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Pramac GSW, Use And Maintenance Manual

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Page 1: ...MIENTO 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 2: ...GSW 57 ...

Page 3: ...se 83 5 2 Preliminary checks for use 83 5 3 Generator control panel 84 5 4 Electronic control board commands 86 5 5 Starting up the generator 87 5 6 Stopping the generator 88 5 7 Emergency stop of the generator 89 5 8 Manual refuelling 89 5 9 Using the generator at high altitudes or high ambient temperatures 91 6 MAINTENANCE 92 6 1 Importance of maintenance 93 6 2 Safety precautions for maintenanc...

Page 4: ...WORD 59 1 1 Preamble 60 1 2 Symbols 60 1 3 Purpose of the manual and its preservation 60 1 4 Whom this manual is intended for and personnel qualification 60 1 5 Technical assistance and spare parts service 61 1 FOREWORD 59 ...

Page 5: ...serious or fatal injuries if not avoided WARNING Indicates a situation of potential risk which can cause serious or fatal injuries if not avoided ATTENTION Indicates a situation of potential risk which can cause slight to moderate injuries if not avoided NOTE Indicates the obligation for certain behaviour or special activities for the machine to be handled safely 1 3 Purpose of the manual and its ...

Page 6: ...one can come in contact with e g spent lubricant coolant etc 1 5 Technical assistance and spare parts service In order to guarantee after sales service of the purchased generator to the users and a continuous update on the range of products and solutions the manufacturer provides the following services on internet A Technical assistance and spare parts service A technical area that allows you to c...

Page 7: ...D TECHNICAL DATA 62 2 1 Identification of the generator 63 2 2 Certification of the generator 63 2 3 CE Declaration of Conformity 64 2 4 Description of the generator 64 2 5 Technical data 65 2 5 1 Overall dimensions 65 62 2 DESCRIPTION AND TECHNICAL DATA ...

Page 8: ...ication of the generator paragraph for further details The generator is uniquely identified according to the model 3 the machine code 4 the serial number 5 and the year of manufacture 6 NOTE The model data plate 3 machine code 4 serial number 5 and year of manufacture 6 may be asked for if technical assistance is requested The plate also indicates the weight 7 of the generator including the circui...

Page 9: ...puts based on the specific model Another difference is the possibility of choosing between the OPEN SET and the SOUNDPROOF model The OPEN SET model is made up of a bearing base upon which the main components are mounted engine alternator control panel etc The SOUNDPROOF generator built with the same criteria as OPEN SET is equipped with soundproof panels which completely enclose all the main compo...

Page 10: ...8528 10 SOUNDPROOF Refer to the data provided in the technical installation drawing supplied for the overall dimensions Refer to the plate applied to the machine for the weight and sound emission level measured according to the reference standard ISO8528 10 SOUNDPROOF HIGH CAPACITY TANK Refer to the data provided in the technical installation drawing supplied for the overall dimensions Refer to th...

Page 11: ...GSW 3 SAFETY 3 SAFETY 66 3 1 Intended use 67 3 2 Reasonably foreseeable misuse 67 3 3 Reasonably foreseeable misuse 68 3 4 Safety and warning signs 68 3 5 Airborne noise emission 70 66 3 SAFETY ...

Page 12: ...thout making sure there is adequate ventilation when installed indoors it is mandatory to expel the exhaust gases deriving from combustion outside the rooms where the generator is installed or at a safe distance from where it operates and or the user is by means of ducts or other suitable devices for this purpose It is FORBIDDEN to use the generator on tilted surfaces that could block the flows of...

Page 13: ...r when the hood is totally or partially removed or if the doors are open DANGER Using the SOUNDPROOF generator with the bonnet fully or partially removed or with the doors open is extremely dangerous and can cause serious burns and or injuries due to contact with internal parts of the generator It is prohibited to approach the engine suction zone with long loose hair or baggy clothing 3 3 Reasonab...

Page 14: ...BIDDEN to smoke or use naked flames near the tank and fuel when refuelling Refuel in a well ventilated area and always dry any fuel leak before starting the engine Description Precaution Hazards deriving from inhalation of toxic and harmful substances Fumes containing poisonous substances are emitted from the silencer into the air while the generator engine is ON The fumes contain substances that ...

Page 15: ...Wear individual hearing protective devices PPE according to the noise risk assessment of the relative work environment and in accordance with the legislation in force in the country of use Indication of a lifting anchor point Identify the devices and lifting anchor points on the generator Read and understand the lifting instructions provided in the specific paragraph in this manual before proceedi...

Page 16: ...he utilities 76 4 2 1 Cable dimensions 76 4 2 2 Cable arrangement 76 4 2 3 Earthing the masses 77 4 2 4 Implementing the electrical connections 77 4 3 Connections for the automatic start up of the generator 80 4 4 Commissioning operations 80 4 4 1 Visual checks 80 4 4 2 Checking the engine oil level 80 4 4 3 First fuel fill up 80 4 4 4 Connecting the battery cables 80 4 5 Start up operations after...

Page 17: ...enerator with adjustable chains Proceed as follows to lift the generator with adjustable chains Hook the lifting chains 1 in the relative anchor points 2 set up on the generator The lifting anchor point is indicated on the machine by the relative information sticker Move away and gradually lift the generator verifying that it is balanced with respect to the centre of gravity Otherwise lower the lo...

Page 18: ... chains at a distance to prevent them from coming into contact with the generator Adjust the length of the lifting chains in order to balance the load and to minimise the angle between them chains as vertical as possible SOUNDPROOF 1 lifting point NOTE It is mandatory to use the preset lifting points 2 on the roof The lifting hook must be positioned as close as possible to the vertical of the gene...

Page 19: ...n the lifting elements STANDARD SOUNDPROOF 4 lifting points Detail of the position of the lifting points below NOTE It is mandatory to use all 4 lifting points 2 set up on the roof 2 from the controls side and the other 2 on the opposite side The main lifting hook 3 must be positioned as close to the centre of the generator s four lifting points as possible to keep it from swaying when lifted If n...

Page 20: ...g 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 position of the forks according to the centre of gravity 4 1 3 Transport and storage Proceed as follows when transporting the generator The generator can ONLY be transported with fuel on vehicles that are approved and certified to transport equipm...

Page 21: ...uipment connected simultaneously must be considered All the generators are equipped with protections against over current over voltage and short circuit In any case do not intentionally connect loads with maximum currents that exceed the specifications of the sockets they are connected to Do not connect a number of generators in parallel unless equipped with the special parallel board NOTE All the...

Page 22: ...or is indicated by the following symbol 4 2 4 Implementing the electrical connections Depending on the type of the electric panel installed on the machine there can be differences with respect to the images shown on these pages even though not significant If any doubt should arise do not hesitate to contact the generator supplier for clarification Connections to panel type A Remove the two fixing ...

Page 23: ... blocking them with the specific clip 3 Connect the cables to the specific terminals 4 following the indications on the wiring diagrams supplied with the generator 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...

Page 24: ...r alternator Control board Closed power board 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 Connect the cables to the specific terminals 4 following the indications on the wiring diagrams supplied with the generator Close the pr...

Page 25: ...nk cap etc Otherwise restore the optimal conditions 4 4 2 Checking the engine oil level Generally the generator is shipped with oil in the engine however check the level according to the instructions provided in the Inspecting and topping up the oil paragraph WARNING Running the engine without oil or with oil below the minimum level will seriously damage it 4 4 3 First fuel fill up The generator i...

Page 26: ...ncorrect isolation values are detected it is recommended to consult the nearest PRAMAC assistance centre Follow the specific guidelines provided in the manuals of the relative manufacturers according to the type of engine in order to carry out the restart operations correctly The main operations that must be carried out are Remove any covers from the engine air filter and drain pipe If necessary t...

Page 27: ... 83 5 3 Generator control panel 84 5 4 Electronic control board commands 86 5 5 Starting up the generator 87 5 6 Stopping the generator 88 5 7 Emergency stop of the generator 89 5 8 Manual refuelling 89 5 9 Using the generator at high altitudes or high ambient temperatures 91 82 5 USE ...

Page 28: ...safety devices have been removed Do not intentionally bypass protections and safety devices Preserve the characteristics of the generator by avoiding to implement modifications altering the functionality and tampering with protections or safety devices Do not use the generator in the presence of malfunctions or persistent faulty conditions 5 2 Preliminary checks for use Perform a visual check arou...

Page 29: ...ontrol boards are provided here Refer to read and understand the use and maintenance manual of the specific electronic boards and the supplied wiring diagrams Automatic panel with electronic board parallel to the mains or between several generators Even in this type of board the commands are located on the same control panel from where the various work parameters can be changed and or the generato...

Page 30: ...lls under this configuration refer to the following verification inside the control panel With the generator off see specific paragraph disconnect the power to the board selector CP 3 in figure Connect the signal and power cables appropriately inside the control panel referring to the wiring diagram supplied with the generator Normally unless agreed otherwise the generators are supplied set up for...

Page 31: ... 1 Main switch or disconnecting device 2 Emergency button 3 Control panel power ON OFF key selector 1st click to the right to switch on panel and instruments optional 2nd rotation to the right to start the generator Vertical key position to switch generator off 4 Circuit breaker differential switches for each electric socket of the panel 5 Manual control board with indicator LEDs 6 Space reserved ...

Page 32: ...n automatic mode AUTO the connections described in the Connections for automatic start of generator paragraph must be implemented Refer to the supplied use and maintenance manual of the electronic board for details Generators equipped with the Manual panel with digital board can be started in manual mode directly from the controls on the panel remotely in manual mode by using the specific accessor...

Page 33: ...t where present can be set to ON Set the main switch CP 1 to ON Check that the generated voltage frequency and current values are suitable for the connected utilities Automatic panel with standard electronic board automatic starting Make sure that the emergency button CP 2 is not pressed Set the main switch CP 1 and main circuit breaker of the socket kit where present to ON Select the AUTO operati...

Page 34: ... fire persists due to the flammability of the fuels used The following is FORBIDDEN during the entire operation To use naked flames To smoke To refuel the generator with the engine running WARNING During refuelling there is the risk of the fuel coming in contact with skin or eyes or inhalation of fumes Use the specific personal protective equipment PPE such as protective gloves and goggles remain ...

Page 35: ...on the digital board is not on Switch the generator engine off see the Stopping generator paragraph When refuelling with an external pipe top up the fuel according to the relative type of refuelling system e g open the external tank valve etc The figures below show an example of windows or holes for the pipes 1 to be passed towards the external tank If NO piping for external refuelling is set up o...

Page 36: ...on of the air has an adverse effect on engine operation decreasing the maximum power deteriorating the quality of the exhaust gas increasing temperatures and in extreme cases making it hard to start up If the actual environmental conditions are not specified when drafting the contract the power of the generator is intended to refer to standard environmental conditions indicated in the technical da...

Page 37: ...intenance interventions 96 6 5 1 Checking and topping up the engine oil level 96 6 5 2 Changing the engine oil and filter 96 6 5 3 Verifying the coolant level and topping up 96 6 5 4 Replacing the coolant filter 97 6 5 5 Replacing the air filter 97 6 5 6 Replacing the fuel pre filter and filter 98 6 5 7 Draining fuel from the tank 98 6 6 Maintenance schedule 99 6 6 1 Electrical system maintenance ...

Page 38: ...intenance operations must only be carried out by specialised personnel The following are the main safety precautions which the user must comply with However since it is impossible to include all the dangers that could arise during maintenance remember that the decision whether an operation is to be performed is strictly personal Comply with the following precautions when performing maintenance on ...

Page 39: ...bject to being damaged or broken by electrostatic charges and therefore also from contact made with the human body Touch an isolated metal structure to discharge your potential charge before working on the component NOTE Do not use compressed air to remove the dust during the cleaning operations of the electrical system Blowing compressed air inside the panel can cause the components to break and ...

Page 40: ...t using ammonium diluted with water and a hard brush Once the corrosion has been removed and the terminals reconnected lubricate the poles with suitable grease If the generator remains idle for a long time more than 30 days disconnect the poles of the battery to keep it from discharging Always disconnect the negative pole 2 first and then the positive pole 3 6 4 Checking the alternator Checking th...

Page 41: ...fore performing any operation on it Topping up the engine oil Use engine oil that the type and viscosity comply with the operating environment temperature and while the engine is running Follow the instructions provided in the supplied use and maintenance manual of the engine to choose the SAE oil viscosity rating according to the external operating temperature 6 5 2 Changing the engine oil and fi...

Page 42: ...ot When the engine is hot steam and boiling water could be violently ejected Replace the coolant filter referring to the supplied use and maintenance manual of the engine Replacing the coolant filter Refer to the supplied use and maintenance manual of the engine 6 5 5 Replacing the air filter NOTE The air filter must always be clean and in good condition otherwise it must be replaced Eliminate old...

Page 43: ...se and maintenance manual of the engine 6 5 7 Draining fuel from the tank WARNING The fuel must be drained when the engine is cool to prevent the risk of fire caused by a fuel leak on red hot surfaces Wait at least 1 HOUR after the generator has been switched off NOTE Do not dispose of fuel in the environment Use a suitable container to collect the fuel drained from the tank Should the containment...

Page 44: ... 1000 hours six monthly Check the tightness of the alternator terminals R Check the state of the power cable connectors I 2000 hours yearly Internal cleaning of the electric boards and control panel C Check the condition and or replace the electric wires I 6 6 2 Maintenance schedule of the mechanical parts The maintenance schedule is based on an average use If the engine is activated in adverse co...

Page 45: ...GSW 7 TROUBLESHOOTING 7 TROUBLESHOOTING 100 7 1 Problems causes and solutions 101 100 7 TROUBLESHOOTING ...

Page 46: ... if necessary Discharged batteries Check and recharge the batteries Replace them if necessary Corroded or loose battery connections Check the cables and terminals If the terminals and bolts are corroded replace them Fix them in safe conditions Inefficient connections damaged batteries or battery charger Check the connections to the battery charger and the batteries Faulty starter motor Contact the...

Page 47: ...al The main switch has been activated Short circuit or faulty earthing Check all the circuits in relation to any type of machine damage or connection cables Faulty auxiliary services Contact the after sales assistance centre to request assistance No power supply Check the power circuits The oil level is high Remove excess oil The oil level is low Add oil to restore the oil level in the engine bloc...

Page 48: ... oil pressure High water temperatures Excessive speed Low fuel level Discharged battery Black smoke Noisy engine Possible cause Solution Dirty or blocked radiator heat exchanger Make sure the radiator heat 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 centre for a sol...

Page 49: ...F SERVICE AND SCRAPPING 104 8 1 Safety when placing out of service and scrapping 105 8 2 Placing out of service for long periods 105 8 3 Decommissioning and scrapping 106 8 3 1 Special waste disposal requirements 106 104 8 PLACING OUT OF SERVICE AND SCRAPPING ...

Page 50: ...t be stored in conditions other than those described refer to the nearest assistance centre NOTE The fuel and oil used in the engine of the generator and therefore any oil preservatives used are harmful for the environment dispose of them in compliance with the legislation in force in the country of use and if present by contacting collection and disposal associations If the generator is not to be...

Page 51: ...02 96 EC WEEE Waste from electrical and electronic equipment may contain hazardous substances with potentially harmful effects on the environment and human health They must be disposed of in accordance with the legislation in force in the country of use With reference to Directive 2002 96 EC WEEE Waste Electrical and Electronic Equipment the electrical and electronic components must be separated w...

Page 52: ...GSW 9 SPECIFICATIONS 9 SPECIFICATIONS 107 9 1 Information concerning lubricants liquids and coolants 108 9 2 Derating due to environmental conditions 110 9 SPECIFICATIONS 107 ...

Page 53: ...ality criteria are complied with Refer to the supplied manual of the engine where you will find further details for starting up the engine Fuel The fuel must comply with the national and international standards regarding commercial fuels Refer to the supplied use and maintenance manual of the engine Sulphur content In compliance with the law if the sulphur content is greater than 0 5 the periodic ...

Page 54: ... must not exceed 60 Mixing over 60 concentrated antifreeze with water could reduce the efficiency of the heat exchange between the engine and the coolant thereby posing a risk of overheating the engine and resulting in less protection of the liquid from freezing The coolant must be mixed with clear water always use distilled deionised water The water must always conform to the requirements specifi...

Page 55: ...dicating the environmental conditions in which the generator will operate ISO8528 1 The minimum and maximum barometric pressure at the installation site or the altitude above sea level The minimum maximum and average monthly temperature during the coldest and hottest months of the year The lowest and highest ambient temperature around the generator engine The relative humidity the water vapour pre...

Page 56: ...________ Installed by Installer ________________ Date of installation and commission Year Month Day ________ ____ ____ Relative components code and description Reason for intervention Supplier of the intervention and or component s Date when problem was noted Date of intervention 10 ROUTINE AND EXTRAORDINARY MAINTENANCE LOG 111 ...

Page 57: ...GSW 112 10 ROUTINE AND EXTRAORDINARY MAINTENANCE LOG ...

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