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MOSA Weld NEW MAGIC WELD Service Manual
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MOSA Weld NEW MAGIC WELD Service Manual

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SERVICE MANUAL
NEW MAGIC WELD
MAGIC WELD 200
MAGIC WELD YD/YDE
Motosaldatrici
•
Engine driven welders
•
ENGINE DRIVEN WELDER SERVICE MANUAL
WITH ELECTRONIC REGULATION OF WELDING PROCESSES
AND CHOPPER BRIDGE
(engine troubleshooting and technical data dedicated to
HONDA GX 200/270 – YANMAR L70N)
SM 07.1
Codice
SM 07.1
Code
Edizione
1
Edition
DATE
06/2015
1

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Summary of Contents for MOSA Weld NEW MAGIC WELD

  • Page 1 SERVICE MANUAL NEW MAGIC WELD Codice ENGINE DRIVEN WELDER SERVICE MANUAL SM 07.1 MAGIC WELD 200 Code WITH ELECTRONIC REGULATION OF WELDING PROCESSES MAGIC WELD YD/YDE AND CHOPPER BRIDGE Edizione (engine troubleshooting and technical data dedicated to Edition HONDA GX 200/270 – YANMAR L70N) Motosaldatrici •...
  • Page 2 Service Manual MAGIC WELD INDEX 1 INTRODUCTION 2 ELECTRICAL DIAGRAMS 2.1 - Diagram for magic weld. 2.2 - Diagram for magic weld 200. 2.3 - Diagram for magic weld YD-YDE. 3 MAINTENANCE 3.1 - Maintenance schedule for machines with Honda GX 200-270. 3.2 - Disassembly procedures for normal maintenance.
  • Page 3 Service Manual MAGIC WELD 1 INTRODUCTION This service manual covers products assembled by MOSA – Division of BCS S.p.A. The information contained within this manual is the exclusive property of MOSA – Division of BCS S.p.A. As such, no reproduction or replication in whole or in part is prohibited without the written permission of MOSA –...

  • Page 4: Electrical Diagram

    Service Manual MAGIC WELD 2 ELECTRICAL DIAGRAM SM 07.1...
  • Page 5 Service Manual MAGIC WELD SM 07.1...
  • Page 6 Service Manual MAGIC WELD SM 07.1...

  • Page 7: Electrical Diagrams

    Service Manual MAGIC WELD 2 ELECTRICAL DIAGRAMS 2.1 – Diagram for magic weld. SM 07.1...
  • Page 8 Service Manual MAGIC WELD SM 07.1...
  • Page 9 Service Manual MAGIC WELD 2 ELECTRICAL DIAGRAMS 2.2 – Diagram for magic weld 200. SM 07.1...
  • Page 10 Service Manual MAGIC WELD SM 07.1...
  • Page 11 Service Manual MAGIC WELD 2 ELECTRICAL DIAGRAMS 2.3 – Diagram for magic weld YD-YDE. SM 07.1...
  • Page 12 Service Manual MAGIC WELD SM 07.1...

  • Page 13: Maintenance

    Service Manual MAGIC WELD 3 MAINTENANCE 3.1 - Maintenance schedule for machines with engine Honda GX 200 – 270. SM 07.1...
  • Page 14 Service Manual MAGIC WELD 3.2 Disassembly procedures for normal maintenance GX 200-270. 3.2.1. Oil level check SM 07.1...
  • Page 15 Service Manual MAGIC WELD 3.2.2. Oil change. SM 07.1...
  • Page 16 Service Manual MAGIC WELD 3.2.3. Air cleaner. SM 07.1...
  • Page 17 Service Manual MAGIC WELD 3.2.4. Spark plug. SM 07.1...
  • Page 18 Service Manual MAGIC WELD 3.3 - Maintenance schedule for machines with engine Yanmar L70N. SM 07.1...
  • Page 19 Service Manual MAGIC WELD 3.4 - Disassembly procedures for normal maintenance L70N. 3.4.1 – Air cleaner. SM 07.1...
  • Page 20 Service Manual MAGIC WELD 3.4.2 – Oil filter. SM 07.1...
  • Page 21 Service Manual MAGIC WELD 3.4.3 – Fuel filter. SM 07.1...

  • Page 22: Troubleshooting

    Service Manual MAGIC WELD 4 TROUBLE SHOOTING 4.1.1 – Trouble shooting only for engine Honda GX 200/270 PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Auto-idle Check the correct If it is confirmed that the origin of the Adjust and lubricate the linkage.
  • Page 23 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO ATTENTION: Failure of the If the welding control is recovered the problem Replace the Hall sensor. hypothesis of failure of current sensor.
  • Page 24 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Harness damaged. If the investigations on Harness damaged. Repair or replace the harness. the possible causes of failure previously analyzed do not identify the source of the...
  • Page 25 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine TEST 1 WELDING BOARD SAMPLE TEST Keep at your disposal a welding sample board ,of which you are sure of the proper operation , as tool of troubleshooting Take extra care to use this board only after intergrtity and functionality chopper test, in order to avoid possible failure propagations from chopper Bridge TEST 2...
  • Page 26 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine PROBLEM THE ENGINE RPM IS NOT REDUCED AT NO LOAD POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Auto-idle linkage Check the correct If it is confirmed that the origin of the Adjust and lubricate the linkage locked.
  • Page 27 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine PROBLEM THE ENGINE RPM IS NOT REDUCED AT NO LOAD POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Failure of the current CAUTION: the hypothesis of If the sample Hall sensor retrieves the Replace the Hall sensor.
  • Page 28 Service Manual MAGIC WELD 4.1.1 – Trouble shooting engine TEST 2 HALL SENSOR SAMPLE TEST Keep at your disposal an Hall sensor sample ,of which you are sure of proper operation , as tool of troubleshooting. SM 07.1...
  • Page 29 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Auto-idle actuator not TEST 3 – Check the If the actuator, controlled by an external switch, does Replace the actuator.
  • Page 30 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. TEST 3 ACTUATOR COMMAND TEST Collegamento di un deviatore al posto del relè Connection to external switch to by pass relay SM 07.1...
  • Page 31 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Welding control board Perform a test with the If the test result is that the engine runs at full speed Replace the actuator.
  • Page 32 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. PROBLEM THE ENGINE RPM DOESN’T RISE AT LOAD. POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Failure of the current ATTENTION: the hypothesis of If the welding control is recovered the Replace the Hall sensor.
  • Page 33 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. TEST 1 WELDING BOARD SAMPLE TEST Keep at your disposal a welding sample board ,of which you are sure of the proper operation , as tool of troubleshooting Take extra care to use this board only after intergrtity and functionality chopper test, in order to avoid possible failure propagations from chopper Bridge...
  • Page 34 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. PROBLEM THE ENGINE RPM IS NOT REDUCED AT NO LOAD POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Auto-idle actuator not TEST 3 – check the Actuator If the actuator, controlled by an external Replace the actuator.
  • Page 35 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. TEST 1 WELDING BOARD SAMPLE TEST Keep at your disposal a welding sample board ,of which you are sure of the proper operation , as tool of troubleshooting Take extra care to use this board only after intergrtity and functionality chopper test, in order to avoid possible failure propagations from choppe Bridge...
  • Page 36 Service Manual MAGIC WELD 4.1.2 – Trouble shooting only for engine Yanmar L70N. PROBLEM THE ENGINE RPM IS NOT REDUCED AT NO LOAD POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Failure of the current CAUTION: the hypothesis of failure If the sample Hall sensor retrieves the Replace the Hall sensor.
  • Page 37 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. PROBLEM LACK OF WELDING VOLTAGE IN OPEN CIRCUIT POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Harness damaged. Inspect the harness. Harness damaged Repair or replace the harness No damages found on harness Next step: test 4 Open circuit failure of TEST 4...
  • Page 38 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 4 CHOPPER INTEGRITY TEST Check on each pair pin value of 3,3 k± MAGIC WELD MAGIC WELD 200 CT 230 DSP 400 DSP 2x400 DSP 500 DSP 600 SM 07.1...
  • Page 39 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 5 CHOPPER FUNCTIONALITY TEST BLACK (NEGATIVE POLE) 9V BATTERY SNAP CONNECTOR CHOPPER TEST JIG RED (POSITIVE POLE) MOLEX 90130-1114 Electrical schematic of the test jig Pictures: Example of implementation SM 07.1...
  • Page 40 Service Manual MAGIC WELD 4.2.1 – Ricerca guasti saldatura. TEST 5 CHOPPER FUNCTIONALITY TEST Disconnect from the welding pcb the cable coming from the chopper. Start the welder engine leaving the welding circuit unloaded (i.e. in open circuit). Check that, in this condition, the voltage on the welding sockets is below 1V.
  • Page 41 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. PROBLEM LACK OF WELDING VOLTAGE IN OPEN CIRCUIT POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Lack of drive signal from TEST 6 - Drive signal test. in case of lack of the drive signal it is the welding control confirmed that the problem resides board...
  • Page 42 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 6 WELDING PCB DRIVE SIGNAL TEST SM 07.1...
  • Page 43 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 7 CURRENT SENSOR DISCONNECTING TEST Disconnect Hall Sensor cable from welding pcb on CON3 connector. Start the welder engine paying attention that the welding circuit be kept unloaded, as no current control is present in this condition. Check that across the welding sockets there is a voltage approximately equal to the nominal open circuit voltage.
  • Page 44 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. PROBLEM LACK OF WELDING VOLTAGE IN OPEN CIRCUIT POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the welding control Welding control board TEST 1 - Test with the sample board If the test sample card eliminates the fault it board not working.
  • Page 45 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 1 WELDING BOARD SAMPLE TEST Keep at your disposal a welding sample board ,of which you are sure of the proper operation , as tool of troubleshooting Take extra care to use this board only after intergrtity and functionality chopper test, in order to avoid possible failure propagations from choppe Bridge SM 07.1...
  • Page 46 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. Only for MAGIC WELD 200 / MAGIC WELD 200 YD-YDE PROBLEM LACK OF WELDING VOLTAGE IN OPEN CIRCUIT POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the remote control Remote control TEST 8 - Test with sample remote If one of the two tests shows that the management board.
  • Page 47 Service Manual MAGIC WELD 4.2.2 – Trouble shooting Welding. PROBLEM LACK OF WELDING CURRENT CONTROL (NO CURRENT REGULATION) POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Repair or replace the harness. Harness damaged. Inspect the harness. Harness damaged. No damages found on harness Next step: test 4 Short circuit failure of TEST 4...
  • Page 48 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 4 CHOPPER INTEGRITY TEST Check on each pair pin value of 3,3 k± MAGIC WELD MAGIC WELD 200 CT 230 DSP 400 DSP 2x400 DSP 500 DSP 600 SM 07.1...
  • Page 49 Service Manual MAGIC WELD 4.2.1 – Trouble shooting Welding. TEST 5 CHOPPER FUNCTIONALITY TEST BLACK (NEGATIVE POLE) 9V BATTERY SNAP CONNECTOR CHOPPER TEST JIG RED (POSITIVE POLE) MOLEX 90130-1114 Electrical schematic of the test jig Pictures: Example of implementation SM 07.1...
  • Page 50 Service Manual MAGIC WELD 4.2.1 – Ricerca guasti saldatura. TEST 5 CHOPPER FUNCTIONALITY TEST Disconnect from the welding pcb the cable coming from the chopper. Start the welder engine leaving the welding circuit unloaded (i.e. in open circuit). Check that, in this condition, the voltage on the welding sockets is below 1V.
  • Page 51 Service Manual MAGIC WELD 4.2.2 – Trouble shooting Welding. TEST 1 WELDING BOARD SAMPLE TEST Keep at your disposal a welding sample board ,of which you are sure of the proper operation , as tool of troubleshooting Take extra care to use this board only after intergrtity and functionality chopper test, in order to avoid possible failure propagations from choppe Bridge TEST 2...
  • Page 52 Service Manual MAGIC WELD 4.2.2 – Trouble shooting Welding. PROBLEM LACK OF WELDING CURRENT CONTROL (NO CURRENT REGULATION) POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the welding control Welding control board TEST 1 - Test with the sample board If the test sample card eliminates the fault it board.
  • Page 53 Service Manual MAGIC WELD 4.3.1 – Trouble shooting Auxiliary. Only for New Magic Weld PROBLEM LACK OF AUXILIARY VOLTAGE POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the fuse Blown fuse. Check the fuse integrity. Fuse blown. Replace the rectifiers. Damaged rectifiers.
  • Page 54 Service Manual MAGIC WELD 4.3.1 – Trouble shooting Auxiliary. Only for New Magic Weld PROBLEM LACK OF AUXILIARY VOLTAGE POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Stator replacement. Damaged stator. Check the presence of around The voltage values are incorrect 175Vac (about 87Vac for the 110V...
  • Page 55 Service Manual MAGIC WELD 4.3.1 – Trouble shooting Auxiliary. Only for MAGIC WELD 200 / MAGIC WELD 200 YD-YDE PROBLEM LACK OF AUXILIARY VOLTAGE POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the inverter. Inverter damaged. Check that the voltage at the If the input voltage of the inverter is correct inverter input is a about 420 Vdc but it does not provide any output voltage /...
  • Page 56 Service Manual MAGIC WELD 4.3.1 – Trouble shooting Auxiliary. Only for MAGIC WELD 200 / MAGIC WELD 200 YD-YDE PROBLEM LACK OF AUXILIARY VOLTAGE POSSIBLE CAUSE VERIFICATIONS WHAT TO DO Replace the wiring. Harness damaged. If the wiring is damaged, with Damages not caused by overheating.

  • Page 57: Technical Data

    Service Manual MAGIC WELD 5 TECHNICAL DATA 5.1 – Technical data for New Magic Weld. SM 07.1...
  • Page 58 Service Manual MAGIC WELD 5 TECHNICAL DATA 5.2 – Technical data for Magic Weld 200. SM 07.1...
  • Page 59 Service Manual MAGIC WELD 5 TECHNICAL DATA 5.2 – Technical data for Magic Weld 200 YD-YDE. SM 07.1...
  • Page 60 Service Manual MAGIC WELD 5 TECHNICAL DATA 5.2 – Technical data for Magic Weld 200 YD-YDE. SM 07.1...
  • Page 61 Service Manual MAGIC WELD MEMO SM 07.1...
  • Page 62 Service Manual MAGIC WELD MEMO SM 07.1...
  • Page 63 Service Manual MAGIC WELD MEMO SM 07.1...
  • Page 64 Service Manual MAGIC WELD MEMO SM 07.1...
  • Page 65 WWW.MOSA.IT MOSA div. della BCS S.p.A. Stabilimento di Viale Europa, 59 20090 Cusago (MI) Italia Tel. + 39 - 0290352.1 Fax + 39 - 0290390466...

This manual is also suitable for:

Magic weld 200Magic weld ydMagic weld yde