Mosa GE 7000 HSX, GE 7500 HSX Maintance Manual
GE 7000 - 7500 HSX
357709003 - GB
1 0 1 1
© MOSA - 01/09/08 35770M00
preparato da UPT
approvato da DITE
USE AND MAINTENANCE MANUAL
SPARE PARTS CATALOGS
DESCRIPTION OF THE MACHINE GE 7000-7500 HSX
M
0
REV.1-10/11
The generating set GE 7000-7500 is a unit which transforms the mechanical energy, generated by endothermic engine, into
electric energy, through an alternator.
Is 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.
BATTERY
ENGINE
BASE
FRONT
PANEL
CANOPY
ALTERNATOR
HANDLES
VIBRATIONDAMPER
Quality system
M
01
UNI EN ISO 9001 : 2008
10/10/02 M01-GB
MOSA has certied its quality system according
to UNI EN ISO 9001:2008 to ensure a constant,
highquality of its products. This certication covers
thedesign, production and servicing of engine drivenwelders and generating sets.
The certifying institute, ICIM, which is a member
ofthe International Certication Network IQNet,
awarded the ofcial approval to MOSA after anexamination of its operations at the head ofce
andplant in Cusago (MI), Italy.
This certication is not a point of arrival but a
pledgeon the part of the entire company to maintain
a levelof quality of both its products and services
whichwill continue to satisfy the needs of its clients,
aswell as to improve the transparency and thecommunications regarding all the company’s activesin
accordance with the ofcial procedures and inharmony with the MOSA Manual of Quality.
The advantages for MOSA clients are:
·Constant quality of products and services at thehigh
level which the client expects;
· Continuous efforts to improve the products andtheir
performance at competitive conditions;
· Competent support in the solution of problems;
· Information and training in the correct applicationand use of the products to assure the security
ofthe operator and protect the environment;
· Regular inspections by ICIM to conrm that therequirements of the company’s quality systemand
ISO 9001 are being respected.
All these advantages are guaranteed by the CERTIFICATE OF QUALITY SYSTEM No.0192 issued
by ICIM S.p.A. - Milano (Italy ) - www.icim.it
© MOSA REV.3-02/09
INDEX
GE 7000-7500 HSX
M
1
REV.1-10/11
01/09/08 35770-GB
M 0 DESCRIPTION OF THE MACHINE
M 01
QUALITY SYSTEM
M 1.01 COPYRIGHT
M 1.1 NOTE
M 1.4 CE MARK
M 1.4.1 DECLARATION OF CONFORMITY
M 1.5 TECHNICAL DATA
M 2 .... SYMBOLS USED AND SAFETY PRECAUTIONS
M 2.5 INSTALLATION AND ADVICE BEFORE USE
M 2.6 INSTALLATION WARNINGS
M 2.7 INSTALLATION AND DIMENSIONS
M 3 PACKING
M 4.1 TRANSPORT AND HANDLING
M 6.13 ASSEMBLY CTM
M 25 SET-UP FOR OPERATION
M 26 STARTING THE ENGINE
M 27 STOPPING THE ENGINE
M 31 CONTROLS
M 37... USING THE GENERATOR
M 38.5 REMOTE CONTROL
M 40.2... TROUBLE SHOOTING
M 43… MACHINE MAINTENANCE
M 45 STORAGE
M 46 CAST OFF
M 60 ELECTRICAL SYSTEM LEGEND
M 61-….. ELECTRICAL SYSTEM
R1 SPARE PARTS TABLES
GU.. SPARE PARTS
K.. ACCESSORIES
Copyright GE_, MS_, TS_, EAS
M
1.01
© MOSA 1.0-10/02
ATTENTION
© All rights are reserved to said Company.
It is a property logo of MOSA division of B.C.S.
S.p.A. All other possible logos contained in 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
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).
INFORMATION
Dear Customer,
We wish to thank you for having bought from
MOSA a high quality set.
Our sections for Technical Service and Spare
Parts will work at best to help you if it were
necessary.
To this purpose we advise you, for all control and
overhaul operations, to turn to the nearest
authorized Service Centre, where you will obtain
a prompt and specialized intervention.
☞
In case you do not profit on these Services and
some parts are replaced, please ask and be
sure that are used exclusively original MOSA
parts; this to guarantee that the performances
and the initial safety prescribed by the norms in
force are re-established.
☞
The use of non original spare parts will cancel
immediately any guarantee and Technical Ser-
vice obligation from MOSA.
NOTES ABOUT THE MANUAL
Before actioning the machine please read this
manual attentively. Follow the instructions
contained in it, in this way you will avoid
inconveniences due to negligence, mistakes or
incorrect maintenance. The manual is for qualified
personnel, who knows the rules: about safety and
health, installation and use of sets movable as
well as fixed.
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
is an integrant part of the product. It must be kept
with care during all the life of the product.
In case the machine and/or the set should be
yielded to another user, this manual must also
given to him.
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
contained in it want only to identify the described
parts and therefore might not correspond to the
machine in your possession.
INFORMATION OF GENERAL TYPE
In the envelope given together with the machine
and/or set you will find: the manual for Use
Maintenance and Spare Parts, the manual for
use of the engine and the tools (if included in the
equipment), the guarantee (in the countries where
it is prescribed by law).
Our products have been designed for the use of
generation for welding, electric and hydraulic
system; ANY OTHER DIFFERENT USE NOT
INCLUDED IN THE ONE INDICATED, relieves
MOSA from the risks which could happen or,
anyway, from that which was agreed when selling
the machine; MOSA excludes any responsibility
for damages to the machine, to the things or to
persons in this case.
Our products are made in conformity with the
safety norms in force, for which it is advisable to
use all these devices or information so that the
use does not bring damage to persons or things.
While working it is advisable to keep to the
personal safety norms in force in the countries to
which the product is destined (clothing, work tools,
etc.).
Do not modify for any motive parts of the machine
(fastenings, holes, electric or mechanical devices,
others..) if not duly authorized in writing by MOSA:
the responsibility coming from any potential
intervention will fall on the executioner as in fact
he becomes maker of the machine.
Notes GE_, MS_, TS_, EAS_
M
1-1
© MOSA 1.0-10/02
☞
Notice: this manual does not engage MOSA,
who keeps the faculty, apart the essential
characteristics of the model here described and
illustrated, to bring betterments and modifications
to parts and accessories, without putting this
manual uptodate immediately.
10/10/02 M 1-1 GB
CE MARK
M
1.4
10/10/02 M1-4 GB
Any of our product is labelled with CE marking attesting its conformity to appliable directives and
also the fulllment 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:
The indication is shown in a clear, readable and indeleble way on a sticker.
REV.5-03/11
04/06/10 M1.4.1
Dichiarazione conformità
Declaration of conformity
Déclaration de conformité
M
1.4.1
REV.0-06/10
MM 083.0
BCS S.p.A.
Sede legale:
Via Marradi 1
20123 Milano - Italia
Stabilimento di Cusago, 20090 (MI) - Italia
V.le Europa 59
Tel.: +39 02 903521
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
CEO
Konformitätserklärung
Declaración de conformidad
01/09/08 35770-GB
Technical data GE 7000-7500 HSX
M
1.5
REV.2-10/11
Technical data GE 7000 HSX GE 7500 HSX
GENERATORE
*Stand-by three-phase output - 7.5 kVA (6 kW) / 400 V / 10.8 (8.7) A
**PRP three-phase output - 6.5 kVA (5.2 kW) / 400 V / 9.4 A
*Stand-by single-phase output) 6.7 kVA (6 kW) / 230 V / 29.1 (26.1) A **PRP single-phase output 5.5 kVA (5 kW) / 230 V / 23.9 A 4 kVA (4 kW) / 230 V / 17.4 A
Frequency 50 Hz 50 Hz
Cos ϕ 0.9 0.8
ALTERNATOR self-excited, self-regulated, brushless self-excited, self-regulated, with brush
Type synchronous, single-phase synchronous, three-phase
Insulating class H H
ENGINE
Mark / Model HONDA / GX 390
Type / Cooling system gasoline 4-Stroke, OHV / air
Cylinders / Displacement 1 / 389 cm
3
*Stand-by net power 8.2 kW (11.1 HP)
*PRP net power 6.4 kW (8.7 HP)
Speed 3000 rpm
Fuel consumption (75% of PRP) 2.4 l/h
Engine oil capacity 1.1 l
Starter Electric
GENERAL SPECIFICATIONS
Tank capacity 20 l
Running time (75% of PRP) 8.3 h
Protection IP 23
*Dimensions max. on base Lxwxh (mm) 1060x570x665
*Weight (dry) 155 Kg 165 Kg
Measured acoustic power LwA (pression LpA) 88 dB(A) (63 dB(A) @ 7 m)
Guaranteed acoustic power LwA (pression LpA) 89 dB(A) (64 dB(A) @ 7 m)
* Dimensions and weight are inclusive of all parts.
2000/ 14/ CE
2000 /14 / CE
OUTPUT
Declared power according to ISO 8528-1 (temperature 25°C, 30% relative humidity, altitude 100 m above sea level).
(*Stand-by) = maximum available power for use at variable loads for a yearly number of hours limited at 500 h. No overload is
admitted.
(**Prime power PRP) = maximum available power for use at variable loads for a yearly illimited number of hours. The average
power to be taken during a period of 24 h must not be over 80% of the PRP.
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 specic 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
according to 2000/14/CE directive.
SYMBOLS AND SAFETY PRECAUTIONS
GE_, MS_, TS_
M
2
© MOSA 1.0-11/99
SYMBOLS IN THIS MANUAL
- The symbols used in this manual are designed to call
your attention to important aspects of the operation of
the machine as well as potential hazards and dangers
for persons and things.
IMPORTANT ADVICE
- Advice to the User about the safety:
+ 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.
Remember that the non observance of the indications
reported by us might cause damage to persons or
things. It is understood, that local dispositions and/or
laws must be respected.
WARNING
Situations of danger - no harm to persons
or things
Do not use without protective devices provided
Removing or disabling protective devices on the
machine is prohibited.
Do not use the machine if it is not in good technical
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.
SAFETY PRECAUTIONS
This heading warns of an immediate danger for persons
as well for things. Not following the advice can result in
serious injury or death.
This heading warns of situations which could result in
injury for persons or damage to things.
To this advice can appear a danger for persons as well
as for things, for which can appear situations bringing
material damage to things.
These headings refer to information which will assis you
in the correct use of the machine and/or accessories.
!
26/11/99 M2GB
WARNING
DANGEROUS
CAUTION
IMPORTANT
NOTE
ATTENTION
!!!
!
!
!
SYMBOLS AND SAFETY PRECAUTIONS
M
2-1
REV.2-06/10
SYMBOLS
STOP - Read absolutely and be duly attentive
Read and pay due attention
GENERAL ADVICE - If the advice is not
respected damage can happen to persons or
things.
HIGH VOLTAGE - Attention High Voltage.
There can be parts in voltage, dangerous
to touch. The non observance of the advice
implies life danger.
FIRE - Danger of ame or re. If the advice is
not respected res can happen.
HEAT - Hot surfaces. If the advice is not
respected burns or damage to things can be
caused.
EXPLOSION - Explosive material or danger
of explosion. in general. If the advice is not
respected there can be explosions.
WATER - Danger of shortcircuit. If the advice
is not respected res or damage to persons
can be caused.
SMOKING - The cigarette can cause re or
explosion. If the advice is not respected res
or explosions can be caused.
ACIDS - Danger of corrosion. If the advice is
not respected the acids can cause corrosions
with damage to persons or things.
WRENCH - Use of the tools. If the advice is
not respected damage can be caused to things
and even to persons.
PRESSION - Danger of burns caused by the
expulsion of hot liquids under pressure.
PROHIBITIONS No harm for persons
Use only with safety clothing -
It is compulsory to use the personal
protection means given in equipment.
Use only with safety clothing -
It is compulsory to use the personal protection
means given in equipment.
Use only with safety protections -
It is a must to use protection means suitable for
the different welding works.
Use with only safety material -
It is prohibited to use water to quench res on
the electric machines.
Use only with non inserted voltage -
It is prohibited to make interventions before
having disinserted the voltage.
No smoking -
It is prohibited to smoke while lling the tank
with fuel.
No welding -
It is forbidden to weld in rooms containing
explosive gases.
ADVICE No harm for persons and things
Use only with safety tools, adapted to the specic
use -
It is advisable to use tools adapted to the various
maintenance works.
Use only with safety protections, specically suitable
It is advisable to use protections suitable for the
different welding works.
Use only with safety protections -
It is advisable to use protections suitable for
the different daily checking works.
Use only with safety protections -
It is advisable to use all protections while
shifting the machine.
Use only with safety protections -
It is advisable to use protections suitable for
the different daily checking works.and/or of
maintenance.
!
26/11/99 M2-1GB
ACCES FORBIDDEN to non authorizad peaple.
INSTALLATION AND ADVICE BEFORE USE
GE_, MS_, TS_
M
2-5
© MOSA 1.0-06/00
The installation and the general advice concerning the operations, are nalized to the correct use of the machine, in the place where it is used as generator group and/or welder.
!
+ FIRSTAID. 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 rst aid in accordance
with the ruling labour accident standards or of local instructions.
+ FIREPREVENTION. In case the working zone,for whatsoever cause goes on re with ames liable to
cause severe wounds or death, follow the rst aid as described by the ruling norms or local ones.
10/06/00 M2-5I
ENGINE
Stop engine when fueling
CHECKINGBOARD
Do not touch electric devices
if you are barefoot or with wet
clothes.
Do not smoke, avoid ames, sparks or electric tools when fueling.
Unscrew the cap slowly to let out the fuel vapours.
Always keep off leaning surfaces during work operations.
Slowly unscrew the cooling liquid tap if the liquid must be topped up.
The vapor and the heated cooling liquid under pressure can burn face, eyes, skin.
Static electricity can demage
the parts on the circuit.
Do not ll tank completely.
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
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
lungs
If you suppose that vomit has entered the lungs (as in case of spontaneous vomit) take the subject to the
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
EXTINCTIONMEANS
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 re with foam or sand, use water jets to cool off the surfaces close to the re
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 inamability
point is very low.
WARNING
THE MACHINE MUST NOT BE USED IN AREAS WITH EX-
PLOSIVE ATMOSPHERE
WARNING CAUTION
DANGE-
ROUS
!
!
!
!
INSTALLATION AND ADVICE
M
2.6
© MOSA REV.1-06/07
INSTALLATION AND ADVICE BEFORE USE
GASOLINE ENGINES
+
Use in open space, air swept or vent exhaust gases,
which contain the deathly carbone oxyde, far from
the work area.
DIESEL ENGINES
+ Use in open space, air swept or vent exhaust gases
far from the work area.
POSITION
Place the machine on a level surface at a distance of at
least 1,5 m from buildings or other plants.
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.
+ Make sure that the machine does not move during the
work: block it possibly with tools and/or devices made
to this purpose.
Maximum leaning of the machine (in case of dislevel)
26/11/99 M2-6GB
1,5 m
1,5 m
1,5 m
GAS DI SCARICO
EXHAUST OUTPUT
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
t the machine in locations with high risk
of ood.
Please do not use the machine in weather
conditions which are beyond IP protection
shown both in the data plate and on page
named "technical data" in this same manual.
!
Installazione
Installation
Installation
Luftzirkulation
Instalación GE 7000-7500 HSX
REV.1-10/11
01/09/08 35770-I
M
2.7
Loading...