Pramac Gsw User manual

MANUALE

USO

MANUTENZIONE

USE

AND

MAINTENANCE

MANUAL

MANUAL DE

USO

MANTENIMIENTO

MANUEL D’

UTILISATIONET

MAINTENANCE

MANUAL DE

UTILIZAÇÃO

MANUTENÇÃO

www.pramac.com

GSW

GSW
GENERAL INDEX
FOREWORD 59
1 Preamble 60
2 Symbols 60
3 Purpose of the manual and its preservation 60
4   Whom   this   manual   is   intended   for   and
personnel qualification 60
5 Technical assistance and spare parts service
61
DESCRIPTION AND TECHNICAL DATA 62
1 Identification of the generator 63
2 Certification of the generator 63
3 CE Declaration of Conformity 64
4 Description of the generator 64
5 Technical data 65
5.1 Overall dimensions 65
SAFETY 66
1 Intended use 67
2 Reasonably foreseeable misuse 67
3 Reasonably foreseeable misuse 68
4 Safety and warning signs 68
5 Airborne noise emission 70
INSTALLATION 71
1 Transport and positioning 72
1.1   Lifting   the   generator   with   adjustable
chains 72
1.2 Lifting the generator with a forklift 75
1.3 Transport and storage 75
1.4 Positioning 76
2 Connecting the utilities 76
2.1 Cable dimensions 76
2.2 Cable arrangement 76
2.3 Earthing the masses 77
2.4 Implementing the electrical connections
77
3 Connections for the automatic start up of the
generator 80
4 Commissioning operations 80
4.1 Visual checks 80
4.2 Checking the engine oil level 80
4.3 First fuel fill-up 80
4.4 Connecting the battery cables 80
5 Start up operations after a long idle period 81
USE 82
1 Safety precautions for use 83
2 Preliminary checks for use 83
3 Generator control panel 84
4 Electronic control board commands  86
5 Starting up the generator 87
6 Stopping the generator 88
7 Emergency stop of the generator 89
8 Manual refuelling 89
9 Using the generator at high altitudes or high
ambient temperatures 91
MAINTENANCE 92
1 Importance of maintenance 93
2 Safety precautions for maintenance 94
3 Electrical maintenance interventions 94
3.1 General checks on the electrical system 
94
3.2 Checking the battery 95
4 Checking the alternator 95
5 Mechanical maintenance interventions 96
5.1 Checking and topping up the engine oil
level 96
5.2 Changing the engine oil and filter 96
5.3 Verifying the coolant level and  topping
up 96
5.4 Replacing the coolant filter 97
5.5 Replacing the air filter 97
5.6 Replacing the fuel pre-filter and filter 98
5.7 Draining fuel from the tank 98
6 Maintenance schedule 99
6.1 Electrical system maintenance schedule
99
6.2   Maintenance   schedule   of   the
mechanical parts 99
TROUBLESHOOTING 100
1 Problems, causes and solutions 101
PLACING OUT OF SERVICE AND SCRAPPING
104
1   Safety   when   placing   out   of   service   and
scrapping 105
2 Placing out of service for long periods 105
3 Decommissioning and scrapping 106
3.1 Special waste disposal requirements 106
SPECIFICATIONS 107
1 Information concerning lubricants, liquids and
coolants 108
2 Derating due to environmental conditions 110
ROUTINE AND EXTRAORDINARY 
MAINTENANCE LOG 111
             

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1. FOREWORD

1.FOREWORD 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

1.FOREWORD 59

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1.1 Preamble

Thank you for having purchase this

generator!

This manual is an integral part of the purchased

generator and provides useful guidelines for it to

work properly and for maintenance purposes. It is

mandatory to refer to the instructions provided for

your own safety and that of the persons involved

and the manufacturer must always be contacted if

any doubt should arise from the lack of or difficulty in

understanding the instructions.

This manual does NOT replace the laws and local

regulations in any way. Always comply with the law

and local regulations in the place where the

generator is used.

•This manual must always accompany the

generator throughout the operating period.

•The “original instructions” are compiled in

ITALIAN.

•Any other language is a “translation of the

original instructions”, in compliance with that

stipulated by the EU Directive 2006/42/EC.

•All rights for reproduction of this manual are

reserved to the manufacturer.

•The descriptions and illustrations provided in this

publication are not binding. The manufacturer

reserves the right to make any change deemed

necessary at any time and without prior notice.

•This manual cannot be reproduced or disclosed

to third parties without written authorisation from the

manufacturer.

1.2 Symbols

The following symbols and styles of the text listed

below are used in the manual to communicate

information regarding:

DANGER

Indicates a situation of imminent

risk, which can cause 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 preservation

In compliance with that stipulated in the Machinery

Directive 2006/42/EC, this manual provides the

information regarding safety and the lifetime phases

of the generator (transport, installation, use,

maintenance and disposal).

•Carefully read and understand this technical

publication before operating on the generator and/or

adjusting and/or servicing.

•If in doubt while consulting this manual, always

contact the manufacturer before commencing any

operation.

•Please contact the expert personnel of the

manufacturer to resolve any problem that may arise

during the operating lifetime of the generator as

soon as possible, which has not been covered in this

technical publication.

•The manufacturer declines any liability related to

non-compliance of that stipulated in this manual.

•Keep this manual and all the attached

publications in a safe place, which is accessible and

known to all the users of the generator.

1.4 Whom this manual is

intended for and personnel

qualification

The generator has been designed to be used by

duly qualified personnel and the content of this

manual is intended for such personnel.

The personnel must receive adequate technical

training and be familiar with commonly used tools:

spanners, screwdrivers, etc.

60 1.FOREWORD

GSW

The personnel must have read and understood this

entire manual. The operator must be aware of the

operating modes of the generator, be able to follow

the user instructions provided in the manual and pay

utmost attention when using the generator.

Besides hazards deriving from electricity, those

related to explosive and flammable substances must

be considered (fuel and lubricating oils) as well as

those related to moving parts, combustion gases,

hot parts and waste products 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 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 61

GSW

2. DESCRIPTION AND

TECHNICAL DATA

2.DESCRIPTION AND 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

GSW

2.1 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.

NOTE

The identification plate (1) is

designed to last. However, it is

recommended to take note of the

data on the plate in order to have

them stored. Contact the

manufacturer if the plate must be

replaced.

OPENSET

OUNDPROOF

The “CE” symbol (2) may not be present on the

plate. Refer to the following "Certification 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

circuit liquids (oil, coolant, etc.)

excluding the fuel. Consult this

information before proceeding with

the lifting operations.

2.2 Certification of the

generator

The generators marketed within the European

Community are accompanied by the relative CE

Declaration of Conformity, Annex IIA, of the EU

Directive 2006/42/EC. In this case, the identification

plate bears the “CE” symbol (see the “identification

of the generator” paragraph).

2.DESCRIPTION AND TECHNICAL DATA 63

GSW

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” symbol (see the "identification of the

generator” paragraph).

2.3 CE Declaration of

Conformity

The CE Declaration of Conformity is attached to this

instruction manual

2.4 Description of the

generator

The paragraph identifies the main components of

the generator, which are normally supplied as

standard. Additional components, called "extras” can

be installed.

The generator is supplied with different diesel

engines and rated power outputs 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

components mounted on the base.

OPEN SET

SOUNDPROOF

NOTE

Both models must be installed by

trained and qualified personnel. In

particular, OPEN SET models

installed within the European

Community must be positioned in a

safe place, which is only accessible

to trained and qualified personnel

and sufficiently sheltered against the

direct action of atmospheric agents.

# Component

1 Base

2Engine

3 Silencer

4Air filter

5Radiator

6Control panel

7 Utilities connection

8Alternator

9Soundproof panels

10 Doors

64 2.DESCRIPTION AND TECHNICAL DATA

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2.5 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 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

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 the plate applied to the machine for the

weight and sound emission level (measured

according to the reference standard ISO8528-10).

2.DESCRIPTION AND TECHNICAL DATA 65

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

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3.1 Intended use

The generators described in this manual are

designed and built for professional use to supply

electricity by means of a combustion engine coupled

with an electric generator. The generators are solely

suitable for land use, outdoors as well as indoors, in

compliance with the environmental limits and those

of the installation conditions stipulated by the

manufacturer.

The generator must always be positioned according

to the instructions found in the installation diagram

provided by the manufacturer.

Any other use is strictly prohibited and can lead to

safety hazards for the user and damage the

generator.

The generator is built in compliance with the

following EU Directives:

- 2006/42/EEC Machinery directive.

- 2006/95/EC Low voltage directive.

- 2004/108/EC Electromagnetic compatibility

directive.

- 2000/14/EC Environmental noise emission

by machinery and equipment

intended for outdoor use.

In order to help the planning phase, EU standards

harmonised with the EU Directives and/or

international product standards may have been

applied, particularly:

- EN 12601 Reciprocating internal

combustion engine driven

generating sets – Safety.

- ISO 8528 Reciprocating internal

combustion engine driven

alternating current generating

sets.

3.2 Reasonably foreseeable

misuse

DANGER

Improper use of the generator is

extremely hazardous. The

manufacturer declines any liability

for any damage to people, objects

and/or animal deriving from

improper use of the generator.

Reasonably foreseeable misuse refers to any use other

than that intended (for which the generator has been

designed), carried out with methods other than those

intended or specifically forbidden in the manual.

The following cases of evident product misuse can

be indicated beforehand based on the

manufacturer's experience:

•It is FORBIDDEN to activate the generator in

closed areas without 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 oil and

fuel required for operation.

•It is FORBIDDEN to use the OPEN SET type

of generator outdoors without having set up

adequate protection against atmospheric agents

such as water, snow and frost. If used outdoors, the

environmental limits stipulated by the manufacturer

must be complied with.

•It is FORBIDDEN to use the generator in

environments classified according to the EU ATEX

Directive 1999/92/EC, where an explosive

atmosphere is likely to be formed or lasts for brief or

long periods during regular operation.

•It is FORBIDDEN to use the generator to

warm up an environment by means of the heat

radiated from the engine.

•It is FORBIDDEN to use the generator when

faults or malfunctions are noted.

•It is FORBIDDEN to allow people who have

not reached the minimum age applicable by law in

the respective countries of use to use and service

the generator and who have not been previously

informed and trained on the residual risks posed

while working on the generator.

•It is FORBIDDEN to allow people to use and

service the generator before having read and

understood the instructions provided in the manual.