TS 200 DS-DES/CF

0211 272709003 - GB

USE AND MAINTENANCE MANUAL

SPARE PARTS CATALOG

© MOSA 04/11/02 27270M00

preparato da UPT
approvato da DITE
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DESCRIPTION OF THE MACHINE TS 200 DS-DES/CF 0
REV.0-02/11

The TS 200 engine driven welder ia a unit which ensures the function as:
a) a current source for are welding
b) a current source for the auxiliary generation
Unit meant for industrial and professional use, powered by an endothermic engine; it is composed of various
main parts such as: engine, alternator, electric and electronic controls, the fairing or a protective structure.
The assembling is made on a steel structure, on which are provided elastic support which must damp the
vibrations and also eliminate sounds which would produce noise.

ENGINE

FRONT PANEL

FRAME

VIBRATION
DAMPER

ALTERNATOR
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Quality system 01
© MOSA REV.3-02/09

UNI EN ISO 9001 : 2008

MOSA has certified its quality system according The advantages for MOSA clients are:
to UNI EN ISO 9001:2008 to ensure a constant, ·Constant quality of products and services at thehigh
highquality of its products. This certification covers level which the client expects;
thedesign, production and servicing of engine dri-
venwelders and generating sets. · Continuous efforts to improve the products andtheir
performance at competitive conditions;
The certifying institute, ICIM, which is a member
· Competent support in the solution of problems;
ofthe International Certification Network IQNet,
awarded the official approval to MOSA after an- · Information and training in the correct applicatio-
examination of its operations at the head office nand use of the products to assure the security
andplant in Cusago (MI), Italy. ofthe operator and protect the environment;
· Regular inspections by ICIM to confirm that the-
This certification is not a point of arrival but a
requirements of the company’s quality systemand
pledgeon the part of the entire company to maintain ISO 9001 are being respected.
a levelof quality of both its products and services
whichwill continue to satisfy the needs of its clients, All these advantages are guaranteed by the CER-
aswell as to improve the transparency and thecom- TIFICATE OF QUALITY SYSTEM No.0192 issued
munications regarding all the company’s activesin by ICIM S.p.A. - Milano (Italy ) - www.icim.it
accordance with the official procedures and inhar-
mony with the MOSA Manual of Quality.
10/10/02 M01-GB
 M
Index TS 200 DS-DES/CF 1
REV.1-02/11

M 01 QUALITY SYSTEM
M 1.01 COPYRIGHT
M 1.1 NOTES
M 1.4 MARCHIO CE
M 1.5 DATI TECNICI
M 2 - ... SYMBOLS AND SAFETY PRECAUTIONS
M 2.5 -…. INSTALLATION AND ADVICE BEFORE USE
M 2.6 INSTALLATION AND ADVICE
M 2.7 INSTALLATION
M3 UNPACKING
M 4.1 TRANSPORT AND DISPLACEMENTS
M 6.5 ASSEMBLY: CTM 6/2 - PB3
M 20 SET-UP FOR OPERATION
M 21 STARTING THE ENGINE
M 22 STOPPING THE ENGINE
M 31 CONTROLS
M 34 USE AS A WELDER
M 37 USE AS A GENERATOR
M 39.6 ENGINE PROTECTION
M 40.1 TROUBLE SHOOTING
M 43... MAINTENANCE
M 45 STORAGE
M 46 CUST OFF
M 53 DIMENSIONS
M 55 RECOMMENDED ELECTRODES
M 60 ELECTRICAL SYSTEM LEGEND
M 61-….. ELECTRICAL SYSTEM

R 1 SPARE PARTS TABLES

DR ... SPARE PARTS

04/11/02 27270-GB
 M
Copyright GE_, MS_, TS_, EAS 1.01
© MOSA 1.0-10/02

ATTENTION
This use and maintenance manual is an important
part of the machines in question.
The assistance and maintenance personel must
keep said manual at disposal, as well as that for
the engine and alternator (if the machine is
synchronous) and all other documentation about the
machine.

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
documentation are registered by the respective
owners.

➠ The reproduction and total or partial use, in any

form and/or with any means, of the
documentation is allowed to nobody without a
written permission by MOSA division of B.C.S.
S.p.A.
To this aim is 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
 M
Notes GE_, MS_, TS_, EAS_ 1-1
© MOSA 1.0-10/02

INFORMATION INFORMATION OF GENERAL TYPE

Dear Customer,
We wish to thank you for having bought from In the envelope given together with the machine
MOSA a high quality set. and/or set you will find: the manual for Use
Maintenance and Spare Parts, the manual for
Our sections for Technical Service and Spare use of the engine and the tools (if included in the
Parts will work at best to help you if it were equipment), the guarantee (in the countries where
necessary. it is prescribed by law).

To this purpose we advise you, for all control and Our products have been designed for the use of
overhaul operations, to turn to the nearest generation for welding, electric and hydraulic
authorized Service Centre, where you will obtain system; ANY OTHER DIFFERENT USE NOT
a prompt and specialized intervention. INCLUDED IN THE ONE INDICATED, relieves
MOSA from the risks which could happen or,
anyway, from that which was agreed when selling
☞ In case you do not profit on these Services and the machine; MOSA excludes any responsibility
some parts are replaced, please ask and be
sure that are used exclusively original MOSA for damages to the machine, to the things or to
parts; this to guarantee that the performances persons in this case.
and the initial safety prescribed by the norms in
force are re-established. Our products are made in conformity with the
safety norms in force, for which it is advisable to
☞ The use of non original spare parts will cancel use all these devices or information so that the
immediately any guarantee and Technical Ser- use does not bring damage to persons or things.
vice obligation from MOSA.
While working it is advisable to keep to the
NOTES ABOUT THE MANUAL personal safety norms in force in the countries to
Before actioning the machine please read this which the product is destined (clothing, work tools,
manual attentively. Follow the instructions etc.).
contained in it, in this way you will avoid
inconveniences due to negligence, mistakes or Do not modify for any motive parts of the machine
incorrect maintenance. The manual is for qualified (fastenings, holes, electric or mechanical devices,
personnel, who knows the rules: about safety and others..) if not duly authorized in writing by MOSA:
health, installation and use of sets movable as the responsibility coming from any potential
well as fixed. intervention will fall on the executioner as in fact
he becomes maker of the machine.
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 ☞ Notice: this manual does not engage MOSA,
is an integrant part of the product. It must be kept who keeps the faculty, apart the essential
with care during all the life of the product. characteristics of the model here described and
In case the machine and/or the set should be illustrated, to bring betterments and modifications
yielded to another user, this manual must also to parts and accessories, without putting this
given to him. manual uptodate immediately.
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

10/10/02 M 1-1 GB

contained in it want only to identify the described

parts and therefore might not correspond to the
machine in your possession.
 M
CE MARK 1.4
REV.5-03/11

Any of our product is labelled with CE marking attesting its conformity to appliable directives and
also the fulfillment of safety requirements of the product itself; the list of these directives is part
of the declaration of conformity included in any machine standard equipment.
Here below the adopted symbol:

CE marking is clearly readable and unerasable and it can be either part of the data-plate.

Furthermore, on each model it is shown the noise level value; the symbol used is the following:
10/10/02 M1-4 GB

The indication is shown in a clear, readable and indeleble way on a sticker.

 Dichiarazione conformità Konformitätserklärung M
Declaration of conformity Declaración de conformidad 1.4.1
REV.0-06/10 Déclaration de conformité

BCS S.p.A. Stabilimento di Cusago, 20090 (MI) - Italia

Sede legale: V.le Europa 59
Via Marradi 1 Tel.: +39 02 903521
20123 Milano - Italia Fax: +39 02 90390466

DICHIARAZIONE DI CONFORMITA'

Déclaration de Conformité – Declaration of Conformity – Konformitätserklärung

Conformiteitsverklaring – Declaración de Conformidad

BCS S.p.A. dichiara sotto la propria responsabilità che la macchina:

BCS S.p.A. déclare, sous sa propre responsabilité, que la machine:
BCS S.p.A. declares, under its own responsibility, that the machine:
BCS S.p.A. erklärt, daß die Aggregate:
BCS S.p.A. verklaard, onder haar eigen verantwoordelijkheid, dat de machine:
BCS S.p.A. declara bajo su responsabilidad que la máquina:

GRUPPO ELETTROGENO DI SALDATURA / WELDING GENERATOR

GRUPPO ELETTROGENO / POWER GENERATOR

Marchio / Brand : _MOSA_____________________________________________

Modello / Model : ______________________________________________

Matricola / Serial number : ______________________________

è conforme con quanto previsto dalle Direttive Comunitarie e relative modifiche:

est en conformité avec ce qui est prévu par les Directives Communautaires et relatives modifications:
conforms with the Community Directives and related modifications:
mit den Vorschriften der Gemeinschaft und deren Ergänzungen übereinstimmt:
in overeenkomst is met de inhoud van gemeenschapsrichtlijnemen gerelateerde modificaties:
comple con los requisítos de la Directiva Comunitaria y sus anexos:

2006/42/CE - 2006/95/CE - 2004/108/CE

Nome e indirizzo della persona autorizzata a costituire il fascicolo tecnico :

Nom et adresse de la personne autorisée à composer le Dossier Technique :
Person authorized to compile the technical file and address :
Name und Adresse der zur Ausfüllung der technischen Akten ermächtigten Person :
Persoon bevoegd om het technische document , en bedrijf gegevens in te vullen
Nombre y dirección de la persona autorizada a componer el expediente técnico :

ing. Benso Marelli - Amministratore Delegato / CEO; V.le Europa 59, 20090 Cusago (MI) - Italy

_______________
Cusago, Ing. Benso Marelli
Amministratore Delegato
04/06/10 M1.4.1

CEO

MM 083.0
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Technical data TS 200 DS-DES/CF 1.5
REV.1-02/11

Technical data TS 200 DS/CF TS 200 DES/CF

D.C. WELDING C.C.
Duty cycle 190A/35% - 160A/60% - 120A/100%
Welding current regulation (I scale) 20 - 100A
(II scale) 90 - 190A
Welding voltage 98V
Welding voltage 20-27V
GENERATOR
Three-phase generation 6 kVA / 400 V / 8.7 A
Single-phase generation 5 kVA / 230 V / 21.7 A
Single-phase generation 2.5 kVA / 110 V / 22.7 A
Single-phase generation 2 kVA / 48 V / 41.6 A
Frequency 50 Hz
Cos ϕ 0.8
ALTERNATOR Self-excited, self-regulated, brushless Self-excited, self-regulated
Type three-phase, asynchronous
Insulating class H
ENGINE
Mark / Model Yanmar / L 100 N
Type / Cooling system Diesel 4-Stroke / air
Cylinders / Displacement 1 / 435 cm3
Output 6.5 kW (8.8 HP)
Speed 3000 rpm
Fuel consumption (Welding 60%) 1 l/h
Engine oil capacity 1.6 l
Starter recoil electric
GENERAL SPECIFICATIONS
Tank capacity 5.5 l
Running time (Welding 60%) 5.5 h
Protection IP 23
*Dimensions Lxwxh (mm) 900x550x622
*Weight 130 Kg 131 Kg
**Acoustic power LwA (pressure LpA) 99 LWA (74 dB(A) - 7 m)
*Dimensions and weight are inclusive of all parts without wheels and towbar CTM. - ** For fixed installation only

POWER
Declared power according to ISO 3046-1 (temperature 25°C, 30% relative hummidity, altitude 100 m above sea level).
It’s admitted overload of 10% each hour every 12 h.
In an approximative way one reduces: of 1% every 100 m altitude and of 2.5% for every 5°C above 25°C.

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 limits
2000 / 14 / CE

according to 2000/14/CE directive.

 M
SYMBOLS AND SAFETY PRECAUTIONS GE_, MS_, TS_ 2
© MOSA 1.0-11/99

SYMBOLS IN THIS MANUAL SAFETY PRECAUTIONS

- The symbols used in this manual are designed to call ! DANGEROUS

your attention to important aspects of the operation of
the machine as well as potential hazards and dangers This heading warns of an immediate danger for persons
for persons and things. as well for things. Not following the advice can result in
serious injury or death.

IMPORTANT ADVICE
! WARNING
- Advice to the User about the safety:
This heading warns of situations which could result in
injury for persons or damage to things.
+ 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. ! CAUTION
Remember that the non observance of the indications
reported by us might cause damage to persons or To this advice can appear a danger for persons as well
things. It is understood, that local dispositions and/or as for things, for which can appear situations bringing
laws must be respected. material damage to things.

WARNING
! IMPORTANT
Situations of danger - no harm to persons
! or things ! NOTE
Do not use without protective devices provided
Removing or disabling protective devices on the ! ATTENTION
machine is prohibited.
These headings refer to information which will assis you
Do not use the machine if it is not in good technical in the correct use of the machine and/or accessories.
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.
26/11/99 M2GB
 M
SYMBOLS AND SAFETY PRECAUTIONS 2-1
© MOSA REV.2-06/10

SYMBOLS PROHIBITIONS No harm for persons

Use only with safety clothing -
STOP - Read absolutely and be duly attentive
It is compulsory to use the personal
protection means given in equip-
ment.

Read and pay due attention Use only with safety clothing -
It is compulsory to use the personal protection
means given in equipment.

Use only with safety protections -

GENERAL ADVICE - If the advice is not It is a must to use protection means suitable for
! respected damage can happen to persons or
things.
the different welding works.

Use with only safety material -

HIGH VOLTAGE - Attention High Voltage. It is prohibited to use water to quench fires on
There can be parts in voltage, dangerous the electric machines.
to touch. The non observance of the advice
implies life danger. Use only with non inserted voltage -
It is prohibited to make interventions before
having disinserted the voltage.
FIRE - Danger of flame or fire. If the advice is
not respected fires can happen. No smoking -
It is prohibited to smoke while filling the tank
HEAT - Hot surfaces. If the advice is not with fuel.
respected burns or damage to things can be
caused. No welding -
It is forbidden to weld in rooms containing
EXPLOSION - Explosive material or danger explosive gases.
of explosion. in general. If the advice is not
respected there can be explosions.
ADVICE No harm for persons and things
WATER - Danger of shortcircuit. If the advice
is not respected fires or damage to persons Use only with safety tools, adapted to the specific
can be caused. use -
It is advisable to use tools adapted to the various
maintenance works.
SMOKING - The cigarette can cause fire or
explosion. If the advice is not respected fires Use only with safety protections, specifically suitable
or explosions can be caused. It is advisable to use protections suitable for the
different welding works.
ACIDS - Danger of corrosion. If the advice is
not respected the acids can cause corrosions
with damage to persons or things. Use only with safety protections -
It is advisable to use protections suitable for
the different daily checking works.

WRENCH - Use of the tools. If the advice is Use only with safety protections -
not respected damage can be caused to things It is advisable to use all protections while
and even to persons. shifting the machine.

Use only with safety protections -

PRESSION - Danger of burns caused by the It is advisable to use protections suitable for
expulsion of hot liquids under pressure. the different daily checking works.and/or of
maintenance.
26/11/99 M2-1GB

ACCES FORBIDDEN to non authorizad peaple.

 M
INSTALLATION AND ADVICE BEFORE USE GE_, MS_, TS_ 2-5
© MOSA 1.0-06/00

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

Stop engine when fueling Do not touch electric devices

if you are barefoot or with wet
Do not smoke, avoid flames, sparks or electric tools when fueling. clothes.

CHECKING BOARD
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.
ENGINE

The vapor and the heated cooling liquid under pressure can burn face, eyes, skin. Static electricity can demage
Do not fill tank completely. the parts on the circuit.
Wipe up spilled fuel before starting engine.
An electric shock can kill
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

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

Skin contact Wash with water and soap

Eyes contact Irrigate with plenty of water, if the irritation persists contact a specialist
Ingestion 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

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

EXTINCTION MEANS
Appropriated Carbonate anhydride (or carbon dioxyde) powder, foam, nebulized water
Not to be used Avoid the use of water jets
Other indications Cover eventual shedding not on fire with foam or sand, use water jets to cool off the surfaces close to the fire
Particular protection Wear an autorespiratory mask when heavy smoke is present
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.

! WARNING ! CAUTION
DANGE-
ROUS
!

10/06/00 M2-5I

! THE MACHINE MUST NOT BE USED IN AREAS WITH EX-

WARNING PLOSIVE ATMOSPHERE
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PRECAUTION (ENGINE DRIVEN WELDER) GE_, MS_, TS_ 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
the vicinity.
The security measures must satisfy the rules and regulations for engine driven welders.
The information given below is in addition to the local security norms.

Estimate possible electromagnetic problems in the work area taking into account the following indications.
1. Telephonic wirings and/or of communication, check wirings and so on, in the immediate vicinity.
2. Radio and television receptors and transmettors.
3. Computer and other checking devices.
4. Critical devices for safety and/or for industrial checks.
5. Peapol who, for instance, use pace-maker, hearing-aid for deaf or something and else.
6. Devices used for rating and measuring.
7. The immunity of other devices in the operation area of the welder. Make sure that other used devices are
compatible. If it is the case, provide other additional measures of protection.
8. The daily duration of the welding time.

! WARNING

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

àDo not touch any bare wires, leads or contacts as they may be live and there is danger of electric shock
which can cause death or serious burns. The electrode and welding cables, etc. are live when the unit
is operating.
àDo not touch any electrical parts or the electrode while standing in water or with wet hands, feet or clothes.
àInsulate yourself from the work surface while welding. Use carpets or other insulating materials to avoid
physical contact with the work surface and the floor.
àAlways wear dry, insulating glovers, without holes, and body protection.
àDo not wind cables around the body.
àUse ear protections if the noise level is high.
àKeep flamable material away from the welding area.
àDo not weld on containers which contain flamable material.
àDo not weld near refuelling areas.
àDo not weld on easily flamable surfaces.
àDo not use the welder to defrost (thaw) pipes.
àRemove the electrode from the electrode holder, when not welding.
àAvoid inhaling fumes by providing a ventilation system or, if not possible, use an approved air breather.
àDo not work in closed areas where there is no fresh air flow.
30/03/00 M2-5GB

àProtect face and eyes (protective mask with suitable dark lens and side screens), ears and body (non-
flamable protective clothers).
 M
INSTALLATION AND ADVICE 2.6
© MOSA REV.1-06/07

INSTALLATION AND ADVICE BEFORE USE Check that the air gets changed completely and the hot
air sent out does not come back inside the set so as to
cause a dangerous increase of the temperature.
GASOLINE ENGINES
+ Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far from
the work area.

1,5
DIESEL ENGINES m

m
1,5
+ Use in open space, air swept or vent exhaust gases
far from the work area. 1,5
m

PUT
UICTO
TC AOR
DISS
SU
GHAA
EX

+ Make sure that the machine does not move during the
work: block it possibly with tools and/or devices made
to this purpose.

MOVES OF THE MACHINE

+ At any move check that the engine is off, that there are
no connections with cables which impede the moves.

PLACE OF THE MACHINE

! ATTENTION
For a safer use from the operator DO NOT
fit the machine in locations with high risk
of flood.
POSITION Please do not use the machine in weather
Place the machine on a level surface at a distance of at conditions which are beyond IP protection
least 1,5 m from buildings or other plants. shown both in the data plate and on page
named "technical data" in this same manual.

Maximum leaning of the machine (in case of dislevel)

26/11/99 M2-6GB
 Installazione e dimensioni Luftzirkulation und abmessungen M
Installation and dimensions Instalación y dimensiones TS 200 DS-DES/CF 2.7
REV.2-02/11 Installation et dimensions

04/11/02 27270-I
 M
UNPACKING 3
© MOSA REV.1-02/04

! NOTE
+ Be sure that the lifting devices are: correctly mounted,
adequate for the weight of the machine with it’s pack-
aging, and conforms to local rules and regulations.
When receiving the goods make sure that the product
has not suffered damage during the transport, that
there has not been rough handling or taking away of
parts contained inside the packing or in the set.
In case you find damages, rough handling or absence
of parts (envelopes, manuals, etc.), we advise you to
inform immediately our Technical Service.

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.

1 Take out of the envelope (A) the user’s manual (B).
A 2) Read: the user’s manual (B), the plates fixed on the
machine, the data plate.
B

2
30/03/00 M3GB
 M
TRANSPORT AND DISPLACEMENTS COVERED UNITS 4-1
© MOSA REV.1-06/10

! NOTE
Transportation must always take place with the engine off, electrical cables and starting battery disconnected and
fuel tank empty.
Be sure that the lifting devices are: correctly mounted, adequate for the weight of the machine with it’s packaging,
and conform to local rules and regulations.
Only authorized persons involved in the transport of the machine should be in the area of movement.

DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION.
IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE (model with
no CTM accessory).
If you did not keep to the instructions, you could damage the structure of the machine.

Weight max. per person: 35 kg

Total max. weight; 140 kg

15/01/01 M4GB
 CTM 6/6UK PB1 M
ASSEMBLY CTM 6/2 PB2 6
© MOSA 1.1-01/04 CTM 200 PB3

ATTENTION
The CTM accessory cannot be removed from the machine and used separately (actioned manually or
following vehicles) for the transport of loads or anyway for used different from the machine movements.

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

CTM 6/2

PB1
PB2
PB3

CTM 6/6UK

CTM 200

GE 7000 BS/GS CTM 200 C 145 mm

GE 6000 DS/GS CTM 6/2 A 310 mm
GE 6000 DES/GS CTM 6/6UK B 400 mm
21/05/03 M6GB

GE 7500 BS/GS CTM 200 C 205 mm

GE 6500 DS/GS CTM 6/2 A 400 mm
GE 6500 DES/GS CTM 6/6UK B 400 mm
 M
Set-up for operation (Engine diesel) Air cooled systems 20
© MOSA 1.1-09/05

BATTERY WITHOUT MAINTENANCE OIL BATH AIR FILTER

Connect the cable + (positive) Fill the air filter using the same engine oil up to the
to the pole + (positive) of the level indicated on the filter.
battery (after having   taken
away the protection), by FUEL
properly tightening the clamp.
Check the state of the battery
from the colour of the warning light which is in the ! ATTENTION
upper part.
Do not smoke or use open flames during
refuelling operations, in order to avoid
- Green colour: battery OK
explosions or fire hazards.
- Black colour: battery to be recharged
Fuel fumes are highly toxic; carry out
- White colour: battery to be replaced
operations outdoors only, or in a well-
DO NOT OPEN THE BATTERY. ventilated environment.
Avoid accidentally spilling fuel. Clean
LUBRICANT any eventual leaks before starting up
RECOMMENDED OIL motor.
MOSA recommends selecting AGIP engine oil.
Refer to the label on the motor for the recommended Refill the tank with good quality diesel fuel, such as
products. automobile type diesel fuel, for example.

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.

Please refer to the motor operating manual for the In rigid environmental temperature conditions, use
recommended viscosity. special winterized diesel fuels or specific additives
REFUELLING AND CONTROL: in order to avoid the formation of paraffin.
Carry out refuelling and controls with motor at level
position. GROUNDING CONNECTION
1. Remove the oil-fill tap (24)
2. Pour oil and replace the tap
The grounding connection to an earthed installation
3. Check the oil level using the dipstick (23); the oil is obligatory for all models equipped with a diffe-
level must be comprised between the minimum rential switch (circuit breaker). In these groups the
and maximum indicators. generator star point is generally connected to the
machine’s earthing; by employing the TN or TT di-
! ATTENTION stribution system, the differential switch guarantees
protection against indirect contacts.
It is dangerous to fill the motor with too much oil,
In the case of powering complex installations re-
as its combustion can provoke a sudden increase
quiring or employing additional electrical protection
in rotation speed.
devices, the coordination between the protection
devices must be verified.
For the grounding connection, use the terminal (12);
DRY AIR FILTER comply to local and/or current regulations in force
for electrical installations and safety.
16/07/03 M20-R-A-GB

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.
 M
Starting TS 200 DS-DES/CF 21
REV.0-11/02

check daily
7) push the decompression le-
ver down and release

! NOTE
Do not alter the primary conditions of regulation
and do not touch the sealed parts.
8) hold the starting handle firmly
MANUAL RECOIL VERSION

9) pull the rope hard and fast.

Pull it all the way out. Use two
hands if necessary.

1) Open the fuel cock

ELECTRIC STARTING VERSION
Effect the operations 1), 2) and 7) as reported in
the para Recoil starter.
OFF

Turn the starting key (Q1) completely

ON

2) turn the welding current START

clockwise, until the motor starts.

control knob (16T) to the
maximum (fully counter-
clockwise) Let the engine run for some minutes before drawing
the load.

+ In case of unsuccessful start-up, do not

insist for longer than 5 seconds. Wait 10
3) hold the starting handle pro- seconds before attempting another start-
perly up.

Emergency recoil start

Turn the starting key (Q1) in “ON” position and
repeat the process of recoil starting.
4) pull the starting handle slow-
ly...

! ATTENTION
If battery is not connected, disconnect voltage
5) ... until you feel resistance regulator to prevent damage.

! CAUTION
RUNNING IN
During the first 50 hours do not use the unit at
more than 60% of full load. Check the oil level
04/11/02 27270-GB

regularly.
6) then return it slowly
 M
Stopping the engine TS 200 DS-DES/CF 22
REV.0-11/02

+ Before stopping the engine it is compulsory to

stop the load:
- shut off any loads which are connected to the
unit auxiliary outputs;
- disconnect the electric protection device (D);
- stop welding

stopping the engine:

- Reduce the speed of the engine
turning the knob (16/T) on the MIN
position (counter clockwise) and let
it idle for about 3 minutes

- Turn off the engine turning the knob

(16/T) on the position STOP (comple-
tely counter clockwise).

Electric starting version

OFF
ON
Remove the key (Q1) turning it counter
clockwise, OFF position, then take it
START

out.

+ NB.: for safety reason the key must be kept by qualified

personel.

Shut the fuel cock.

04/11/02 27270-GB
 Comandi Bedienelemente M
Controls Mandos TS 200 DS-DES/CF 31
REV.1-04/07 Commandes

Pos. Descrizione Description Description Descripción

9 Presa di saldatura (+) Welding socket ( + ) Prise de soudage ( + ) Toma de soldadura ( + )
10 Presa di saldatura (-) Welding socket ( - ) Prise de soudage ( - ) Toma de soldadura ( - )
12 Presa di messa a terra Earth terminal Prise de mise à terre Toma de puesta a tierra
15 Presa di corrente in c.a. A.C. socket Prises de courant en c.a. Toma de corriente en c.a
16 Comando acceler./puls. marcia Accelerator lever Commande accélér./bouton marche Mando de acel./pulsador marcha
22 Filtro aria motore Engine air filter Filtre air moteur Filtro aire motor
26 Tappo serbatoio Fuel tank cap Bouchon - réservoir Tapón depósito
27 Silenziatore di scarico Muffler Silencieux d’échappement Silenciador de descarga
59B Protezione termica corrente aux Aux current thermal switch Protection thermique courant aux. Protección térmica corr. aux
D Interruttore differenziale (30mA) G.F.I. lnterrupteur différentiel Interruptor diferencial (30 mA)
L Spia luminosa corrente alternata A.C. output indicator Voyants tension alternative Indicadores luminosos c. alter.
N1 Spia carica batteria Battery charge warning light Voyant charge batterie Piloto carga bateria
O1 Spia lumin. press. olio/oil alert Oil press.warning light/oil alert Voyant lumin. press.huile / oil alert Indic.lum.pres. aceite/oil alert
04/11/02 27270-I

Q1 Chiave di avviamento Starter key Clé de démarrage Llave de arranque

S1 Batteria Battery Batterie Batería
T Regolatore corrente di saldatura Welding current regulator Régulateur courant soudage Regulador corr. de soldadura
Z2 Interruttore magnetotermico Thermal-magnetic circ.breaker lnterrupteur magnétothermique Interruptor magnetotérmico
 M
Use as a welder TS 200 DS-DES/CF 34
REV.0-11/02

This symbol (Norm EN 60974-1 security

standards for arc welders) signifies that the
welders can be used in areas with increa-
sed risk of electrical shock.

CONNECT WELDING CABLES

For direct current electrode positive, connect work

cable to negative (-) terminal and electrode holder
to positive (+) terminal. For direct current electrode
negative, reverse cable connections. Turn them
clockwise to lock them in position. Loose plugs will
result in poor welding and damage to both plug and
socket.

PUSH AND
TWIST

WELDING CURRENT REGULATION

Once the welding current range has

been chosen by attaching the elec-
trode holder lead to the correspon-
ding socket, the welding current is
adjusted by turning the knob on the
front panel. The knob regulates the
rpm of the engine.

! ATTENTION
To reduce the risk of electromagnetic interfe-
rence, keep the welding cable length short and
keep them on or near the ground. Ensure that
04/11/02 27270-GB

the machine is grounded. If possible, welding

operations should not be done near sensitive
electronic devices.
 M
Using the generator TS 200 DS-DES/CF 37
REV.0-11/02

In case of another intervention, verify that

! WARNING no faulty tools are connected, or replace
It is absolutely forbidden to connect the unit the G.F.I. switch with another of matching
to the public mains and/or another electrical specifications and/or contact the Service
power source . Department.
Areas for which access by non-authorized per-
sonnel is forbidden are: + Notes: verify the operation of the G.F.I. switch
- the control panel (at the front) - the endothermic at least once a month by pressing the TEST button.
motor discharge. The generator must be running and the differential
lever in the ON position.

ENGINE SPEED FOR CORRECT VOLTAGE AND CIRCUIT BREAKERS FOR SOCKETS
FREQUENCY If you overload the socket the circuit breaker will
Turn the welding current regulating knob fully automatically switch off the power.
clockwise to put the engine at its maximum rpm. If
the engine is not at full rpm the voltage and the fre- To reset the circuit breaker, disconnect the load,
quency of the auxiliary power will not be correct. At wait a few seconds for the circuit breaket to cool
no load the voltage can be 10% above nominal and down and then push the button. The button should
at full load the voltage can be 10% below nominal. stay depressed. If the circuit breaker button does
not stay in, let it cool down and try again. If it still
PLUGS AND CABLES will not stay in call the service.
Before connecting a load to the socket check that
the cables are in good condition and that the plug
is wired correctly. PUSH TO
RESET

POWER ON LIGHT
The light (L), located above each socket, lights up
when there is power available from the socket. ON OFF
+ If the warning light does not light, check that the
engine is at maximum rpm, that the GFI (ground ON OFF
fault interrupter) is inserted and that the circuit
breaker is functioning.
Before reconnecting the load check that the power
When drawing power from more than one socket at required is within the rating of the socket. A load
the same time, the power available is that indicated which is too large for the socket will cause the cir-
for each socket but the total cannot exceed the cuit breaker to intervene. If, after reconnecting the
maximum shown on the rating plate. load, the circuit breaker opens again, check the
connections, wires, etc. of the load to find the fault.

GROUND FAULT INTERRUPTOR SWITCH UNIT FITTED WITH THERMAL MAGNETIC BRE-
The high-sensitivity ground fault interruptor switch AKER
[G.F.I.] (30mA) (D), guarantees protection against
indirect contacts due to faulty ground currents . Turn on the thermal magnetic
When the G.F.I. switch picks up a faulty ground breaker (Z2) by pushing it to
current that is higher than 30mA, it intervenes by the ON position.
immediately cutting off tension to the AC sockets.
In case of intervention by this protection feature, The thermal-magnetic breaker is a safety device
reset the G.F.I. switch, bringing the lever to the which protects the circuìt in the event of a mal-
ON position. function. In this case the switch disconnects the
three and single-phase circuit when in any part of
the electric connections a short circuit or a current
04/11/02 27270-GB

absorption occurs above the data specified on the

label of the unit.
 M
Engine protection TS 200 DES/CF 39.6
REV.1-04/07 TS 200 DES/EL

The warning lamps brighten by turning the engine

starting key (Q1) and they switch off after some
seconds.

The engine protection, in case of low oil pressure, is

shown by the warning light (O1) without the engine
stopping.

The same as for as the battery charger warning (O1)

light in concerned, the anomaly is shown without
the engine stopping.

If the trouble should persist, please turn to your

Assistance Centre.

Once the cause of the problem is removed, to assu-

re the protection it is enough to put the starting key
(Q1) to zero (“OFF” position) and start the engine
again.

04/11/02 27270-GB
 M
TROUBLE SHOOTING TS 40.1
© MOSA 1.0-04/04

PROBLEM POSSIBLE CAUSE WHAT TO DO

No welding current but 1) Defective diode bridge 1) Check the diodes of the bridge
auxiliary output is OK 2) Problem with welding current control 2) Is the remote control switch in the
(PCB) 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 it
is OK replace the PCB

1) Defective diode bridge 1) Check the open circuit welding

voltage.
Weld poorly
If it is OK the diode bridge is OK. If it
is 1/3 or 2/3 of the nominal value
check the diodes or the SCR’s.
2) Problem with welding current control 2) If the diode bridge is OK replace the
(PCB) PCB.

1) Bad connections to welding current PCB 1) Check that the pins of the green
Intermittently welds poorly
connectors are clean and making good
contact.
Check that shunt connections are tight.

2) Problem with welding current control 2) Replace the welding current control
PCB PCB

No welding output and 1) Short circuit in wiring 1) Check the wiring inside the welder for
no auxiliary power a short circuit between cables or to
output ground.

2) Defective condenser 2) If the wiring is OK, short circuit the

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 stator.
4) Short circuited diode bridge
4) If there is output from all windings
reconnect the diode bridge and check
if there is welding current. If not the
diode bridge is defective. If there is
welding current connect the auxiliary
power leads one at a time until there
is no output; at this point, the short
circuit is in that line.
06/04/04 M40-1-I

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

 M
MAINTENANCE 43
© MOSA REV.0-06/10

! WARNING
Have qualified personnel do maintenance and troubleshooting work.
l Stop the engine before doing any work inside the machine. If for
any reason the machine must be operated while working inside, pay
attention moving parts, hot parts (exhaust manifold and muffler,
etc.) electrical parts which may be unprotected when the machine
is open.
l Remove guards only when necessary to perform maintenance,

and replace them when the maintenance requiring their removal is

complete.
MOVING l Use suitable tools and clothes. HOT surface
PARTS l Do not modify the components if not authorized. can
can injure - See pag. M1.1 - hurt you

NOTE maintenance intervals and specific checks for each

model: it is necessary to consult the specific engine or
By maintenance at care of the utilizer we intend all the alternator USER AND MAINTENANCE manual.
operatios concerning the verification of mechanical
parts, electrical parts and of the fluids subject to use or VENTILATION
consumption during the normal operation of the machine. Make certain there are no obstructions (rags, leaves or
other) in the air inlet and outlet openings on the machine,
For what concerns the fluids we must consider as main- alternator and motor.
tenance even the periodical change and or the refills
eventually necessary. ELECTRICAL PANELS
Check condition of cables and connections daily.
Maintenance operations also include machine cleaning Clean periodically using a vacuum cleaner, DO NOT USE
operations when carried out on a periodic basis outside COMPRESSED AIR.
of the normal work cycle.
DECALS AND LABELS
The repairs cannot be considered among the main- All warning and decals should be checked once a year
tenance activities, i.e. the replacement of parts subject and replaced if missing or unreadable.
to occasional damages and the replacement of electric
and mechanic components consumed in normal use, by STRENUOUS OPERATING CONDITIONS
the Assistance Authorized Center as well as by MOSA. Under extreme operating conditions (frequent stops
and starts, dusty environment, cold weather,extended
The replacement of tires (for machines equipped with periods of no load operation, fuel with over 0.5% sulphur
trolleys) must be considered as repair since it is not de- content) do maintenance more frequently.
livered as standard equipment any lifting system.
BATTERY WITHOUT MAINTENANCE
The periodic maintenance should be performed accor- DO NOT OPEN THE BATTERY
ding to the schedule shown in the engine manual. An
optional hour counter (M) is available to simplify the The battery is charged automatically from the battery
determination of the working hours. charger circuit suppplied with the engine.

! IMPORTANT Check the state of the battery from the colour of the
warning light which is in the upper part.
In the maintenance operations avoid that
polluting substances, liquids, exhausted oils, - Green colour: battery OK
etc. bring damage to people or things or can - Black colour: battery to be recharged
cause negative effects to surroindings, health - White colour: battery to be replaced
or safety respecting completely the laws and/
or dispositions in force in the place.

ENGINE and ALTERNATOR ! NOTE

THE ENGINE PROTECTION NOT WORK WHEN THE
05/09/05 M43GB

PLEASE REFER TO THE SPECIFIC MANUALS

PROVIDED. OIL IS OF LOW QUALITY BECAUSE NOT CHARGED
REGULARLY AT INTERVALS AS PRESCRIBED IN THE
Every engine and alternator manufacturer has OWNER’S ENGINE MANUAL.
 M
STORAGE 45
© MOSA REV.0-06/07

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

Start the engine: lt will run until it stops due to the lack
of fuel. ! IMPORTANT
Drain the oil from the engine sump and fill it with new oil In the storage operations avoid that
(see page M25). polluting substances, liquids, exhausted
oils, etc. bring damage to people or
Pour about 10 cc of oil into the spark plug hole and things or can cause negative effects to
screw the spark plug, after having rotated the crankshaft surroindings, health or safety respecting
several times. completely the laws and/or dispositions
in force in the place.
Rotate the crankshaft slowly until you feel a certain com-
pression, then leave it.

In case the battery, for the electric start, is assembled,

disconnect it.

Clean the covers and all the other parts of the machine
carefully.

Protect the machine with a plastic hood and store it in o

dry place.

DIESEL ENGINE

For short periods of time it is advisable, about every

10 days, to make the machine work with load for 15-30
minutes, for a correct distribution of the lubricant, to re-
charge the battery and to prevent any possible bloking
of the injection system.

For long periods of inactivity, turn to the after soles service

of the engine manufacturer.

Clean the covers and all the other parts of the machine
carefully.

Protect the machine with a plastic hood and store it in a

dry place.
04/06/07 M45GB
 M
CUST OFF 46
© MOSA REV.0-06/07

+ Have qualified personnel disassemble the In case of necessity for first aid and fire prevention,
machine and dispose of the parts, including the see page M2.5.
oil, fuel, etc., in a correct manner when it is to
be taken out of service.

! IMPORTANT
As cust off we intend all operations to be made, at In the cust-off operations avoid that
utilizer’s care, at the end of the use of the machine. polluting substances, liquids, exhausted
This comprises the dismantling of the machine, the oils, etc. bring damage to people or
subdivision of the several components for a further things or can cause negative effects to
reutilization or for getting rid of them, the eventual surroindings, health or safety respecting
packing and transportation of the eliminated parts completely the laws and/or dispositions
up to their delivery to the store, or to the bureau in force in the place.
encharged to the cust off or to the storage office, etc.

The several operations concerning the cust off, invol-

ve the manipulation of fluids potentially dangerous
such as: lubricating oil and battery electrolyte.

The dismantling of metallic parts liable to cause

injuries or wounds, must be made wearing heavy
gloves and using suitable tools.

The getting rid of the various components of the

machine must be made accordingly to rules in force
of law a/o local rules.
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.
04/06/07 M45GB
 M
RECOMMENDED ELECTRODES (In accordance with A.W.S Standard) MS_, TS_ 55
© MOSA 1.0-10/03

The information here below are to be intended only as indicative since the above norm is much larger.
For further details please see the specific norms and/or the manufacturers of the product to be used in the welding
process.

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/mm2 . 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/mm2. Weld in all position. volatile slag.

ELECTRODES IDENTIFICATION ACCORDING TO A.W.S. STANDARDS

E XX Y Z
2 digits: type of coating
and electric power
conditions.
(see table 3)
1 digits: welding
positions.
(see table 2)
N° Descrizione
2÷3 digits: tesile strenght of
the weld deposit. 10 Cellulose electrodes for d.c.
(see table 1) 11 Cellulose electrodes for a.c.
symbol for 12 Rutile electrode for d.c.
"Coated 13 Rutile electrode for a.c.
electrode" 14 High yield rutile electrodes
15 Basic electrodes for d.c.
Number Strenght 16 Basic electrodes for c.a.
K.s.l. Kg/mm2 18 High yield basic electrodes for d.c.
(inverse polarity)
60 60.000 42 20 Acid electrodes for flat or front position welding for
70 70.000 49
d.c. (- pole) and for a.c.
80 80.000 56
90 90.000 63 24 High yield rutile electrodes for flat or front plane
100 100.000 70 position welding for d.c. and a.c.
110 110.000 77 27 High yield acid electrodes for flat or front plane
120 120.000 84 position welding for d.c. (- pole) and a.c..
28 High yield basic electrodes for flat or front plane
Table 1 position welding for d.c. (inverse polarity)
30 Extra high yield acid electrodes, extra high
for all positions penetration if required, for flat position welding only
10/10/03 M55GB

1
2 for plane and verticl for d.c. (- pole) and a.c.
3 for plane posotion only
Table 2 Table 3
 M
ELECTRICAL SYSTEM LEGENDE 60
© MOSA REV.7-10/09

A : Alternator A3 : Insulation moitoring A6 : Commutator/switch

B : Wire connection unit B3 : E.A.S. connector B6 : Key switch, on/off
C : Capacitor C3 : E.A.S. PCB C6 : QEA control unit
D : G.F.I. D3 : Booster socket D6 : Connector, PAC
E : Welding PCB transformer E3 : Open circuit voltage switch E6 : Frequency rpm regulator
F : Fuse F3 : Stop push-button F6 : Arc-Force selector
G : 400V 3-phase socket G3 : Ignition coil G6 : Device starting motor
H : 230V 1phase socket H3 : Spark plug H6 : Fuel electro pump 12V c.c.
I : 110V 1-phase socket I3 : Range switch I6 : Start Local/Remote selector
L : Socket warning light L3 : Oil shut-down button L6 : Choke button
M : Hour-counter M3 : Battery charge diode M6 : Switch CC/CV
N : Voltmeter N3 : Relay N6 : Connector – wire feeder
P : Welding arc regulator O3 : Resistor O6 : 420V/110V 3-phase transformer
Q : 230V 3-phase socket P3 : Sparkler reactor P6 : Switch IDLE/RUN
R : Welding control PCB Q3 : Output power unit Q6 : Hz/V/A analogic instrument
S : Welding current ammeter R3 : Electric siren R6 : EMC filter
T : Welding current regulator S3 : E.P.4 engine protection S6 : Wire feeder supply switch
U : Current transformer T3 : Engine control PCB T6 : Wire feeder socket
V : Welding voltage voltmeter U3 : R.P.M. electronic regulator U6 : DSP chopper PCB
Z : Welding sockets V3 : PTO HI control PCB V6 : Power chopper supply PCB
X : Shunt Z3 : PTO HI 20 l/min push-button Z6 : Switch and leds PCB
W : D.C. inductor W3 : PTO HI 30 l/min push-button W6 : Hall sensor
Y : Welding diode bridge X3 : PTO HI reset push-button X6 : Water heather indicator
Y3 : PTO HI 20 l/min indicator Y6 : Battery charge indicator
A1 : Arc striking resistor
B1 : Arc striking circuit A4 : PTO HI 30 l/min indicator A7 : Transfer pump selector AUT-0-MAN
C1 : 110V D.C./48V D.C. diode bridge B4 : PTO HI reset indicator B7 : Fuel transfer pump
D1 : E.P.1 engine protection C4 : PTO HI 20 l/min solenoid valve C7 : "GECO" generating set test
E1 : Engine stop solenoid D4 : PTO HI 30 l/ min solenoid valve D7 : Flooting with level switches
F1 : Acceleration solenoid E4 : Hydraulic oil pressure switch E7 : Voltmeter regulator
G1 : Fuel level transmitter F4 : Hycraulic oil level gauge F7 : WELD/AUX switch
H1 : Oil or water thermostat G4 : Preheating glow plugs G7 : Reactor, 3-phase
I1 : 48V D.C. socket H4 : Preheating gearbox H7 : Switch disconnector
L1 : Oil pressure switch I4 : Preheating indicator I7 : Solenoid stop timer
M1 : Fuel warning light L4 : R.C. filter L7 : "VODIA" connector
N1 : Battery charge warning light M4 : Heater with thermostat M7 : "F" EDC4 connector
O1 : Oil pressure warning light N4 : Choke solenoid N7 : OFF-ON-DIAGN. selector
P1 : Fuse O4 : Step relay O7 : DIAGNOSTIC push-button
Q1 : Starter key P4 : Circuit breaker P7 : DIAGNOSTIC indicator
R1 : Starter motor Q4 : Battery charge sockets Q7 : Welding selector mode
S1 : Battery R4 : Sensor, cooling liquid temperature R7 : VRD load
T1 : Battery charge alternator S4 : Sensor, air filter clogging S7 : 230V 1-phase plug
U1 : Battery charge voltage regulator T4 : Warning light, air filter clogging T7 : V/Hz analogic instrument
V1 : Solenoid valve control PCBT U4 : Polarity inverter remote control U7 : Engine protection EP6
Z1 : Solenoid valve V4 : Polarity inverter switch V7 : G.F.I. relay supply switch
W1 : Remote control switch Z4 : Transformer 230/48V Z7 : Radio remote control receiver
X1 : Remote control and/or wire feeder socket W4 : Diode bridge, polarity change W7 : Radio remote control trasnsmitter
Y1 : Remote control plug X4 : Base current diode bridge X7 : Isometer test push-button
Y4 : PCB control unit, polarity inverter Y7 : Remote start socket
A2 : Remote control welding regulator
B2 : E.P.2 engine protection A5 : Base current switch A8 : Transfer fuel pump control
C2 : Fuel level gauge B5 : Auxiliary push-button ON/OFF B8 : Ammeter selector switch
D2 : Ammeter C5 : Accelerator electronic control C8 : 400V/230V/115V commutator
E2 : Frequency meter D5 : Actuator D8 : 50/60 Hz switch
F2 : Battery charge trasformer E5 : Pick-up E8 : Cold start advance with temp. switch
G2 : Battery charge PCB F5 : Warning light, high temperature F8 : START/STOP switch
H2 : Voltage selector switch G5 : Commutator auxiliary power G8 : Polarity inverter two way switch
I2 : 48V a.c. socket H5 : 24V diode bridge H8 : Engine protection EP7
L2 : Thermal relay I5 : Y/s commutator I8 : AUTOIDLE switch
M2 : Contactor L5 : Emergency stop button L8 : AUTOIDLE PCB
N2 : G.F.I. and circuit breaker M5 : Engine protection EP5 M8 : A4E2 ECM engine PCB
O2 : 42V EEC socket N5 : Pre-heat push-button N8 : Remote emergency stop connector
P2 : G.F.I. resistor O5 : Accelerator solenoid PCB O8 : V/A digital instruments and led VRD PCB
Q2 : T.E.P. engine protection P5 : Oil pressure switch P8 : Water in fuel
R2 : Solenoid control PCBT Q5 : Water temperature switch Q8 : Battery disconnect switch
S2 : Oil level transmitter R5 : Water heater R8 : Inverter
T2 : Engine stop push-button T.C.1 S5 : Engine connector 24 poles S8 : Overload led
U2 : Engine start push-buttonT.C.1 T5 : Electronic GFI relais T8 : Main IT/TN selector
V2 : 24V c.a. socket U5 : Release coil, circuit breaker U8 : NATO socket 12V
Z2 : Thermal magnetic circuit breaker V5 : Oil pressure indicator V8 : Diesel pressure switch
W2 : S.C.R. protection unit Z5 : Water temperature indicator Z8 : Remote control PCB
26/07/04 M60GB

X2 : Remote control socket W5 : Battery voltmeter W8 : Pressure turbo protection

Y2 : Remote control plug X5 : Contactor, polarity change X8 :
Y5 : Commutator/switch, series/parallel Y8 :
 Schema elettrico Stromlaufplan M
Electric diagram Esquema eléctrique TS 200 DES/CF 61.1
REV.0-11/02 Schemas electriques

04/11/02 27270-I
 REV.1-04/07

A
T1
S1 C
R1
Electric diagram
Schema elettrico

Id
T1
Schemas electriques

Id
S1

Id
R1

Id
Y

N
N
S2
T2
RS
SS
TS
R4
Stromlaufplan

P4
Esquema eléctrique

R3 20A
S3
T3
L L L
R4 SS

48V/32A 400V/16A 230V/16A

O2 G H
TS 200 BS/CF

A Sostituito alternatore (A) con nuovo avvolgimento senza carica batteria. 16.11.2006 N.L.
Esp. Modifica Data Dis. Appr.
Exp. Modification Date Desi. Appr.
TS 200 DS-DES/CF

Da Pag. Denominazione: Progetto: Pag.n° di n°

From Page Denomination: Project: Page n° of n°
Aux. (400T/230M/48M) DT 27272.prg 3 4
Alla Pag. Macchina: Disegnatore: Data: Dis. n°: Approvato:
20090-CUSAGO (MI)-ITALY To Page Machine: Designer: Date: Dwg. n°: Approved:
M

http://www.mosa.it TS 200 DES/CF Leporace N. 01.08.2000 27272.S.020-A

61.2

La MOSA si riserva a termini di legge la proprieta' del presente disegno con divieto di riprodurlo o comunicarlo a terzi senza sua autorizzazione.
04/11/02 27270-I
 REV.0-11/02

A
T1
L2 S1 C
R1

T1
S1 D

Id
R1
Electric diagram

Id
Y
Schema elettrico

Z2
Schemas electriques

20A
S2
T2
Z2
RS 20A
SS
TS
R4
Stromlaufplan

R3 L L L
S3
Esquema eléctrique

T3

110V/16A 110V/16A 230V/16A

I I H

A Sostituito alternatore (A) con nuovo avvolgimento senza carica batteria. 16.11.2006 N.L.
Esp. Modifica Data Dis. Appr.
Exp. Modification Date Desi. Appr.
TS 200 DS-DES/CF

Da Pag. Denominazione: Progetto: Pag.n° di n°

From Page Denomination: Project: Page n° of n°
Aux. (230M/110CTEx2) DM 27273.prg 3 4
Alla Pag. Macchina: Disegnatore: Data: Dis. n°: Approvato:
20090-CUSAGO (MI)-ITALY To Page Machine: Designer: Date: Dwg. n°: Approved:
M
61.3

http://www.mosa.it TS 200 DES/CF Leporace N. 01.08.2000 27273.S.020-A

La MOSA si riserva a termini di legge la proprieta' del presente disegno con divieto di riprodurlo o comunicarlo a terzi senza sua autorizzazione.
04/11/02 27270-I
 REV.0-11/02

Z
Y
1
+ +
A
190A
RS
SS
TS
Electric diagram
Schema elettrico

- 2
Schemas electriques

11 12
+ +
O3 100A
R3
R3
S3
Stromlaufplan

S3
T3
T3
Esquema eléctrique

P3

- -
W W
TS 200 BS/CF

Esp. Modifica Data Dis. Appr.

Exp. Modification Date Desi. Appr.
TS 200 DS-DES/CF

Da Pag. Denominazione: Progetto: Pag.n° di n°

From Page Denomination: Project: Page n° of n°

Welding Power 27272.prg 4 4

Alla Pag. Macchina: Disegnatore: Data: Dis. n°: Approvato:
To Page Machine: Designer: Date: Drwg. n°: Approved:
20090-CUSAGO (MI)-ITALY
M
61.4

http://www.mosa.it TS 200 DES/CF Leporace N. 01/08/2000 27272.S.030

La MOSA si riserva a termini di legge la proprieta' del presente disegno con divieto di riprodurlo o comunicarlo a terzi senza sua autorizzazione
04/11/02 27270-I
 R
SPARE PARTS LIST 1
© 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, always
ask for genuine parts only.

 The requested data are to be found on the data

plate located on the machine structure, quite visible
and easy to consult. Y
When ordering the spare parts, it is recom-
mended to indicate:
V.le Europa,59 - 20090 CUSAGO (MI) ITALY
Tel. +39-02 90352.1 - fax +39-02 90390466
1) Y serial number
TYPE TS 0000 GE
2) Y model of welder and/or generating set SERIAL N° 0987654321

3) u n. table

4) u n. position

5) quantity

EA
TAVOLA RICAMBI - SPARE PARTS - PIECES DE RECHANGE - ERSATZTEILE 1

3 4
50 Hz
50 Hz

EA
1-3 13 18 17 16 20-21-22 12
1 EA
1
12

12
11
0
RS V Hz A
500 65 25 125
60
ST 300 20
h 55 15
HOURMETER TR 200 50 10
0
100

2 OFF
ON

START 0

8 *

19

15

NEUTROCOLLEGATOAMASSA
NEUTROCONECTADOAMASA
NEUTRALBONDEDTOFRAME
21-22-23
NEUTRERACCORDEAUBATI
NULLEITERAUFMASSE
NULVERBONDENMETMASSA
14

* VE
14/12/986Q16M31

4-5-6 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.
22/03/00 R1GB

(QM) When ordering, specify the length in meters

(VS) Special version only
(SR) By request only
 Ricambi Ersatzteile DR
Spare parts Tabla de ricambios TS 200 DS-DES/CF 1
REV.1-04/07 Piéces de rechange

04/11/02 27270-I
 Ricambi Ersatzteile DR
Spare parts Tabla de ricambios TS 200 DS-DES/CF 1.1
REV.2-02/11 Piéces de rechange
Pos. Cod. Descr. Note
1 M272702200 MOTORE YANMAR L100AE-DG / YANMAR ENGINE L100AE-DG Fino a/Up to REV.1-04/07 Del. 12/09 - 17/02/09
1 M256752200 MOTORE YANMAR L100N / YANMAR ENGINE L100N Da/From REV.2-02/11 Del. 12/09 - 17/02/09
1a M272722200 MOTORE YANMAR L100AE-DEG / YANMAR ENGINE L100AE-DEG Fino a /Up to REV.0-11/02 Del. 202/06 - 20/11/06
1a M256862200 MOTORE YANMAR L100AE-DEG / YANMAR ENGINE L100AE-DEG Da/From REV.1-04/07 Del. 202/06 - 20/11/06
Fino a/Up to REV.1-04/07 Del. 285 - 11/01/08
1a M256762200 MOTORE YANMAR L100N / YANMAR ENGINE L100N Da/From REV.2-02/11 Del. 285/07 - 11/01/08
2 M272701050 BARELLA / PROTECTIVE FRAME
5 M272708005 CARENATURA / FRAME
6 M272708205 SCATOLA DI BASE / CASE, BOTTOM HALF
7 M102044400 PRESA DI SALDATURA (-) / WELDING SOCKET (-)
8 M102301310 PRESA DI SALDATURA (+) / WELDING SOCKET (+)
9 M272708235 GRIGLIA DI ASPIRAZIONE / NTAKE GRATE
11 M272707015 COPERCHIO SCATOLA ELETTRICA / COVER ELECTRICAL BOX
12 M1302220 SPIA 220V / WARNING LIGHT 230V Fino a/Up to REV.1-04/07 Del.52/08 - 03/03/08
12 M1302530 SPIA 220V / WARNING LIGHT 220V Da/From REV.2-02/11 Del. 52/08 -03/03/08
12b M1302160 SPIA 110V / WARNING LIGHT 110V Fino a/Up to REV.1-04/07 Del.52/08 - 03/03/08
12b M1302520 SPIA 110V / WARNING LIGHT110V Da/From REV.2-02/11 Del.52/08 - 03/03/08
13 M307047250 PRESA 110V 16A / EEC SOCKET 110V 16A 2 P+N
13a M218137280 PRESA CEE 48V 32A / EEC SOCKET 48V 32A
14 M306467107 PROTEZIONE TERMICA (AUX) / THERMOPROTECTION 20AMP 250 V
15 M307017240 PRESA 220V 16A / EEC SOCKET 16A, 220V 2P+T
16 M305907270 PRESA CEE 16A 400V 3P+N+T / EEC SOCKET 16A 400V 3P+N+T
17 M219937130 COPERCHIO INTERRUT.DIFFERENZ. / COVER GFI
18 M219937036 STAFFA / BRACKET
19a M105111540 INTERRUTTORE DIFFERENZIALE / GROUNDFAULT INTERRUPTOR (GFI) vers. 400/230/48
19b M220237105 INTERRUTTORE DIFFERENZIALE / GROUNDFAULT INTERRUPTOR vers. 230/110/110
19c M105277325 INTERRUTTORE MAGNETOTERMICO / CIRCUIT BREACKER vers. 230/110/110
20 M309049105 COMANDO ACCELERATORE MOTORE / ENGINE ACCELLERATOR CONTROL era/was 272709105
21 M307017037 STAFFA / BRACKET
22 M307809880 BOX CONDENSATORI 3x80 UF / CAPACITOR BOX 3X80 UF
23 M218017226 MORSETTIERA / TERMINAL BOARD
42 M109019702 MANOPOLA / HAND GRIP
43 M272707010 SCATOLA ELETTRICA / ELECTRICAL BOX
44 M272707020 PANNELLO FRONTALE / FRONT PANEL vers. 400/230/48
45 M272717020 PANNELLO FRONTALE / FRONT PANEL vers. 230/110/110
50 M107302460 INTERRUTTORE ACCENS. A CHIAVE / STARTER KEY Da/From REV.1-04/07 Del. 202/06 - 20/11/06
51 M1302040 SPIA 12V ROSSA / RED WARNING LIGHT 12V Da/ From REV.1-04/07 Del. 202/06 - 20/11/06
Fino a/Up to REV.1-04/07 Del. 52/08 - 03/03/08
51 M1302500 SPIA 12V ROSSA / RED WARNING LIGHT 12V Da/ From REV.2-02/11 Del. 52/08 - 03/03/08



04/11/02 27270-I
 Ricambi Ersatzteile DR
Spare parts Tabla de ricambios TS 200 DS-DES/CF 2
REV.1-04/07 Piéces de rechange

04/11/02 27270-I
 Ricambi Ersatzteile DR
Spare parts Tabla de ricambios TS 200 DS-DES/CF 2.1
REV.3-02/11 Piéces de rechange
Pos. Rev. Cod. Descr. Note
3 M307012037 PROTEZIONE ANTIVIBRANTE
4 B M222401035 ANTIVIBRANTE era 256011035
25 M272705100 PONTE DIODI
26 M272704120 REATTORE TRIFASE
27 M272704100 REATTORE DI LIVELLO
28 M271704020 SUPPORTO
29 M271704010 RESISTORE
30 M220014100 REATTORE COMPLETO
31 M232123040 FLANGIA ATTACCO MOTORE
32 M272703025 STATORE AVVOLTO Fino a REV.1-11/06 Del. 202/06 - 20/11/06
32 M272723025 STATORE AVVOLTO Da REV.2-04/07 Del. 202/06 - 20/11/06
33 M232123030 ALBERO CON ROTORE
34 M107011280 TIRANTE
35 M105913045 FLANGIA PORTA ALTERNATORE
36 M232123036 TIRANTE
37 M1001030 CUSCINETTO
38 M105111290 VENTOLA CON FASCETTA
39 M105311370 DISTANZIALE
40 B M272506010 CONVOGLIATORE ARIA era 271706010
41 M105112020 ANTIVIBRANTE
47 M105311380 RONDELLA Fino a REV.0-10/98 Del. 91/06 - 07/06/06 07/06/06
47 M356403038 RONDELLADa REV.1-11/06 Del. 91/06 del
50 M107302460 STARTER A CHIAVE vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
51 M1302040 SPIA 12V vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
52 M256027060 PANNELLO vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
53 M155307107 DISGIUNTORE TERMICO vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
54 M256022275 REGOLATORE DI TENSIONE vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
55 M256027059 SCATOLA SUPPORTO REGOLATORE vers.DES-Fino a REV.1-11/06 Del. 202/06 - 20/11/06
60 B M107815043 BOCCOLA ISOLANTE
61 B M107814013 RONDELLA ISOLANTE
Pos. Rev. Cod. Descr. Note
3 M307012037 PROTECTION, VIBRATION-DAMPER
4 B M222401035 VIBRATION DAMPER was 256011035
25 M272705100 DIODE BRIDGE ASSY
26 M272704120 REACTOR
27 M272704100 LEVEL REACTOR
28 M271704020 SUPPORT
29 M271704010 RESISTOR
30 M220014100 COMPLETE REACTOR
31 M232123040 FLANGE FIXING ENGINE
32 M272703025 STATOR Up to REV.1-11/06 Del. 202/06 - 20/11/06
32 M272723025 STATOR From REV.2-04/07 Del. 202/06 - 20/11/06
33 M232123030 SHAFT WITH ROTOR
34 M107011280 TIE - ROD
35 M105913045 FLANGE, ALTERNATOR HOLDER
36 M232123036 TIE-ROD
37 M1001030 BEARING
38 M105111290 FAN
39 M105311370 SPACER
40 B M272506010 AIR DUCT was 271706010
41 M105112020 VIBRATION DAMPER
47 M105311380 WASHER Up to REV.0-10/98 Del. 91/06 - 07/06/06
47 M356403038 WASHER From REV.1-11/06 Del. 91/06 - 07/06/06
50 M107302460 STARTER KEY vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06
51 M1302040 RED WARNING LIGHT 12V vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06
52 M256027060 PANEL vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06
53 M155307107 THERMAL SWITCH 15A-250V vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06
54 M256022275 VOLTAGE REGULATOR
04/11/02 27270-I

vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06

55 M256027059 BOX, SUPPORT REGULATOR vers.DES-Up to REV.1-11/06 Del. 202/06 - 20/11/06
60 B M107815043 BUSH
61 B M107814013 WASHER
 CTM 6/2 KA
212029080 3
© MOSA REV.1-10/05

Pos. Rev. Cod. Descr. Descr. Note

1 107012150 CAVALLOTTO U-BOLT
2 107012130 MANIGLIA HANDLE
7 205311160 ASSALE AXLE
8 205311180 RONDELLA WASHER
9 6075020 COPIGLIA PIN, SPLIT
10 105311650 RUOTA WHEEL

CTM 200 KA
232120130 4

Pos. Rev. Cod. Descr. Descr. Note

1 107012150 CAVALLOTTO U-BOLT
2a 208101051 MANIGLIA HANDLE
7 205311160 ASSALE AXLE
8 205311180 RONDELLA WASHER
9 6075020 COPIGLIA PIN, SPLIT
10 105311650 RUOTA WHEEL

PB3 KG
256020040 3

Pos. Cod. Descr. Descr. Note

12 256020549 GR.COPERCHIO COMPLETO COMPLETE COVER
13 256029168 CESTELLO PORTA BATTERIA BATTERY HOLDER
21/04/97 KA

14 256029160 CESTELLO P/BATT.+COPERCHIO BATTERY HOLDER WITH COVER

15 209509150 BATTERIA BATTERY (fino a/up to REV.0 04/97 Del. 74/05 del 15/07/05)

15 372859150 BATTERIA BATTERY (da/from REV.1 10/05 Del. 74/05 del 15/07/05)
 MOSA div. della BCS S.p.A.
Stabilimento di Viale Europa, 59
20090 Cusago (MI) Italia

Tel. + 39 - 0290352.1
Fax + 39 - 0290390466