Volpi Tecno Energia PAGURO 2000 User manual

OWNERS MANUAL
PAGURO 2000
MARINE DIESEL GENERATOR

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PAGURO 2000
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We thank you for the confidence you have shown in us, by purchasing the PAGURO for fitting in your boat.
The target of our design, to achieve a diesel unit with the power usually supplied in a small flat, in a compact size and
light weight, is completely reached. So there is not the need to waste a large room in your boat, and even if the
chosen place is away from the centre line of the boat, the reduced weight of the PAGURO will not influence the
stability.
TECHNICAL SPECIFICATION AND PERFORMANCES
PAGURO 2000
Diesel engine maker Yanmar Italy S.p.a.
Engine type / cylinders n. Yanmar L48
50 Hz 3000
Continuous speed (rpm) 60 Hz -
Specific fuel consumption 0.35 lt./KW/h
Cooling system Fresh water with heat exchanger
Cooling pump Johnson system self-priming directly
driven, without belt
Startingsystem 12 V Electrical starter remote controlled
Alternatormaker V.T.E. - Italy
Generator type PMG AC generator
50 Hz 2,5 KVA- 2 KW
Electric continuous power 60 Hz -
50 Hz 230
Voltage 60 Hz -
Auxiliary voltage for starting battery 12 V - 8 A
Remote control
fitted with hourmeter, load indicator, automatic
shut off device for low oil pressure and water
over temperature, starting motor self
disengagement, 15 m cable and socket
Peak current for 2 sec. (230V) 18 A
Noise level a 7 mtrs. 54 dB (A)
Weight, capsule included (kgs) 46
Weight of the electronic box(kgs) 5

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CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm
WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas.
Carbon Monoxide is poisonous and can cause unconsciousness and death.
Symptoms of Carbon Monoxide exposure can include:
-Dizziness
-Nausea
-Headache
-Weakness and sleepiness
-Throbbing in temples
-Muscular twitching
-Vomiting
-Inability to think coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO
THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut
down the unit and do not restart unit until it has been inspected and repaired.

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SAFETY INSTRUCTIONS
INTRODUCTION
Read these safety instructions carefully. Most accidents
are caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protect yourself, your
personnel and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
WARNING:
Do not touch AC electrical connections while
engine is running, or when connected to shore
power. Lethal voltage is present at these
connections!
-Do not operate this machinery without electrical
enclosures and covers in place.
-Shut-off electrical power before accessing electrical
equipment.
-Use insulated mats whenever working on electrical
equipment.
-Make sure your clothing and skin are dry,not damp
(particularly shoes) when handling electrical
equipment.
-Remove wristwatch and all jewelry when working on
electrical equipment.
-Do not connect utility shore power to vessel’s AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel’s AC generator may
result if this procedure is not followed.
-Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together with an insulated tool.
PREVENT BURNS - HOT ENGINE
WARNING:
Do not touch hot engine parts or exhaust
system components. A running engine gets very
hot!
WARNING:
Steam can cause injury or death!
-In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS – FIRE
WARNING:
Fire can cause injury or death!
-Prevent flash fires. Do not smoke or permit flames or
sparks to occur near thefuel line, filter, fuel pump, or
other potential sources of spilled fuel or fuel vapors.
Use a suitable container to catch all fuel when
removing the fuel line or fuel filters.
-Keep the compartment and the engine / generator
clean and free of debris to minimize the chances of
fire. Wipe up all spilled fuel and engine oil.
-Be aware – diesel fuel will burn.
PREVENT BURNS – EXPLOSION
WARNING:
Explosion from fuel vapors can cause injury or
death!
-Follow re-fueling safety instructions. Keep the vessel’s
hatches closed when fueling. Open and ventilate cabin
after fueling. Checkbelowfor fumes / vapor before
running the blower. Run the blower for four minutes
before starting your engine.
-All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-producing equipment
and out of the reach of children.
-Do not fill the fuel tank(s) while the engine is running.
-Shut off the fuel service valve at the engine when
servicing the fuel system. Take care in catching any
fuel that might spill. DO NOT allow any smoking, open
flames, or other sources of fire near the fuel system or
engine when servicing. Ensure proper ventilation
exists when servicing the fuel system.
-Do not alter or modify the fuel system.
-Be sure all fuel supplies have a positive shutoff valve.
-Be certain fuel line fittings are adequately tightened
and free of leaks.
-Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.

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ACCIDENTAL STARTING
WARNING:
Accidental starting can cause injury or death!
-Disconnect the battery cables before servicing the
engine/generator. Remove the negative leadfirstand
reconnect it last.
-Make certain all personnel are clear of the engine
before starting.
-Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
WARNING:
Battery explosion can cause injury or death!
-Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
-Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter
solenoid. Do not test the battery condition by shorting
the terminals together. Sparks could ignite battery
gases or fuel vapors. Ventilate any compartment
containing batteries to prevent accumulation of
explosive gases. To avoid sparks, do not disturb the
battery charger connections while the battery is being
charged.
-Avoid contacting the terminals with tools, etc., to
prevent burns or sparks that could cause an explosion.
Remove wristwatch, rings, and any other jewelry
before handling the battery.
-Always turn the battery charger off before
disconnecting the battery connections. Remove the
negative lead first and reconnect it last when servicing
the battery.
BATTERY ACID
WARNING:
Sulfuric acid in batteries can cause severe injury
or death!
-When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash
it off at once with water. Acid may splash on the skin
or into the eyes inadvertently when removing
electrolyte caps.
TOXIC EXHAUST GASES
WARNING:
Carbon Monoxide (CO) is a deadly gas!
-Ensure that the exhaust system is adequate to expel
gases discharged from the engine. Check the exhaust
system regularly for leaks and make sure the water-
injected exhaust elbow is securely attached.
-Be sure the unitand its surroundings are well
ventilated.
-In addition to routineinspectionof theexhaust
system, install a carbon monoxide detector. Consult
your boat builder or dealer for installation of approved
detectors.
-For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
WARNING:
Carbon Monoxide (CO) is an invisible gas.
Inhalation produces flu-like symptoms, nausea
or death!
-Do not use copper tubing in diesel exhaust system.
Diesel fumes can rapidly destroy copper tubing in
exhaust systems. Exhaust sulfur causesrapid
deterioration of copper tubing resulting in
exhaust/water leakage.
-Do not install exhaust outlet where exhaust can be
drawn through portholes, vents, or air conditioners. If
the engine exhaust discharge outletis near the
waterline, water could enter the exhaust discharge
outlet and close or restrict the flow of exhaust. Avoid
overloading the craft.
-Although diesel engine exhaust gases are not toxic as
exhaust fumes from gasoline engines, carbon
monoxide gas is present in diesel exhaust fumes.
Some of the symptoms or signs of carbonmonoxide
inhalation or poisoning are:
Vomiting
Muscular twitching
Dizziness
Intense headache
Throbbingin temples
Weakness and sleepiness

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AVOID MOVING PARTS
WARNING:
Rotating parts can cause injury or death!
-Do not service the engine while it is running. If a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to
avoid touching moving parts and hot exhaust system
components.
-Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets
that could be caught in moving parts.
-Make sure all attaching hardware is properly
tightened. Keep the protective shields and guards in
their respective places at all times.
-Do not check fluid levels while the engine is operating.
HAZARDOUS NOISE
WARNING:
High noise levels can cause hearing loss!
-Never operate an engine without its muffler installed.
-Do not run engines for long periods with their
enclosures open.
WARNING:
Do not work on machinery when you are
mentally orphysically incapacitated by fatigue!

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EC DECLARATION OF CONFORMITY
The undersigned declares that the generator model:
Code Model
AP02023050M0 PAGURO 2000
Corresponds to the requirements ofthe following EEC Directives:
-89/392/EEC (as amended by the Directive 91/368/EEC and 93/44/EEC)
-89/336/EEC (as amended by the Directive 92/31/EEC)
-73/23/EEC (as amended by 93/68/EEC)

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TABLE OF CONTENTS
 GENERAL INFORMATIONS …………………………………………………………………………………………………………………………….... 3
 SAFETY INSTRUCTIONS ………………………………………………………………………………………………………………………………. 5
 INTRODUCTIONS / RECOMISSIONINGS ……………………………………………………………………………………………………………… 10
1. INSTALLATION ……………………………………………………………………………………………………………………………………………….. 11
EXTERNAL CONNECTIONS ………………………………………………………………………………………………………………………………. 12
VENTILATION ……………………………………………………………………………………………………………………………………………….. 12
LOCATION AND MOUNTINGS ………………………………………………………………………………………………………………………………. 13
FUEL LINES (Fuel Supply Line, Fuel return Line) …………………………………………………………………………………………..... 13
EXHAUST SYSTEM ………………………………………………………………………………………………………………………………………………… 14
RAW WATER COOLING SYSTEM (Siphon break, Raw Water Intake) …………………………………………………………… 15
INVERTER INSTALLATION ……………………………………………………………………………………………………………………………….. 16
STARTING BATTERY CONNECTION ………………………………………………………………………………………………………………. 16
MAIN OUTPUT VOLTAGE (230 V AC) ………………………………………………………………………………………………………………. 17
CONTROL PANEL ………………………………………………………………………………………………………………………………………………… 18
2. PREPARATION FOR INITIAL START-UP ………………………………………………………………………………………………………………. 22
DIESEL FUEL ………………………………………………………………………………………………………………………………………………… 22
ENGINE OIL SPECIFICATION ……………………………………………………………………………………………………………………………….. 22
PRE-START INSPECTION ……………………………………………………………………………………………………………………………….. 22
3. STARTING/STOPPING PROCEDURE ………………………………………………………………………………………………………………. 23
ELECTRIC START ………………………………………………………………………………………………………………………………………………… 23
PRE-HEATING ………………………………………………………………………………………………………………………………………………… 23
STARTING OPERATION ……………………………………………………………………………………………………………………………….. 23
OPERATING THE GENERATOR ……………………………………………………………………………………………………………………………….. 23
INITIAL START UP CHECK LIST ……………………………………………………………………………………………………………………………….. 23
STOPPING THE GENERATOR ……………………………………………………………………………………………………………………………….. 23
4. BREAK-IN PROCEDURE ……………………………………………………………………………………………………………………………….. 24
CHECK LIST ………………………………………………………………………………………………………………………………………………… 24
STOPPING THE GENERATOR ……………………………………………………………………………………………………………………………….. 24
5. MAINTENANCE SCHEDULE ……………………………………………………………………………………………………………………………….. 25
6. EXHAUST SYSTEM ………………………………………………………………………………………………………………………………………………… 27
EXHAUST SYSTEM PRECAUTIONS ………………………………………………………………………………………………………………. 27
7. COOLING SYSTEM ………………………………………………………………………………………………………………………………………………… 28
RAW WATER PUMP (inspecting/changing the raw water pump impeller) …………………………………………………………… 28
RAW WATER INTAKE STRAINER ……………………………………………………………………………………………………………………………….. 28
8. LUBRICATION SYSTEM ……………………………………………………………………………………………………………………………….. 29
ENGINE OIL ………………………………………………………………………………………………………………………………………………… 29
OIL PRESSURE ………………………………………………………………………………………………………………………………………………… 29
OIL COOLER ………………………………………………………………………………………………………………………………………………… 29
OIL FILTER ……………………………….………………………………………………………………………………………………………………. 29
CHECKING THE OIL ………………………………………………………………………………………………………………………………………………… 29
CHANGING THE OIL ………………………………………………………………………………………………………………………………………………… 29
DRAINING THE USED OIL ……………………………………………………………………………………………………………………………….. 29
ADDING NEW OIL ………………………………………………………………………………………………………………………………………………… 30
9. FUEL SYSTEM ………………………………………………………………………………………………………………………………………………... 30
DIESEL FUEL ………………………………………………………………………………………………………………………………………………… 30
FUEL ADDITIVES ………………………………………………………………………………………………………………………………………………… 30
CARE OF THE FUEL SUPPLY ……………………………………………………………………………………………………………………………….. 30
FUEL LIFT PUMP ………………………………………………………………………………………………………………………………………………… 30
FUEL FILTER ……………………………………..…………………………………………………………………………………………………………. 30
FUEL SUPPLY LINE ………………………………………………………………………………………………………………………………………………... 31
FUEL FILTER OF THE WATER-SEPARATING TYPE ……………………………………………………………………………………………... 31
FUEL INJECTION PUMP ……………………………………………………………………………………………………………………………….. 31
FUEL SHUT-OFF SOLENOID ……………………………………………………………………………………………………………………………….. 31
BLEEDING THE FUEL SYSTEM ……………………………………………………………………………………………………………………………….. 31
SPARE PARTS ………………………………………………………………………………………………………………………………………………... 31
10. ENGINE TROUBLESHOOTING ……………………………………………………………………………………………………………………………..... 32
11. DC ELECTRICAL SYSTEM ……………………………………………………………………………………………………………………………….. 33
12 VOLT DC CONTROL CIRCUIT ……………………………………………………………………………………………………………………………….. 33
BATTERY (Battery Care, Checking the service Battery) ……………………………………………………………………………………………… 33
ELECTRICAL SCHEME ………………………………………………………………………………………………………………………………………………... 34
12. GENERATOR INFORMATION ……………………………………………………………………………………………………………………………….. 35
GENERATOR MAINTENANCE ……………………………………………………………………………………………………………………………….. 35
13. GENERATOR TROUBLESHOOTING ………………………………………………………………………………………………………………. 35
14. SHORE POWER TRANSFER SWITCH ………………………………………………………………………………………………………………. 36
15. LAY UP AND RECOMISSIONING ……………………………………………………………………………………………………………………………….. 37

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INSTALLATION
When installing PAGURO generators, it is important that strict attention be paid to the
following information:
CODES AND REGULATIONS
Please follow the basic safety rules, when installing generators in a marine environment.
SIPHON-BREAK
For installation where the external shock absorbers close to or will be below the vessel’s
waterline, provisions must be looped a minimum of 50 cm above the vessel’s waterline.
Failure to use a siphon-break when the external shock absorbers are at or below the
load waterline will result in raw water damage to the engine and possible flooding of
the boat.
If you have any doubt about the position of the external shock absorbers relative to the
vessel’s waterline under any of the vessel’s various operating conditions or when the
vessel is not underway, install a siphon-break. This precaution is necessary to protect
your engine.
NOTE: A siphon-break requires periodic inspections and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic engine
damage.Consult the siphon-break manufacturerfor apropermaintenance schedule.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle of
the vessel’s use.