 ContactorM5 Engine control unit EP5M6 CC/CV switchN VoltmeterN1 Battery charge warning lightN2 Thermal-magnetic circuit breaker/Ground fault interrupterN5 Pre-heat push-buttonN6 Connector - wire feaderO1 Oil pressure warning light/Oil alertP Welding arc regulatorQ1 Starter keyQ3 Derivation boxQ4 Battery charge socketsQ7 Welding selector modeR3 SirenS Welding ammeterS1 BatteryS3 Engine control unit EP4S6 Wire feeder supply switchS7 Plug 230V singlephaseT Welding current regulatorT4 Dirty air filter warning light/indicatorT5 Earth leakage relayT7 Analogic instrument V/HzU Current trasformerU3 R.P.M. adjusterU4 Polarity inverter remote controlU5 Relase coilU7 Engine control unit EP6V Welding voltage voltmeterV4 Polarity inverter controlV5 Oil pressure indicatorW1 Remote control switchW3 Selection push button 30 l/1' PTO HIW5 Battery voltmeterX1 Remote control socketY3 Button indicating light 20 l/1' PTO HIY5 Commutator/switch, serial/parallelZ2 Thermal-magnetic circuit breakerZ3 Selection push button 20 l/1' PTO HIZ5 Water temperature indicator 10

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Mandos TS 250 DM31

USE AS WELDER TSM34

© MOSA 1.0-04/04

This symbol (Norm EN 60974-1 securitystandards for arc welders ) signifies thatthe welder can be used in areas withincreased risk of electrical shock.

The sockets, after the machine is started (seepages M21-26), also with no cables, are anywayunder voltage.

ATTENTION

The areas, access of which is forbiden tounqualified personel, are:- the control switchboard (front) - the exhaust ofthe endothermic engine - the welding process.

ATTENTION

To reduce the risk of electromagneticinterferences, use the minimum lenght of weldingcables and keep them near and down (ex. on thefloor).The welding operations must take place far fromany sensitive electronic device.Make sure thatthe unit is earthed. (see M20 and/or M25). Incase the interference should last, adapt furtherdisposition,such as: move the unit, use screenedcables, line filters, screen the entire work area.In case the above mentioned operations are nonsufficient, please contact our ThechnicalAssistance Service.

ATTENTION

Check at the beginning of any work the electricparameters and/or the control placed on the front.

Make sure that the ground connection (12) is efficent(keep to installation local rules and/or to nationallaws), in order to integrate or ensure the working ofvarius electric protection devices referring to theseveral distribution system TT/TN/IT, operationunnecessary for machine with isometer.

Fully insert the welding cable plugs into thecorresponding sockets (“only gauging”, 9+/10-)turnning them clockwise to lock them in position.

MACHINES WITH E.V. PROTECTIONAccelerate the engine at max. with the acceleratorlever (16).See page M 39.

MACHINE WITH E.P.2 PROTECTION (B2)Accelerate the engine at max. with the acceleratorlever (16) (when assebled).See page M 39

MACHINE WITH E.P.1 PROTECTION (D1)See page M 39.1

REMOTE CONTROL TC…See page M 38

WELDING CURRENT REGULATORPosition welding current adjustingknob (T) in correspondance of thechasen current value, so as toobtain the necessary amperage,taking into acount the diameter andthe type of the electrode.For technical data see page M52

With a welding cable length up to 20 m issuggested a section of 35 mm²; wìth longercables a bigger section is required.

CAUTION

ONLY GOUGING

☞ Make sure that the ground clamp ,whose cablemust be connected to the + or - terminal,depending on the type of electrode, makes agood connection and is near to the weldingposition.Pay attention to the two polarities of the weldingcircuit, which must not come in electric contactbetween themselves.When using the welder for air arc gougingconnect the ground lead to the - socket andthe gouging lead to the socket marked "onlygouging" (if present).

PUSH ANDTWIST

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USE AS WELDER TSM

34.1© MOSA 1.0-04/04

MACHINE WITH REDUCTION SCALESWITCH

For small electrodes (up to Ø 3.25-130Aand 4-200A) it is recommended to use thereduction scale switch (I3) allowing a moreaccurate regulation of the welding current(lever position at 130 A and/or 200A).

When using electrodes of a diameter greater than3.25 and/or 4 set the welding scale knob to 100%and/or max. position.The arc regulator (T) functions equally betweenboth positions (100%-130A and/or 200A).

Protection fuse (when assembled):the fuseprotects the electronic welding PCB in casethe remote control is short circuited.

MACHINE WITH O.C.V.

lt permits to choose, according to the work to bedone and/or the electrode type used,the best O.C.V.

MACHINE WITH POLARITY INVERTER

lt permits to have at the electrodeholder the positive or negativepolarity of the welding diode bridge.It is used above all in the first run

with cellulosic electrodes to lower the bathtemperature and so doing ease up the welding onpipes of small thickness

MACHINE WITH BASIC CURRENT "BC"

Positioning the switch on „ON“, is obtained a lowvoltage welding current which keeps,always, the lit arc necessary for sometypes of cellulosic electrodes or when ahigh penetration is wanted.

For electrodes of basic or rutile type,position the switch on "OFF", the welding currentwill always remain constant.

"CC/CV" MODELS

These models can be used withelectrodes or for TIG welding byselecting the CC (constant current)mode, and with solid wire (MIG, MAG)or flux cored wire selecting the CV(constant voltage) mode. The mode ofoperation is selected by a switch on thefront panel.

MACHINE WITH ARC CONTROLOR SELECTOR "ARC FORCE"

Set the welding arc usingadjuster knob (6) so as to abtain,for the chosen current value,the best arc characteristicaccording to the electrode typeand to the work to be performed.

Polarity

switch

65V

75V

ON

OFF

CC

CV

ARC CONTROL

CONTROLLO ARCO

1

2

3

65

4

9

8

7

ON

OFF

ARC FORCE

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100%

XXX A

max

On machines with an Arc Forceselector, the same result can beobtained by turning the selector "ON"or "OFF". When switched "ON" a basecurrent is applied to the welding currentoutput acting as a sort of "automatic"arc forcing that does not need to beregulated.

For technical data see page M52

☞ At the end of every welding process and/orwork, proceed with all the use operations ininverted sense.

To stop the machine see pages M 22-27.

USE AS AN ENGINE STARTER TS_M35

© MOSA 1.0-01/01

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ENGINE STARTER

Keep to the advice indicated page M 21, 26 -

TSModel

Batteryvoltage

Voltmeterindication(*)

Batteryvoltage

Voltmeterindication(*)

180180 P181181 P200200 P222

12V12V12V12V12V12V12V

120V190V120V190V120V190V235V

24V

24V

24V

24V

235V

235V

235V

235V

PUSH ANDTWIST

If the engine fails to start, do not insist for at least15 seconds.

Space the further operations waiting for at least4 minutes.

CAUTION

Once the engine is started, bring back the engineIMMEDIATELY to MINIMUM speed.

Disconnect the connection cables of the battery.

Connect the machine with the battery taps (12V or24V) of the machine engine of which must bestarted, respecting the polarities (+) et (-).

Fally insert the cable plugs into the correspondingsockets (34-34A) turning them clockwise to lockthem in position.Accelerate the engine so that the voltmeter (N)shows the value reported on table (*).

USE AS A GENERATOR GE_, MS_, TS_M37

© MOSA 1.0-06/99

Sockets are not self-locked: tension is avaibleimmediately after starting also with no plug.

WARNING

☞ It is strictly forbidden to connect the groupto the public mains a/o to another source ofelectric power.

The replacement of the fuse must absolutely bedone with the engine off (remove the mechanicalprotection, then shift down the small lever of thefuse holder placed on the front panel).

CAUTION☞ At the beginning of every work, check the

electric parameters and/or the controls placedon the front.

Make sure the unit is properly grounded (12) (whereit is assembled).- See page M20, 21, 22, 25, 26, 27 -.

Move the accelerator lever (16) and reach the enginemaximum speed, except for the engines withconstant rpm; the voltmeter (N) (where it isassembled) shows the single-phase voltage whetherthree or single-phase current has to be drawn.

*N.B.: with electronic tens. regul. RVT ±1%

Connect up the machine, using proper plugs andcables in good condition to the AC socket (15) todraw single or three-phase power, or, by cableswith adeguate section, to the terminal board, placedinside the derivation box (Q3).

Nominalvoltage

110V230V230V400V

asynchronous±10%±10%±10%±10%

synchronous (*)±5%±5%±5%±5%

Indicative no-load voltage

The areas, access of which is forbidden tounqualified personel, are:- the control switchboard (front), the exhaust ofthe endothermic engine.

WARNING

The warning light (L), located near the currentsocket, lights up when the unit can supply alternatedcurrent, on condition that the engine is at themaximum rpm.

☞ N.B.: if the warning light does not flash, checkthe accelerator which must bebat itsmaximum, or the fuse of the relevantsocket. (single-phase) or thethermoprotection.

Using several sockets at tha same time, themaximum power possible is that indicated on thedata plate.

To draw power simultaneously in the TS welderversion see page M52.

The max. continuous power of the generating set ortheload current must not be exceeded.

MACHINE WITH THERMOPROTECTION

If you overload the genset the thermoprotection willautomatically switch off.lf the thermoprotection is released, disconnect allthe connected loads.

Reset the thermoprotection pressing the centralpole.When reset, connect the loads again.In case the protection should act furtherly, check:the connections, the wires or others, and ifnecessary call the Assistance Service.

AvoId to hold the centralpole of thet h e r m o p r o t e c t i o npressed for a long time.

Otherwise, in case of trouble, it will not click,damaging the generating set.

CLOSED OPEN

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PRESS TORESET

USE AS A GENERATOR GE_, MS_, TS_M

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TS ... PL VERSIONStart the machine and wait for the end of thepreheating time imposed by the EP1, EP2, EP5engine protection device. - See pages M39... -Press the „generation possibility“ push button (B5)placed on the font side of machine.The voltmeter will show the auxiliary voltage which,for machines at 1500/1800 RPM, must. be approx.≈230V ± 10% and for machines at 3000/3600 RPM(engine idling) must. be approx. ≈180V ± 10%.

Push upwards the lever of magnetothermic switchreffering to the socket from which load is to bedrawn.

MACHINE WITHOUT PROTECTIVE DEVICEIn case machine is not equipped wìth protectivedevice of indirect contacts, by means of automaticbreaking of supply, it is necessary to put betweenthe load and the generatíon a differential swítch or asimilar equipment capable, in any case, to observethe regulations in force CEI 64/8 (and/or successi-ve) Part 4 Par. 4.13.1 and harmonzed by directiveNr. 72/23/EEC.

UNIT FITTED WITH GROUND FAULTINTERRUPTER SWITCH (GFI)

Turn on the GFI safety-switch(D) by pushing it upwards.

The GFI is a safety device which protects thecircuit in the event of a malfunction. In this case theswitch disconnects the three and single-phasecircuit when in any part of the electric connectionsa current leakage of more than 30 mA occurs.

UNIT FITTED WITH THERMAL MAGNETICBREAKER

Turn on the thermal magneticbreaker (Z2) by pushing it tothe ON position.

The thermal-magnetic breakeris a safety device which

protects the circuìt in the event of a malfunction. Inthis case the switch disconnects the three andsingle-phase circuit when in any part of the electricconnections a short circuit or a current absorptionoccurs above the data specified on the label of theunit.In the model with setting DO NOT INTERVENE onthe setting itself. To modify it, please contact ourTechnical Assistance Service.

UNIT FITTED WITH GFI SWITCH THERMALMAGNETIC BREAKER

For machines at 3000/3600 RPM the EP1 safetydevice will automatically provide to accelerateengine when load is drawn.- See page M39.1 -

CAUTION

This switch includes the characteristics of bothtypes of breakers (N2).

UNIT WITH VOLTMETRIC COMMUTATOR (ONLYFOR GENERATING SET)

☞ WARNING: the possiblesingle-phase loads mustbe correctly divided in thethree phases, in order toavoid any possible voltagefall on one phase thatresults excessivelyloaded.

Check the voltages on the various phases with theswitch located on the front (H2) and check, readingon the voltmeter (N) about the same voltage value

☞ N.B.: in case of overload, it is possible that theengine lowers its speed and the voltageis reduced remarkably. In this case, it isnecessary to reduce immediately theload.

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ACCESSORY USE REMOTE CONTROLTC2 / TC2/50

M38

© MOSA 1.1-06/05

The remote control device for regulating the weldingcurrent is connected to the front panel by means ofa multipole connector.

To regulate the current from the TC2 / TC2/50,move the switch (7), located above the multipoleconnector (8), to "ON" position.

Position welding current adjusting (T) knob at thenecessary current value for the diameter and typeof electrode.- See page M51 -

ON

OFF

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PUSH ANDSCREW TIGHT

TROUBLE SHOOTING TSM

40.1© MOSA 1.0-04/04

PROBLEMNo welding current butauxiliary output is OK

Weld poorly

Intermittently welds poorly

No welding output andno auxiliary poweroutput

POSSIBLE CAUSE1) Defective diode bridge2) Problem with welding current control

(PCB)

1) Defective diode bridge

2) Problem with welding current control(PCB)

1) Bad connections to welding current PCB

2) Problem with welding current controlPCB

1) Short circuit in wiring

2) Defective condenser

3) Defective stator

4) Short circuited diode bridge

WHAT TO DO1) Check the diodes of the bridge2) Is the remote control switch in the

internal position?3) Check the diodes and SCR’s of the

bridge.4) Check the transformer which supplies

power to the welding control PCB. If itis OK replace the PCB

1) Check the open circuit weldingvoltage.

If it is OK the diode bridge is OK. If itis 1/3 or 2/3 of the nominal valuecheck the diodes or the SCR’s.

2) If the diode bridge is OK replace thePCB.

1) Check that the pins of the greenconnectors are clean and making goodcontact.

Check that shunt connections are tight.

2) Replace the welding current controlPCB

1) Check the wiring inside the welder fora short circuit between cables or toground.

2) If the wiring is OK, short circuit thecondenser to be sure that it isdischarged, disconnect all wires fromcondenser and, using an ohmmeter,check that the condenser is not shortcircuited.

3) If the condenser box is OK,disconnect all leads from the statorexcept for those going to thecondenser box and check the outputfrom the alternator.

If there is no output from the weldingwinding and the auxiliary winding,replace the stator.

4) If there is output from all windingsreconnect the diode bridge and checkif there is welding current. If not thediode bridge is defective. If there iswelding current connect the auxiliarypower leads one at a time until thereis no output; at this point, the shortcircuit is in that line.

only for models with electronic control of welding current.○ ○ ○

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MAINTENANCEM43

© MOSA 1.0-09/05

NOTE

By maintenance at care of the utilizer we intend all theoperatios concerning the verification of mechanical parts,electrical parts and of the fluids subject to use orconsumption during the normal operation of the machine.

For what concerns the fluids we must consider asmaintenance even the periodical change and or the refillseventually necessary.

Maintenance operations also include machine cleaningoperations when carried out on a periodic basis outsideof the normal work cycle.

The repairs cannot be considered among themaintenance activities, i.e. the replacement of partssubject to occasional damages and the replacement ofelectric and mechanic components consumed in normaluse, by the Assistance Authorized Center as well as byMOSA.

The replacement of tires (for machines equipped withtrolleys) must be considered as repair since it is notdelivered as standard equipment any lifting system.

The periodic maintenance should be performed accordingto the schedule shown in the engine manual. An optionalhour counter (M) is available to simplify the determinationof the working hours.

THE ENGINE PROTECTION NOT WORK WHEN THEOIL IS OF LOW QUALITY BECAUSE NOT CHARGEDREGULARLY AT INTERVALS AS PRESCRIBED INTHE OWNER’S ENGINE MANUAL.

NOTE

IMPORTANTIn the maintenance operations avoid thatpolluting substances, liquids, exhausted oils,etc. bring damage to people or things or cancause negative effects to surroindings, healthor safety respecting completely the laws and/or dispositions in force in the place.

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, payattention moving parts, hot parts (exhaust manifold and muffler,etc.) electrical parts which may be unprotected when the machineis open.

● Remove guards only when necessary to perform maintenance, andreplace them when the maintenance requiring their removal iscomplete.

● Use suitable tools and clothes.● Do not modify the components if not authorized.

- See pag. M1.1 -

HOT surfacecan

hurt you

MOVINGPARTS

can injure

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ENGINE and ALTERNATORPLEASE REFER TO THE SPECIFIC MANUALSPROVIDED.

VENTILATIONMake certain there are no obstructions (rags, leaves orother) in the air inlet and outlet openings on the machine,alternator and motor.

ELECTRICAL PANELSCheck condition of cables and connections daily.Clean periodically using a vacuum cleaner, DO NOTUSE COMPRESSED AIR.

DECALS AND LABELSAll warning and decals should be checked once a yearand replaced if missing or unreadable.

STRENUOUS OPERATING CONDITIONSUnder extreme operating conditions (frequent stops andstarts, dusty environment, cold weather,extended periodsof no load operation, fuel with over 0.5% sulphur content)do maintenance more frequently.

BATTERY WITHOUT MAINTENANCEDO NOT OPEN THE BATTERY

The battery is charged automatically from the batterycharger circuit suppplied with the engine.

Check the state of the battery from the colour of thewarning light which is in the upper part.

- Green colour: battery OK- Black colour: battery to be recharged- White colour: battery to be replaced

STORAGE GE_, MS_, TS_M45

© MOSA 1.0-06/00

In case the machine should not be used for more than 30days, make sure that the room in which it is storedpresents a suitable shelter from heat sources, weatherchanges or anything which can cause rust, corrosion ordamages to the machine.

☞ Have qualified personnel prepare the machine forstorage.

GASOLINE ENGINE

Start the engine: lt will run until it stops due to the lack offuel.

Drain the oil from the engine sump and fill it with new oil(see page M25).

Pour about 10 cc of oil into the spark plug hole and screwthe spark plug, after having rotated the crankshaft severaltimes.

Rotate the crankshaft slowly until you feel a certaincompression, then leave it.

In case the battery, for the electric start, is assembled,disconnect it.

Clean the covers and all the other parts of the machinecarefully.

Protect the machine with a plastic hood and store it in odry place.

DIESEL ENGINE

For short periods of time it is advisable, about every 10days, to make the machine work with load for 15-30minutes, for a correct distribution of the lubricant, torecharge the battery and to prevent any possible blokingof the injection system.

For long periods of inactivity, turn to the after solesservice of the engine manufacturer.

Clean the covers and all the other parts of the machinecarefully.

Protect the machine with a plastic hood and store it in adry place.

In the storage operations avoid thatpolluting substances, liquids, exhaustedoils, etc. bring damage to people orthings or can cause negative effects tosurroindings, health or safety respectingcompletely the laws and/or dispositionsin force in the place.

IMPORTANT

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In case of necessity for first aid and of fire prevention,see page. M2.5.

CUST OFF GE_, MS_, TS_M46

© MOSA 1.0-03/00

In the cust-off operations avoid thatpolluting substances, liquids, exhaustedoils, etc. bring damage to people orthings or can cause negative effects tosurroindings, health or safety respectingcompletely the laws and/or dispositionsin force in the place.

IMPORTANT

☞ Have qualified personnel disassemble themachine and dispose of the parts, including theoil, fuel, etc., in a correct manner when it is tobe taken out of service.

As cust off we intend all operations to be made, atutilizer’s care, at the end of the use of the machine.This comprises the dismantling of the machine, thesubdivision of the several components for a furtherreutilization or for getting rid of them, the eventualpacking and transportation of the eliminated partsup to their delivery to the store, or to the bureauencharged to the cust off or to the storage office,etc.

The several operations concerning the cust off,involve the manipulation of fluids potentiallydangerous such as: lubricating oil and batteryelectrolyte.

The dismantling of metallic parts liable to causeinjuries or wounds, must be made wearing heavygloves and using suitable tools.

The getting rid of the various components of themachine must be made accordingly to rules in forceof law a/o local rules.Particular attention must be paid when gettingrid of:lubricating oils, battery electrolyte, andinflamable liquids such as fuel, cooling liquid.

The machine user is responsible for the observanceof the norms concerning the environment conditionswith regard to the elimination of the machine beingcust off and of all its components.

In case the machine should be cust off without anyprevious disassembly it is however compulsory toremove:- tank fuel- engine lubricating oil- cooling liquid from the engine- battery

NOTE: MOSA is involved with custing off themachine only for the second hand ones, when notreparable.This, of course, after authorization.

In case of necessity for first aid and fire prevention,see page M2.5.

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Technical data TS 250 DM51

© MOSA 1.0-09/03

The TS 250 D engine driven welder ia a unit which ensures the function as:a) a current source for are weldingb) a current source for the auxiliary generationUnit meant for industrial and professional use, powered by an endothermic engine; it is composed of various main parts suchas: 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 alsoeliminate sounds which would produce noise.

Technical data TS 250 DALTERNATOR Self-excited, self-regulated

Type three-phase, asynchronousInsulating class H

GENERATORThree-phase generation 6.5 kVA / 400 V / 9.4 ASingle-phase generation 4.5 kVA / 230 V / 19.5 ASingle-phase generation 2.5 kVA / 48 V / 52 AFrequency 50 HzService 100 %

ENGINEMark RuggeriniModel RD 210

Type 4-StrokeDisplacement 954 cm3

Cylinders 2Output max 14 kW (19 HP)Speed 3000 rpmFuel consumption 250 g/kWhCooling system airEngine oil capacity 3 lStarter electricFuel Diesel

GENERAL SPECIFICATIONSBattery 12V - 50AhCapacità serbatoio 9 lRunning time (at duty cycle 60%) 4.5 hProtection IP 23Dimensions Lxwxh (mm) * 1050x530x630Weight * 175 KgRumorosità 103 LWA (78 dB(A) - 7m)* Dimensions and weight are inclusive of all parts without wheels and towbar

OUTPUTDeclared powers at the following ambient conditions: temperature 20*C, relative humidity 30% altitude 100 m abovesea level.In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.For possible modifications or changes to be brought on the engines, with climate conditions different from those abovementioned, please call our Assistance Authorized Centers.

ACOUSTIC POWER LEVELThe machine respects the noise limits, expressed in sound power, given in the a.m. directives.These limits can be used to judge the sound level produced on site.For example: the sound power level of 100 LWA.The sound pressure (noise produced) at 7 meters distance is about 75dBA (the limit value less 25).To calculate the sound level at other distances use this formula:

dBAx = dBAy + 10 log At 4 meters the noise level becomes: 75 dBA + 10 log = 80 dBAry²rx²

7²4²

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Technical data TS 250 DM52

© MOSA 1.0-09/03

WELDINGMax DC welding current 200A/60% - 250A/35%Welding current electronic regulation 20 - 250AOpen circuit voltage 70VWelding voltage 20-30VØ Electrodes (rutile, basic, cellulosic) 2-6 mm

Welding currentregulator positionapprox. currentvalues

25% 50% 75% 100%

20 70 130 190 250

6.5 kVA4 kVA2.5 kVA0AUXILIARY POWER

080 A130 A>170 AWELDING CURRENT

EXIT CHARACTERISTICS

0%

A

SIMULTANEOUS UTILIZATION FACTORS

In case Welding and Generation can be used simultaneously, however, the engine cannot be overloaded.The table below gives the maximum limits to be respected.

DimensioniDimensionsDimensions© MOSA 1.0-09/03

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TS 250 DM53

AbmessungenDimensiones

ELECTRICAL SYSTEM LEGENDE GE_, MS_, TS_M60

© MOSA 1.4-02/06

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A: AlternatorB: Wire connection unitC: CapacitorD: G.F.I.E: Welding PCB transformerF: FuseG: 400V 3-phase socketH: 230V 1phase socketI: 110V 1-phase socketL: Socket warning lightM: Hour-counterN: VoltmeterP: Welding arc regulatorQ: 230V 3-phase socketR: Welding control PCBS: Welding current ammeterT: Welding current regulatorU: Current transformerV: Welding voltage voltmeterZ: Welding socketsX: ShuntW: D.C. inductorY: Welding diode bridge

A1: Arc striking resistorB1: Arc striking circuitC1: 110V D.C./48V D.C. diode bridgeD1: E.P.1 engine protectionE1: Engine stop solenoidF1: Acceleration solenoidG1: Fuel level transmitterH1: Oil or water thermostatI1: 48V D.C. socketL1: Oil pressure switchM1: Fuel warning lightN1: Battery charge warning lightO1: Oil pressure warning lightP1: FuseQ1: Starter keyR1: Starter motorS1: BatteryT1: Battery charge alternatorU1: Battery charge voltage regulatorV1: Solenoid valve control PCBTZ1: Solenoid valveW1: Remote control switchX1: Remote control and/or wire feeder

socketY1: Remote control plug

A2: Remote control welding regulatorB2: E.P.2 engine protectionC2: Fuel level gaugeD2: AmmeterE2: Frequency meterF2: Battery charge trasformerG2: Battery charge PCBH2: Voltage selector switchI2: 48V a.c. socketL2: Thermal relayM2: ContactorN2: G.F.I. and circuit breakerO2: 42V EEC socketP2: G.F.I. resistorQ2: T.E.P. engine protectionR2: Solenoid control PCBTS2: Oil level transmitterT2: Engine stop push-button T.C.1U2: Engine start push-buttonT.C.1V2: 24V c.a. socketZ2: Thermal magnetic circuit breakerW2: S.C.R. protection unitX2: Remote control socketY2: Remote control plug

A3: Insulation moitoringB3: E.A.S. connectorC3: E.A.S. PCBD3: Booster socketE3: Open circuit voltage switchF3: Stop push-buttonG3: Ignition coilH3: Spark plugI3: Range switchL3: Oil shut-down buttonM3: Battery charge diodeN3: RelayO3: ResistorP3: Sparkler reactorQ3: Output power unitR3: Electric sirenS3: E.P.4 engine protectionT3: Engine control PCBU3: R.P.M. electronic regulatorV3: PTO HI control PCBZ3: PTO HI 20 l/min push-buttonW3: PTO HI 30 l/min push-buttonX3: PTO HI reset push-buttonY3: PTO HI 20 l/min indicator

A4: PTO HI 30 l/min indicatorB4: PTO HI reset indicatorC4: PTO HI 20 l/min solenoid valveD4: PTO HI 30 l/ min solenoid valveE4: Hydraulic oil pressure switchF4: Hycraulic oil level gaugeG4: Preheating glow plugsH4: Preheating gearboxI4: Preheating indicatorL4: R.C. filterM4: Heater with thermostatN4: Choke solenoidO4: Step relayP4: Circuit breakerQ4: Battery charge socketsR4: Sensor, cooling liquid temperatureS4: Sensor, air filter cloggingT4: Warning light, air filter cloggingU4: Polarity inverter remote controlV4: Polarity inverter switchZ4: Transformer 230/48VW4: Diode bridge, polarity changeX4: Base current diode bridgeY4: PCB control unit, polarity inverter

A5: Base current switchB5: Auxiliary push-button ON/OFFC5: Accelerator electronic controlD5: ActuatorE5: Pick-upF5: Warning light, high temperatureG5: Commutator auxiliary powerH5: 24V diode bridgeI5: Y/s commutatorL5: Emergency stop buttonM5: Engine protection EP5N5: Pre-heat push-buttonO5: Accelerator solenoid PCBP5: Oil pressure switchQ5: Water temperature switchR5: Water heaterS5: Engine connector 24 polesT5: Electronic GFI relaisU5: Release coil, circuit breakerV5: Oil pressure indicatorZ5: Water temperature indicatorW5: Battery voltmeterX5: Contactor, polarity changeY5: Commutator/switch, series/parallel

A6: Commutator/switchB6: Key switch, on/offC6: QEA control unitD6: Connector, PACE6: Frequency rpm regulatorF6: Arc-Force selectorG6: Device starting motorH6: Fuel electro pump 12V c.c.I6: Start Local/Remote selectorL6: Choke buttonM6: Switch CC/CVN6: Connector – wire feederO6: 420V/110V 3-phase transformerP6: Switch IDLE/RUNQ6: Hz/V/A analogic instrumentR6: EMC filterS6: Wire feeder supply switchT6: Wire feeder socketU6: DSP chopper PCBV6: Power chopper supply PCBZ6: Switch and leds PCBW6: Hall sensorX6: Water heather indicatorY6: Battery charge indicator

A7: Transfer pump selector AUT-0-MANB7: Fuel transfer pumpC7: „GECO“ generating set testD7: Flooting with level switchesE7: Voltmeter regulatorF7: WELD/AUX switchG7: Reactor, 3-phaseH7: Switch disconnectorI7: Solenoid stop timerL7: "VODIA" connectorM7: "F" EDC4 connectorN7: OFF-ON-DIAGN. selectorO7: DIAGNOSTIC push-buttonP7: DIAGNOSTIC indicatorQ7: Welding selector modeR7: R.C. netS7: 230V 1-phase plugT7: V/Hz analogic instrumentU7: Engine protection EP6V7: G.F.I. relay supply switchZ7: Radio remote control receiverW7: Radio remote control trasnsmitterX7: Isometer test push-buttonY7: Remote start socket

A8: Transfer fuel pump controlB8: Ammeter selector switchC8:D8:E8:F8:G8: Polarity inverter two way switchH8:I8:L8:M8:N8:O8:P8:Q8:R8:S8:T8:U8:V8:Z8:W8:X8:Y8:

Schema elettricoElectric diagramSchemas electriques

TS 250 DM

61.1© MOSA 1.0-09/03

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RicambiSpare partsPiéces de rechange© MOSA 1.0-09/03

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ErsatzteileTabla de recambios TS 200 BS-P -

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SPARE PARTS LISTR1

© MOSA 1.0-03/00

MOSA guarantees that any request for spare parts will be satisfied.To keep the machine in full working order, when replacement of MOSA spare parts is required, alwaysask for genuine parts only.

When ordering the spare parts, it isrecommended to indicate:

1) ✹ serial number

2) ✹ model of welder and/or generating set

3) ◆ n. table

4) ◆ n. position

5) quantity

TS 0000 GETS 0000 GE

V.le Europa,59 - 20090 CUSAGO (MI) ITALY

Tel. +39-02 90352.1 - fax +39-02 90390466

0987654321

TYPE

SERIAL N°

22/0

3/00

R1G

B

The requested data are to be found on thedata plate located on the machine structure,quite visible and easy to consult. ✹

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


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ErsatzteileTabla de recambios TS 250 D

DG6

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* C

TM 2

22


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DG6.1

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Pos. Rev. Cod. Descr. Note0 220010130 CTM222 KIT TRAINO MANUALE (*)2 208101051 MANIGLIA3 219861159 MANOPOLA era 1020440704 210011160 ASSALE5 102042490 RUOTA7 6075020 COPIGLIA8 120211050 BARELLA9 1030060 PASSACAVO era 1030030

10 107012120 CESTELLO BATTERIA11 102041790 BATTERIA 50 AH Fino a REV.0 - 09/03 Del. 75/05 del

22/07/0511 359259150 BATTERIA 12V 45AH (Senza Man.) Da REV.1-11/06 Del. 75/05 del 22/

07/0512 102041420 TRAVERSA13 105611270 TIRANTE PER BATTERIA14 209039160 CESTELLO PORTA BATT.(CON COP.)

Pos. Rev. Cod. Descr. Note0 220010130 CTM222 (*)2 208101051 HANDLE3 219861159 KNOB era 1020440704 210011160 AXLE5 102042490 WHEEL7 6075020 PIN, SPLIT8 120211050 PROTECTIVE FRAME9 1030060 GROMMET era 1030030

10 107012120 HOLDER, BATTERY11 102041790 BATTERY 50AH Up to REV.0 - 09/03 Del. 75/05 del

22/07/0511 359259150 BATTERY 12V 45AH (Without Maint.) To REV.1-11/06 Del. 75/05 del 22/

07/0512 102041420 BRACKET13 105611270 TIE ROD, BATTERY14 209039160 HOLDER, BATTERY


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DG7

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DG7.1

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Pos. Rev. Cod. Descr. Note1 307407226 MORSETTIERA2 6062080 TAPPO5 1030060 PASSACAVO6 107509700 POTENZIOMETRO7 107302460 STARTER A CHIAVE

10 1030100 PASSACAVO11 209510017 PREDISPOSIZIONE CD2 era 10750703013 1302040 SPIA 12V14 107509702 MANOPOLA REG.CORRENTE SALDAT.15 102044400 PRESA DI SALDATURA (-)16 282009807 DISTANZ. ISOLANTE PER SCHEDE era 10730257017 102301310 PRESA DI SALDATURA (+)18 208019800 SCHEDA DI CONTROLLO SALDATURA19 106021220 PRESA DINSE (+)20 101131220 PRESA DINSE (-)21 107509870 TRASFORMATORE22 305159880 BOX CONDENSATORI23 307017037 STAFFA24 208019011 SOPPRESSORE PROTEZ.PONTE DIODI25 208019890 SHUNT

Pos. Rev. Cod. Descr. Note1 307407226 TERMINAL BOARD2 6062080 CAP,5 1030060 GROMMET6 107509700 WELDING CURRENT REGULATOR7 107302460 STARTER KEY

10 1030100 GROMMET11 209510017 SOCKET SWITCH REMOTE CONTROL era 10750703013 1302040 WARNING LIGHT 12V14 107509702 KNOB,WELDING CURRENT REGULAT.15 102044400 WELDING SOCKET (-)16 282009807 Manca la descrizione era 10730257017 102301310 WELDING SOCKET (+)18 208019800 PCB, WELDING CONTROL19 106021220 SOCKET, STARTER (+) (+)20 101131220 SOCKET (-)21 107509870 AUXILIARY TRANSFORMER22 305159880 CAPACITOR BOX 3X7523 307017037 BRACKET24 208019011 SUPPRESSOR PROT. DIODE BRIDGE25 208019890 SHUNT


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DG8

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Pos. Rev. Cod. Descr. Note1 220337020 PANNELLO FRONTALE2 305907270 PRESA CEE 16A 400V 3P+N+T3 307017240 PRESA 220V 16A4 218137280 PRESA CEE 48V 32A5 1302220 SPIA 220V6 155307107 DISGIUNTORE TERMICO7 1302080 SPIA PER 48V8 105111540 Vedi Cod.2199371059 232027036 GUIDA

10 232027130 CAPPUCCIO PROTEZIONE I.D.18 103011310 VOLTMETRO19 259107241 PRESA SCHUKO 16A 230V - 2P+T (SR) (Versione SCHUKO)23 220307020 PANNELLO FRONTALE (SR) (Versione con CONTAORE)24 105511810 CONTAORE (SR) (Versione con CONTAORE)

Pos. Rev. Cod. Descr. Note1 220337020 FRONT PANEL2 305907270 EEC SOCKET 16A 400V 3P+N+T3 307017240 EEC SOCKET 16A, 220V 2P+T4 218137280 EEC SOCKET 48V 32A5 1302220 WARNING LIGHT 220V6 155307107 THERMAL SWITCH7 1302080 WARNING LIGHT FOR 48V8 105111540 See part no. 2199371059 232027036 FIXING GUIDE

10 232027130 CAP18 103011310 VOLTMETER19 259107241 SOCKET SCHUKO 16A 230V 2P+T (SR) (Versione SHUKO)23 220307020 FRONT PANEL (SR) (Versione con CONTAORE)24 105511810 HOURMETER


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RicambiSpare partsPiéces de rechange© MOSA REV.1-11/06


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Pos. Rev. Cod. Descr. Note1 220014100 REATTORE COMPLETO2 210015041 STAFFA3 120295100 PONTE DIODI era 210015100 - Fino a REV.0 - 09/

03 Del. Del 113/06 del 03/07/063 120215100 PONTE DIODI Da REV.1 - 11/06 Del. Del 113/06

del 03/07/065 210016020 VENTOLA6 120213038 RONDELLA DI SICUREZZA7 210013039 DISTANZIALE8 1001060 CUSCINETTO9 309509035 UNITA’ DIODI PRITT

10 309503045 FLANGIA PORTA ALTERNATORE11 208109067 STAFFA12 309509065 RESISTENZA DI PRITT13 232129658 PIASTRINA FISSAGGIO RESISTENZA era 10204701014 107011280 TIRANTE15 120213030 ALBERO CON ROTORE16 220133025 STATORE17 309503040 FLANGIA18 120213036 TIRANTE ALBERO ROTORE M18X1,5

Pos. Rev. Cod. Descr. Note1 220014100 COMPLETE REACTOR2 210015041 BRACKET3 120295100 DIODE BRIDGE Was 210015100 - Up to REV.0 -

09/03 Del. Del 113/06 del 03/07/063 120215100 DIODE BRIDGE From REV.1 - 11/06 Del. Del 113/06

del 03/07/065 210016020 FAN6 120213038 WASHER7 210013039 SPACER8 1001060 BEARING9 309509035 DIODES UNIT, PRITT

10 309503045 ALTERNATOR FLANGE11 208109067 BRACKET12 309509065 RESISTOR PRITT13 232129658 RESISTANCE PLATE era 10204701014 107011280 TIE - ROD15 120213030 SHAFT WITH ROTOR16 220133025 STATOR17 309503040 FLANGE18 120213036 TIE-ROD


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DG10.1

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Pos. Rev. Cod. Descr. Note2 120292200 MOTORE RUGGERINI RD210 (M8994)3 120212035 TRAVERSA SUPPORTO MOTORE4 105112020 ANTIVIBRANTE5 307012037 PROTEZIONE ANTIVIBRANTE6 210018205 SCATOLA DI BASE7 210018200 CASSONETTO ASPIRAZIONE (Solo per ricambi)8 210018003 FIANCATA DX9 210018122 COPERCHIO SCHEDA SALDATURA

10 220018004 FIANCATA SX12 210012020 SERBATOIO13 102041740 TAPPO14 1030100 PASSACAVO16 6062080 TAPPO17 210018247 PARATIA

Pos. Rev. Cod. Descr. Note2 120292200 ENGINE RUGGERINI RD 2103 120212035 SUPPORT, ENGINE4 105112020 VIBRATION DAMPER5 307012037 PROTECTION, VIBRATION-DAMPER6 210018205 CASE, BOTTOM HALF7 210018200 BOX, AIR INLET (Solo per ricambi)8 210018003 SIDE, RIGHT9 210018122 COVER, WELDING PCB

10 220018004 SIDE,LEFT12 210012020 FUEL TANK13 102041740 CAP, TANK14 1030100 GROMMET16 6062080 CAP,17 210018247 WALL

TC 2 / TC2-50209510018 - 930600000

KD1

© MOSA 1.0-10/99

18/1

0/99

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Pos. Rev. Cod. Descr. Descr. Note1 102013290 COMMUTATORE COMMUTATOR2 107507032 COPERCHIO COMANDO A DISTANZA BLIND PLATE REMOTE CONTROL3 209509910 CONNETTORE FEMM.CON CAVI FEMALE CONNECTOR WITH CABLES4 209519904 CONNETTORE COMPLETO DI CAVI CONNECTOR WITH CABLES TC2 vers.

4a 930609904 CONNETTORE CON CAVI CONNECTORS WITH CABLES TC2/50 vers.5 107509702 MANOPOLA REG.CORRENTE SALDAT. KNOB,WELDING CURRENT REGULAT.7 107509700 POTENZIOMETRO WELDING CURRENT REGULATOR8 107509900 SCATOLA CASE, BOTTOM HALF9 209519901 COPERCHIO (CD) COVER

10 209510017 PREDISPOSIZIONE CD2 SOCKET SWITCH REMOTE CONTROL11 209510018 TC2 COMANDO DISTANZA STANDARD TC2 STANDARD REMOTE CONTROL11 A 930600018 TC2 COMANDO DISTANZA STANDARD TC2 STANDARD REMOTE CONTROL TC2/50 vers.12 209510019 KIT TC2 COMPLETO KIT TC2 COMPL.12 A 930600019 KIT TC2 COMPLETO KIT TC2 COMPL. TC2/50 vers.

REQUEST FOR ORDER SPARE PARTSR

1.1© MOSA 1.0-04/97

Dear Customer,You can send us the request for order of MOSA original spare parts, filling in this form, with the new spareparts tables as well as with the old ones, by FAX or mail.

18/0

4/97

R1-

1

Request from:...................................................... date:.............................. signature:.........................................

Please send use us following sapre parts for the machine below: MOSA SPARE PARTS:

model type:.................................................................

serial nr:

N E W T A B L E S

t a b le n r. p o s i t io n q . t y

ENGINE SPARE PARTS:

engine model: ............................................. engine serial nr.:.................................................

SYNCHRONOUS ALTERNATOR SPARE PARTS:

alternator model:.......................................... alternator serial nr.:............................................

O L D TA B L E S

c o d e q .ty

�

c o d e a n d /o r p o s it io n d e s c rip tio n a n d /o r ta b le q .ty

c o d e a n d /o r p o s it io n d e s c rip tio n a n d /o r ta b le q .ty

USE AND MAINTENANCE MANUAL SPARE PARTS CATALOG

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