Mase Generators IS 3.5 User manual

IS 3.5 - 4.5 - 5.0 - 6.0
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MASE GENERATORS S.p.A.
Tel.[phone]
Fax [phone] (commercial dept.)
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NR.000000
DICHIARAZIONE CE DI CONFORMITA'
EC DECLARATION OF CONFORMITY
Fabbricante/Manufacturer: MASE GENERATORS S.p.A.
Indirizzo /Address : Via Tortona 345, Pievesestina (FO)
Il sottoscritto Luigi Foresti in qualità di direttore generale della MASE GENERATORS S.p.A., dichiara sotto la
propria responsabilità che il gruppo elettrogeno modello ......... :
The undersigned Luigi Foresti as MASE GENERATORS S.p.A. general manager declares, under his sole
responsability, that the generators model is..................:
Codice / Code Descrizione / Model Matricola / Serial N.
E' conforme alle disposizioni delle Direttive di seguito elencate :
CEE 89/392 (come emendata delle Direttive CEE 91/368 e CEE 93/44)
CEE 89/336 (come emendata delle Direttive CEE 92/31)
CEE 73/23 modificata da CEE 93/68.
Corresponds to the requirements of the 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.
Cesena, / / ......................................................
Direttore Tecnico
Technical Director
GENERATORS
MASE GENERATORS S.p.A.Sede legale ed Amm.: 47023 CESENA (FO) ITALY - Via Tortona, 345 - C.F./P.I. 00687150409 Cap. Soc. milioni
1250 interamente versato - Registro Società Tribunale Forl' n. 6818 - CCIAA Forl' n.164063 - c.c.p. n. 11541471 - EXPORT FO n. 006368

- 3-
IS 3.5 - 4.5 - 5.0 - 6.0
3TAB "A"
S.A.E
Service
Grade
-30 -20 -10 0 10 20 30 40
Ambient temperature (oC)

:
:


:
:
:
:
AAPERTO
OPEN
OUVERT
GEÖFNET
ABIERO
OPEN
2
1
1

IS 3.5 - 4.5 - 5.0 - 6.0
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4
6
5
7
1
1
2
C
A B

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IS 3.5 - 4.5 - 5.0 - 6.0
8
SCHEMAELETTRICO-WIRING DIAGRAM- SCHEMAELECTRIQUE -SCHALTPLAN -ESQUEMA ELE'CTRICO
144
3320 10
2
P1
P2
1
F
F2
18
17
16
15
14
13
12
11
10
7
8
9
1
2
3
4
5
6
7
8
9
5
11
13
12
14
T
19 18
TP
17 16EV P
15 M-
50 30 12V
+
0
19
21
50(60)
5(6)
5(6)
+
1
P
F2

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GB
CONTENTS
FIGURES ...................................................... pag.2
TAB."A" TABLE SUGGESTED OILS............. pag.2
WIRINGDIAGRAM ....................................... pag.4
1SAFETYREGULATIONS .............................. pag.13
2PRELIMINARYCHECKS .............................. pag.13
3GENERATORUSE ....................................... pag.13
Starting
GeneratorStop
4SAFETY DEVICES ....................................... pag.13
Low oil pressure device
Warning
Hightemperature device
Alternatoroverload/overtemperature device
Important
5MAINTENANCE ............................................ pag.14
Important
Enginemaintenance
Important
6INACTIVEPERIOD ....................................... pag.14
7CONTROLPANEL ........................................ pag.14
8PROTECTIONFUSE ..................................... pag.8
9DIMENSIONANDWEIGHT ........................... pag.15
10 DESCRIPTIONWIRINGDIAGRAM ............... pag.15
11 TROUBLEMAINTENANCE ........................... pag.15
12 TROUBLESHOOTIN ..................................... pag.15
13 TECHNICALFEATURES .............................. pag.16
A statement advising of the need to take care lest there be serious consequences resulting in
death of personnel or in hazard to health.
A situation that could occur during the lifetime of a product, system or plant that has the
potential for human injury, damage to property, damage to the environment, or economic loss.
A statement advising of the need to take care lest serious consequences result in harm to
material items such as the asset or the product.
Importantinformation.
Drawing are provided by way of example. Should your machine be quite different from the illustrations contained in this
manual, the safety regulations and relevant information are always granted.
The manufacturer's policy of constant development and updating may lead to modifications without prior notice.
DANGER
WARNING
CAUTION
INFORMATION

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IS 3.5 - 4.0- 5.0 - 6.0
GB
CONGRATULATIONSON HAVINGCHOSENA MASE
PRODUCT
This manual contains all the necessary information for
properinstallation anduseof thegenerator.Its essential,
either for the customers safety and satisfaction or for
good reliability of the generator, to carry out proper
installation and a careful pre-delivery test.
A wrong installation or an oversight on testing may
compromise the efficiency of the generator and even
jeopardize the customers safety.
All information and illustrations in this handbook refer to
the latest produced model at the time of printing.
For any further information, please get in touch with the
nearestMASE SERVICECENTER, theyllbe pleasedto
help you at any time.
MASEreservethe righttointroducechanges withoutprior
notice. No part or illustration contained in this handbook
can be reproduced without previous approval by MASE
MASEGENERATORS S.p.A.
1SAFETY REGULATIONS
- Readcarefullyallthe instructionsgiveninthishandbook
and in the installation manual; they are of the utmost
importancefor correctinstallation anduse ofthe unitand
for prompt intervention in case of need.
- Do not allow unskilled or untrained people to use the
unit.
- Do not allow children or animals to get close to the
generator while it is working.
- Donot handle thegeneratoror theremotecontrolpanel
with wet hands; any misuse may cause electric shocks.
- Any testing of theunit isto becarried outonly whenthe
engine is stopped. Possible checks on the generator
when its running have to be performed only by skilled
workers.
2PRELIMINARYCHECKS
On starting the generator for the first time and after any
servicing, it is advisable to make sure that:
- The oil is at the right level through the rod ref. 1 Fig. 1
, as per table for suggested oils.
- Thegenerator iswellsecured tothesoundproofing box
by means of the proper bolts.
- The electric loads are disconnected so as to avoid
starting the generator on load.
- Everyconnection (fuel, exhaust,remote control,A.C.,
battery) has been properly carried out and there are no
connections in bad conditions.
- The water cock is open, as per (ref. 2 fig. 2)
- Ifanon-return valveis used,the coolingcircuitfrom the
valve up to the pump has been manually filled (ref. 1 fig.
2)
3GENERATORUSE
Before starting the generator, make sure all preliminary
checks, as per item 1 , have been properly carried out
Starting
To start the engine push the button << ON >> (fig. 3 ref.
4),all thepilotand warninglampswill glow for5sec. about
in a self control function, later on only the << panel on >>
(fig. 3 ref. 5) and then start the engine pushing the button
<<Start >> (fig. 3 ref.3), for 5 sec. max. Release it only
when the engine runs. A correct generator functioning is
demostrated by the led (fig .3 ref. 6) glowing on. Once
started,thesafetydevicesofthegenerator areautomaticily
activated (see item. 4).
Generator Stop
The generator can be stopped ushing the <<OFF>>
button on the control panel (fig. 3 ref 2).
4SAFETY DEVICES
The generator has been equipped with a setof safety
devices in case ot any misuse or running trouble, as
follows:
- Low oil-pressure device:
it causes the generator shut-down in case of insufficient
oil pressure.Its interventionisshown bythe warning light
going on (fig. 3 Ref. 7). It is usually enough to top up the
oil before starting the generator again.
The low oil-pressure device does not necessarily show
the oil level; a check of the oil level is consequently
necessary at regular intervals.
-High temperature device:
itcauses generatorshut-down in caseof hightemperatu-
re of the engine. Its intervention is shown by the warning
light going on (fig.3 ref.8).Should this device come in to
operation,look for and eliminate the causes of the
intervention and then start the generator again.
-Alternator overload/over temperature device:
it comes into operation, stopping the generator, in case
of thermic or electric overload of the alternator.
Itsintervention isshownbythe relativewarninglight going
on(fig.3 ref.9).Waituntil thetemperatureofthealternator
windings goes back to the normal values. Its however
recommendedto look forandeliminate thecauses ofthe
intervention before starting the generator again.
Ifone oftheabove safetydevices intervenes,lookfor and
eliminatethe causesof theintervention,then pushthe <<
STOP >> button to avoid that signal keeps stored.
WARNING
WARNING

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WARNING
INFORMATION
7 CONTROL PANEL (fig. 3)
1)HOURSMETER
2)OFF BUTTON
3)START BUTTON
4)BUTTON ON
5) PANEL ON LED (GREEN)
6) GENERATOR OUTPUT LED (GREEN)
7) OIL PRESSURE LED (RED)
8)ENGINETEMPERATURE LED (RED)
9) GENERATOR TEMPERATURE LED (RED)
When the unit stops because a circuit breaker trips, the
operating time indication disappears from the control panel
display and a code appears to indicate the cause of the
generator stop.
In the table below all the codes and their meaning are
listed.
ALARM CODES
CODE CAUSE OF CIRCUIT-BREAKER TRIP
E - 80 No power on generator
E - 81 Low oil pressure
E - 82 High motor temperature
E - 83 High alternator temperature
E - 85 Generator overload
E - 87 At 30" from start unit does not reach 80%
of nominal voltage
batt Low battery
Code E - 80 This code indicates that the unit has
stopped because of no voltage = 0 Volt. When this code
appears, it means:
- that the control panel is unable to measure the alternator
voltage for cut-off of an electrical connection;
- that the alternator is damaged.
Code E - 81 This code indicates that the unit has
stopped because the motor lubrication system pressure
is insufficient.
Code E - 82 This code indicates that the unit has
stopped because the motor has reached too high
temperatures.
Code E - 83 This code indicates that the unit has
stopped because the alternator has reached too high
temperatures.
Code E - 85 This code indicates that the unit has
stopped because the voltage has dropped to below 70%
of the nominal value for longer than 15 seconds.
In case of the fuse (ref.1 Fig.4) got burnt,
a protectio inserts and does not allows the generator to
start.
5MAINTENANCE
Anyservicing isto becarried outwith theengine stopped
after it has cooled enough, and only by skilled and
licensed staff.
Engine maintenance
The engine has to be serviced at regular intervals, as
shown in the table:
for any further and more detailed information,please
consult the handbook supplied by the engine
manufacturer, accompanying every generator.
Cheek oil level by means of the proper dipstick (fig. 5 ref.
1) and make sure it is always between the minimum and
maximum levels of the dipstick.
Engine carter capacity:
IS 3.5 - 4.0 lt.1.1 IS 5.0 - 6.0 lt 1.65
Oiltoppingup andreplacement canbecarriedout through
the hole. (fig. 1 ref. 1).
Forchangingoil, removethelevelstickand replaceoil with
the special pipe..
We suggest to carry out the draining when the oil is still
warm enough, to allow an easy flowing out.
6INACTIVE PERIOD
Should the unit remain unused for a long time, its
necessary to act as follows:
- Replace sump oil.
- Replace oil filter.
- Replace fuel filter.
- Replace the zinc anodes (ref. 1 fig. 6)
- If the room temperature is near or below 0°C it is
indispensableto draintheengine coolingcircuit using the
lever cock (ref. 3 fig. 2)
- Lubrificate the water pump impeller.
CAUTION

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IS 3.5 - 4.0- 5.0 - 6.0
GB
Code E - 87 This code indicates that the unit has
stopped because the generator voltage has not reached
80% of the nominal value 30 seconds after starting. This
could be caused by insufficient motor RPM or a broken
alternator.
batt This code indicates that the battery
is low. When this code appears, the generator is not
stopped.
When a circuit breaker has tripped with a consequent
generator stop, the panel must be reset by pressing the
OFF button in order to restart the unit.
If the unit is started and the alternator does not produce
voltage, or the control panel does not read voltage, the
latter switches off completely after one minute, stopping
the unit.
8 PROTECTION FUSE ( fig. 4 )
1)RELAYCIRCUITFUSE
2)BATTERY CHARGERFUSE
3)THERMALSWITCH
9 DIMENSIONS AND WEIGHT ( fig. 7 )
10 DESCRIPTION WIRING DIAGRAM (fig. 8 )
1ROTOR
2STATOR
3DIODE3A
4VARISTOR
5PRINTED CIRCUIT RELAY
6POWER TERMINAL BOARD
7RELAY CIRCUIT TERMINAL BOARD
8CONTROLPANELTERMINALBOARD
9FUSE 1A
10 CAPACITOR
11 BATTERY CHARGER REGULATOR
12 FUSE
13 STARTER
14 BATTERY
15 FUEL PUMP
16 FUEL SOLENOID
17 OIL PRESSURE SWITCH
18 OVERHEAD ENGINE THERMOSTAT
19 WATER TERMOSTAT
20 ALTERNATOR THERMOSTAT
21 THERMALSWITCH
11TROUBLEMAINTENANCE
12TROUBLE SHOOTING
INFORMATION
WARNING
COMPLAINT
PROBABLE REASON
Defective starting buttons
l
Defective fuel solenoid
ll
Defective battery Battery
cable section
l
Defective starting motor
l
Piping fuel filter choked
ll
12V circuit fuse
l
Avv./Ev.relay
l
Too much oil in crankcase
ll
Safety device intervention
l l
Overload
l
Defective governor linkage
l
Worm valve guides
l
Blocked valves
l
Worm cylinder and position rings
l
Defective injector
l l
Defective injector pump
l ll l
Defective feeding pump
l l
BLACK SMOCKE START AND STOP UNSTABLE RUNNING DOES NOT START WHITE SMOCKE
,6 ,6
D
Lengh
PPLQFK
590-23 675-26.6
E
Width
PPLQFK
406-15.9 468-18.4
F
Height
PPLQFK
515-20.2 565-22.2
Weight
NJOE
96-213 130-289

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GB
13TECHNICALFEATURES
1cylinder,4stroke,internal combustion
air-cooleddiesel
Displacement
Model
R.P.M.
Bore for stroke
PowerHp
Fuel consumption g./Hp.h
Starting system
Oil capacity
Max inclination
ALTERNATOR
Continuousoutput
Powerfactor
Insulation class
Frequecy Hz
Fuel
Synchronous,self-excited,single
phase, 2 poles, brushless
YANMAR YANMAR
L70AE L100AE
296cc 406cc
78 X 62
3000 3600
86 X 70
3000 3600
220 230
DIESEL
ELECTRIC
1,1 lt.
20°
5,5/6,1 6,0/6,7
220 230
DIESEL
ELECTRIC
1,65 lt.
20°
7,7/8,8 9/10
1
F
1
F
60
IS 3.5- 4.0
ENGINE
60
2700W 4800W
2900W 4000W
IS 5.0- 6.0