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CONTROLS LEGENDE

M

30

REV.3-04/13

I

GB

F

4A 

Hydraulic oil level light

Welding socket ( + )

10 

Welding socket ( - )

12 

Earth terminal

15 

A.C. socket

16 

Accelerator lever

17 

Feed pump

19 

48V D.C. socket

22 

Engine air filter

23 

Oil level dipstick

24 

Engine oil reservoir cap

24A 

Hydraulic oil reservoir cap

24B 

Water filling cap

25 

Fuel prefilter

26 

Fuel tank cap

27 

Muffler

28 

Stop control

29 

Engine protection cover

30 

Engine cooling/alternator fan belt

31 

Oil drain tap

31A 

Hydraulic oil drain tap

31B 

Water drain tap

31C 

Exhaust tap for tank fuel

32 

Button

33 

Start button

34 

Booster socket 12V

34A 

Booster socket 24V

35 

Battery charge fuse

36 

Space for remote control

37 

Remote control

42 

Space for E.A.S.

42A 

Space for PAC

47 

Fuel pump 

49 

Electric start socket

54 

Reset button PTO HI

55 

Quick coupling m. PTO HI

55A 

Quick coupling f. PTO HI

56 

Hydraulic oil filter

59 

Battery charger thermal switch

59A 

Engine thermal switch

59B 

Aux current thermal switch 

59C 

Supply thermal switch wire feeder-42V

59D 

Pre-heater (spark plug) thermal switch

59E 

Supply thermal switch oil/water heather

59F

 

Electropump

 

thermal switch

63 

No load voltage control

66 

Choke control

67A 

Auxiliary / welding current control

68 

Cellulosic electrodes control

69A 

Voltmeter relay

70 

Warning lights

71 

Selecting knob

72 

Load commut. push button

73 

Starting push button

74 

Operating mode selector

75 

Power on warning light

76 

Display 

79 

Wire connection unit

86 

Selector

86A 

Setting confirmation

87 

Fuel valve

88 

Oil syringe

A3 

Insulation monitoring

A4  

Button indicating light 30 l/1' PTO HI

B2 

Engine control unit EP2

B3 

E.A.S. connector

B4 

Exclusion indicating light PTO HI

B5 

Auxiliary current push button

C2 

Fuel level light

C3 

E.A.S. PCB

C6 

Control unit for generating sets QEA

Ground fault interrupter ( 30 mA )

D1 

Engine control unit and economiser 

EP1

D2 

Ammeter

E2 

Frequency meter

E6 

Frequency rpm regulator

E7 

Voltmeter regulator

Fuse

F3 

Stop switch

F5 

Warning light, high temperature

F6 

Arc-Force selector

G1 

Fuel level transmitter

H2 

Voltage commutator

H6 

Fuel electro pump

H8 

Engine control unit EP7

I2 

48V A.C. socket

I3 

Welding scale switch

I4 

Preheating indicator

I5 

Y/

 switch

I6 

Start Local/Remote selector

I8 

AUTOIDLE switch

A.C. output indicator

L5 

Emergency button

L6 

Choke button

Hour counter

M1 

Warning level light

M2 

Contactor

M5 

Engine control unit EP5

M6 

CC/CV switch

Voltmeter

N1 

Battery charge warning light

N2 

Thermal-magnetic circuit breaker/

Ground fault interrupter

N5 

Pre-heat push-button

N6 

Connector - wire feader

O1 

Oil pressure warning light/Oil alert

O8

 

V/A digital instruments and led VRD PCB

Welding arc regulator

P8 

Water in fuel

Q1 

Starter key

Q3 

Derivation box

Q4 

Battery charge sockets

Q7 

Welding selector mode

R3 

Siren

Welding ammeter

S1 

Battery

S3 

Engine control unit EP4

S6 

Wire feeder supply switch

S7 

Plug 230V singlephase

Welding current regulator

T4 

Dirty air filter warning light/indicator

T5 

Earth leakage relay

T7 

Analogic instrument V/Hz

Current trasformer 

U3 

R.P.M. adjuster

U4 

Polarity inverter remote control

U5 

Relase coil

U7 

Engine control unit EP6

Welding voltage voltmeter

V4 

Polarity inverter control

V5 

Oil pressure indicator

W1 

Remote control switch 

10/05/01  M30-GB

W3 

Selection push button 30 l/1' PTO HI

W5 

Battery voltmeter

X1 

Remote control socket

Y3 

Button indicating light 20 l/1' PTO HI

Y5 

Commutator/switch, serial/parallel

Z2 

Thermal-magnetic circuit breaker

Z3 

Selection push button 20 l/1' PTO HI

Z5 

Water temperature indicator

Summary of Contents for TS 300 KS

Page 1: ...USE AND MAINTENANCE MANUAL M A D E I N I T A L Y TS 300 KS TS 300 KSX Codice Code Codigo Kodezahl 373049003 Edizione Edition Edici n Ausgabe 04 2014...

Page 2: ......

Page 3: ...REGULATION CONNECTOR FOR REMOTE CONTROL BATTERY FILTER The engine driven welder has a base constructed in steel which includes the tank A cover which is hinged to the roll bar facilitates a rapid chec...

Page 4: ...G 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 STO...

Page 5: ...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 w...

Page 6: ...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...

Page 7: ...ke 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 theref...

Page 8: ...luded in any machine standard equipment Here below the adopted symbol CE marking is clearly readable and unerasable and it can be either part of the data plate Furthermore on each model it is shown th...

Page 9: ...Marchio Brand Modello Model Matricola Serial number conforme con quanto previsto dalle Direttive Comunitarie e relative modifiche est en conformit avec ce qui est pr vu par les Directives Communautair...

Page 10: ...Weight with CTM 370 Kg 390 Kg Weight with CTL 410 Kg 440 Kg Acoustic power LwA pression LpA 99 dB A 74 dB A 7m Measured acoustic power LwA pression LpA 96 dB A 71 dB A 7m Guaranteed acoustic power LwA...

Page 11: ...ical data TS 300 KS KSX M 1 6 REV 0 04 14 SIMULTANEOUS UTILIZATION FACTORS In case Welding and Generation can be used simultaneously however the engine cannot be overloaded The table below gives the m...

Page 12: ...r whatever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions FIRE PREVENTION In case the working...

Page 13: ...ersons Use only with safety clothing It is compulsory to use the personal protection means given in equip ment Use only with safety clothing It is compulsory to use the personal protection means given...

Page 14: ...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 shock which can cause death or serious burns The el...

Page 15: ...a dangerous increase of the temperature Make sure that the machine does not move during the work block it possibly with tools and or devices made to this purpose Maximum leaning of the machine in cas...

Page 16: ...Installazione Installation Installation TS 300 KS KSX TS 300 EP1 M 2 7 Luftzirkulation Instalaci n D E NL 14 04 14 37304 I...

Page 17: ...14 04 14 37304 I Dimensioni Dimensions Dimensions Abmessungen Dimensiones TS 300 KS KSX M 2 7 1 D E NL...

Page 18: ...rough handling or taking away of parts contained inside the packing or in the set In case you find damages rough handling or absence of parts envelopes manuals etc we advise you to inform immediately...

Page 19: ...s 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 STRIC...

Page 20: ...th 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...

Page 21: ...s the M10 nuts and the washers so as to let the foot sprag go through 3 Split unscrewing them the two parts of the foot 4S 4I to be able later to assemble them on the jaw 4 Introduce into the jaw 3 th...

Page 22: ...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...

Page 23: ...N2 lever towards above and where mounted check the isolation monitor A3 see page M37 Introduce the key Q1 turn it clockwi se completely leaving it as soon as the engine starts and or the push button 3...

Page 24: ...F THE ENGINE Using the engine in special conditions which need an immediate intervention such as emergency plants etc use advise to use our EngineAssistance Centres for specific interventions or our T...

Page 25: ...ke 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...

Page 26: ...5 Auxiliary current push button C2 Fuel level light C3 E A S PCB C6 Control unit for generating sets QEA D Ground fault interrupter 30 mA D1 Engine control unit and economiser EP1 D2 Ammeter E2 Freque...

Page 27: ...M N D T 15 16 15 28 W1 X1 P 10 9 D1 M1 N1 Q1 E P 1 LOW ENGINE PRESS HIGH OK ON OFF 20 100 F L Comandi Controls Commandes 14 04 14 37304 I D E NL Bedienelemente Mandos TS 300 KS KSX M 31...

Page 28: ...page M 39 MACHINE WITH E P 2 PROTECTION B2 Accelerate the engine at max with the accelerator lever 16 when assebled See page M 39 MACHINE WITH E P 1 PRO ONLYGOUGING TECTION D1 See page M 39 1 REMOTE C...

Page 29: ...e polarity of the welding diode bridge It is used above all in the first run with cellulosic electrodes to lower the bath temperature and so doing ease up the welding on pipes of small thickness MACHI...

Page 30: ...10 synchronous 5 5 5 5 Indicative no load voltage The areas access of which is forbidden to un qualified personel are the control switchboard front the exhaust of the endothermic engine WARNING The wa...

Page 31: ...ions a current leakage of more than 30 mA occurs UNIT FITTED WITH THERMAL MAGNETIC BRE AKER Turn on the thermal magnetic breaker Z2 by pushing it to the ON position The thermal magnetic brea ker is a...

Page 32: ...ed to the front panel by means of a multipole connector To regulate the current from the TC2 TC2 50 move the switch 7 located above the multipole connector 8 to ON position Position welding current ad...

Page 33: ...of cooling liquid high temperature the war ning light D1 4 will light up and the engine will stop thus preventing to draw power In this case it is SUGGESTED to stop the engine and control the cooling...

Page 34: ...n operation when the engine starts and in case of low oil pressure and high temperature will stop the machine and show the cause of the stop with the warning light of high temperature or low oil press...

Page 35: ...ins of the green connec tors are clean and making good contact Check that shunt connections are tight 2 Replace the welding current control PCB No welding output and no auxiliary power output 1 Short...

Page 36: ...O NOT USE COMPRESSED AIR DECALS AND LABELS All warning and decals should be checked once a year and replaced if missing or unreadable STRENUOUS OPERATING CONDITIONS Under extreme operating conditions...

Page 37: ...n 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...

Page 38: ...he 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 in...

Page 39: ...ground clamp Special for steels run on pipes with R max 55 kg mm2 Weld in all position volatile slag ELECTRODES IDENTIFICATION ACCORDING TO A W S STANDARDS E X X Y Z 2 digits type of coating and elect...

Page 40: ...4 Polarity inverter switch Z4 Transformer 230 48V W4 Diode bridge polarity change X4 Base current diode bridge Y4 PCB control unit polarity inverter A5 Base current switch B5 Auxiliary push button ON...

Page 41: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 1 14 04 14 37304 I...

Page 42: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 2 14 04 14 37304 I...

Page 43: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 3 14 04 14 37304 I...

Page 44: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 4 14 04 14 37304 I...

Page 45: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 5 14 04 14 37304 I...

Page 46: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 6 14 04 14 37304 I...

Page 47: ...Ricambi Spare parts Pi ces de rechange E D NL Ersatzteile Tabla de recambios TS 300 KS KSX M 61 7 14 04 14 37304 I...

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Page 50: ...MOSA div della BCS S p A Stabilimento di Viale Europa 59 20090 Cusago MI Italia Tel 39 0290352 1 Fax 39 0290390466 WWW MOSA IT...

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