View and Print The Pramac Generator Owner`s Manual

View and Print The Pramac Generator Owner`s Manual

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WARNING :

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

NOTICE

FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA

EMISSION CONTROL WARRANTY are applicable to only those engines/ generators complied with EPA (Environmental Protection Agency) and CARB

(California Air Resources Board) emission regulations in the U.S.A.

NOTICE

To the engines/generators exported to and used in the countries other than the

U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard engine/generator warranty policy as applicable.

AIR INDEX

To show compliance with California emission regulations, a hangtag has been provided displaying the Air Index level and durability period of this engine.

The Air Index level defines how clean an engine’s exhaust is over a period of time. A bar graph scaled from “0” (most clean) to “10” (least clean) is used to show an engine’s Air Index level. A lower Air Index level represents cleaner exhaust from an engine.

The period of time (in hours) that the Air Index level is measured is known as the durability period. Depending on the size of the engine, a selection of time periods can be used to measure the Air Index level (see below).

Descriptive Term Applicable to Emissions Durability Period

Moderate - 50 hours (engine from 0 to 80 cc)

125 hours (engine greater than 80 cc)

Intermediate 125 hours (engine from 0 to 80 cc)

250 hours (engine greater than 80 cc)

Extended 300 hours (engine from 0 to 80 cc)

500 hours (engine greater than 80 cc)

Notice :

This hangtag must remain on this engine or piece of equipment, and only be removed by the ultimate purchaser before operation.

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FOREWORD

Thank you very much for purchasing a PRAMAC GENERATOR.

This manual covers operation and maintenance of the PRAMAC GENERATOR.

This PRAMAC GENERATOR can be used for general electrical equipments, appliances, lamps, tools as an

AC power source. With regards to DC application, the terminals are used only for charging 12 volt battery.

Never use this generator for any other purposes.

Please take a moment to familiarize yourself with the proper operation and maintenance procedures in order to maximize the safe and efficient use of this product.

Keep this owner’s manual at hand, so that you can refer to it at any time.

Due to constant efforts to improve our products, certain procedures and specifications are subject to change without notice.

When ordering spare parts, always give us the MODEL, PRODUCTION NUMBER (PROD No.) and

SERIAL NUMBER (SER No.) of your Product.

Please fill in the following blanks after checking the production number on your product.

(Location of label is different depending on the product model.)

PROD No. / SER No. (Label)

CONTENTS

1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. WATTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

6. SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

7. MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

8. "HOW-TO" MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

9. PERIODIC OPERATION AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

10. TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

11. PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

13. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

14. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

NOTE

Please refer to the illustrations on the back page of the front cover or back cover

1

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1. SAFETY PRECAUTIONS

Please make sure you review each precaution carefully.

Pay special attention to statement preceded by the following words.

WARNING “WARNING” indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

CAUTION “CAUTION” indicates a possibility of personal injury or equipment damage if instructions are not followed.

WARNING

Do not operate the generator near gasoline or gaseous fuel because of the potential danger of explosion or fire.

Do not fill the fuel tank with fuel while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel during refueling. If fuel is spilt, wipe it off and let dry before starting the engine.

WARNING

Do not place in flammables near the generator.

Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other in flammables near the generator.

WARNING

Do not operate the generator inside a room, cave, tunnel, or other insufficiently ventilated area. Always operate it in a well-ventilated area, otherwise the engine may become overheated, and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives.

Keep the generator at least 1 meter (3 feet) away from any structure or building during use.

If the generator must be used indoors, the area must be well-ventilated and extreme caution must be taken regarding the discharge of exhaust gases.

1m (3feet)

1m

(3feet)

WARNING

Do not enclose the generator nor cover it with a box.

The generator has a built-in forced air cooling system, and may become overheated if it is enclosed.

If generator has been covered to protect it from the weather during non use, be sure to remove it and keep it well away from the area during generator use.

WARNING

Operate the generator on a level surface.

It is not necessary to prepare a special foundation for the generator.

However, the generator will vibrate on an irregular surface, so choose a level place without surface irregularities.

If the generator is tilted or moved during operation, fuel may spill and / or the generator may tip over, causing a hazardous situation.

Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such a case, piston seizure may occur even if the oil is above the upper level.

2

WARNING

Pay attention to the wiring or extension cords from the generator to the connected device.

If the wire is under the generator or in contact with a vibrating part, it may break and possibly cause a fire, generator burnout, or electric shock hazard.

Replace damaged or worn cords immediately.

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WARNING

Do not operate in rain, in wet or damp conditions, or with wet hands.

The operator may suffer severe electric shock if the generator is wet due to rain or snow.

WARNING

If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash it with water.

WARNING

Be extremely careful that all necessary electrical grounding procedures are followed during each and every use. Failure to do so can be fatal.

WARNING

Do not contact the generator to a commercial power line. Connection to a commercial power line may short circuit the generator and ruin it or cause electric shock hazard. Use the transfer switch for connecting to domestic circuit.

WARNING

No smoking while handling the battery. The battery emits flammable hydrogen gas, which can explode if exposed to electric arcing or open flame.

Keep the area well-ventilated and keep open flames/sparks away when handling the battery.

WARNING

Engine becomes extremely hot during and for some time after operation. Keep combustible materials well away from generator area.

Be very careful not to touch any parts of the hot engine especially the muffler area or serious burns may result.

WARNING

Keep children and all bystanders at a safe distance from work areas.

WARNING

It is absolutely essential that you know the safe and proper use of the power tool or appliance that you intend to use. All operators must read, understand and follow the tool/appliance owners manual. Tool and appliance applications and limitations must be understood. Follow all directions given on labels and warnings. Keep all instruction manuals and literature in a safe place for future reference.

WARNING

Use only "LISTED" extension cords.

When a tool or appliance is used outdoors, use only extension cords marked "For Outdoor Use". Extension cords, when not in use should be stored in a dry and well ventilated area.

WARNING

Always switch off generator's AC circuit breaker and disconnect tools or appliances when not in use, before servicing, adjusting, or installing accessories and attachments.

CAUTION

Make sure the engine is stopped before starting any maintenance, servicing or repair.

Make sure maintenance and repair of the generator set are performed by properly trained personnel only.

3

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Symbols and Meanings

In accordance with the European requirements (eec Directives),the specified symbols as shown in the following table are used for the products and this instruction manual.

Read the operator's instruction manual.

Fire, open light and smoking prohibited.

Stay clear of the hot surface.

Exhaust gas is poisonous.

Do not operate in an unventilated room.

Stop the engine before refueling.

Caution, risk of electric shock.

Do not connect the generator to the commercial power lines.

HOT, avoid touching the hot area.

ON

(power and Engine)

OFF

(power and Engine)

Alternating current

Direct current

Plus ; positive polarity

Minus ; negative polarity

OUT-position of a bistable push control

IN-position of a bistable push control

Protective earth

(ground)

Fuse

Engine oil

Add oil

Battery charging condition

Choke ; cold starting aid

Engine start

(Electric start)

Engine stop

Gasoline

Fast

Slow

Fuel start / Open

Fuel stop / Close

P

r

Rated power (kW)

COP

Continuous power

COS

r

Rated power factor

I

r

Rated current (A) f

r

Rated frequency (Hz)

U

r

Rated voltage (V)

H

max

Maximum site altitude above sea-level (m)

T

max

Maximum ambient temperature ( )

m

Mass (kg)

4

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NOTE

Please refer to the illustrations on the back page of indicated in the sentence.

q CONTROL PANEL w FUEL TANK e FUEL GAUGE r SIDE PANEL (R) t OIL DRAIN PLUG y RECOIL STARTER (HANDLE) u STOPPER i TANK CAP o SPARK PLUG CAP

!0 AIR CLEANER

!1 FUEL STRAINER

!2 BATTERY [Electric starter model]

!3 OIL GAUGE (OIL FILLER)

!4 SIDE PANEL (L)

!5 EXHAUST OUTLET

3. PRE-OPERATION CHECKS

Recommended engine oil:

Use 4-stroke automotive detergent oil of API service class

SE or higher grade (SG, SH or SJ is recommended).

SAE 10W-30 or 10W-40 is recommended for general, all-temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area.

Single grade

Multigrade

Ambient temperature

5W

10W

20W

#20

10W-30

10W-40

#30

#40

Before checking or refilling oil, be sure generator is located on stable and level surface with engine stopped.

Remove oil filler cap and check the engine oil level.(See Fig. 2-q) q OIL GAUGE w OIL FILLER e UPPER LEVEL r LOWER LEVEL

If oil level is below the lower level line, refill with suitable oil (see table) to upper level line.

Do not screw in the oil filler cap when checking oil level.(See Fig. 2-w) q UPPER LEVEL w LOWER LEVEL

Change oil if contaminated.

(See "How-To" Maintenance.)

Oil capacity (Upper level) : (L)

Pi2800 . . . . . . . . . . . . . . . . . . . . . . . . 0.6

Pi4300 . . . . . . . . . . . . . . . . . . . . . . . . 1.0

WARNING

Do not refuel while smoking or near open flame or other such potential fire hazards.

Otherwise fire accident may occur.

NOTE

THIS ENGINE IS CERTIFIED TO OPERATE ON

AUTOMOTIVE UNLEADED GASOLINE.

Check fuel level at fuel level gauge.

(See Fig. 2-r) q EMPTY (E) w FULL (F) e "LEVEL" MARK r FUEL LEVEL LINE

If fuel level is low, refill with unleaded automotive gasoline.

Be sure to use the fuel filter screen on the fuel filter neck.(See Fig. 2-e) q FUEL FILTER SCREEN w TANK CAP

Fuel tank capacity : (L)

Pi2800 . . . . . . . . . . . . . . . . . . . . 10.8

Pi4300 . . . . . . . . . . . . . . . . . . . . 12.8

5

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6

WARNING

Make sure you review each warning in order to prevent fire hazard.

Do not refill tank while engine is running or hot.

Before filling fuel, turn the engine switch into

" "

(Fuel stop/close) position.

Be careful not to admit dust, dirt, water or other foreign objects Into fuel.

Wipe off spilt fuel thoroughly before starting engine.

Keep open flames away.

5. GROUNDING THE GENERATOR

To ground the generator to the earth, connect the grounding lug of the generator to the grounding spike driven into the earth or to the conductor which has been already grounded to the earth. (See Fig. 2-t) q GROUNDING SPIKE

If such grounding conductor or grounding electrode is unavailable, connect the grounding lug of the generator to the grounding terminal of the using electric tool or appliance. (See Fig. 2-y) q GROUND TERMINAL

3. CHECKING COMPONENT PARTS

Check following items before starting engine:

Fuel leakage from fuel hose, etc.

Bolts and nuts for looseness.

Components for damage or breakage.

Generator not resting on or against any adjacent wiring.

4. CHECK GENERATOR SURROUNDINGS.

WARNING

Make sure you review each warning in order to prevent fire hazard.

Keep area clear of in flammables or other hazardous materials.

Keep generator at least 3 feet (1 meter) away from buildings or other structures.

Only operate generator in a dry, well ventilated area.

Keep exhaust pipe clear of foreign objects.

Keep generator away from open flame.

No smoking!

Keep generator on a stable and level surface.

Do not block generator air vents with paper or other material.

6. NOTES ON INSTALLATION

Always be sure to place the generator on a level surface, locking the wheel with the stopper and/or chocking the wheels.

(See Fig. 2-u) q STOPPER w UNLOCK e LOCK

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4. OPERATING PROCEDURES

1. STARTING THE GENERATOR

CAUTION

Check the oil level before each operations as outlined on page 5.

(e) [Electric starter model]

Insert the key into the key switch and turn it clockwise to the " "(ON) position to start the engine.

Then turn the key further to the " "(START) position. The engine will be started by starting motor.

(a) Make sure the appliance is disconnected.

(b)Turn engine switch to " "(CHOKE) position.

(When engine is warm or temperature is high, start engine with the switch at " " (OPEN) position.) (See Fig. 3-q) q " w "

" (CLOSE)

" (CHOKE)

CAUTION

Do not connect defective appliances including lines and plugs.

Be sure appliances are not connected to generator when starting up.

Starting the generator with an appliance connected could result in damage to the generator and/or appliance and in personal injury.

OFF

ON

START

CAUTION

Do not run the starting motor over 5 seconds continuously.

If the engine fails to start, return the key to the " "(ON) position and wait about 10 seconds then start again.

Do not turn the key switch to " "(START) position when the engine is running to prevent damage of starting motor.

When starting the engine by recoil starter, set the key switch at the " "(ON) position and pull the starter handle.

(c) [Recoil starter model]

Pull the starter handle slowly until passing the compression point (resistance will be felt), then return the handle to its original position and pull briskly. (See Fig. 3-w) q RECOIL STARTER HANDLE w PULL BRISKLY

(d)After starting, allow the starter handle to return to its original position with the handle still in your hand.

NOTE

When engine fails to start after several attempts, repeat the starting procedures mentioned above with the engine switch placed at

" " (OPEN) position.

(f) After 20 to 30 seconds of warm-up is completed, turn the engine switch to " " (OPEN) position.

(See Fig. 3-e) q " w "

" (CHOKE)

" (OPEN)

(g) By changing over the LE display in the multi monitor into the "voltage" indication, make sure the generating voltage is the normal level

(approx.120V).

NOTE

If no generating condition is found out, please consult nearest PRAMAC dealer.

7

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2. USING ELECTRIC POWER

WARNING

Make sure that the appliance is switched OFF before connecting it to the generator.

Do not move the generator while it is running.

Be sure to ground the generator if the connected appliance is grounded. Failure to ground unit may lead to electrical shock.

(1) CONTROL PANEL

1 2 3

MULTI MONITOR

Hours

V

Hz

AUTO

P-SAVE

q MULTI MONITOR w AC RECEPTACLES (20A) e AC RECEPTACLES (30A)

MULTI MONITOR

8 7 6

r GROUND TERMINAL t DC TERMINALS y DC CIRCUIT BREAKER

5 4

u KEY SWITCH [Electric starter model] i ENGINE SWITCH

1 2 3

Operation hour, voltage and frequency are indicated in turns by means of depressing the LE display changeover switch.

In addition, "O_Lod" (overload) will be indicated when the generator is in the overload condition or appliance(s) will be out of order.

In this case, stop the engine immediately and check the appliance and/or generator for overloading.

After the check and remedy, restarting the engine will resume displaying in the normal manner.

8 7

MULTI MONITOR

AUTO

P-SAVE

6

Lamp (red) is turned on when changing over into operation hour indication in the LE display.

Lamp (red) is turned on when changing over into voltage indication in the LE display.

Hours

V

Hz

4

5

Lamp (red) is turned on when changing over into frequency indication in the LE display.

When depressing this switch, indication in LE display is changed over in turns; operation hour → voltage → frequency → operation hour.

When starting the engine, operation hour is indicated in LE display at first.

When depressing this switch, auto-power saving function is activated.

8

Lamp (green) is turned on while auto-power saving function is activated.

i Engine oil level warning lamp

When the engine oil level is lower than the specified level, the lamp is turned on.

Then engine will be stopped.

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(a) Make sure the voltage indicated in the LE display is the normal level (approx. 120V).

This generator is thoroughly tested and adjusted in the factory.

If the generator does not produce the specified voltage, consult your nearest PRAMAC dealer or service shop.

(b) Turn off the switch(es) of the electrical appliance(s) before connecting to the generator.

(c) Insert the plug(s) of the electrical appliance(s) into the receptacle. (See Fig. 4-q)

Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take a current exceeding the specified amperage.

Be sure that the total wattage of all appliances dose not exceed the rated output of the generator.

Style Ampere Receptacle AC plug

Up to 20A

NEMA

5-20R

Description

NEMA

5-20P

GFCI (Ground Fault

Circuit Interrupter)

Receptacle, duplex

Up to 30A

NEMA

5-30R

NEMA

5-30P

Locking Receptacle

TABLE 1

WARNING

To take power out from the TWIST LOCK RECEPTACLE, insert the plug into the

Be sure to ground the generator if the connected electrical device is grounded.

NOTE

When the "O_Lod" (overload) is indicated in the LE display, AC output is cut off on the grounds that the generator operation is in overload condition or appliance(s) will be out of order.

In this case, stop the engine immediately and check the appliance and/or generator for overloading.

After the check and remedy, restarting the engine will resume displaying in the normal manner.

(d) Turn on the switch of the appliance.

The DC terminal is used only for charging 12 volt batteries.

It provides up to 12V-8.3A (100W) of maximum power. q Positive terminal (RED) w Negative terminal (BLACK)

CONNECTION OF CABLE :

Connect positive terminal (red) on generator to positive (+) terminal on battery.

Connect negative terminal (black) on generator to negative (-) terminal on battery.

Both AC and DC output can be used at the same time if the total output is within rated output of the generator.

9

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SAFETY PRECAUTIONS WHILE CHARGING

An explosive hydrogen gas is discharged through vent holes in the battery during the charging process. Do not allow spark or open flame around the generator or battery during the charging process.

Electrolyte fluid can burn eyes and clothing.

Be extremely careful to avoid contact. If injured, wash the affected area immediately with large quantities of water and consult a doctor for treatment.

When charging a large capacity battery or totally discharged battery, excessive current may force the DC circuit breaker to turn off.

In such cases, use a battery charger to charge a large battery with AC output.

Battery defects may cause the DC circuit breaker to turn off.

Check the battery before replacing the DC circuit breaker.

3. STOPPING THE GENERATOR

(a) Turn off the power switch of the electric equipment and unplug the cord from receptacle of the generator.

(b) Allow the engine about 3 minutes to cool down at no load before stopping.

(c) Turn the engine switch to the position

" " (CLOSE). (See Fig. 4-r) q "

" (OPEN) w "

" (CLOSE)

(d) [Electric starter model]

Turn the key switch to the " "(OFF) position.

OFF

ON

START

10

q OIL SENSOR

(a) The oil sensor detects the fall in oil level in the crankcase and automatically stops the engine when the oil level falls below a predetermined level.

(b) When engine has stopped automatically, switch off generator's AC circuit breaker, and check the oil level.

Refill engine oil to the upper level as instructed on page 5 and restart the engine.

(c) If the engine does not start by usual starting procedures, check the oil level.

CAUTION

Do not remove OIL SENSOR PROBE when refilling with oil.

Remove oil filler cap on the opposite side of carburetor.

5. WATTAGE INFORMATION

Some appliances need a "surge" of energy when starting.

This means that the amount of electrical power needed to start the appliance may exceed the amount needed to maintain its use.

Electrical appliances and tools normally come with a label indicating voltage, cycles / Hz, amperage

(amps) and electrical power needed to run the appliance or tool.

Check with your nearest dealer or service center with questions regarding power surge of certain appliances or power tools.

Electrical loads such as incandescent lamps and hot plates require the same wattage to start as is needed to maintain use.

Loads such as fluorescent lamps require 1.2

to 2 times the indicated wattage during start-up.

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Electrical motors require a large starting current. Power requirements depend on the type of motor and its use. Once enough

"surge" is attained to start the motor, the appliance will require only 50% to 30% of the wattage to continue running.

Most electrical tools require 1.2 to 3 times their wattage for running under load during use. For example, a 5000 watt generator can power a 1800 to 4000 watt electrical tool.

Loads such as submersible pumps and air compressors require a very large force to start. They need 3 to 5 times the normal running wattage in order to start.

For example, a 5000 watt generator would only be able to drive a 1000 to 1700 watt pump.

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NOTE

The following wattage chart is general guide only. Refer to your specific appliance for correct wattage.

To determine the total wattage required to run a particular electrical appliance or tool, multiply the voltage figure of the appliance/tool by the amperage (amps) figure of same. The voltage and amperage (amps) information can be found on a name plate which is normally attached to electrical appliances and tools.

Applications

Incandescent lamp, Heater

Applicable Wattage (approx. W)

Pi2800 Pi4300

60Hz

2500 3800

Fluorescent lamp, Electric tool

Mercury lamp

Pump, Compressor

1300

800

500

1900

1600

800

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS

When a long electric extension cord is used to connect an appliance or tool to the generator, a certain amount of voltage drop or loss occurs in the extension cord which reduces the effective voltage available for the appliance or tool.

The chart below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet

(approx. 100 meters) is used to connect an appliance or tool to the generator.

Nominal cross section

mm

2

0.75

1.27

2.0

3.5

5.5

A.W.G.

No.

18

16

14

12 to 10

10 to 8

Allowable current

No.of strands

/ strands dia.

Resistance

A

7

12

17

23

35

No./mm

70/0.32

Ω/100m

0.332

1A

3A

1V

Current Amp.

5A 8A 10A 12A 15A

30/0.18

2.477

2.5V 8V 12.5V ─

─ ─ ─

50/0.16

1.486

1.5V 5V 7.5V 12V 15V 18V

37/0.26

0.952

1V 3V 5V 8V 10V 12V 15V

45/0.32

0.517

1.5V 2.5V 4V 5V 6.5V 7.5V

2V 2.5V 3.5V 4V 5V

11

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6. SPARK ARRESTER

In a dry or wooded area, it is recommendable to use the prodoct with a spark arrester. Some areas require the use of a spark arrester. Please check your local laws and regulations before operating your prodoct.

The spark arrester must be cleaned regularly to keep it functioning as designed.

A clogged spark arrester :

Prevents the flow of exhaust gas

Reduces engine output

Increases fuel consumption

Makes starting difficult

If the engine has been running, the muffler and the spark arrester will be very hot. Allow the muffler to cool before cleaning the spark arrester.

How to remove the spark arrester

1. Remove the flange bolts from the muffler cover and remove the muffler cover.

2. Remove the special screw from the spark arrester and remove the spark arrester from the muffler.

SPARK

ARRESTER

SCREEN

NUT

MUFFLER

TAIL SCREEN

SCREW

TAIL SCREEN COVER

Clean the spark arrester screen

Use a brush to remove carbon deposits from the spark arrester screen.

Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes.

Replace the spark arrester if it is damaged.

Install the spark arrester, and muffler protector in the reverse order of disassembly.

SPARK ARESSTER SCREEN

12

Pi4300(US)_GU2258 06.7.11 11:09 AM ページ13

7. MAINTENANCE SCHEDULE

MAINTENANCE, REPLACEMENT, OR REPAIR OF THE EMISSION CONTROL DEVICES

AND SYSTEMS MAY BE PERFORMED BY ANY NONROAD ENGINE REPAIR

ESTABLISHMENT OR INDIVIDUAL.

DAILY INSPECTION

Before running the generator, check the following service items:

Safe surroundings

Leakage of gasoline and engine oil

Enough clean engine oil

AC and DC terminals for damage

Enough gasoline

Excessive vibration,noise

Clean air cleaner element

Loose or broken bolts and nuts

PERIODIC MAINTENANCE

Periodic maintenance is vital to safe and efficient operation of your generator.

Check the table below for periodic maintenance intervals.

IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO

CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-

RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL

SYSTEM EFFECTIVE.

The emission control system consists of the following parts :

(1) Carburetor and internal parts (5) Spark plug

(2) Cold start enrichment system, if applicable

(6) Magneto or electronic ignition system

(3) Intake manifold, if applicable

(4) Air cleaner elements

(7) Spark advance/retard system, if applicable

(8) Exhaust manifold, if applicable

(9) Hoses, belts, connectors, and assemblies

The maintenance schedule indicated in the table is based on the normal generator operation. Should the generator be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.

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14

Periodic Maintenance Schedule table

Maintenance Items

Every

8 hours

(Daily)

Clean generator and check bolt and nuts

(Daily)

Every

50 hours

(Weekly)

Every

200 hours

(Monthly)

Check and refill engine oil

Change engine oil (*Note 1)

Clean spark plug

Clean air cleaner

Clean spark arrester

Replace air cleaner element

Clean fuel cup

Clean and adjust spark plug and electrodes

(Refill daily up to upper level)

(Initial

20 hours)

(Every

100 hours)

(Every 100 hours)

(Every 100 hours)

Every

500 hours

Replace spark plug

Remove carbon from cylinder head (*Note 2)

Check and adjust valve clearance (*Note 2)

Clean and adjust carburetor (*Note 2)

Replace fuel lines

Overhaul engine (*Note 2)

Check AC receptacles

Check DC termianl

Check engine switch

Check multi monitor

(Daily)

(Daily)

(Daily)

(Daily)

Check rotor

Check stator

Replace engine mount

MS2231

Every

1000 hours

● (Yearly)

*Note 1: Initial oil change should be performed after first twenty (20) hours of operation. Thereafter change oil every hundred (100) hours.

Before changing oil, check for a suitable way to dispose of old oil.

Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instructions on proper disposal.

*Note 2: As to the procedures for these items, please refer to the SERVICE MANUAL or consult your nearest service dealer.

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8. "HOW-TO" MAINTENANCE

CAUTION

Make sure the engine is stopped before starting any maintenance, servicing or repair.

NOTE

It is recommended to use ear protection when performing operation, maintenance and repair of the generator set.

To access the following items for servicing, take the applicable side panel out by removing the screw with screwdriver or coin.

LH-side panel ---- Oil level gauge, Air cleaner,

Spark plug, Battery etc.

RH-side panel ---- Oil drain screw etc.

Change engine oil every 50 hours.

(For new engine, change oil after 20 hours.)

(a) Drain oil by removing the drain plug and the oil filler cap while the engine is warm.

q OIL DRAIN PLUG

(b) Reinstall the drain plug and fill the engine with oil until it reaches the upper level on the oil filler cap.

Use fresh and high quality lubricating oil to the specified level as directed on page 5.

If contaminated or deteriorated oil is used or the quantity of the engine oil is not sufficient, the engine damage will result and its life will be greatly shortened.

3. SERVICING THE AIR CLEANER

Maintaining an air cleaner in proper condition is very important.

Dirt induced through improperly installed, improperly serviced or inadequate elements damages and wears out engines. Keep the element always clean.

(a) Unhook the cover and remove the cleaner element.

q w ELEMENT (Urethane form)

(b) Urethane form : Wash the element with fresh water. Squeeze out the water then dry the element. (Do not twist.)

4. CLEANING AND ADJUSTING

(a) If the plug is contaminated with carbon, remove it using a plug cleaner or wire brush.

(b) Adjust the electrode gap to 0.6 to 0.7 mm (0.024

to 0.028 in.).

q SPARK PLUG w PLUG WRENCH e SPARK PLUG CAP

Spark plug :

BR6HS (NGK) or RL86C (CHAMPION)

When replacing with new spark plug, use the above-recommended one.

If not available by all means, make sure to replace with equivalent one of resistance type.

5. CLEANING FUEL STRAINER

Dirt and water in the fuel are removed by the fuel strainer.

q FUEL STRAINER CUP

(a) Remove the strainer cup and throw away water and dirt.

(b) Clean the screen and strainer cup with gasoline.

(c) Tightly fasten the cup to main body, making sure to avoid fuel leak.

6. BATTERY INSTALLATION

Recommended Battery

Lead-acid battery :

Pi2800

A capacity of 12V-6A・h or larger.

Pi4300

A capacity of 12V-12A・h or larger.

(a) Attach terminals to a lead-acid battery already charged. Mount the battery onto the position as specified below, with its terminals facing inward.

(b) Insert each long bolt through the specified hole, its tip pointing outward.

(c) Put the supporting arm on the long bolts and tighten with the butterfly nuts.

(Push the lead-acid battery all the way inward.)

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(d) Arrange the wiring so that it won't be damaged by possible vibration caused by the engine.

(e) Only after checking that the engine's starter key is in the "OFF" position, securely connect the red cable, to the positive (+) terminal. And then connect the other cable to the negative (-) terminal.

Red cable : to the (+) terminal

Black cable : to the (-) terminal

CAUTION

Should the connection be made in incorrect manner, the engine will be broken.

1 Battery Base

2

3

Flange Bolt

Screw

4 Battery Band

5 Bolt and Nut

6 Battery cover

5

Accessory parts

6

1

4

3

RED

CABEL

LESS THAN

131 mm [5.2 in.] (Pi2800)

162 mm [6.4 in.] (Pi4300)

LESS THAN

114 mm [4.5 in.] (Pi2800)

136 mm [5.4 in.] (Pi4300)

2

LESS THAN

71 mm [2.8 in.] (Pi2800)

82 mm [3.2 in.] (Pi4300)

RED CABEL

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9. PERIODIC OPERATION AND

INSPECTION

When furnishing the generator as emergency electric power source, periodic operation and inspection are needed.

Fuel (gasoline) and engine oil will be deteriorated with time, and this causes that the engine is difficult to start and as the results improper engine operation and fault.

CAUTION

Since the fuel (gasoline) will be deteriorated with time, replace fuel (gasoline) with fresh one periodically; once every three (3) months is recommended.

(a) Check the fuel (gasoline), engine oil and air cleaner.

(b) Start engine.

(c) With appliance such as lightings activated, run the engine for over ten minutes.

(d) Check for the following items;

Proper engine running.

Adequate output and the indicator lamp turned on properly.

The engine switch normally operated.

No leakage of engine oil and fuel (gasoline).

10. TRANSPORTING

When transporting the generator, make sure that the fuel (gasoline) should be drained from the tank.

WARNING

To prevent fuel spillage due to the vibration and impact, never transport the generator with the fuel (gasoline) filled in the tank.

Secure the tank cap thoroughly.

To avoid the risk of the gasoline flammability, never leave the generator in an area exposed to direct sunlight or high temperatures for a long time.

Keep the fuel (gasoline) in the exclusive gasoline storage tank made by steel when transporting.

(a) Turn the engine switch to the

" " (CLOSE) position.

CLOSE

OPEN

CHOKE

(b) Drain the fuel from the tank.

(c) Secure the tank cap.

CAUTION

Do not place any heavy objects on the generator.

Select and place the generator in the proper position of the transport vehicle so that the generator not be moved or fallen down.

Fix the generator with rope as necessary.

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The following procedures should be followed prior to storage of your generator for periods of 6 months or longer.

Drain fuel from fuel tank carefully by disconnecting the fuel line.

Gasoline left in the fuel tank will eventually deteriorate making engine-starting difficult.

Remove the drain screw of the carburetor.(See Fig. 6q) q DRAIN SCREW

Change engine oil.

Check for loose bolts and screws, tighten them if necessary.

Clean generator thoroughly with oiled cloth. Spray with preservative if available. NEVER USE WATER

TO CLEAN GENERATOR !

Pull starter handle until resistance is felt, leaving handle in that position.

Store generator in a well ventilated, low humidity area.

12. TROUBLESHOOTING

When generator engine fails to start after several attempts, or if no electricity is available at the output socket, check the following chart. If your generator still fails to start or generate electricity, contact your nearest PRAMAC dealer or service shop for further information or corrective procedures.

When Engine Fails to Start:

Check if engine switch is in its proper position.

Check fuel level.

Check to make sure generator is not connected to an appliance.

Check spark plug for loose spark plug cap.

Check spark plug for contamination.

Check if the recommended spark plug would be adopted.

Check engine oil level.

Turn engine switch to " "(CHOKE) position.

If empty, refill fuel tank making sure not to overfill.

If connected, turn off the power switch on the connected appliance and unplug.

If loose, push spark plug cap back into place.

Remove spark plug and clean electrode.

If not, replace with the recommended spark plug.

If the recommended spark plug is not available by all means, make sure to replace with equivalent one of resistance type.

If the engine oil level is low, add the oil to the upper level line on the oil gauge.

18

When No Electricity Is Generated at Receptacle:

Check if the "O_Lod"(overload) is indicated in the Multi Monitor.

Check if the DC circuit breaker is turned OFF.

Stop the engine and check the appliance and/or generator for overloading.

Depress the circuit breaker into ON position, after making sure the charging current level is proper and the battery is in the normal condition.

Check AC receptacle and DC terminals for loose connection.

Check to see if engine starting was attempted with appliances already connected to generator.

Secure connection if necessary.

Turn off switch on the appliance, and disconnect cable from receptacle. Reconnect after generator has been started properly.

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13. SPECIFICATIONS

Type

Rated Power [COP] kVA

Rated Power Factor

Rated Frequency

Rated Voltage

Rated Current

DC output

Hz

V

A

V-A

Over Current Protection (AC line)

Over Current Protection (DC line)

Multi Monitor unit

Model

Type

MODEL Pi2800 Pi4300

Multi-Pole, Revolving Field Inverter type

2.5

3.8

1.0

60

120

20.8

31.7

12 - 8.3

Electronic breaker

Circuit breaker

Standard

EX17 EX27

Forced air-cooled,4-cycle,single cylinder

OHC type gasoline engine

169 (10.31) 265 (16.17)

Automotive unleaded gasoline Fuel

Fuel tank capacity

L (U.S. gal)

Rated continuous operation

Spark plug

Starting system

Oil sensor

Valve Clearance

(Intake & Exhaust) mm(in.)

Emissions Durability Period

(California only) hours

10.8 (2.85)

500

12.8 (3.38)

7.6

5.3

BR6HS (NGK) or RL86C (CHAMPION)

Recoil starter

Standard

0.12

(0.0047 )

Note : Adjust the valve clearance while the engine is cold.

Dry weight kg (lb)

537 (21.1)

482 (19.0)

583 (23.0)

54 (119.1)

580 (22.8)

527 (20.8)

618 (24.3)

74 (163.1)

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14.WIRING DIAGRAM

Pi2800 (60Hz-120V)

GENERATOR

Diode rectifier

DC

Winding

Sub Coil 1

Sub Coil 2

Org

Gry

Brn

Brn

W

W

Grn/Y

Org

Brn/W

Circuit

Breaker

Org

+

-

DC Output

Terminal

Grn/Y

Engine

Switch

Grn/Y

CONTROL PANEL

Main Coil

R

W

Blu

R

W

Blu

INV&E/G

C/U

Grn

Blu

Y

MONITOR

C/U

Blk

Stepping

Motor

Oil Level

Sensor

Spark

Plug

Ignition

Coil

Grn

Blu

Pur

Gry

Org

Blk

Blu

Engine

Switch

Brn

Blk

Grn/Y

R

AC

Receptacle

W

30A

Grn/Y

W

R

AC

Receptacle

W

Grn/Y

W

Earth

(Ground)

Terminal

ENGINE

Wiring color code

Blk : Black Grn : Green Brn : Brown Pur : Purple Y : Yellow Brn/W : Brown/White

Gry : Gray Blu : Blue Org : Orange W : White R : Red Grn/Y : Green/Yellow

20

Pi4300(US)_GU2258 06.7.11 11:09 AM ページ21

Pi4300 (60Hz-120V)

GENERATOR

DC

Winding

Diode rectifier

Sub Coil 1

Sub Coil 2

Org

Gry

Brn

Brn

W

W

Grn/Y

Main Coil

R

W

Blu

Org

Gry

Brn

Brn

Circuit

Breaker

Org

Y

Y

+

-

DC Output

Terminal

Regulator

R

Grn/Y

Grn/Y

Grn/Y

ST

M-

L.IG

M+

B

Key Switch

CONTROL PANEL

R

W

Blu

INV&E/G C/U

Grn

Blu

Y

MONITOR

C/U

Stepping

Motor

Oil Level

Sensor

Plug

Ignition

Coil

Spark

Grn

Blu

Pur

Gry

Org

Blk

Blu

Engine

Switch

Brn

Blk

Grn/Y

R

AC

Receptacle

W

30A

Grn/Y

Earth

(Ground)

Terminal

W

R

W

AC

Receptacle

W

Starting

Motor

M

Battery

R

R

W

Blk

ENGINE

Wiring color code

Blk : Black Pin : Pink Grn : Green Gry : Gray Y : Yellow Pur : Purple

Brn : Brown R : Red Blu : Blue Org : Orange W : White Grn/Y : Green/Yellow

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