Mase MW 170 HB-RE User manual

MULTIWORK
MW 170 HB-RE
230V 3~
REV.0MC.15-01-02 cod.42056
masemase masemase
mase
GENERATORS
MANUALEDIUSOEMANUTENZIONE
USEANDMAINTENANCEMANUAL
GEBRAUCHSANWEISUNGUNDWARTUNGSVORSCHRIFTEN
MANUAL USO Y MANTENIMIENTO
MANUELD’INSTRUCTIONSETD’ENTRETIEN
KÄYTTÖ-JAHUOLTO-OPAS
I
GB
F
E
D
FIN

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NR.000000 MASE GENERATORS S.p.A.
Tel.[phone]
Fax [phone]
DICHIARAZIONECEDICONFORMITA'
ECDECLARATIONOFCONFORMITY
Fabbricante/Manufacturer:MASEGENERATORS S.p.A.
Indirizzo /Address : ViaTortona 345, Pievesestina (FC)
Il sottoscritto Luigi Foresti in qualità di direttore tecnico della MASE GENERATORS S.p.A., dichiara sotto la
propria responsabilità che il gruppo elettrogeno modello .................... :
The undersigned Luigi Foresti as MASE GENERATORS S.p.A. technical manager declares, under his sole
responsability, that the generator model................:
Codice/Code Descrizione/Model No. matricola / Serial No.
E'conformealledisposizionidelleDirettivediseguitoelencate:
CEE89/392(comeemendatadelle Direttive CEE 91/368 e CEE 93/44)
CEE89/336(comeemendata delle Direttive CEE92/31)
CEE 73/23 modificata da CEE 93/68.
Correspondstotherequirements of the following EEC Directives:
89/392/EEC(asamendedby the Directive 91/368/EECand93/44/EEC)
89/336/EEC(asamendedbythe Directive 92/31/EEC )
73/23//EECasamendedby93/68/EEC.
Cesena, / / ......................................................
DirettoreTecnico
TechnicalDirector
MASE GENERATORS S.p.A.Sede legale ed Amm.: 47023 CESENA (FC) ITALY - Via Tortona, 345 - C.F./P.I. 00687150409 Cap. Soc. milioni 1250
interamente versato - Registro Società Tribunale Forl' n. 6818 - CCIAA Forl' n.164063 - c.c.p. n. 11541471 - EXPORT FO n. 006368
Fig.1

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Fig.2
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7
8
9
7
21
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8
6
5
4
3
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11 9
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SERIAL No.
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Fig.3
1
2 3
4
5
11
G
M
10 A
C
E
D
B
6 7 8 H
9
FL
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Fig.5
2
1
Fig.4
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3
1
Fig.6
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1
0.7 - 0.8
Fig.9
Fig.7
S.A.E
Service
Grade
-30 -20 -10 0 10 20 30 40
Ambient temperature (oC)
40
20W
20W40
20
30
5W
5W30
10W
10W30
MAX
MIN Fig.8

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Fig.10
CODE 45225
µ3x80 F +
-
1
3

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INDEX
1 GENERALINFORMATION......................................................................................18
1.1 Purposeandfieldofapplication of the manual .........................................................18
1.2 Symbols .................................................................................................................18
1.3 Referencedocuments .............................................................................................19
1.4 FacsimileofCEdeclarationofconformity................................................................19
1.5 Referenceregulationsandlegislativeprovisions ......................................................19
1.6 Marking...................................................................................................................19
1.7 Machine identification..............................................................................................19
1.8 Configurations ......................................................................................................... 19
1.9 Composition of the motor welding sets ....................................................................20
1.10 Instrumentpanel ..................................................................................................... 20
2 TECHNICALCHARACTERISTICS.......................................................................... 20
2.1 General characteristics ...........................................................................................20
2.2 Weldinggraph......................................................................................................... 20
2.3 Tables of technical characteristics...........................................................................20
3 SAFETYREGULATIONS ........................................................................................ 21
3.1 Generalprecautions ................................................................................................21
3.2 Prescriptions for safetyduring installation and setup ...............................................21
3.3 Connectingthemotorweldingsettoearth ..............................................................21
4 USING THE MOTOR WELDING SET .....................................................................22
4.1 Positioning .............................................................................................................. 22
4.2 Preliminary checks .................................................................................................22
4.3 Refuelling ................................................................................................................22
4.4 Startingthe engine ..................................................................................................22
4.5 UseasACgenerator...............................................................................................23
4.6 Use aswelder .........................................................................................................23
4.7 Usingtheremotecontrol(optional)..........................................................................23
4.8 Stopping..................................................................................................................23
5 PROTECTIONSAND WARNING SIGNALS............................................................24
6 MAINTENANCE ...................................................................................................... 24
6.1 Preamble ................................................................................................................24
6.2 Ordinaryenginemaintenance..................................................................................24
6.3 Engine oilchange ...................................................................................................24
6.4 Spark plug maintenance..........................................................................................24
6.5 Airfiltercartridgecleaning/replacement ...................................................................24
6.6 Scheduled maintenance table .................................................................................25
6.7 Troubleshooting.......................................................................................................25
7 TRANSPORTAND HANDLING ..............................................................................26
8 STORAGE .............................................................................................................. 26
9 SCRAPPING .......................................................................................................... 26
10 WIRING DIAGRAM ................................................................................................26

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1 GENERALINFORMATION
Carefully consult this manual before proceeding with any operation on the generator.
1.1 Purpose and field of application of the manual
Thank you for choosinga MASE product.
Thismanualhasbeendrawnupbythemanufacturerwiththepurposeofprovidingessentialinformationandinstructions
forproperuseandmaintenanceinconditionsofsafetyandconstitutesanintegralpartofthegeneratorequipment.The
manualmust bekeptsafely,protectedfrom anyagentwhichmightdamage it,for theentirelifeofthe generatorand
mustaccompanythegeneratoriftransferredtoanotheruserorowner.
Theinformationcontainedinthemanualisaddressedto all those persons involved in the operating life cycle of the
generator, and is necessary to inform both those who effectively carry out the different operations and those who
coordinatetheactivities,arrangethenecessarylogisticsandregulateaccesstotheplacewherethegeneratorwillbe
installedandoperated.
Themanualdefinesthepurposeforwhichthegeneratorwasconstructedandcontainsalltheinformationnecessary
toguaranteesafeandproperuse.
Constant observance of the instructions contained in this manual guarantees the safety of the operator, operating
economyand alongerlifeofthegenerator.
Itiswarmlyrecommendedto carefullyreadthecontentsofthismanualandthereferencedocuments;onlythuscan
regularfunctioningandreliabilityofthegeneratorbeguaranteedovertime,andprotectionagainstdamagetopersons
or things.
Thedrawingsareprovidedbywayofexample.Evenifthegeneratorinyourpossessiondiffersconsiderablyfromthe
illustrations contained in this manual, the safety of the generator and the information provided are nevertheless
guaranteed.
Tofacilitateconsultation,ithasbeendividedintosectionsidentifyingthemainconcepts;foraquicklookatthetopics,
consult the index.
Note: the information contained in this publication is correct at the time of printing. The manufacturer in his pursuit
ofapolicyofconstantdevelopmentandupgradingoftheproductreservestherighttomakemodificationswithoutprior
notice.
1.2 Symbols
Thosepartsofthetextnottobeignoredarehighlightedinboldtypeprecededbyasymbol,asillustratedanddefined
below.
Indicatesthatparticularattentionmustbepaidinordertopreventrunningintoseriousdangerwhich
could lead to death or possible hazards to the health of personnel.
A condition which may occur during the lifetime of a product, system or plant considered at risk
regardingdamagetopersons,property,theenvironmentoreconomicloss.
Indicatesthat particularattentionmust bepaidinorderto preventseriousconsequences which
could result in damage to tangible goods, such as the resources or the product.
Instructions of particular importance.
FAILURETORESPECTTHESPECIFICATIONSCONTAINEDINTHISUSEANDMAINTENANCE
MANUALWILLRESULTINFORFEITUREOFTHEGUARANTEEONTHEPRODUCT

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1.3 Reference documents
Theinstructionsforuseprovidedwitheachmotorwelding
setaremadeupofacollectionofdocumentsofwhichthis
manual represents the General Part. Normally, the fol-
lowingdocumentsareprovided:
a - CE declaration of conformity.
b - Instruction manual for use of the motor welding set
(thismanual)
c - Wiring diagrams of the control panels and power
board.
d-Engine useandmaintenancemanual
e - Warranty card
f - List of Mase Service Centres
1.4 Facsimile of CE declaration of conformity
The generators constructed by MASE, intended for
countriesintheEuropeanCommunity,areinconformity
with the applicable EEC Directives (see 1.5) and are
furnishedwithanEC declaration of conformity (Fig. 1).
1.5 Reference regulations and legislative provi-
sions
AlltheMASEdieselgeneratorsaredesignedandmanu-
factured in compliance with the legislation in force.
The generator and its components are constructed in
accordancewiththefollowingapplicableregulationsand
directives:
EN292-1/2:Machinesafetyregulations.
Generaldesignprinciples.
EN294:Machinesafetyregulations.
Safetydistances to prevent contact of dangerous parts
with the upper limbs.
ISO3046:Alternateinternal-combustionengines.
IEC 34-1: Rotary electric machines.
ISO8528-1:Alternatecurrentgeneratorsdrivenbyalter-
nateinternal-combustionengines.
EN60204-1(CEI44-5):
- Machinesafety.
- Electricalequipment of machines.
EN 60439-1 (CEI 17-13/1): Assembled protection and
manoeuvringequipmentforlowvoltage(low-voltagepan-
els).
EN50081-1/2(Electromagneticcompatibility):General
regulationonemission
– Part 1: Residential, commercial and light-industry
environments.
-Part2:Industrialenvironment.
EN50082-1/2(Electromagneticcompatibility):General
regulationonimmunity.
- Part 1: Residential, commercial and light-industry
environments.
- Part2:Industrialenvironment.
89/392/EECandsubsequentamendmentscontainedin
theDirectives91/368/EEC,93/44/EECand93/68/EEC:
Essential machine requirements for safety and health
protection(“Machine”directive).
73/23/EEC and subsequent amendments contained in
theDirective93/68/EEC:Guaranteeofsafetyofelectrical
material intended for use within certain voltage limits
(“LowVoltage”directives).
1.6 Marking
Thegeneratoridentificationplatecarriesalltheidentifica-
tiondatainconformitywithISO8528andinaccordance
withtheprovisionsforCEmarkingforthosecaseswhere
required. Below is a facsimile of the identification plate
fixedonthecontrol panelof eachgenerator (Fig.2)
1.7 Machine identification
See Fig.2
1 – Manufacturer
2 – Machine code
3 – Year of construction
4 – Power during welding
5 – Power factor
6 – Declared frequency
7 – Continuous power
8 – Nominal tension
9 – Nominal current
10 – Weight
11–Performancerating
12–Serialnumber
Themachine codenumber,theserialnumber andthe
year of construction must always be quoted when
contactingthemanufacturerforinformation,requests
for spare parts, etc.
1.8 Configurations
Oneofthecharacteristicsofthe Multiwork series is that
itcan be supplied in different configurations:
-without trailer (Fig.2)
- on trailer with handles

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1.9 Composition of the motor welding sets
See Fig.2
The motor welding sets are essentially made up of the
followingcomponents:
A - Frame
B - Engine
C - Fuel tank
D-Recoil assy
E - Muffler
F - Alternator
G - Controlpanel
H - Tapspanel
H - Inductor
L - Diodebridge
M - Liftup
1.10 Instrument panel
Eachmotor weldingsetis fittedwithan instrumentpanel
forthe controls with the following components:
See Fig.3
1 - Voltmeter
2 - Weldingcurrent regulation
3 - Weldingarc regulation
4 - Remotecontrol connector
5 - Hourcounter
6 - Three-phaseoutlet,EEC16A230V 3P+GND
7 - Differentialswitch 4P
8 - Single-phaseoutlet, EEC 16A230V2P+GND
9 - Earthconnection terminal
10 - 48V Outlet (AC)
11 - Welding couplings (+/-)
2 TECHNICALCHARACTERISTICS
2.1 General characteristics
ThemotorweldingsetsoftheMultiworkMW70 HB-RE
series (HONDA powered) are designed for use in the
industrialfield in the welding sector.
The4-strokegasolineenginewithaircoolingdesigned
for heavy duty is extremely reliable and robust.
Particularattentionhasbeenpaidtothe degree of pro-
tection against external agents, engine protection and
protectionoftheelectrical partsagainst overloador over-
heating.
Thealternatoristhe2-pole asynchronous type with ex-
citation capacitors and is fitted with electronic control
oftheweldingcurrent. It is able to deliver direct current
forwelding,and230Vthree-phase,230Vsingle-phase
and48V single-phase alternate current.
2.2 Welding graph
2.3 Tables of technical characteristics
DIMENSIONS (L x W x H) 800x530x520 mm
DRY WEIGHT (WITHOUT BATTERY) 98 Kg
CAPACITA' SERBATOIO CARBURANTE 6,5 Liters
MAX. INCLINATION 25°
ASYNCHRONOUS, THREE-PHASE,
SELF-EXCITED AND SELF-REGULATING
INSULATION CLASS F
CONTROL ELECTRONIC
CURRENT AND SERVICE FACTORS 145 at 35% - 135 at 60%
FLASHOVER VOLTAGE 68 V
ELECTRODE DIAMETER 4 mm MAX
THREE-PHASE POWER (230V) 4.600 VA
SINGLE-PHASE POWER (230V) 3.000 VA
48 V POWER 2.000 VA
FREQUENCY 50 Hz
VOLTAGE STABILITY 10%
FREQUENCY STABILITY 3%
POWER FACTOR 0,8
TYPE HONDA
MODEL GX 270
COOLING AIR
NUMBER OF CYLINDERS 1
DISPLACEMENT 270 cm3
POWER SUPPLY GREEN GASOLINE
POWER 6 KW / 8,2 HP
SUCTION NATURAL
ENGINE RPM 3000 rpm
OIL SUMP CAPACITY 1.1 Litres
FUEL CONSUMPTION 230 g/HP/h
STARTING MANUAL
GENERATOR
ENGINE
GENERAL CHARACTERISTICS
ALTERNATOR
TYPE
WELDER

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3 SAFETYREGULATIONS
3.1 General precautions
Beforestartingthe motor weldingsetandbefore starting
anylubricationormaintenanceoperation,itisindispen-
sableforthe staff responsibletoreadand understand all
theWARNINGSandall the CAUTION andDANGERin-
dicationslistedinthismanualandinthesupplementary
documentationfurnished.
Nevertheless, the manufacturer cannot foresee all the
possiblecircumstances which mayleadto potentialrisks
intheeffectiveconditions of use of the generator.
Anyoperations and/or procedures for maintenance not
expresslyrecommendedorindicatedintheusermanu-
alsmustalwaysbe notifiedto andapprovedbytheManu-
facturer.
In the event that a procedure not specifically recom-
mendedneedstobeapplied,theuserisresponsiblefor
assuringthatsuch procedureissafe and doesnotcause
harm to persons or things.
Themanufacturerdeclinesallresponsibility for damage
to persons or things deriving from inobservance of the
safetyregulations.
Carefullyexaminethe safety warning plates on the ma-
chineand respect the relevant instructions.
-Do notpermitincompetent personsorwithoutadequate
training to use the motor welding set.
-Do not permit children or animals to approach the mo-
tor welding set when it is in operation.
- Do not access the motor welding set with wet hands,
since it is a potential source of electric shock if im-
properlyused.
-Any inspections of the motor welding set must be car-
ried out with the engine off. Inspections with the en-
gineonaretobecarriedoutbyspecialisedpersonnel
only.
-Exhaustgas contains carbon monoxideandothernox-
ious residues. Never operate the generator in inad-
equatelyventilatedplaces.
-Do not operate the motor welding set near places with
adangerof explosion or fire.
-Refuelling must be carried out exclusively with the en-
gineoff.
-The motor welding set must be connected to earth us-
ing a copper wire of suitable cross-section (see sec-
tion 3.3).
- Do not allow access to persons wearing a pace-
maker because of possible electromagnetic inter-
ference with the device.
- In the event of fire, use a homologated fire extin-
guisher and never use water.
When using the motor welding set, bear in mind that
in wet or very humid places and in confined
conduction spaces it is obligatory to comply with
Articles 313 and 318 of Presidential Decree No. 547
27/04/55, as well as CHAP. 11 SECT. IV of the CEI 64-
8 regulation.
3.2 Prescriptions for safety during installation and
setup
- The personnel in charge of installation and starting
of the motor welding set must always wear a
protective helmet; wear safety shoes and overalls.
- Immediately change wet overalls.
-Useprotective gloves.
- Do not leave disassembled parts, tools or anything
else not forming part of the system on or near the
engine.
- Never leave inflammable liquids or cloths soaked
in inflammable liquids in proximity of the motor
welding set, near electric equipment (including
lamps) or parts of the electrical system.
- Take the necessary precautions to prevent the
danger of electrocution.
- Check that the earthing system has been installed
and constructed in accordance with regulations.
3.3 Connecting the motor welding set to earth
For the safety of the users, the earth connection of the
motor welding set must always be carried out paying
particularattentiontothe cablecross-section used,which
must be at least 10 mm2.
Forthe connection of the earth cable use the dedicated
terminal on the control panel (Fig. 3 Ref. 9).
Themanufacturer is not responsiblefor any damage
caused by failure to earth the system.

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tor is not started on load;
- that the fuel pipes are undamaged and properly con-
nected;
- that there are no electrical connections in a bad state.
4.3 Refuelling
Refuellingmustbecarriedoutwithextremecare,ensur-
ing that fuel does not overflow from the engine tank and
respectingthemaximum level.
Whenrefuellinghasbeencompleted,carefullyclose the
fillercap(Fig.4Ref.1)
- Fuel is toxic and inflammable and must therefore
be kept in special airtight containers and stored in
inaccessibleplaces.
- Refuelling must always be carried out with the en-
gine off.
- Do not smoke and do not use open flames during
refuelling.
- Refuel in well-ventilated places.
- Avoid contact of fuel with the skin and do not in-
hale the fumes.Vaseline.
4.4 Starting
Before starting the generator check that all the utilities
areoff topreventputting thestillcold engineunderstress.
The generator engine has been calibrated, in idle, to 3240
rpm equal to 54 Hz, as the engine stabilises at about 3000
rpm equal to 50Hz with a load. For this reason, the
accelerator lever, (Fig. 3, ref. 14), must never shift for any
reason, since the output voltage, frequency and power
values of the generator would be compromised.
To start proceed as follows.
• Disconnect the outlets, (alternatively the
magnetothermaldifferentialswitch), to preventputting
the still cold engine under stress.
• Turn the engine stop switch to position "I", (Fig. 3,
ref.15).
• Open the fuel cock by turning the lever shown in Fig.
3, ref. 12.
• Iftheengineiscold,closetheairstartleverbyturning
itasshown in Fig.3,ref.16,before attempting tostart.
If the engine is hot the start lever need not be turned.
• Proceedbyfirmly pulling theself-windingcord,(Fig.3,
ref. D), to start engine rotation.
• Repeat the operation if the engine has not started at
the first attempt.
• As soon as the engine has started, gradually return
the air start lever to the original position.
4 USING THE MOTOR WELDING SET
4.1 Positioning
The motor welding sets of the Multiwork MW170 HB-
RE series must be positioned as horizontally as possi-
ble, i.e. placed on a flat surface or made to sit horizon-
tally by placing shims under the frame.
Ifnecessary with theversions with trailer, usesome
chocks on both wheels.
The engine functions properly if it does not exceed
a maximum inclination of 25°, both on the longitu-
dinal and the transversal axis. Should the engine be
operatedinconditions at agreater inclination, there
is a risk of insufficient lubrication or suction of en-
gine oil from the air filter.
4.2 Preliminary checks
Before beginning with any starting procedure, it is ex-
tremely important to become “familiar” with the motor
welding set and its controls. Furthermore, a visual in-
spection must be carried out on the machine and the
installation.
Any source of potential or real danger must be elimi-
natedbefore proceeding.
Identify the position of the Ignition / stopping key,
switches and other emergency systems on the motor
weldingset.
Learn the special emergency procedures relative to
the installation in question.
Identify the position of the fire extinguisher or other
protectionandemergencydevices and learn theirfunc-
tioning.
Identify any sources of danger such as fuel, engine
oil or acid solution leaks, condensate in the drip caps,
highvoltage,highpressure.
Ensure that the motor welding set is clean and that
thesurroundingareasare clean and free of obstacles.
Checkthat there are no obstructions in the inlets and
ventilationducts.
Check that the exhaust pipe is not oriented against
obstacles, or make sure that these are at least two
metres away.
Checkthat the earthconnectionhasbeencarried out
properly.
At first starting of the motor welding set, after having
done any type of maintenance work, it is always good
practice to check:
- the oil level by means of the dipstick (Fig.2 Ref.13);
-thatalltheelectrical utilities are off so that the genera-

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To prevent damage to the self-winding cord of the engine,
never release it abruptly after having pulled it out fully,
but guide it until complete rewinding.
4.5 Use as AC generator
Beforepoweringanyutility, leave the enginetorunwith-
outappliedloadforatleast five minutes so that it gradu-
ally reaches the operating temperature. This will guar-
antee longer life of the engine and eliminate the risk of
seizures.
Each motor welding set is equipped with:
- a three-phase outlet, EEC 16A 230V 3P+GND
- a single-phase outlet, EEC 16A 230V 2P+GND
- 48VAC couplings
Theavailable powerisas indicatedonthe adhesivelabel
carrying the technical characteristics (Fig.2).
- The sum of absorption of all the utilities connected
to the motor welding set must never exceed the
continuous power value of the motor welding set.
-During the first 50 hours of operation, do not draw
more than 60% of maximum suppliable power and
frequently check the oil level with the graduated
dipstick (Fig.3, Ref.1). The oil level must always
be between the MAX and MIN notches on the dip-
stick (Fig.8).
4.6 Use as welder
The motor welding sets of the Multiwork MW 170 HB-
RE may be used as direct current generators for arc
welding. Before doing any welding, leave the engine to
idle for at least five minutes so that it gradually reaches
the operating temperature. This will guarantee longer
life of the engine and eliminate the risk of seizures.
The welding cables must be connected to the special
couplings(Fig.3,Ref.11)respecting thepolarity indicated.
Regulate the welding current with the regulating knob
(Fig.3,Ref.3):
- turning clockwise, the current increases,
- turning anticlockwise, the current decreases.
The welding arc is regulated with the regulating knob
(Fig.3,Ref.2):
- turning clockwise, the arc penetration increases,
- turning anticlockwise, the arc penetration decreases.
Bear in mind that for use of the
majority of basic, rutile and basic cellulose elec-
trodes,theelectrodeholderclipisconnectedtothe
“+” outlet while for rutile acid and rutile cellulose
electrodestheelectrodeholderclipisconnectedto
the “-” outlet.
Forthe bestresults, referto theinstructions normally
given on the electrode packaging.
During the first 50 hours of operation, do not draw
more than 60% of maximum suppliable power and
frequently check the oil level with the graduated dip-
stick (Fig.2, Ref.13). The oil level must always be be-
tween the MAX and MIN notches on the dipstick
(Fig.8).
4.7 Using the remote control (optional)
The welding current can be remote-controlled by using
the special control (Fig.7, Ref. 6 ).
To do this the remote control plug(Fig.6,Ref.1)mustbe
inserted in the special connector (Fig.3, Ref.4) located
on the control panel . In this way the control device on
thecontrolpanelofthegeneratorareoverriddenandthose
of the remote control enabled. The welding current is
regulated in the same way as described in the preced-
ing paragraph, by means of the potentiometer (Fig.6,
Ref. 2). The regulation of the arc of welding, is taken
placealways through the potentiometer (Fig.3, Ref. 2).
The remote controlcomes with a 20m cable. Should
it be necessary to modify the length, “MASE” tech-
nical service must first be consulted.
4.8 Stopping
Before stopping the engine it is recommended to run it
without load for a few minutes and with the accelerator
atminimum,thusallowingtheinsidetemperatureofthe
engineandthealternatortograduallyreduce.

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5 PROTECTIONSAND WARNINGSIGNALS
Thegenerators areequippedwithaseries ofprotections
whichsafeguard them against improper use and faults
which may compromise integrity and are:
Low oil pressure protection
Intervenesswitching offthe unitwhensumpoillevel gets
down to the minimum. Its intervention is not signaled
bywarninglights,therefore,incase machine stops it is
alwaysnecessarytocheck oil level to make sure that it
is not the cause of generator’s stopping.
Add the necessary quantity of oil to start up the
generatoragain.
Protection against short-circuit and overload
Incaseofshort-circuitandoverloaded,themotorwelding
setsareautoprotette,disconnectincaseofshort-circuit
and limiting the tension of exit in case of overload
arriving up to the disconnect. Eliminating the cause of
the short-circuit or overloaded, he will restore initial
condition. The motor welding sets are provisions of a
generaldifferentialinterrupter,thatpourearthincaseof
dispersionoftide,ithastheassignmenttointerruptthe
disbursement of the tide to all the taking. (Fig.3, rif.7)
6 MAINTENANCE
6.1 Preamble
Any maintenance operation on the motor welding
set must be carried out with the engine off and leav-
ing it to cool down sufficiently, and must only be
carried out by authorised and suitably trained per-
sonnel.
It is recommended to scrupulously follow the instruc-
tions in the manual provided by the engine Manufac-
turer with each motor welding set.
Itisimportanttoregularlyinspect and carry out mainte-
nanceonthe motorweldingset.The frequency ofmain-
tenance should be decided on the basis of the number
of hours of operation indicated in the table at point 6.6.
6.2 Ordinary engine maintenance
Theperiodic maintenance operations to be carried out
on the engine are indicated in the table at point 6.6.
For more detailed information consult the manual pro-
videdby theenginemanufacturer witheachmotor weld-
ing set.
Daily check the oil level with the graduated dipstick
(Fig.2, Ref. 13)
The oil level must always be between the MAX and
MIN notches on the dipstick (see FIG.8).
6.3 Engine oil change
The engine is provided with oil for petrol engines with
viscosity SAE 10W/30.
Always check correct viscosity of lubricating oil in relation
to range of temperatures of the environment in which the
generator works, as indicated in table of Fig. 7.
Top-upandfillthrough theholeindicatedin Fig.2,ref. 13.
Forreplacementofengine oil, remove the taplocatedon
the bottom part of the oil sump, (Fig. 2, rif. 14), and let it
flow into a suitable container.
It is recommended to drain the oil when it is still
sufficiently warm to flow easily.
Closethedraintapandaddthenecessaryquantityofoil
in the sump.
Oil sump capacity is 1.1 lt.
• Do not disperse of exhausted oil in the environment as
it is a polluting product.
• Deliver the exhausted engine oil to proper disposal
collecting centers.
• The first engine oil change must be carried out after
the first 20 working hours and, afterwards, at intervals
of 50 working hours.
6.4 Spark plug maintenance
Spark plug type: NGK - BR6HS
DENSO- W20EPR-U
Itisnecessaryto periodicallyremovethecarbonresidues,
that, due to use, deposit on the spark plug, by using a
small metal brush or specific detergent.
Adjust distance of spark plug electrodes setting a value
of 0.7 - 0.8 mm, (Fig. 9).
6.5 Air filter cleaning/replacement
For good operation and for a long life of the engine, it is
important to periodically clean and replace the air filter.
Anonefficient filtercouldbethe causeoflossof power of
the engine and excessive exhaust smoke.
To clean or replace the air filter, follow the steps here
below.
• Removethefilterholder cover, (Fig.4,ref. 2), undoing
the butterfly retaining nut (Fig. 4, ref. 3).
• Extract the filter complete with the two elements: the
spongeelementandthepaperelement.
• Thespongeelement issimplywashed with adomestic
detergentorwithalow-flammablesolvent.

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• Leavetodrywelland soakthecleanelementinengine
oil, then wring it out to remove the excess oil, since
toomuchoilin the element causes excessivesmoke
at the exhaust.
• The paper element is cleaned with a blast of dry air,
from the inside to the outside, with a pressure not
exceeding2 bar. Shoulditbeverydirtyorhave holes,
replace it.
Clean the air filter every 50 hours of operation.
Reduce the intervals if the generator operates in
particularly dusty environments.
On average replace the complete air filter every three
cleaning operations.
Never clean the air filter with petrol or highly inflammable
solvents since this might cause fire or explosions.
6.6 Table of scheduled maintenance
OPERATION HOURS
Check engine oil level in sump 8
Cleanairfilter 50
Replacesump oil (*) 100
Cleanandadjust spark plug electrode 100
Checkvalveslack 300
Fuel tank and screen cleaning 300
(*) For the first time,
replace oil after 20 working hours.
6.7 Troubleshooting
The generator switches off during the operating
period.
• Check if there is fuel in the tank. Fill up.
• Checkifthelowoillevelprotection hasbeenactivated,
check the level and if low, add the oil necessary to
bringit up to the correct level. There are no warning
lights;avisual inspection mustalwaysbe carried out.
The engine runs irregularly.
• Check the position of the starter lever. It must have
beenre-openedafterstarting.
• Check the spark plug condition. Carry out
maintenanceor replace it.
• Checktheairfilter. Cleanitselementsor, ifnecessary,
replacethem.
There is high smoke emission from the exhaust.
• Check theairfilter. Cleanitselementsor, ifnecessary,
replacethem.
• Check that the oil level does not exceed the MAX
notch. Bring it down to the correct level.
The alternator voltage is too low.
• Check that the engine rpm is 3240 without applied
loads. Consultan authorised Service Centre.
• Check the state of the air filter. Clean or replace if
necessary.
The generator does not deliver power to the outlets
but the voltmeter indicates that voltage is present.
• Checkthatthemagnetothermaldifferential switch, or
a magnetothermal switch, is in the ON position.
The generator does not deliver power to the outlets
and the voltmeter does not indicate that voltage is
present.
• Likely alternator fault. ConsultServiceCentre.
7 TRANSPORTANDHANDLING
Themotorweldingset arefittedwithalifting hook to be
usedforhandling(Fig.3Ref. M).
Hookthemachinecarefullyand lift it slowly without sud-
denmovements.
- Hooking the motor welding set at points different
from that indicated may cause damage to the mo-
tor welding set or be dangerous to the operators.
- During lifting all personnel must keep a safe dis-
tance and the operators must wear protective hel-
mets.
Formovementontheground,theversionwithtrolleycan
bemovedonthewheelsprovided.

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8 STORAGE
Ifthegeneratorisnot going to be used for a long period
of time it is necessary to proceed as follows.
• Remove the spark plug and pour from 3to 5 cm3of
engine oil in the spark plug hole on the head of the
cylinder and make a couple of start-up attempts but
without turning on the generator; this will make the
engine turn a few times and let the oil expand and
lubricatecylinder and piston thus preventing rust on
cylinderandvalve. Aftertheaboveoperation,putback
spark plug in its housing.
• Empty the fuel tank
• Replaceengineoil
• Cleanairfilter
• Externallyclean thegeneratorunit removingdustand
impurities.
• Protectthe generatorunitwith anyloncover andstow
awaypositioningit horizontallyinadry andventilated
environment.
Refer to the engine use and maintenance manual
for more details.
9 SCRAPPING
At the end of its lifetime the motor welding set must be
taken to official scrapyards.
Do not dispose of the motor welding set at house-
hold refuse disposal sites, as many of its parts are
polluting.
10 WIRINGDIAGRAMREFERENCES
See Fig.10
1 ALTERNATOR
2 HOURCOUNTER
3 POWERTERMINALBOARD
4 OUTLET2P+GND16A
5 VOLTMETER
6 SETOFTHREECAPACITORS
7 EARTH CONNECTIONSCREW
8 48VA.C.COUPLINGS
9 SCRDIODEBRIDGE
10 WELDINGADJUSTMENTCARD
11 WELDINGADJUSTMENTPOTENTIOMETER
12 ARCADJUSTMENTPOTENTIOMETER
13 POTENTIOMETERCARD
14 REMOTE-CONTROLCONNECTOR
15 WELDINGCOUPLINGS(+/-)
16 SHUNT
17 IMPEDENCE
18 OUTLET3P+T16A
19 DIFFERENTIAL SWITCH4P