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MG 8000 I-HMANUAL NUMBER

MI-G-00005700

GENERATING SET USE AND MAINTENANCE MANUALGB

GEN SET S.p.a.Via Stazione,5 - 27030 Villanova D’Ardenghi (Pavia) Italy

Tel. (+39) 0382-5091 - Fax (+39) 0382-509-244E-mail: [email protected] - internet: //www.genset.it

REVISION LEVEL 029-09-2008

Machine specifications can be modified at any time without any obligation to update thispublication. It is recommended to read this manual thoroughly because incorrect

operation may result in the warranty being void. Therefore it is also recommended to useonly original Gen Set S.p.A. spare parts.

Reproduction of this manual is not permitted, unless written approval is obtained fromGen Set S.p.A.

3MG 8000 I-H

MI-G-00005700

GBTABLE OF CONTENTS

01. REFERENCE GUIDE page 4

02. ACCIDENT PREVENTION / SAFETY REGULATIONS page 7

03. ENVIRONMENTAL DIRECTIONS page 14

04. THE POWER GENERATOR page 16

05. TECHNICAL DATA page 19

06. INSTALLING AND STARTING THE POWER GENERATOR page 23

07. USING THE GENERATOR page 26

08. MOVING THE GENERATOR page 30

09. GENERATOR MAINTENANCE page 33OIL

10. SPARE PARTS page 39

11. ELECTRICAL DIAGRAM page 46

12. ATTACHMENTS page 48

4

GB 01. REFERENCE GUIDE

MG 8000 I-HMI-G-00005700

01.1- This publication.....................................................................................................................page.5

01.2- Purpose................................................................................................................................page.5

01.3- Reference to regulations........................................................................................................page.5

01.4- Using this manual..................................................................................................................page.6

01.5- Terminology..........................................................................................................................page.6

01.6- Abbreviations........................................................................................................................page.6

5

GB01. REFERENCE GUIDE

MG 8000 I-HMI-G-00005700

01.1 THIS PUBLICATION

The “USE AND MAINTENANCE MANUAL”, publishedby the manufacturer, GEN SET S.p.A., is an integral partof the power generator. The manual is identified by apublication identifier, printed on the cover page and repeatedat the foot of every page, which allows the reader to identifyand locate the publication and/or make subsequent referenceto it.All the information included herein is brought up to the dateof publishing. The manufacturer reserves the right to modifyit without notice, and accepts no responsibility for any errorand/or omission.

01.2 PURPOSE

The USE AND MAINTENANCE MANUAL is intendedfor users and holds all the information necessary for usingthe product and perform its regular maintenance. Goodworking conditions, long life of the power generator, andthe protection and safety of users, will be dependent uponstrict observance of the instructions included in this manual.It is advisable to read thoroughly and observe the directionsincluded in this publication, which are organised, as far aspossible, according to the chronological sequence ofoperations when approaching the unit.

01.3 REFERENCE TO REGULATIONS

This manual has been produced according to the regulationsprovided by:– Attachment “I” to 2006/42/CE 98/37/EC Directive andsubsequent amendments (paragraphs “b”, “c” of article1.1.2 and article 1.7.4);– UNI EN 292/2 - 1992, article 5.5.This generator is complying with the provisions of thefollowing directives:– 2006/42/EC: Machine Directive (former 98/37/EC);– 89/336/EC, 93/68/EC: Electromagnetic Compatibility Directive;– 73/23/EC: Low Voltage Directive;– 2000/14/EC: Noise Emission in the Environment Directive.SOME NOTES ABOUT NOISE EMISSION(2000/14/EC Directive)Sound power level (LWA):Indicates the level of noise as required by the EuropeanDirective. It represents the amount of sound energy emittedin the time unit and is a characteristic of the sound sourceindependent of the distance from the point of measurement.dB(A) is the unit of measurement.

Sound pressure (Lp):Measurement of the pressure generated by the emission ofsound waves taken at a certain distance from the source.Its value changes with the distance from the source and isalso measured in dB(A).WARNING! Special attention must be paid to avoidingconfusion between LWA and Lp. In this manual the noiseemission is indicated as sound power level (LWA) and soundpressure (Lp) as well. Sound pressure values (Lp), as afunction of distance, can be calculated for equipment witha given sound power level (LWA) using the following table:Lp at 1 m = LWA -8 dBLp at 4 m = LWA -20 dBLp at 7 m = LWA -25 dBLp at 10 m = LWA -28 dBLp at 16 m = LWA -32 dBExample: for equipment with LWA = 90 dB:Lp at 1 m = 90 dB - 8 dB = 82 dBLp at 4 m = 90 dB - 20 dB = 70 dBLp at 7 m = 90 dB - 25 dB = 65 dBLp at 10 m = 90 dB - 28 dB = 62 dBLp at 16 m = 90 dB - 32 dB = 58 dBThe Directive 2000/14/EC specifies that the limits of soundemissions are dependent on the power output of powergenerators or welding generators. The limits set down bythis Directive are relating to the sound power levelguaranteed and not to the sound power level measured,which does not take account of all the possible variablesresulting from either the production stage or the differentmeasurement procedures.The reduction of the limits provided for has been divided intwo phases: the first phase in force from 03/01/02 and thesecond phase in force from 03/01/06. The following tableshows the sound power levels (LWA) approved for powergenerators and welding generators.

The Directive 2000/14/EC requires that the power generatoror welding generator is marked with the sound power levelguaranteed and the CE Marking relating to the ECDeclaration of Conformity.The marking of the sound power levelguaranteed consists of a number in dB,the LWA mark and the specific symbol:

Electric power output

Pel kW

Sound power levelpermitted

from 03/01/02 Phase 1

Pel

2 < Pel

Pel

LWA dB (A) 97 + log Pel



Sound power levelpermitted

from 03/01/06 Phase 2




6

GB 01. REFERENCE GUIDE

MG 8000 I-HMI-G-00005700

01.4 USING THIS MANUAL

“Symbols” are used along with text to highlight and pointout visually the relevance of different types of information.Graphic representation of symbols and their meaning:

Points out to important complementary information.

The non-observance of associated directions can causedamage, even irreparable, to the power generator.

Points out to possible situations dangerous for people.

This manual, together with appendices and any inclusions,must be kept with the utmost care and always beunabridged, undamaged and readable in its entirety.If lost, a copy must be promptly requested to themanufacturer.

01.5 TERMINOLOGY

Explanation of some of the terms relating to the powergenerator and used in this publication.

FRONT: the part of the unit where the control panel islocated.

BACK: the opposite part.

RIGHT OR LEFT SIDE: referred to an operator standing infront of the unit and looking at the control panel.

01.6 ABBREVIATIONS

A ampere

V volt

ca alternate current

cc direct current

3F + N three phase plus neutral

Ah ampere / hour

Hz hertz

hp horsepower (1hp = 0,736 kW)

cos power factor

kW kilowatt

kWm kilowatt motor

kVA kilovolt ampere

kg kilogram

l litre

l/h litre / hour

mm millimetre

m metre

s second

°C degree Celsius

LWA sound power level

Lp sound pressure

dB(A) decibel

Y collegamento a stella

D collegamento a triangolo

7

GB02. ACCIDENT PREVENTION / SAFETY REGULATIONS

MG 8000 I-HMI-G-00005700

02.1- Precautions to be observed...................................................................................................page.8

02.2- Risks for the operator when using this unit.............................................................................page.9

02.3- Protective clothing recommended for operators......................................................................page.9

02.4- Meaning of safety signs......................................................................................................page.10

02.5- Location of safety signs provided on the unit........................................................................page.13

8

GB 02. ACCIDENT PREVENTION / SAFETY REGULATIONS

MG 8000 I-HMI-G-00005700

Read carefully the instructions for use; operate accordingto the regulations in force in your country.

02.1 SAFETY PRECAUTIONS TO BE OBSERVED

WHEN FUELLING

Engine fuel can cause fire or explosion:• Stop the engine before fuelling and let the machine cool.• Do not fuel while smoking or near sparks or flames.• Do not overfill the tank. In case, clean up any spilled fuel immediately before starting the engine.

WHEN PERFORMING MAINTENANCE

• Always switch off the generator before performing any service.• It is not advisable that maintenance operations are performed by unskilled personnel.• Always use the necessary individual protection equipment.• The battery contains sulphuric acid in solution, and can cause explosion:

- Always disconnect the battery.- Never short battery’s positive and negative terminals, as this can cause battery explosion.- Battery explosion can cause burns and blindness.- Always wear protection gloves, face masks and acid resistant cloth.

• In case of contact with acid do the following:- In case of splash of acid into the eyes: wash immediately with clean water and seek medical advice as soon as possible.- In case of splash of acid on the skin: wash immediately with clean water and seek medical advice as soon as possible.- In case of ingestion of acid: seek medical advice immediately.

• When checking the engine oil level or changing the oil:- Beware: hot oil can cause burns. Always wear protective gloves.

BEFORE STARTING THE GENERATOR

• Connect the power generator to earth using the proper terminal and a cable of suitable size without interposing switches or other devices capable of breaking the electrical connection. Make sure that no load is connected to the machine.

WHEN MOVING THE GENERATOR

• When transporting the generator to the place of use, it must be firmly fastened to the vehicle.• When moving and transporting the generator, do not tilt excessively.• Lift the generator using the lifting eye provided on the top of the unit.• If it is necessary to lift the generator using a forklift, the position of forks in such a way as to balance the generator weight correctly.• When lifting and moving the generator, do not stay or walk within the proximity of the lifting and moving equipment.• Never leave the generator slung overhead.

WHEN USING THE GENERATOR

• Check that the generator is properly connected to earth.• Check that your tools’ cables are in perfect conditions.• Make sure that switches and controls are correctly set for starting (see Chapter 07).• Operate the generator in well-ventilated areas, making sure that the exhaust is not restricted.• Keep the generator away from walls or other obstructions to avoid the hot air or exhaust recycling that would cause generator overheating.• Use fume extractors to ensure the correct air turnover when operating indoors.• Do not operate near flammable materials.• Fill fuel tank when engine is stopped. Do not smoke when fuelling.• Do not overfill the tank and clean up any spilled fuel.

9


MG 8000 I-HMI-G-00005700

• Check the level of any liquids that may leak into the bund..Empty the bund if necessary. Do not dump the liquids ontoland but dispose of them according to the local legislation.• Check daily that there are no leaks of liquids from the engine.

Do not disconnect the battery cables when the powergenerator is running.

USES NOT ALLOWED

• Do not connect the power generator to the commercial electrical grid.• Do not operate near flammable materials or if explosive gases or vapours are present.• Do not operate in narrow or poorly ventilated places.• Do not operate if the electrical protections are not effective.• Do not touch the silencer and the engine parts close to it.• Do not perform service when the engine is running.• Do not tamper with electrical components.• Any service operation on electrical components must be performed after stopping the engine and by skilled personnel.• Stay away from moving parts and do not get close wearing loose clothing, ties, necklaces, bracelets, and anything that can be caught by moving parts.

02.2 RISKS FOR THE OPERATOR WHEN USING THIS UNIT

ELECTRIC SHOCK

Electric shock can injure or kill. This electric energy cancause severe or fatal shock to the operator or others in theworkplace.• Always connect the generator to earth.• Never touch any parts that are electrically live.• Repair or replace all worn or damaged parts.• Install and maintain equipment according to regulations.• Switch off the generator and disconnect the battery before performing any service or repairs.• Read and follow all the instructions in this Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag or sparks.• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.• Ventilate all flammable or explosive vapours from the workplace.• Do not cut or weld on containers that may have held combustibles.• Provide a fire watch when working in an area where fire hazards may exist.

NOISE

Noise can cause permanent hearing loss.You must protect your ears from loud noise to prevent lossof hearing.• To protect your hearing, wear protective ear plugs and/or

earmuffs. Protect others in the workplace.• Noise levels should be measured to be sure the decibels

(sound) do not exceed safe levels.• For information on how to measure noise, please refer to

Section 01.3 on page 5.

GASES AND FUMES

Combustion gases produced by the machine, if inhaled, arehazardous to your health. Make sure that these candissipate in the atmosphere without obstructions.

02.3 PROTECTIVE CLOTH RECOMMENDED FOR OPERATORS

It is recommended that operators wear the followingequipment:• Coveralls• Medium/heavy duty gloves• Acid resistant gloves (only for battery maintenance)• Protective ear plugs and/or earmuffs

N.B.: material not supplied.

10


MG 8000 I-HMI-G-00005700

02.4 MEANING OF SAFETY SIGNS

These signs inform the user about any hazards that can cause severe injury. Read carefully the meanings and precautionsindicated in this manual.

If the original stickers attached to the machine get lost, damaged or even partially unreadable, they must be replaced.

Danger: the generator can be started remotely, do not stay in the proximity.

Danger: do not open when the engine is hot.

Danger: belt and fan propeller. Turn off the generator before opening covers or raising the canopy.

Danger: belt. Turn off the generator before opening covers or raising the canopy.

Danger signs

Read and understand the Use and Maintenance Manual before operating the generator. The machine has been designed in such a way as to guarantee the safe and reliable operation, as long as the instructions are followed; otherwise personal injury or equipment damage could result.

Danger of electric discharges: read the manual.

Danger of burns: hot surfaces.

Danger of electric discharges.

Meaning

11


MG 8000 I-HMI-G-00005700

Exhaust gases contain carbon monoxide, and other components dangerous to your health.. Never operate the generator in a closed room. If installed inside, strictly observe the rules in force about ventilation.

Fuels are extremely flammable, and in certain conditions even explosive. Fuel in a well ventilated area and after stopping the engine. Do not bring close cigarettes, sparks or flames while fuelling. Clean any diesel oil spill immediately.

Prohibition signs

Danger signs

Electrical connections to an emergency grid must be carried out by qualified electricians and in conformity with the rules in force on that matter. Improper connections can result in current returns from generator to connected lines. Such current returns can result in electric shocks received by workers of the electric company or by people coming into contact with electric lines during failure recovery. Moreover, as soon as the line is recovered, the generator can explode, burn or cause fires in the building electrical system.

Prohibition of using flames or smoking.

Prohibition of extinguishing fires with water; use fire extinguishers containing proper extinguishing agents.

Prohibition of cleaning, lubricating, repairing or adjusting moving parts.

Danger of crushing the upper limbs.

Meaning

Fuels are extremely flammable, and in certain conditions even explosive. Fuel in a well ventilated area and after stopping the engine. Do not bring close cigarettes, sparks or flames while fuelling. Clean any petrol spill immediately.

Danger of burns! Do not touch the exhaust manifold or the engine when the generator is in operation. Stay away from the generator.

Danger of leaks of corrosive liquids.

Meaning

STOP

12


MG 8000 I-HMI-G-00005700

Obligation signs Meaning

Informationsigns Meaning

Indicates the location of a point for lifting the generator unit.

Do not go close to the generator with flames. Obligation of wearing protection goggles when using grinders, power tools etc., connected to the generator.

Do not perform service when the generator is in operation. Wear protective ear plugs and/or earmuffs when close to the generator.

This card warns that the battery that the has no acid. Before starting the generator, prepare the battery according to the instructions of Chapter "06".

Marks the position of the points for lifting the unit using a fork lift.

13


MG 8000 I-HMI-G-00005700

02.5 LOCATION OF SAFETY SIGNS PROVIDED ON THE UNIT

TOP VIEW

FRONT VIEW

TEMPERATURES AND ALTITUDES PLEASE CONSULT FACTORY TO CHECK

UP TO 40° C AND 1000 MT ALTITUDE − FOR H IGHER VALUES OF GENERATOR SET IS DESIGNED TO OPERATE IN AMB IENT TEMPERATURES

AVAILABLE POWER ISO 8528

Cosf

100

120V AC

MG 8000 I-H

240V AC

Circuit BreakersCircuit Breakers40A 40A

Circuit Breakers20A

Circuit Breakers20A

14

GB 03. ENVIRONMENTAL DIRECTIONS

MG 8000 I-HMI-G-00005700

03.1- Waste material and lubricating oil.........................................................................................page.15

03.2- Disposal of the unit.............................................................................................................page.15

15

GB03. ENVIRONMENTAL DIRECTIONS

MG 8000 I-HMI-G-00005700

03.1 WASTE MATERIAL AND LUBRICATING OIL

When running, the generator produces no waste material.Spare parts replaced during the unit life and the lubricatingoil are counted as waste, and must be disposed of accordingto the laws in force in the country where the generator islocated.

03.2 DISPOSAL OF THE UNIT

Procedure

1. Disassemble the unit and classify its componentsaccording to the following rule:- Reusable components- Components made of recyclable material- Components to be disposed of and lubricating oil (waste)

The parts so disassembled must be disposed of accordingto the laws in force in the country where the powergenerator is located.

Do not dispose of any type of lubricating oil,mineral or synthetic, onto land,drains orsewers.Dispose of batteries as instructed by locallegislation.

16

GB 04. THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

04.1- Generator components........................................................................................................page.17

04.2- Control panel description.....................................................................................................page.18

17

GB04. THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

04.1 GENERATOR COMPONENTS

Fuel filler cap

Fuel tank

Muffler

Control panel

Recoil starter

Electric starter

Oil drain plug

Left side rear view

Right side front view

Air cleaner Starter grip

Frame

AlternatorOil filler cap/dipstick

18

GB 04. THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

LEGEND

1. 40 A circuit breaker2. Hour meter3. 20 A circuit breaker4. 240 V 50 A socket5. 120 V 2x15 A socket6. Data plate7. Earth clamp

04.2 CONTROL PANEL DESCRIPTION

TEMPERATURES AND ALTITUDES PLEASE CONSULT FACTORY TO CHECK UP TO 40°C AND 1000 MT ALTITUDE − FOR HIGHER VALUES OF GENERATOR SET IS DESIGNED TO OPERATE IN AMBIENT TEMPERATURES


Cosf

100

120V AC

MG 8000 I-H

240V AC

Circuit BreakersCircuit Breakers40A 40A

Circuit Breakers20A

Circuit Breakers20A

1 2 3

4 5

6

7

19

GB05. TECHNICAL DATA

MG 8000 I-HMI-G-00005700

05.1- Generator............................................................................................................................page.20

05.2- Engine.................................................................................................................................page.20

05.3- General specifications..........................................................................................................page.20

05.4- Rating plate description........................................................................................................page.21

05.5- Outline dimensions...............................................................................................................page.22

20

GB 05. TECHNICAL DATA

MG 8000 I-HMI-G-00005700

05.1 GENERATOR

05.2 ENGINE

05.3 GENERAL SPECIFICATIONS

Prime power: 10% overload permitted for 1 hour every 12 hoursStandby power: no overload permitted

Engine type Honda GX390

Number of cylinders 1

Displacement 390 cm3

Power (emergency service) 13 CV (9,6 kWm)

Engine speed 3600 rpm

Cooling system Air

Fuel type Gasoline

Oil tank capacity 1,1 l

Starting system Manual

Consumption per hour (at 75% of continuous service) 2,9 l/h

Noise power emission level Lwa 100

Fuel tank capacity 30 lOperating range at 75% of continuous service power 10 h 30 min. ~

Weight 91 Kg

Dimensions (L x W x H) 727 x 525 x 606

Type Synchronous

Single phase power (Standby Power) 8 kVA - 240 V (according to DIN 6271)

Single phase power (Standby Power) 4 kVA - 120 V (according to DIN 6271)

Frequency 60 Hz

Power factor 0,8

Insulation class F

Degree of protection IP 23

21

GB05. TECHNICAL DATA

MG 8000 I-HMI-G-00005700

05.4 RATING PLATE DESCRIPTION

A rating plate showing the operation capabilities and performance limits is provided on the unit.

LEGEND1. Manufacturer’s logo2. Power generator model3. Power factor4. Rated frequency5. Unit’s degree of protection6. Insulation class7. Ambient temperature8. Altitude reference9. Engine speed10. Unit’s serial number11. Year of manufacture12. EC Marking13. Machine weight14. Noise power emission level (Lwa)

15. Rated current values16. Rated voltage values17. Rated power kW18. Rated power kVA19. Manufacturer’s address

100

TEMPERATERES AND ALTITUDES PLEASE CONSULT FACTORY TO CHECK UP TO 40°C AND 1000 MT ALTITUDE − FOR HIGHER VALUES OF GENERATOR SET IS DESIGNED TO OPERATE IN AMBIENT TEMPERATURES

ISO 8528AVAILABLE POWER

1

2

3

4

6

7

8

910

11

12

13

14

15

16

17

18

19

5

22

GB 05. TECHNICAL DATA

MG 8000 I-HMI-G-00005700

05.5 OUTLINE DIMENSIONS

dimensions in mm

Trolley-mounted unit (dimensions in mm)

AVAILABLE POWER

GENERATOR SET IS DESIGNED TO OPERATE IN A MBIENT TEM PERATURES UP TO 40°C AND 1000 M T ALTITUDE − FO R HIGHER VALUES OF TEM PERATURES AND ALT IT UDES PLEASE CONSULT FACTORY TO CHECK

ISO 8528

100

Cosf

120V AC240V AC

G 8000 I-H

Circuit Breakers40A

Circuit B reakers40A 20A

Circuit Breaker s20A

Circ ui t Breakers

727525

606

C os f

120V AC240V AC

G 8000 I-H

Circuit Breakers40A

Circuit B reakers40A 20A

Circuit B reakers20A

Circuit Breakers

AVA ILABL E P OWE R

GENERATOR SE T IS DE SIGNE D TO OP ERATE IN AMBIE NT TEMP ERATUR ES U P TO 4 0°C AND 1000 MT ALT ITU D E − F OR HIGHER VALU ES OF TEMPE RATUR ES AND AL TITUD ES PL EASE CONSU LT F ACTOR Y TO CHE CK

ISO 8528

100

1035688

705

23

GB06. INSTALLING AND STARTING THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

06.1-Preliminary operations..........................................................................................................page 24

06.2-Maximum operating angles...................................................................................................page 25

06.3-Location..............................................................................................................................page 25

06.4-Checking generator operation................................................................................................page 25

06.5-Generator unit run-in............................................................................................................page 25

24

GB 06. INSTALLING AND STARTING THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

06.1 PRELIMINARY OPERATIONS

BEFORE STARTING THE MACHINE

CHECKING THE MOTOR OIL (picture 1)

The machine is not supplied with lubricatingoil. Before starting the machine it is necessaryto get a provision of oil. Do not overfill.

Before checking or topping up the motor oil, check that themachine is on a stable surface and is perfectly level.To check the level of the motor oil, use the special graduateddipstick on the left hand side of the motor (n.1) (seeChecking the oil level on page 35); if the amount of oil islow, top up the motor using the special oil filler (n.2). UseSAE 10W-30 multigrade oil for petrol motors, suitable fortemperatures from - 20 °C a + 40 °C, (for differenttemperatures consult the table on page 35).

pic.2

pic.1

CHECKING THE FUEL (picture 2)

Before starting the machine check the fuel level, and if it islow top it up.For filling up with fuel, do as follows:• Stop the motor and remove the fuel tank cap (n.1).• Close the fuel tap before filling up (n.2).• Do not fill the tank beyond the fuel limit (n.3). Otherwise the fuel might spill out of the tank when it warms and expands after the machine has been turned on turned on.• When filling up always use the fuel filter.• Carefully clean up any trace of fuel that came out before starting the motor.

1

25

GB06. INSTALLING AND STARTING THE POWER GENERATOR

MG 8000 I-HMI-G-00005700

06.2 MAXIMUM OPERATING ANGLES (picture 3)

Do not exceed the operating angles shown inthe figure while running the power generatorunit, or engine damage will occur.

06.3 LOCATION

Operate in open, well-ventilated areas; ifoperated indoors, vent the engine exhaustoutside the building and make sure that theroom has good air turnover. Keep the engineexhaust outlet away from building exteriorand interior walls and air intakes.

A proper installation site should be selected for the powergenerator if the unit is to provide dependable service.

06.4 CHECKING GENERATOR OPERATIONPerform a test of operation according to the instructionsincluded in the following Chapter.

06.5 GENERATOR UNIT RUN-INThe application of heavy loads to a new engine has theeffect of shortening the engine life. During the first 20 hoursof operation, and to allow for a good engine run-in, do notuse more than 70% of the maximum power output rated inthe technical specifications. After first 20 hours of operationchange the engine oil.

TEMPE RA TU RES AN D A LTITU DE S PL EA SE C ON SU LT F ACT OR Y TO CH EC K

UP T O 4 0°C AN D 1 00 0 MT ALT ITUD E − FO R H IG HE R VA LU ES O F GE NE RAT OR SET IS DE SIGN ED T O O PE RA TE IN A MBIEN T TE MPER AT URE S

AV AILA BLE POWE R IS O 852 8

1 00

Cosf

G 8000 I-H

240V AC

C ircu it B reakers40A 40A

C irc uit Break ers

120V AC

C ircu it Breakers20A

Circuit Break ers20A

10°

10°

10°

10°

pic.3

26

GB 07. USING THE GENERATOR

MG 8000 I-HMI-G-00005700

07.1- Earthing the power generator...............................................................................................page 27

07.2- Starting the engine...............................................................................................................page 27

07.3- Using the power generator unit............................................................................................page 28

07.4- Stopping the engine.............................................................................................................page 28

07.5- Adjustments and settings.....................................................................................................page 29

07.6- Putting the power generator temporarily out of service and restarting operation......................page 29

27

GB07. USING THE GENERATOR

MG 8000 I-HMI-G-00005700

07.1 EARTHING THE POWER GENERATOR(picture 1)

Before starting the machine, connect it to the ground usingthe special clamp (1) using a suitable broad cable withoutthe interpositioning of any switches or other devices thatmight interfere with grounding. The grounding system shouldconform to CEI 64-8 standards.

Always ground the machine. Make sure thatthe cables of your equipment are in perfectorder.

07.2 STARTING THE ENGINE (picture 2)

After having checked and topped up the oil level if necessaryand after making sure the machine has fuel, proceed asfollows:• Make sure that no load is connected to the machine.• Open the fuel tap (n.1).• Put the starting switch to the “ON” position (n.2).• Put the speed control lever to a position about 1/3 in the direction of maximum speed (n.3).• Close the air lever (n.4). - When the motor is cold, or if the ambient temperature is very low, completely close the air lever. - When the motor is hot, or if the ambient temperature is very high, leave the air lever half or fully open.• Slowly pull the handle of the starting device until it meets with a certain resistance. Put the handle back in its initial position and then pull it again sharply. Never completely pull out the selfwinding cable. After starting the motor let the handle of the starting device go back to its initial position while holding it with the hand (n.5).• After starting the motor, gradually open the air by rotating the relative lever until it is completely open. Do not fully open the air level immediately after the start-up if the motor was cold started and is not still warmed up, or if the ambient temperature is particularly cold, because in this case the motor might switch off (n.4).• After starting the motor, put the speed control lever to the low speed position (MIN) and wait until it warms up, without any load, for a few minutes (n.3).• Gradually shift the speed control lever to a position of high speed (MAX), stopping at the position corresponding to the desired speed (n.3). - At those times when it is not necessary to run the motor at a high speed, put the speed control lever at a minimum in order to save fuel and extend the life of the motor itself.

pic.1

pic.2

1 TEMPERATURES AND ALTITUDES PLEASE CONSULT FACTORY TO CHECK UP TO 40°C AND 1000 MT ALTITUDE − FOR HIGHER VALUES OF GENERATOR SET IS DESIGNED TO OPERATE IN AMBIENT TEMPERATURES


100

28

GB 07. USING THE GENERATOR

MG 8000 I-HMI-G-00005700

07.3 USING THE POWER GENERATOR

Ther machine is fitted with a circuit breaker that ensuresthe machine is protected in the event of a fault or electricaloverload.

CIRCUIT BREAKER

For operations involving the electrics contactonly an authorised Gen Set centre.

• Before connecting a load to the grip at the front of the machine make sure that the generator is providing sufficient power for the tools that are being connected.

Attention: at start-up the electric motorrequire a breakaway current that is a lothigher than the nominal values.

• Connect to the machine’s outlets using only cables that have a sufficiently broad cross-section and in optimal condition, with plugs that fit the outlets on the control panel.

07.4 STOPPING THE ENGINE (picture 3)

To stop the motor in the event of an emergency, simply turnthe motor switch to the “OFF” position (n.2). In normalconditions use the following procedure.• Put the speed control lever to a low speed position and let the motor run at the minimum for 2 or 3 minutes before switching it off (n.1).• Turn the starting switch in an anti-clockwise direction until it reaches the "OFF" position (n.2).• Close the fuel tap (n.3).• Slowly pull the handle of the starting device and then bring it back to its original position as soon as a slight resistance is felt. This operation is needed in order to prevent humid air entering the combustion chamber (n.4).

Stopping the motor using the fuel valve

Close the fuel valve and wait a few seconds for the motorto stop. Do not let fuel stay in the carburettor for long periodsof time, because the passages of the carburettor couldbecome blocked by impurities, with consequent possiblemalfunctions.

pic.3

29

GB07. USING THE GENERATOR

MG 8000 I-HMI-G-00005700

07.5 ADJUSTMENTS AND SETTINGS

All controls for the adjustments and settings necessarywhen using the generator are mounted on the control paneland are described in this Chapter.It is forbidden to perform further adjustments and settingsother than those described here.

Any adjustment and setting other than thosemade by the manufacturer may compromisethe reliability of the power generator andmake the warranty void.The engine oil level should be checked dailyby the operator, using the dipstick located onthe left side of the unit.

Stop the engine before fuelling. Do not smokewhen fuelling. Do not perform fuelling nearflames.

Do not overfill the fuel tank and clean up anyspillages. Check daily that there is no leakageof fuel or oil from the engine.

07.6 PUTTING THE GENERATOR TEMPORARILY OUT OF SERVICE AND RESTARTING OPERATION

If the generator is put out of service for longer than 6 months,it is advisable to disconnect the negative terminal of thebattery and to leave engine oil and fuel in to protectmechanical parts, along with the fuel supply, injection systemand the fuel tank from oxidation.When putting the generator back to service, all fluids shouldbe replaced, the battery should be charged, engine belts, ifany, all couplings and fuel pipes and seals should be checked.In case of longer out of service periods, contact Gen SetService Department.

30

GB 08. MOVING THE GENERATOR

MG 8000 I-HMI-G-00005700

08.1- Packing, transporting and storing the unit...............................................................................page 31

08.2- Lifting and moving the unit....................................................................................................page 32

31

GB08. MOVING THE GENERATOR

MG 8000 I-HMI-G-00005700

pic.2

pic.1

GENER ATOR SET IS DESIG NED T O OPE RATE IN AMBI ENT TE MPERAT URES

UP TO 40°C AND 1000 MT ALTIT UDE − FOR H IGHER VALUE S OF TEMPE RATUR ES A ND ALT ITUDE S PLEA SE CO NSULT FACTOR Y TO C HECK

ISO 8528

10 0

AVAIL ABLE P OWER

1 2 0V A C

Cosf

2 4 0V A C

G 800 0 I -H

Ci rcui t Br eak ers40A

Ci rcui t Br eak ers40A 2 0A

Cir cuit Bre ake rs Circ uit Bre ake rs2 0A

08.1 PACKING, TRANSPORTING AND STORING THE UNIT

The package is provided by Gen Set S.p.A..

Packaging

Disposing of packaging onto land is strictlyforbidden.

Do not overturn the generator (with or without packaging)during transport.The generator must be transported without fuel to avoidany leakage.The generator must be secured to the vehicle duringtransportation.

Transport (picture 1)

The generator unit must be stored in the horizontal position.

Storage

In case of long term installation, secure thegenerator using the anchor points providedin its base (picture 2).

Bottom view (dimensions in mm)

445

600

Ø9

32

GB 08. MOVING THE GENERATOR

MG 8000 I-HMI-G-00005700

pic.3

pic.4

The generator must be lifted and moved as indicated inpictures 3, 4.

Lifting and moving

Never leave the load insecure.

Lay the generator on the ground gently.

When lifting and moving the generator, do notstay or walk within it’s proximity.

Never leave the generator slung overhead(picture 4).

08.2 LIFTING AND MOVING THE UNIT

All lifting operations must be carried out byqualified personnel, such as fork lift operators,crane operators and slingers. The operatorshould be deemed responsible for using thecorrect method of slinging and lifting thegenerator unit.

When moving and transporting the generator,do not tilt it excessively.

33

GB09. GENERATOR MAINTENANCE

MG 8000 I-HMI-G-00005700

OIL

09.1- Maintenance........................................................................................................................page 34

34

GB 09. GENERATOR MAINTENANCE

MG 8000 I-HMI-G-00005700

OPERATIONS

Cleaning of the engine and control of the serration of nuts and bolts

Cleaning of the fuel tank cap

Control and regulation of the valve backlash

Elimination of the coal residual of the head of the cylinder

Cleaning of the air filter

Control of the engine oil level and eventual oil topping up

Cleaning and regulation of the carburetor

Cleaning of the candle

To replace the element of the air strainer

Substitution of the engine oil

Cleaning and regulation of the candle and the electrodes

General review of the engine, if necessary

(Before time after 20 hours of operation)

Every8 h

Every50 h

Every200 h

Every100 h

Every300 h

FREQUENCY

Every1000 h

Every500 h

09.1 MAINTENANCE

For service and maintenance operations relating to theengine, refer to the engine manufacturer’s manual providedwith the generator unit.To prevent breakdowns to the generator it is important tokeep the engine properly serviced and maintained.Observe the maintenance directions provided in this Chapterand the “Use and Maintenance Manual” provided by theengine manufacturer.

REGULAR MAINTENANCE

MAINTENANCE SHEDULE

If the generator works in adverse conditions, the intervals between maintenance schedules must be reduced.

35


MG 8000 I-HMI-G-00005700

• Checking the oil level should be carried out when the motor is cold before start-up or at least 5 minutes from when the motor stops.

Checking the oil level (picture 1)

The lubricating oil and the motor can be veryhot, so be very careful during the oil checkand especially when cleaning the dipstick.

Check the oil level using the dipstick (1), located on the leftside of the motor.• Pull out the dipstick and clean it with a cloth or absorbent paper.• Put the dipstick back in the hole without turning it.• Take it out again and make sure the level of the oil is between the minimum and maximum level marks.

If the oil level is too low add fresh oil (see Engine oiltable) using the dipstick (1).Wait at least five minutes and check that the level is betweenthe minimum and maximum level marks.

Do not fill up with oil beyond the maximumlimit (picture 2).

pic.1

In order to correctly carry out the check themachine should be perfectly level.

Engine oil table

pic.2The Oil Alert system will automatically stopthe motor before the oil drops below the safetylimit. Nevertheless, to avoid the nuisance ofan unexpected shutdown, always check theoil level of the motor before starting it.

36


MG 8000 I-HMI-G-00005700

Replace the motor oil after the first 20 hours of running andafter that every 100 hours.To replace the oil do as follows:• Stop the motor if it is running.• Unscrew the oil drain plug.• Tilt the machine slightly.• Let the hot motor oil drain out. Hot oil drains away quickly and completely.

Replacing the oil (picture 3)

Be careful, hot oil can burn, always useprotective gloves.

Rescrew and lock tight the oil drain plug. Get fresh oil,selecting the type on the basis of the “Engine oil table”on page 35.Put in the fresh oil level using the dipstick (picture 4), locatedon the left side of the engine.Once five minutes have passed check the level of the oilusing the dipstick.It is important that the machine is perfectly level.

The specified maximum level (picture 2, page35) should never be exceeded.

The drained oil should be collected in asuitable container and delivered to authorisedcollection centres. Check regulations andlegislation in force in your country regardingthe disposal of dangerous materials.

pic.3

Always use the best grade, clean oil. The useof contaminated or low quality oil and aninsufficient amount of oil can damage themotor and shorten its life.

pic.4

37


MG 8000 I-HMI-G-00005700

A dirty air filter makes it difficult to start the motor, lessensits power, causes malfunctions and shortens the life of themotor. The filter element should always be kept clean.Proceed as follows:• Remove the wing nut from the cover of the air filter and remove the cover.• Remove the wing nut from the air filter and remove the filter.• Remove the foam filter from the paper filter.• Inspect both filter elements and clean them if they are dirty or replace them if they are damaged.

Cleaning the air filter (picture 5)

The use of open flames is prohibited.

Replace the cartridge when the power of themotor drops, or the exhaust fumes increase.

Never use the generator set without the airfilter cartridge.

• Make sure that in the fuel tank plug (1) there is no water or dirt.• If so, in order to remove the water or dirt first of all close the fuel tap and then remove the plug.• After removing the water of dirt wash the plug with gasoline. When putting it back tighten it well to avoid leaks later.

Cleaning the fuel tank plug (picture 6)

pic.5

The use of open flames is prohibited.

pic.6

38


MG 8000 I-HMI-G-00005700

• If it necessary to wash the machine it is recommended that the water jet is not directed towards the alternator and/ or its electronic components and electronics of the machine.• At the end of the washing operations disconnect the capacitor from the alternator before starting the machine.• Let the machine run like this until it is completely dry.• Only then, after the machine has been switched off, reconnect the capacitor to the alternator.

Washing

Water is an excellent electrical conductor soit causes short-circuits.

Apply only to authorised Gen Set centres for any unplannedservice operations related to electrical components. Applyto service centres authorised by the manufacturer of theengine for any problems related to the engine (page 39).

Unplanned maintenance

Replace the fuel hose every 2 years. If there are any visibleleaks from the hose, it should be replaced immediately.

Replacing the fuel hose (picture 7)

Be very careful when replacing the fuel hose:benzine is extremely inflammable.

Checking the spark plug (picture 8)

• Remove carbon deposits and crusts on the electrode of the spark plug using a suitable spark plug cleaner or an iron brush.• Check the clearance of the plug: this should be between 0.7 and 0.8 mm. Adjust it if needed, by carefully bending the side electrode.Types of spark plugs recommended:NGK BR-6HS (CHAMPION RL86C)

pic.7

pic.8

39

GB10. SPARE PARTS

MG 8000 I-HMI-G-00005700

10.1- Spare part codes.......................................................................... ........................................page 40

40

GB 10. SPARE PARTS

MG 8000 I-HMI-G-00005700

10.1 SPARE PART CODESSTICKER SPARE PART CODE

41810

41811

41776

41775

41777

41778

41781

42353

42109

42132

42108

42110

42111

42112

42119

42114

STOP

STICKER SPARE PART CODE

42117

42115

42348

42349 (120X30)42352 (160X40)

42467

42653

42350

42351

42466

42573

42397

RATING PLATE SPARE PART CODE

138250

42116

COMPONENTS SPARE PART CODE

GX 390 OHV HONDA ENGINE

Air filter 17210ZE3505Fuel filter 16955ZE1000

Spark plug 98079-56846

41

GB10. SPARE PARTS

MG 8000 I-HMI-G-00005700

List of spare part codes

NNNNNooooo..... NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSED NOITPIRCSEDERAPS ERAPS ERAPS ERAPS ERAPS

EDOCTRAP EDOCTRAP EDOCTRAP EDOCTRAP EDOCTRAP

1 gulpraeR A010AK01E

2 revocraeR C700AK01E

3 dleihsraeR A700ES01E

4 rotatshtiwemarF 3VA640AC01E

5 draoblanimretduts4 A210AK01E

6 roticapaC --------

7 revocpoT B500TB01E

8 revoC B610AK01E

9 tuN --------

01 rehsaW --------

11 doreitlartneC --------

21 gniraebraeR 023434114XE

31dnaedoiddelbaC

srotsiravC600102145XE

41 rotcudnignitatoR --------

51 naF B000EV01E

61 dleihstnorF B100BS01E

42

GB 10. SPARE PARTS

MG 8000 I-HMI-G-00005700

43

GB10. SPARE PARTS

MG 8000 I-HMI-G-00005700




1 revoctekcosA51x2V021 302411

2 tekcosA51x2V021 579311

3 etalpmuinimulA 314341

4 pmalchtraE 055201

5 revoctekcosA05V042 263711

6 xobtnorF R/599241

7 redloheriwrebbur12CD 325101

8 tekcosA05V042 120721

9 gnirrekaerbtiucriC 892101

01 rekaerbtiucricA04 962411

11 troppusrotanretlA 031341

21 rebrosbakcohcs04x04 615101

31 troppusknatleuF 131341

41 nurforetimiL 3913

51 rotanretlazniL 733341

61 knatleuF 859241

71 pacrellifleuF 381611

81 etalpgnitalusniknatleuF 510341

91 enigneadnoH1U093XG --------

02 rebrosbakcohcs03x03 7101

12 emarF 331341

22 troppusenignE 360001

32 etalpelffaB R/303341

42 recaps02x5M 6681

52 rekaerbtiucricA02 726101

62 retemruoH 245421

72 pacrekaerbtiucriC N/4289

44

GB 10. SPARE PARTS

MG 8000 I-HMI-G-00005700

BOTTOM VIEW

45

GB10. SPARE PARTS

MG 8000 I-HMI-G-00005700




1 niptilpS 112711

2 elxA 014341

3 tun6M N608855TV

4 rehsaw6M N602956TV

5 troppuselxA 114341

6 leehw002.D 1881

7 rehsaw02M N022956TV

8 wercs02x6M N02607375TV

9 paceldnaH 012121

01 eldnaH 080121

11 wercs04x6M N04607375TV

21 etalptroppuS 034341

46

GB 11. ELECTRICAL DIAGRAM

MG 8000 I-HMI-G-00005700

11.1- Electrical diagram..............................................................................................................page 47

47

GB11. ELECTRICAL DIAGRAM

MG 8000 I-HMI-G-00005700

11.1 ELECTRICAL DIAGRAM

Pt Pt

H

2A

120V

PE

CAPACITOR

CONTROL PANEL

STATOR ROTOR3 4

12

Pt: 20APt1: 40A

Pt1Pt1

48

GB 12. ATTACHMENTS

MG 8000 I-HMI-G-00005700

12.1- Authorised service centre......................................................................................................page 49

12.2- List of documents..................................................................................................................page 50

12.3- Statement of warranty...........................................................................................................page 50

49

GB12. ATTACHMENTS

MG 8000 I-HMI-G-00005700

12.1 AUTHORISED SERVICE CENTRE

SERVICE: MASE GENERATORS OF NORTH AMERICA

E-MAIL: [email protected]

ADDRESS: 3750 HACIENDA BOULEVARD SUITE E

LOCALITY: FL 33314 DAVIE (USA)

FOR SERVICE OR REPAIR, PLEASE CONTACT

PHONE NUMBER: +1/954/3270234

50

GB 12. ATTACHMENTS

MG 8000 I-HMI-G-00005700

12.2 LIST OF DOCUMENTSThe instructions for use supplied with each generator set are made up of documents of which this manual is the GeneralPart. Normally the following documents are supplied:

• Declaration of CE conformity.• Instruction manual for the use and maintenance of the generating sets including the list of service centres and the Gen Set S.p.A certificate of guarantee.• Instruction manual for the use and maintenance of the motor.• Warranty card.

12.3 STATEMENT OF WARRANTY

GEN SET S.p.A. warrants its products, on condition that they are not altered, for a period of 12 (twelve) monthsbeginning on the date of sale to the first user.Within this time period, in the countries where a service organisation is established, GEN SET S.p.A. undertakes toreplace or repair the defective parts because of material defects, workmanship and/or assembly by means of its ownAUTHORISED WOKSHOPS.The option if repairing or replacing the defective parts is in the sole judgement of the MANUFACTURER or theAUTHORISED WOKSHOPS.The warranty in the rest of the world consists exclusively of the supply free of charge, ex works at theVillanova D’Ardenghi facility, the parts no longer usable because of material defect.The warranty is applied by the manufacturer, subject to examination of the defective materials.All travelling and expenses for the personnel performing the repairs under warranty shall be borne by the user, as well asthe packaging and shipment expenses for both the defective and replacment parts.The purchaser cannot terminate the contract or make a claim for compensation or damage resulting from the use or theimpossibility to use the equipment, both total or partial.This warranty does not apply to batteries, diesel or petrol engines installed on Gen Set equipment These are covered bythe respective manufacturers.The rights under this warranty are void if:• the customer has not complied with their contractual payment obligations• the factory seals have been broken• disassembly, repairs or alterations have been carried out by personnel that do not belong to GEN SET service organisation• the equipment has been subject to misuse or neglect.This warranty is not applicable for deterioration due to normal wear and tear.

DIRECTIONS FOR EXERCISING YOUR RIGHTS UNDER THIS WARRANTYEvery GEN SET unit is provided with a certification of warranty.Complete the certification and have it validated with seller’s stamp and signature.Mail to: GEN SET S.p.A. - Servizio AssistenzaVia Stazione, 5 - 27030 Villanova D’Ardenghi (Pavia).The certification of warranty must be kept and used as a reference when requesting service.

ENGINE WARRANTYCompliance with the maintenance directions reported in the manual ENGINE USE AND MAINTENANCE, will ensurea safe use of the generator unit.When purchasing the generator, fill in the engine certification of warranty and mail it to the manufacturer.

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