Pramac GSW Use And Maintenance Manual
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Pramac GSW Use And Maintenance Manual

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USO E MANUTENZIONE
USE AND MAINTENANCE MANUAL
MANUAL DE USO Y MANTENIMIENTO
MANUEL D'UTILISATIONET DE MAINTENANCE
MANUAL DE UTILIZAÇÃO E E E MANUTENÇÃO
MANTENIMIENTO
MANTENIMIENTO
MANTENIMIENTO
MANTENIMIENTO
MANTENIMIENTO
MANTENIMIENTO
MANTENIMIENTO
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MAINTENANCE
MANUTENÇÃO
MANUTENÇÃO
MANUTENÇÃO
MANUTENÇÃO
MANUTENÇÃO
www.pramac.com

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  • Page 1 USE AND MAINTENANCE MANUAL MANUAL DE USO Y MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANTENIMIENTO MANUEL D’UTILISATIONET DE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MANUAL DE UTILIZAÇÃO E E E MANUTENÇÃO MANUTENÇÃO MANUTENÇÃO MANUTENÇÃO MANUTENÇÃO MANUTENÇÃO www.pramac.com...
  • Page 3 GENERAL INDEX 6.3.2 Checking the battery 6.4 Checking the alternator 6.5 Mechanical maintenance interventions 1.FOREWORD 6.5.1 Checking and topping up the engine oil 1.1 Preamble level 1.2 Symbols 6.5.2 Changing the engine oil and filter 1.3 Purpose of the manual and its preservation 60 6.5.3 Verifying the coolant level and topping 1.4 Whom this manual is intended for and personnel qualification...
  • Page 4 1. FOREWORD 1.FOREWORD 1.1 Preamble 1.2 Symbols 1.3 Purpose of the manual and its preservation 60 1.4 Whom this manual is intended for and personnel qualification 1.5 Technical assistance and spare parts service 1.FOREWORD...
  • Page 5 Preamble ATTENTION Thank you for having purchase this Indicates a situation of potential generator! risk, which can cause slight to moderate injuries if not avoided. This manual is an integral part of the purchased generator and provides useful guidelines for it to work properly and for maintenance purposes.
  • Page 6 A technical area that allows you to contact qualified operators whom to refer to, to request assistance and spare parts. http://www.pramacparts.com B) A sales and products area. The main area for products and solutions from where you can access the sales department and sales network. http://www.pramac.com 1.FOREWORD...

  • Page 7: Table Of Contents

    DESCRIPTION TECHNICAL DATA 2.DESCRIPTION AND TECHNICAL DATA 2.1 Identification of the generator 2.2 Certification of the generator 2.3 CE Declaration of Conformity 2.4 Description of the generator 2.5 Technical data 2.5.1 Overall dimensions 2.DESCRIPTION AND TECHNICAL DATA...

  • Page 8: Description And Technical Data

    Identification of the generator The generator is identified by a special identification plate (1), which is compliant with the requirements of the Machinery Directive 2006/42/EC, affixed on the metal frame. WARNING It is strictly prohibited to remove the identification plate (1) from the generator or to alter or delete the data on the plate itself.

  • Page 9: Ce Declaration Of Conformity

    SOUNDPROOF The generators that do not belong to the category described previously are constructed in compliance with the technical standards harmonised with the EU Directive 2006/42/EC, however, they are not accompanied by the CE Declaration of Conformity; in this case, the identification plate does not bear the “CE”...

  • Page 10: Technical Data

    SOUNDPROOF HIGH CAPACITY TANK Technical data 2.5.1 Overall dimensions The overall dimensions provided refer to the models listed in the table. OPEN SET Refer to the data provided in the technical installation drawing supplied overall dimensions. Refer to the plate applied to the machine for the Refer to the data provided in the technical weight and sound emission level (measured installation...
  • Page 11 3. SAFETY 3.SAFETY 3.1 Intended use 3.2 Reasonably foreseeable misuse 3.3 Reasonably foreseeable misuse 3.4 Safety and warning signs 3.5 Airborne noise emission 3.SAFETY...

  • Page 12: Safety

    The following cases of evident product misuse can Intended use indicated beforehand based manufacturer's experience: The generators described in this manual are designed and built for professional use to supply It is FORBIDDEN to activate the generator in • electricity by means of a combustion engine coupled closed areas without making sure there is adequate with an electric generator.

  • Page 13: Reasonably Foreseeable Misuse

    It is FORBIDDEN to carry out installation, use pictograms are found on the generator and/or in the • manual, and their meaning is described in the and servicing operations that are specifically following table. prohibited in the manual. It is FORBIDDEN to refuel and perform •...
  • Page 14 Description Precaution Description Precaution • Pay attention to the • Use the generator in areas close well ventilated alternator and electrical environments to disperse connection points. the fumes. • Keep a safe distance • used closed so as to prevent hazards environments, convey the Electrical hazard deriving Hazards...

  • Page 15: Airborne Noise Emission

    Description Precaution • Read and understand the instructions provided in the instruction manual. • If the instructions are missing clear, always contact Always refer manufacturer before instruction manual. operating generator. The complete instructions • Always keep the use to use and service the and maintenance manual generator are present in near the generator, in...

  • Page 16: Installation

    INSTALLATION 4.INSTALLATION 4.1 Transport and positioning 4.1.1 Lifting the generator with adjustable chains 4.1.2 Lifting the generator with a forklift 4.1.3 Transport and storage 4.1.4 Positioning 4.2 Connecting the utilities 4.2.1 Cable dimensions 4.2.2 Cable arrangement 4.2.3 Earthing the masses 4.2.4 Implementing the electrical connections 4.3 Connections for the automatic start up of the generator...

  • Page 17: Transport And Positioning

    Transport and positioning • Move away and gradually lift the generator, verifying that it is balanced with respect to the centre of gravity. Otherwise, lower the load until it rests on the floor of the transport vehicle and adjust the WARNING length of the chains according to the centre of gravity.
  • Page 18 OPEN SET: 4 lifting points SOUNDPROOF: 1 lifting point NOTE NOTE It is mandatory to use the preset It is mandatory to use all four lifting lifting points (2) on the roof. The points (2) set up on the base on the lifting hook must be positioned as control side and on the opposite side.
  • Page 19 NOTE NOTE It is mandatory to use all 4 lifting It is mandatory to use both lifting points (2) set up on the roof: 2 from points (2) set up on the roof from the the controls side and the other 2 on control side and on the opposite the opposite side.

  • Page 20: Lifting The Generator With A Forklift

    NOTE It is mandatory to use all 4 lifting points (2) set up on the oversized tank: 2 from the controls side and 2 on the opposite side. The main lifting hook (1) must be used together with a rocker arm (1), which keeps the lifting chains at a distance to prevent them from coming into contact with the generator.

  • Page 21: Positioning

    NOTE WARNING If the generator is to be stored for a The following requirements for use long time after being transported must be complied with to prevent (over 30 days), follow the guidelines risks posed persons provided in the “Placing damage caused to the generator : service for long periods”...

  • Page 22: Earthing The Masses

    4.2.3 Earthing the masses • Fix the plate (2) then close the protective panel and tighten the two fixing screws (1). NOTE The sizing of the connection cable to the earth plate and the relative contact resistance must compliant with the regulations and laws in force in the country in which the generator is used.
  • Page 23 • Close the protection panel and tighten the two fixing screws (1). Connections to panel type (D): • Remove the two fixing screws (1) using the appropriate spanner and open the protection panel (2). • Pass the cables through the bottom side of the panel through the specific opening positioned underneath the electric panel (3).
  • Page 24 Connections to panel type (E): • Connect the cables to the specific terminals (4) following the indications on the wiring diagrams In some generator models the electric control part supplied with the generator. could be installed separately from the power part. In •...

  • Page 25: Connections For The Automatic Start Up Of The Generator

    Connections for the Commissioning automatic start up of the operations generator operations described following paragraphs must be carried out before proceeding with the commissioning of the engine. 4.4.1 Visual checks WARNING • Verify that the generator has not been damaged The electrical connections must during transport.

  • Page 26: Start Up Operations After A Long Idle Period

    If incorrect isolation values are detected, If necessary, disconnect the battery it is recommended to consult the nearest PRAMAC assistance centre. - always disconnect the negative pole (2) first and then the positive Follow the specific guidelines provided in the pole (3).
  • Page 27 5.USE 5.1 Safety precautions for use 5.2 Preliminary checks for use 5.3 Generator control panel 5.4 Electronic control board commands 5.5 Starting up the generator 5.6 Stopping the generator 5.7 Emergency stop of the generator 5.8 Manual refuelling 5.9 Using the generator at high altitudes or high ambient temperatures 5.USE...

  • Page 28: Use

    • Check the efficiency of all generator protections Safety precautions for and safety devices daily and before use. • Do not operate if the protections and/or safety devices have been removed. • Do not intentionally bypass protections and safety devices. Preserve the characteristics of the WARNING generator by avoiding to implement modifications, altering...

  • Page 29: Generator Control Panel

    NOTE: in the following paragraphs, the controls can Generator control panel be identified as in this example: “Emergency button (CP.2)”. Automatic panel with standard electronic board: NOTE The commands are located on the same control panel from where the various work parameters can General guidelines concerning...
  • Page 30 b) Generators (G) connected in parallel, in an in parallel, the cover terminal (in position "B" in the island network, powering a LOAD. In this case, figure) is only required on the first and last generator the board is equipped with parallel connectors. of the parallel sequence.

  • Page 31: Electronic Control Board Commands

    Description Description Switch with double fuel loading pump Main switch or disconnecting device. (optional). Emergency button. Emergency button. Control panel power ON/OFF key selector: Acoustic alarm signal emitter for faults • 1st click to the right to switch on detected by the electronic control board. panel and instruments (optional).

  • Page 32: Starting Up The Generator

    Starting up the generator • in manual mode “MAN” using the start and stop buttons on the control board , • automatically “AUTO”, when the generator NOTE is connected and set up to start when it detects a power failure. •...

  • Page 33: Stopping The Generator

    • After approximately 2-3 minutes of operation, check the frequency and voltage values; when they WARNING are stable, the main circuit breaker of the socket kit (where present) can be set to ON. • Set the main switch (CP.1) to ON. check proper operating...

  • Page 34: Emergency Stop Of The Generator

    Emergency stop of the Manual refuelling generator WARNING In this operating mode, press the emergency button (CP.2) to stop the generator quickly. During refuelling, the risk of fire NOTE persists due to the flammability of the fuels used. The following is Before switching the generator back FORBIDDEN during...
  • Page 35 NOTE Do not pour fuel on the hot engine or on other parts of the generator. Remove fuel spills from painted surfaces with a rag. Be careful not to touch or hit hot parts of the engine. Never use fuels that are old contaminated with other...

  • Page 36: Using The Generator At High Altitudes Or High Ambient Temperatures

    Using the generator at high altitudes or high ambient temperatures NOTE Should it be necessary to perform modifications to adapt operation of the generator, always request the manufacturer's assistance. It is FORBIDDEN to adjust engine parameters and/or to add additives to the fuel to enhance engine power over the limits recommended by the manufacturer.
  • Page 37 6. MAINTENANCE 6.MAINTENANCE 6.1 Importance of maintenance 6.2 Safety precautions for maintenance 6.3 Electrical maintenance interventions 6.3.1 General checks on the electrical system 6.3.2 Checking the battery 6.4 Checking the alternator 6.5 Mechanical maintenance interventions 6.5.1 Checking and topping up the engine oil level 6.5.2 Changing the engine oil and filter 6.5.3 Verifying the coolant level and topping...

  • Page 38: Maintenance

    Importance of WARNING maintenance maintenance operations must only carried WARNING specialised personnel. maintenance performed incorrectly or if a problem is not The following are the main safety precautions which the user must comply with. However, since it is resolved before activating impossible to include all the dangers that could arise generator, this could malfunction...

  • Page 39: Safety Precautions For Maintenance

    Safety precautions for NOTE maintenance attention when handling electronic circuits. Many WARNING components are subject to being Before performing any maintenance, damaged or broken by electrostatic turn the selector switch with the charges and therefore, also from removable key to the "OFF" position contact made with the human body.

  • Page 40: Checking The Battery

    Internal cleaning of the electric boards Checking the alternator and control panel • Use a vacuum cleaner to remove dust from Checking the connections: inside the electric board. Visually check the condition of the equipment Make sure that the electric connection cables are and devices firmly fixed to the connection terminals;...

  • Page 41: Mechanical Maintenance Interventions

    Topping up the engine oil: Mechanical maintenance • Use engine oil that the type and viscosity comply interventions with the operating environment temperature and while the engine is running. • Follow the instructions provided in the supplied 6.5.1 Checking and topping up use and maintenance manual of the engine to the engine oil level choose the SAE oil viscosity rating according to the...

  • Page 42: Replacing The Coolant Filter

    6.5.4 Replacing the coolant shown in the photo with number (1) (purely indicative) (the shape and colour of the tank could filter differ depending on the version of the generator). ATTENTION Do not open the filler cap with the engine hot. When the engine is hot, steam and boiling water could be violently ejected.

  • Page 43: Replacing The Fuel Pre-Filter And Filter

    NOTE Do not fill the new filter with fuel before mounting it as impurities could enter system causing damage and malfunctioning. Replace the filter while referring to the supplied use and maintenance manual of the engine. Replacing the fuel pre-filter: •...

  • Page 44: Maintenance Schedule

    Maintenance schedule The maintenance interventions are divided between those on the electrical system and those on the mechanical parts. All the interventions are summarised in the following tables forming part of the routine maintenance schedule of the generator. 6.6.1 Electrical system maintenance schedule I Inspect R Regulate, replace C Clean...
  • Page 45 TROUBLESHOOTING 7.TROUBLESHOOTING 7.1 Problems, causes and solutions 7.TROUBLESHOOTING...
  • Page 46 Problems, causes and solutions WARNING Perform the troubleshooting operations according to the safety information provided in this manual. Do not try to resolve problems whose possible causes are not described in this paragraph so as to safeguard the persons exposed and prevent the generator from being damaged.
  • Page 47 Possible cause Solution Speed is too low. Check the speed regulator if the engine is equipped with it. If the engine is not equipped with a ● ● ● mechanical speed regulator, contact the after-sales assistance centre to request assistance. ●...
  • Page 48 Possible cause Solution Dirty blocked radiator/heat Make sure radiator/heat exchanger. exchanger is clean. Check that no ● blocks occur in the air circulation or in the outlet air recirculation at the air inlet. Other possible causes. Contact the after-sales assistance ●...
  • Page 49 8. PLACING OUT OF SERVICE AND SCRAPPING 8.PLACING OUT OF SERVICE AND SCRAPPING 8.1 Safety when placing out of service and scrapping 8.2 Placing out of service for long periods 8.3 Decommissioning and scrapping 8.3.1 Special waste disposal requirements 106 8.PLACING OUT OF SERVICE AND SCRAPPING...
  • Page 50 Safety when placing out NOTE of service and scrapping The following are the main safety precautions which If the generator must be stored in the user must comply with. However, since it is conditions other than those impossible to include all the dangers that could arise described, refer nearest...
  • Page 51 Decommissioning and scrapping Application Directive 2002/95/EC (RoHS): WARNING • in relation to the restrictions on the use of hazardous substances, it should be noted that the Scrapping placing electrical and electronic components used in the generator do not contain harmful or hazardous generator out of service must be substances that exceed the legally accepted limits.
  • Page 52 9. SPECIFICATIONS 9.SPECIFICATIONS 9.1 Information concerning lubricants, liquids and coolants 9.2 Derating due to environmental conditions 110 9.SPECIFICATIONS...
  • Page 53 Information concerning lubricants, liquids and coolants Engine oil Refer to the supplied use and maintenance manual of the engine. NOTE standard equipment supplied with SAE 15W/40 oil. Engine oil viscosity Refer to the supplied use and maintenance manual of the engine. NOTE Pure mineral oils or partially synthetic oils can be used as...
  • Page 54 Engine coolant The radiator coolant even protects against internal corrosion, cavitation, erosion and damage caused by freezing. Different additives can also be mixed to improve the characteristics of the coolants. NOTE The standard supply includes the following coolant: a mixture of 30% antifreeze concentrated in 70% water.
  • Page 55 Derating due to environmental conditions Performance could be subject to “derating” with respect to the nominal values as a result of the environmental conditions being different from the nominal conditions stipulated by the reference standard (ISO8528-1), such as different temperature, altitude and humidity. This applies to both the engine and the alternator it is coupled to and therefore, for the overall performance of the generator.
  • Page 56 ROUTINE AND EXTRAORDINARY MAINTENANCE LOG • Purchase date (Year/Month/Day): ________/____/____ • Purchased from (Dealer): ________________ • Installed by (Installer): ________________ • Date of installation and commission (Year/Month/Day): ________/____/____ Relative components Reason for intervention Supplier of the Date when Date of (code and description) intervention and/or problem was...
  • Page 57 10.ROUTINE AND EXTRAORDINARY MAINTENANCE LOG...

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