Mosa GE 3900 User manual

Use and Maintenance Manual
CR0000119003_EN
11-2023
D5264080
Generating set
GE 3900
GE 6900
Original instructions

i-1
Contents
Contents
1. Introduction.......................................................................................................................................1
1.1 Foreword ............................................................................................................................................1
1.2 Supplied documentation .....................................................................................................................1
1.3 Customer service................................................................................................................................2
1.4 Spare parts .........................................................................................................................................2
1.5 Declaration of conformity....................................................................................................................2
1.6 Unauthorized changes........................................................................................................................2
1.7 Allowed and non-allowed use.............................................................................................................2
1.8 Identicationdata ...............................................................................................................................3
2. Safety.................................................................................................................................................5
2.1 Safety information...............................................................................................................................5
2.2 Positioning of safety decal and information........................................................................................6
2.2.1 Decal explanation ..................................................................................................................7
2.3 General precautions ...........................................................................................................................9
2.3.1 Personal protective equipment ..............................................................................................9
2.3.2 Check the work area..............................................................................................................9
2.4 Fire prevention..................................................................................................................................10
2.4.1 Fire due to fuel, oil ...............................................................................................................10
2.4.2 Firescausedbyammablematerialbuild-up ......................................................................10
2.4.3 Fire caused by electrical wiring ...........................................................................................10
2.4.4 Fire caused by piping ..........................................................................................................10
2.5 Lifting and transport precautions ...................................................................................................... 11
2.5.1 Lifting by chains or ropes..................................................................................................... 11
2.5.2 Lifting and manual transport (Mod. GE 3900) ..................................................................... 11
2.5.3 Transport with towing carriage............................................................................................. 11
2.6 Precautions for positioning the machine...........................................................................................12
2.6.1 Positioning site precautions.................................................................................................12
2.6.2 Precautions for electric connections....................................................................................12
2.7 Precautions during operation............................................................................................................12
2.8 Precautions against noise ................................................................................................................13
2.9 Precautionsduringfuelandengineoillling ....................................................................................13
2.10 Maintenance precautions .................................................................................................................13
2.11 Precautions for disposal of waste material .......................................................................................14
2.12 Disposal of the machine ...................................................................................................................14
3. Technical data.................................................................................................................................15
3.1 Machine dimensions.........................................................................................................................15
3.2 Technical data (mod. GE 3900) ........................................................................................................16
3.3 Technical data (mod. GE 6900) ........................................................................................................17
3.4 Electrical diagram .............................................................................................................................18
4. Description......................................................................................................................................19
4.1 Main components of GE 3900 ..........................................................................................................19
4.2 Main components of GE 6900 ..........................................................................................................20
5. Delivery, unpacking and installation ............................................................................................21

Contents
i-2
5.1 Delivery.............................................................................................................................................21
5.2 Unpacking.........................................................................................................................................21
6. Operation.........................................................................................................................................23
6.1 Operating conditions.........................................................................................................................23
6.1.1 Power ..................................................................................................................................23
6.1.2 Voltage.................................................................................................................................23
6.1.3 Frequency............................................................................................................................23
6.2 Grounding.........................................................................................................................................24
6.3 Checks before start-up .....................................................................................................................25
6.4 Starting and stopping the engine......................................................................................................25
6.4.1 Starting the engine ..............................................................................................................25
7. Maintenance....................................................................................................................................29
7.1 Ordinary Maintenance Schedule ......................................................................................................29
7.2 Fuel...................................................................................................................................................30
7.3 Engine oil..........................................................................................................................................30
7.3.1 Refuelling and checks .........................................................................................................30
7.3.2 Replacement .......................................................................................................................31
7.4 Engineairlter..................................................................................................................................31
7.4.1 Check and clean..................................................................................................................31
7.4.2 Replacement .......................................................................................................................32
7.5 Cleaning the carburetor tank ............................................................................................................32
7.6 Checking and replacing the spark plug ............................................................................................32
7.7 Storage .............................................................................................................................................33
7.8 Disposal............................................................................................................................................33

1
1. Introduction
1. Introduction
1.1 Foreword
ThismanualsuppliestheOperatorandqualiedandauthorisedTechnicianswithtechnicalinformationonthe
GE 3900 and GE 6900 generating sets (hereinafter also referred to as the "machine") produced by MOSA
Div. of BCS S.p.A. (hereinafter also referred to as the "manufacturer").
Inthismanual,theOperatorinchargeandthequaliedTechnicianswillndtheindicationsfor:
• Getting familiar with the safety measures and basic standards to be adopted, to prevent hazards and
damage to people, to the machine and to the environment.
• Getting to know the main components of the machine and its operation.
• Performing the programmed routine maintenance.
• Getting to know any extraordinary maintenance operation.
Thismanualisanintegralpartofthemachineandmustfollowitinanychangesofownership,untilthenal
dismantling.
The manual and all the publications attached to it must be kept with care, in an easily accessible place,
knowntotheoperatorandtothequaliedtechniciansauthorizedformaintenance.Readthedescriptions
carefully before starting to work or carrying out the required adjustments or maintenance.
If the manual is lost, damaged or becomes illegible, request a copy to MOSA, indicating the model of the
machine, the serial number and the year of construction.
If the machine is transferred, the transferor must deliver this manual to the new owner.
The machine is subject to updates to improve its performance; this manual summarises the information
regarding the current state of technology at the moment of the supply.
MOSAreservestherighttomakeimprovementsandmodicationstopartsandaccessories,withoutprompt-
ly updating this manual, except in exceptional cases of fundamental integrations concerning safe operation.
CAUTION
• Improper use or maintenance can cause serious damage to people and shorten the "useful
life" of the machine.
• The Operator and the qualied Technicians must be familiar with all the indications given in
this manual before using the machine or carrying out maintenance operations on it.
• The procedures contained in this manual are intended to be applicable to machine only for
permitted uses, and with all safety devices in function.
If the machine is used for purposes other than those indicated or in safety conditions other
than those indicated, the Customer becomes directly responsible for any person possibly in-
volved in accidents or injuries and for abnormal wear and tear of the machine.
1.2 Supplied documentation
The documents supplied with the machine include this Use and Maintenance Manual.

1. Introduction
2
1.3 Customer service
The Technical Assistance and Spare Parts Service are available to the Customers.
MOSA recommends that you contact the nearest authorised service centre for specialised intervention for all
control and overhaul operations.
Inordertoobtainquickande󰀨ectiveresponses,indicatetheModelandSerialNumbershownontheidenti-
cation plate (see “1.8Identicationdata”).
1.4 Spare parts
Only original spare parts that guarantee functionality and durability must be used.
The use of non-original spare parts will void all warranty and Technical Support obligations.
1.5 Declaration of conformity
Themanufacturer:
MOSA Div. of BCS S.p.A.
Viale Europa, 59 20047 Cusago (Milano) Italy
Declaresthatthemachines:
GE 3900
GE 6900
ComplywiththerequirementsofthefollowingEC/EUDirectives:
• Machine Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• Electromagnetic Compatibility Directive 2014/30/EU
andwiththerequirementsofthefollowingUKregulations:
• The Supply of Machinery (Safety) Regulations 2008/1597
• The Electrical Equipment (Safety) - Regulations 2016/1101
• Electromagnetic Compatibility - Regulations 2016/1091
1.6 Unauthorized changes
NochangescanbemadetothemachinewithoutMOSA'Sauthorization.
Unauthorized changes void any form of warranty on the machine and any civil and/or criminal liability in case
of accidents or injuries
1.7 Allowed and non-allowed use
Thisgeneratingsetisusedtogenerateelectricalcurrentinaccordancewiththespecicationsofthede-
clared electrical system.

3
1. Introduction
1.8 Identication data
ThedataidentifyingthemachinearespeciedontheIDplateappliedintheareaindicatedinthegure.
They are necessary for spare parts requests and communications with the Customer Service Department.
Low-power generating set
BCS S.p.A. Viale Europa 59 - 20090 Cusago (MI) ITALY - www.mosa.it
Model:
(Serial N./Matricola)CXXXXX
Rated Power kW V
A
kg
kW
Hz
IP23M
Rated Voltage
Maximum Power Rated Current
Rated Frequency Mass Weight
Quality Class
Performance Class
Power Factor
Year of manifactureIP Grade
EN ISO 8528-13
A
A
B
B
B
C
D5264090
A- Manufacturer'sdata
B - Machine data
• Model: model
• Reference technical standard
• Year of manifacture:Yearofmanufacture
• Serial No.:MachineSerialNumber
C - Machine technical data
• Rated Power:Ratedpower-kW
• Maximum Power:MaximumPower-kW
• Rated Frequency:RatedfrequencyHz
• IP Grade:IPprotectiondegree
• Rated Voltage:Ratedvoltage-V
• Rated Current:Ratedcurrent-A
• Mass Weight:Dryweight(kg)
• Quality Class:Qualityclass-Output
• Performance Class:Performanceclass-
Output
• Power Factor:Ratedcosφ(powerfactor)

1. Introduction
4
NOTES:

5
2. Safety
2. Safety
2.1 Safety information
Always respect the warnings contained in this manual and present on the decal applied to the machine.
This allows the machine to be used safely, avoiding damage to property and injury or death to people.
The following words and symbols were used to identify important safety messages.
Symbol identiesimportantsafetymessagesonthemachine,inthemanualandelsewhere.Whenyou
see this symbol, follow the instructions in the safety messages.
DANGER
• This word indicates a situation of imminent risk that, if not avoided, could cause serious injury
or even death to people and serious damage to property.
WARNING
• This word indicates a potential risk situation which, if not avoided, could result in serious inju-
ry or even death to people and serious damage to property.
CAUTION
• This word indicates a potential risk situation that, if not avoided, could cause minor or moder-
ate injuries.
It can also be used to prevent dangerous operations that can cause damage to the machine.
The following terms are used to transmit the information to be followed to the user, to avoid damage to the
machine.
* Important
• If the precautions described are not observed, the machine could be damaged and its useful life re-
duced.
Note:
• This word is used to indicate further useful information.

2. Safety
6
2.2 Positioning of safety decal and information
D5264140
1
2
4
6
5
3
7
8
9

7
2. Safety
2.2.1 Decal explanation
G8815G0502000
Using a generator in doors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or
garage, EVEN IF doors and
windows are open.
Only use OUTSIDE and far
away from windows, doors
and vents.
• Pos. 1 - Danger!
Using the generator set inside a building could be fatal.
The exhaust gases from the generator set contain car-
bon monoxide, a colourless and odourless poison.
Do not use the generator set inside a building even if
windows and doors are kept open.
Use the generator set outdoors in a ventilated place
away from doors and windows.
G8820G0502000
• Pos. 2 -Warning
Consult the manual
The following dangers may arise during use and main-
tenance.
◦Danger of electric shock.
Do not install the machine in damp areas and do
not expose it to rain or snow.
Do not handle the machine with wet hands or feet.
◦Risk of electrocution.
Ground the generator set.
◦ Dangerofre.
Do not refuel while the machine is running.
◦Danger of inhaling toxic gases.
Use the machine in a ventilated place.
◦Do not expose electrical sockets to rain or mois-
ture.
G8806G0101000G8806G0102000
• Pos. 3 - Maximum fuel level
• Pos. 4 - Low fuel level (on reserve)
G8821G0508000
• Pos. 5 -Starting and stopping procedure.
G8802E0103010
• Pos. 6 - Air lter maintenance.
Cleantheairlterevery50hours(every10hoursin
case of dusty environments) and dry it.
Immerse it in clean oil.
Wipeo󰀨anyexcessoil.

2. Safety
8
G8806E0102000
• Pos. 7 - Access plug for engine oil control, top-up and
replacement.
G8812G0101000
• Pos. 8 -Warning
Risk of burns.
Risk of inhaling toxic gases
Keep a safe distance from and do not touch hot surfac-
es.
GE 3900 GE 6900
D5264100
• Pos. 9 - Sound power level
Unit of measurement dB(A); represents the amount of
acoustic energy emitted in the unit of time, regardless
of the distance of the measuring point.

9
2. Safety
2.3 General precautions
Any errors during use, checks or maintenance could cause
the risk of injury, even serious
• Before performing the operations, read this manual and
the decals applied to the machine and follow the warn-
ings.
Ifyoudon'tunderstandanypartofthemanual,askyour
SafetyO󰀩cerforexplanations.
• The machine can only be used and repaired by trained
and authorized personnel.
• Do not work if you feel unwell, have drunk alcohol or
take medicines that impair your ability to work safely or
repair the machine.
• Before starting the operations, check the machine. If
anomalies are detected, do not operate on the machine
before having completed the necessary repairs.
• Comply with the provisions and laws in force in the coun-
try in which you work.
D5260050
2.3.1 Personal protective equipment
• Do not wear clothes that are too loose or accessories, to
prevent them from becoming entangled, causing person-
al injury.
• Always wear the personal protective equipment pre-
scribed for the place where you work, such as a protec-
tive helmet, safety footwear, safety glasses, gloves and
noise protection headphones.
• Before using personal protective equipment, check that it
is in perfect condition. D5260060
2.3.2 Check the work area
• Ask the site safety manager for information on the regu-
lations to be observed.
• Understand the signs and indications on site.
• Makesurethatreextinguishersandrstaidkitare
available on site and inquire about where they are locat-
ed.
• Check that the area is clear of materials that may be
hazardous during the operation of the generating set
(suchasammablematerialsorliquids).
• Make sure that there are no unauthorized persons in the
area.
D5260070
D5260080

2. Safety
10
2.4 Fire prevention
2.4.1 Fire due to fuel, oil
• Avoidapproachinganyametoammablesubstances
such as fuel and oil.
• Donotsmokeoruseopenamesnearammablesub-
stances.
• Stop the machine before refuelling.
• Makesurenottospillammablesubstancesonover-
heated surfaces or on parts of the electrical system.
• Afterrefuelling,removeanyspillsandtightenalllling
caps tightly.
• For safety in the workplace, store the cloths soaked in
ammablematerialsinacontainer.
• Store oil and fuel in pre-established and well-ventilated
locations and prohibit the entry of unauthorised person-
nel.
• Whencleaningthemachine,donotuseammablesub-
stances such as diesel or gasoline.
2.4.2 Fires caused by ammable material build-up
• Removedryleaves,chips,piecesofpaper,carbondust,orotherammablematerialsaccumulatedfrom
the machine.
2.4.3 Fire caused by electrical wiring
• Always keep the electrical wiring clean and tightened.
• Periodically check that there are no loose or damaged parts. Tighten loose wiring connectors or termi-
nals.
• Repair or replace any damaged cables.
2.4.4 Fire caused by piping
• Periodicallycheckthatthehoseclampsarermlyxed.
• Ifloosened,theymayvibrateduringmachineoperationandcauseleakageofliquids,provokingresand
serious injuries, including fatalities.
D5260090

11
2. Safety
2.5 Lifting and transport precautions
2.5.1 Lifting by chains or ropes
• Make sure that the handling area is clear of obstacles
and people.
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
• Lift the machine only by the frame.
• Check the condition of the frame. If it is damaged, re-
place it before lifting the machine.
• Always use lifting equipment adequately sized and con-
trolled by authorized bodies.
• Do not harness the machine with a single rope.
Use two ropes placed symmetrically to keep the machine
in a horizontal position.
• Do not subject the machine and the lifting equipment
used to undulating or abrupt movements that transmit
dynamic stresses to the structure.
• Do not lift the machine at a height higher than that nec-
essary for handling.
• Do not leave the machine suspended for longer than
necessary for handling.
D5264330
2.5.2 Lifting and manual transport (Mod. GE 3900)
• The machine should be lifted and transported by at least
2 people.
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
D5264340
2.5.3 Transport with towing carriage
• The machine is equipped with a towing carriage for easy
handling, which is to be assembled according to the
instructions that are included in the packaging.
• Handlethemachinewiththeengineo󰀨,theelectrical
cables disconnected and the fuel tank empty.
D5264350

2. Safety
12
2.6 Precautions for positioning the machine
2.6.1 Positioning site precautions
• The machine may not be used indoors, such as in homes and garages, even if the doors and windows
are open.
This machine has been designed for outdoor use and can therefore be positioned outdoors.
In case of meteorological precipitation (rain, snow, etc.), place the machine in an adequately sheltered
place. If this is not possible, do not use the machine.
• Donotplacemachinesorequipmentnearheatsources,inareasatriskwithexplosionhazardorre
hazard.
Placethemachineatasafedistancefromfueltanks,fromammablematerial(rags,paper,etc.),from
chemicals.
Follow the instructions of the competent authorities.
• To limit potentially dangerous situations, isolate the area around the machine, thus preventing any unau-
thorized personnel from getting close to it.
• Although the machines produced comply with the regulations on electromagnetic compatibility, do not
placethemachinenearequipmentinuencedbythepresenceofmagneticelds.
• Make sure that the area immediately surrounding the machine is clean and free of debris.
• Alwaysplacethemachineonaat,solidsurfacethatisnotsubjecttofailureinordertoavoidtipping,
slipping or falling during operation.
• The machine must always be positioned so that exhaust
gases disperse into the air without being inhaled by
people or animals.
The exhaust gases of an engine contain carbon mon-
oxide:thissubstanceisharmfultohealthand,inhigh
concentration, can cause poisoning and death.
• If the machine is used indoors, make sure that the area
is well ventilated.
D5260150
2.6.2 Precautions for electric connections
• Use appropriate electrical plugs at the machine output
sockets and make sure that the electrical cables are in
good condition.
• Do not use the machine with wet or damp hands and/or
clothing.
D5260160
2.7 Precautions during operation
• Keep all panels closed during normal operation.
• Access to the internal parts of the machine must only be carried out for maintenance purposes.
• Keeptheareanearthemu󰀪erfreefromobjectssuchasrags,paper,cartons.
Thehightemperatureofthemu󰀪ercouldcausetheobjectstoburnandcauseare.
• Immediately stop the machine in case of malfunctions.
Donotrestartthemachinewithoutrstidentifyingandsolvingtheproblem.
• Do not wrap or cover the machine with cloths while it is running.
Before covering the machine, make sure that the engine parts are cold

13
2. Safety
Iftheenginepartsarestillwarm,thereisariskofdamagetothemachineandre.
• Do not place objects or obstacles near the air suction and expulsion windows; a possible overheating of
themachinecouldcauseare.
2.8 Precautions against noise
• Excessive noise can cause temporary or permanent hearing problems.
The actual risk arising from the use of the machine depends on its use conditions.
• There is a decal on the machine that declares the sound power level dB(A) emitted by it. The value pro-
vides an indication of the noise level emitted by the machine when used, in order to assess the noise in
the environment where the generator is placed.
• Theadoptionofspecicmeasures(suchasheadphonesorearplugs)mustbeassessedbytheoperator.
2.9 Precautions during fuel and engine oil lling
• Fuelandengineoilareammable.
Rellwiththeengineo󰀨.
• Refuel only outdoors or in well-ventilated environments.
• Donotsmokeorusenakedamesduringrefuelling.
• Do not fuel with the engine running or hot.
• Clean and dry any leaks of engine oil and fuel before
restarting the machine.
• After refuelling, fully tighten the tank caps.
• Donotllthefueltankcompletelytoallowexpansionof
the fuel inside it.
• Do not exceed the MAXIMUM engine oil level.
D5260090
2.10 Maintenance precautions
• Stop the machine and disconnect all electrical devices.
• To avoid injury, do not perform maintenance with the
engine running.
◦Rotating parts, such as the fan, are dangerous and
can get entangled on body parts or a worn object.
Whenperformingmaintenance,becarefultoap-
proach rotating parts.
◦Make sure not to drop or insert tools or other objects
in the fan or other rotating parts. They can touch the
rotating parts and be projected.
D5260190

2. Safety
14
• Donottouchtheengine,pipesandmu󰀪erduringoper-
ationorimmediatelyaftershut-o󰀨.Allowtheengineto
cool before performing any operation.
• Whendischargingtheengineoil,theenginemustbehot.
Engine oil may come into contact with the skin and
cause burns.
• Do not remove the guards and safety devices.
If it is necessary to remove them, after completing the
maintenance, install the removed guards and restore the
safety devices.
• Use work tools in good condition and suitable for the
work to be performed.
If you use a damaged or deformed tool or if you use a
tool for a purpose other than its intended purpose, there
is a danger of causing serious personal injury or death.
• Be careful not to damage the electric starter battery, as it
contains lithium.
If lithium leaks out and comes in contact with oxygen in
theair,itcancatchrecausinganexplosion.
D5260210
2.11 Precautions for disposal of waste material
• Be sure to store the waste liquid in containers or tanks.
• Do not discharge the oil directly into the soil or sewage
system, rivers, seas or lakes.
• Whendisposingofharmfulwastesuchasoil,fuel,cool-
ant,solvents,ltersandbatteries,followcurrentlaws
and regulations.
• Entrust the authorized companies with the disposal of
rubber material, plastic and components that contain
them (hoses, cables, wiring, etc.) in accordance with the
applicable laws and regulations.
2.12 Disposal of the machine
ThismachineisclassiedasElectricalEquipment.
For disposal, comply with Directive 2012/19/EU on waste of
electricandelectronicequipment(WEEE).
Thesymbola󰀩xedtotheproductortothedocumentation
states that, at the end of its useful life, the machine must be
disposed of separately.
Adequate separate collection helps avoid possible negative
e󰀨ectsontheenvironmentandhealthandpromotesthe
reuse and/or recycling of the materials that make up the
equipment.
D5260220

D5260250

15
3. Technical data
3. Technical data
3.1 Machine dimensions
GE 3900
GE 6900
D5264110
590
590
440
652
920
62
510
Ø25
450
7575
Ø200
686
690
516
751
1050
60
625
Ø28
546
8787
Ø238

3. Technical data
16
3.2 Technical data (mod. GE 3900)
Rated output powers
* Single-phase stand-by power (LTP) 3.3kVA/kW/230V/14.3A
* Single-phase PRP power 3kVA/kW/230V/13A
Frequency 50Hz
Cosφ 1
* Declared powers according to ISO 8528
Note
• The declared powers are valid at a temperature of 25 °C and an altitude of 100 metres above sea level
• Stand-by power (LTP): emergency power. Maximum power available for use with variable loads for a
number of hours/year limited to 500h. Overloading is not allowed.
• PRP power: continuous power with variable loads. Prime power available for use at constant load for an
unlimited number of hours/year. The average power that can be drawn over a 24-hour period must not
exceed 70% of the PRP.
Alternator
Continuous power 3 kVA
Stand-by power 3.3 kVA
Single-phase voltage 230 Vac
Frequency 50Hz
Insulation ClassH
Harmonicdistortion-THD < 5 %
Engine
Model GK 225
Engine type Single-cylinder,4-stroke,air-cooled,OHV
Displacement 1 / 223 cm³ (0.223 l)
Fuel Gasoline fuel
Compression ratio 8,7:1
Engine oil quantity 0.55ℓ
General specications
Fuel tank capacity 15ℓ
Autonomy (50% PRP) 9 h
Autonomy (100% PRP) 6.5 h
IP protection degree IP 23M
LwA Acoustic power (LpA sound pressure) 96 dB(A) (71 dB(A) @ 7m)
Performance class G1
Weight(Dry) 45 kg