Mase IS. 2.5 Instruction manual

masemase masemase
mase
GENERATORS
WORKSHOP MANUAL
IS. 2.5 50 Hz

IS 2.5
2
Index
1 Machine identification........................5
1.1 Generatorscomposition .......................... 5
2 TOOLTABLE .......................................... 9
3 ALTERNATOR ..................................... 13
3.1 Stator.................................................... 15
3.1.1 Powerwindings..................................... 15
3.1.2 Excitation windings ............................... 17
3.1.3 Alternator thermostat ............................ 17
3.1.4 Battery charger windings ................ 19
3.2 Rotor ..................................................... 21
3.2.1 Rotorwinding(n°2) ............................... 21
3.2.2 Rotor diodes (n°2) ................................. 23
3.2.3 Rotor varistors (n°2) ............................ 23
3.3 Capacitors ............................................ 25
4 ENGINE ................................................ 27
4.1 Technical features ................................. 25
4.2 Maintenance ......................................... 28
4.3 Trouble-shooting ................................... 30
4.4 Fuel ...................................................... 35
4.5 Electric diesel fuel pump ...................... 37
4.6 Lubrication ............................................ 39
5 SENSORS ............................................ 41
5.1 Closed-circuit engine thermal switch .... 41
5.2 Open-circuit engine thermostat (sea) .... 43
5.3 Oil pressure switch ............................... 45
6 SEA WATER COOLING ....................... 47
6.1 Seawater/closed-circuit system ............ 47
6.2 Water pump .......................................... 49
6.3 Water pump belt ................................... 51
6.4 Water/air heat exchanger ...................... 53
7 ADJUSTMENTS ................................... 55
7.1 Rpm adjustment ................................... 55
7.2 Closing cover motor............................. 57
7.3 Engine air filter cleaning ...................... 59
7.4 Level oil check ..................................... 61
7.5 Engine oil filter cleaning ...................... 61
8 ELECTRICAL SYSTEM ........................ 63
8.1 Command circuit .................................. 63
8.1.1 Multicore cable ..................................... 69
8.2 Stop solenoid........................................ 71
8.3 Thermal switch (ACcircuit breaker) ........... 73
8.4 Enginewiring ........................................ 75
8.5 Battery charger ..................................... 77
8.6 Fuse ..................................................... 79
8.7 Starter motor ........................................ 81
8.8 Battery .................................................. 83
9 DISASSEMBLY .................................... 85
9.1 Removing the casing ............................. 85
9.2 Removingthe alternator ........................ 89
9.3 Removingthealternatorcover
on the bearing side ............................... 91
9.4 Removing the stator .............................. 93
9.5 Removing the rotor ................................ 95
9.6 Removingtherotor bearing ................... 95

IS 2.5
3
I
SCREW SHUT ..................................... 95
SPARE PARTS .................................... 96
ENGINE-ALTERNATOR...................... 96
FRAME ................................................ 98
WIRING DIAGRAM ............................... 101

IS 2.5
4
1
1
2
3
5
6
7
8
9
4
10
SERIAL No.
2
1
3
5
4
6
7

IS 2.5
5
1 Machine identification
(Fig.1)
1 - Manufacturer
2 - Machine code
3 - Year of construction
4 - Power factor
5 - Declared frequency
6 - Continuous power
7 - Rated voltage
8 - Rated current
9 - Weight
10 - Serial number
The machine code number, the serial number
and the year of construction must always be
quoted when contacting the manufacturer for
information, requests for spare parts, etc.
1.1 Generators composition
The generators are essentially composed of
the following components (Fig.1-2):
1- Soundproof casing
2- Top access door
3- Motor side access door
4- Anchoring brackets
5- Exhaust and cooling water pipe fitting
6- Seawater intake connection pipe fitting
7- Connection pipe fittings to fuel tank

IS 2.5
6
2
12
8A
11
9
19
18
21
16
14 13
15
10
20
8B
17
23
22

IS 2.5
7
8A-Connection to battery +
8B-Connection to battery -
9- RPM adjusting screw of engine
10- Engine air filter
11- Staff oil level
12- Seawater pump
13- Fuel pump
14- Oil filter cartridge
15- Oil fillercap
16- Electric line connection box
17- Battery charger regolator
18- Water/air heat exchanger
19- Exhaust manifold
20- Starter motor
21- Remote control panel connector
22- Capacitor
23- Fuse

IS 2.5
8
3

IS 2.5
9
2 TOOL TABLE
Denomination: Torque spanner
Use: To tighten the nuts and bolts to the
prescribed torque
Denomination: Battery tester
Use: To check the electrolyte level of the battery
Denomination: Digital thermometer
Use: Measures the temperature of the
components
Denomination: Contact tachometer
Use: Measures the rpm of the rotary shaft by
bringing the indicator tip in contact with the
central hole of the shaft.
Denomination: Photocell tachometer
Use: Allows measuring the rpm of the rotary
shaft when it is in uncomfortable positions,
holding the tachometer at a certain distance.
Denomination: Terminal tachometer for high-
pressure fuel pipe
Use: Measures the engine rpm using a pulse
system not taking into account the centre of the
rotary shaft and the circumference of the rotating
object.

IS 2.5
10
4

IS 2.5
11
Denomination: Tester
Use: Measures the AC/DC voltage, the resistors
and the diodes
Denomination: Amperometric caliper
Use: Measures the AC voltage, frequency
(engine rpm) and AC current.
The power drawn from the generator can thus
be measured.
Denomination:Ammeter
Use: Measures the line current connecting it in
series
Denomination:Frequency meter
Use: Measures the frequency (engine rpm)
connecting it in parallel to the 230-115V line of
the generator.
Denomination: Extractor
Use: Used to extract the alternator bearing
cover and the rotor bearing.

IS 2.5
12
5

IS 2.5
13
3 ALTERNATOR
The generators of the IS 2.5, series are equipped
with a brushless, synchronous, 2-pole, self-
regulating, self-excited alternator with 1 capacitor
(Fig. 2 Ref. 22) connected to the auxiliary winding
for stator excitation. The alternator generates
alternate voltage available at the terminals at a
frequency of 50/60 Hz (corresponding to the speed
of the prime mover of 3000/3600 rpm) according to
the principle described below.
Upon starting, the rotor magnetism (residual
magnetism of the nucleus) induces a voltage in the
auxiliary excitation windings.
This voltage is applied to the capacitor, and makes
a capacitive current circulate in the closed circuit
composedofthecapacitor and the auxiliarywinding.
This current produces a magnetic field which
strengthens the rotor magnetism generating a
voltage inside it which, rectified by the diodes,
makes a continuous current circulate in the rotor
field windings.
The rotating magnetic field due to circulation of this
current in its turn generates in the primary winding
the rated voltage to the generator terminals.
TESTS
All the resistance measurements are made with
the alternator cold, ambient temperature 10 - 30
°C, and with instrumentation such as to allow
reading the values indicated.
The tolerance with respect to the values listed is
approximately ± 10%.
Approximate readings made with instruments with
inadequate range, can only indicate continuity of
the winding but do not give an indication of any
short-circuits.
N.B.
Apart from the failure possibilities indicated below,
there might be one or more earth windings. It is
therefore recommended to test these possibilities,
checking with a tester that there is no continuity
between the various windings (identified in the
following paragraphs) to earth and between them.

IS 2.5
14
6
144
33
20 10
20
50(60)
2
311
4
1
2
3
4
5
1

IS 2.5
15
3.1 Stator (Fig.6, ref5)
3.1.1 Power windings (Fig.6, ref.1)
Features:
Test method:
- Ensure that the onboard thermal switch is ar-
moured
- Disconnect from the terminal board, the wires
coming from the stator, marked by the letters P1F1
P2F2.
- Verify that the resistance values between the two
pairs of wire terminals P1F1and P2F2 are within the
limits as reported in the table above.
N.B. The total resistance value for power winding
(220 V 240 V) is measured connecting F1and P2.
the resistance value measured between P1and F2
is double of that indicated in the table above.
REMEDY: Replace the stator
WARNING: The windings have been treated
with resin and paint for humid-saline climates. If
these treatments have deteriorated, replace !

IS 2.5
16
3 ALTERNATORE
7
8
1
2

IS 2.5
17
3.1.2 Excitation windings (Fig.6, ref.2)
Features:
Test method
- Remove the protective cap.
- Disconnect the cables (Fig. 7 Ref.1) coming
from the stator from the capacitor (Fig. 7 Ref.2).
- Check that the resistance between the ends of
the cables falls within the values indicated in the
table.
REMEDY: Replace the stator.
3.1.3 Alternator thermostat (Fig.6, ref.4)
Characteristics: Normally closed.
Operating temperature: 180° C.
Test method:
-Access the power connection terminal board
area (Fig. 8).
-Disconnect the 1.0 mm2red (or white) wires
from the 17 and 18 terminal board.
-Check continuity between the two ends of the
cables.
REMEDY: Replace the stator
N.B.: The alternator thermostat may intervene
because of an overload or overtemperature.
Therefore, check if necessary, the applied loads
and the operating temperature of the generator
with particular attention to its installation.
n° colore IS 3,5 n° colore IS 4,0
0Rosso-Red 0Rosso-Red
50 Nero-black 60 Bianco-White
ECCITAZIONE 2,76 2,29
50Hz 60Hz
Colore / Color
ECCITAZIONE /
EXCITATION
Colore / Color
2,52 2,08

IS 2.5
18
9
1
2

IS 2.5
19
3.1.4 Battery charger windings
(Fig.6, Ref.3)
Characteristics:
Test method
- Disconnect the battery from the generator.
- Disconnect the 2 cables marked 5 or 6 (Fig. 9
Ref.1) from the regulator (the corresponding
symbols “~” “~” on the regulator) and check that
the resistance falls within the values indicated in
the table.
- Check that the resistance between each cable
and the black wire (2.5 mm2cross-section
marked + Fig. 9 Ref.2 ) is half the value
indicated in the table.
IS 3,5 IS 4,0
5Blù-Blue 6Verde-Green
5Blù-Blue 6Verde-Green
CARICA
BATTERIA 0,13 0,11
n° colore n° colore
50Hz 60Hz
0,162 0,127

IS 2.5
20
3 ALTERNATORE
10
1