Mase IS 25T User manual

mase
GENERATORS
IS 25T - 30T - 34T 50Hz
REV.1 S.S. 21/03/2004
cod.42531
GB
GENSET USE AND MAINTENANCE MANUAL

IS 25T - IS30T - IS34T 50 Hz
- 2
MASE GENERATORS S.p.A.
Sede legale ed Amm.: 47023 CESENA (FC) ITALY - Via Tor ona, 345
C.F./P.I. 00687150409 Cap. Soc. milioni 1625 in eramen e versa o
Regis ro Socie à Tribunale Forl' n. 6818 - CCIAA Forl' n.164063
c.c.p. n. 11541471 - EXPORT FO n. 006368

IS 25T - IS30T - IS34T 50 Hz
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Fig. 2
KVA
Hz
Cos.Ø
VV
AA
Degrees of protection IP
°C
m
Performance class
year of manifacture
Rated power factor
Rated voltage
declared frequency
0DVV.J
Class of insulation
Temp. max of use
Altitude max. of use
Rated current
Rated power 3F
Code Serial n°
1
2
5
4
14
6
7
8
9
10
11
12
13
15
16
3
Fig.A

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1
2
Fig. 3
19 20 10 22
23 26
3
18
24 13 17 25 15
1112 16 14
17
4
5
6
7
8
9
21

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Fig. 5
Fig. 4
1
3
2
2
45
5
2
1
3
4
6
7
812
11
10
9

IS 25T - IS30T - IS34T 50 Hz
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S.A.E
S
ervice
Grade
-30 -20 -10 0 10 20 30 4
0
Ambient temperature (
o
C)

:
:


:
:
:
:
Fig. 7
Fig. 8Fig. 6 TAB "A"
1
2
3
1
MIN MAX
4
3
472 65

IS 25T - IS30T - IS34T 50 Hz
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2
1
109
Fig. 9
4
5
3
4
1
24

IS 25T - IS30T - IS34T 50 Hz
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Fig. 11
Cod. 45772
Schema e ettrico versione "Po i Iso ati"
8
1
A.V.R.
4 5B 5A 7 6 5C 3A 5 3
100Kohm
60HZ
13

IS 25T - IS30T - IS34T 50 Hz
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Fig. 12
Cod. 45795
Schema e ettrico versione "Standard"
1
A.V.R.
4 5B 5A 7 6 5C 3A 5 3
100Kohm
60HZ
12
7

IS 25T - IS30T - IS34T 50 Hz
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INDEX
Pictures .................................................................. 2
Wiring diagram ...................................................... 8
1 GENERAL INF RMATI N ............................ 11
1.1 Purpose and field of application of the manual11
1.2 Symbols ....................................................... 11
1.3 Reference documents ................................... 12
1.5 Reference regulations and ............................ 12
legislative provisions ..................................... 12
1.6 Machine identification ................................... 12
1. Generetors conposition ................................. 13
1.8 Instrument panel ........................................... 13
2 GENERAL INF RMATI N ............................ 14
2.1 Reference documents ................................... 14
2.2 Reference regulations and legislative provisions
14
2.3 Marking ........................................................ 14
2.4 Identification of the generator unit ................. 14
3 GENERAT R CARACTERISTIC .................... 15
3.1 General caracteristic .................................... 15
3.2 Cooling system ............................................ 15
3.3 Control panel ................................................ 15
3.3.1 Data sheet IS 25 ......................................... 16
3.3.2 Data sheet IS 30 ......................................... 16
3.3.3 Data sheet IS 34 ......................................... 1
4 SAFETY REGULATI NS ............................... 17
4.1 General precautions ..................................... 1
4.2 Prescriptions for safety during installation ..... 18
and setup ..................................................... 18
5 USING THE GENERAT R ............................. 18
5.1 Preliminary checks ........................................ 18
5.2 Bleeding the fuel system .............................. 18
5.3 Starting ........................................................ 18
5.4 Stopping ....................................................... 18
6 PR TECTI NS ............................................. 19
6.1 Low oil pressure protection ........................... 19
6.2 High water temperature protection ................ 19
6.3 Alternator overheating protection ................... 19
6.4 Protection against short-circuit and overload . 19
6.5 Protection against short-circuit of the ........... 19
low-voltage electric system ........................... 19
7 MAINTENANCE ............................................. 19
.1 Preamble ...................................................... 19
.2 Ordinary engine maintenance ....................... 19
.3 Engine oil and oil filter change ...................... 20
.4 Air filter cleaning ........................................... 20
.5 Fuel filter replacement .................................. 20
.6 Coolant check .............................................. 20
. V-belt tension check ..................................... 20
.8 Emptying the cooling system ....................... 21
.9 Coolant replacement ..................................... 21
.10 Zinc anode replacement................................ 21
.11 Seawater pump maintenance........................ 21
.12 Alternator maintenance ................................. 21
.13 Battery maintenance .................................... 21
.14 Periods of inactivity....................................... 22
.15 Table of scheduled maintenance ................... 22
.16 Troubleshooting ............................................ 22
8 TRANSP RT AND HANDLING ..................... 23
9 SCRAPPING ................................................. 23
10 WIRING DIAGRAM REFERENCES ................ 23

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1 GENERAL INF RMATI N
Carefully consult this manual before proceeding with any operation on the generator.
FAILURE TO RESPECT THE SPECIFICATIONS CONTAINED IN THIS USE AND MAINTENANCE MANUAL WILL
RESULT IN FORFEITURE OF THE GUARANTEE ON THE PRODUCT
1.1 Purpose and field of application of the manual
Thank you for choosing a mase product.
This manual has been drawn up by the manufacturer with the purpose of providing essential information and instructions
for proper use and maintenance in conditions of safety and constitutes an integral part of the generator equipment. The
manual must be kept safely, protected from any agent which might damage it, for the entire life of the generator and must
accompany the generator if transferred to another user or owner.
The information contained in the manual is addressed to all those persons involved in the operating life cycle of the
generator, and is necessary to inform both those who effectively carry out the different operations and those who coordinate
the activities, arrange the necessary logistics and regulate access to the place where the generator will be installed and
operated.
The manual defines the purpose for which the generator was constructed and contains all the information necessary to
guarantee safe and proper use.
Constant observance of the instructions contained in this manual guarantees the safety of the operator, operating
economy and a longer life of the generator.
It is warmly recommended to carefully read the contents of this manual and the reference documents; only thus can regular
functioning and reliability of the generator be guaranteed over time, and protection against damage to persons or things.
The drawings are provided by way of example. Even if the generator in your possession differs considerably from the
illustrations contained in this manual, the safety of the generator and the information provided are nevertheless guaranteed.
To facilitate consultation, it has been divided into sections identifying the main concepts; for a quick look at the topics,
consult the index.
Note: the information contained in this publication is correct at the time of printing. The manufacturer in his pursuit of
a policy of constant development and upgrading of the product reserves the right to make modifications without prior
notice.
1.2 Symbols
Those parts of the text not to be ignored are highlighted in bold type preceded by a symbol, as illustrated and defined
below.
Indicates that particular attention must be paid in order to prevent running into serious danger which
could lead to death or possible hazards to the health of personnel.
A condition which may occur during the lifetime of a product, system or plant considered at risk
regarding damage to persons, property, the environment or economic loss.
Indicates that particular attention must be paid in order to prevent serious consequences which could
result in damage to tangible goods, such as the resources or the product.
Instructions of particular importance.

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1.3 Reference documents
The instructions for use provided with each generator are
made up of a collection of documents of which this manual
represents the General Part.
Normally, the following documents are provided:
a - CE declaration of conformity.
b - Instruction manual for use and maintenaqnce of the
generators (this manual).
c - Installation manual of the generators.
d - Wiring diagrams of the control panels and power
board.
e - Engine use and maintenance manual
f - Alternator use and maintenance manual
g - Any other manuals for the optional accessories issued
by the respective manufacturers.
h - List of Mase Service Centres
i - Certificate of guarantee
l - Guarantee card
1.4 Facsimile of CE declaration of conformity
The generators constructed by mase, intended for countries
in the European Community, are in conformity with the
applicable EEC Directives (see 1.5) and are furnished with
an EC declaration of conformity.
1.5 Reference regulations and
legislative provisions
All the mase diesel generators are designed and
manufactured in compliance with the legislation in force.
The generator and its components are constructed in
accordance with the following applicable regulations and
directives:
EN 292-1/2: Machine safety regulations.
General design principles.
EN 294: Machine safety regulations.
Safety distances to prevent contact of dangerous parts with
the upper limbs.
IS 3046: Alternate internal-combustion engines.
IEC 34-1: Rotary electric machines.
IS 8528-1: Alternate current generators driven by alterna-
te internal-combustion engines.
EN 60204-1 (CEI 44-5):
- Machine safety.
- Electrical equipment of machines.
EN 60439-1 (CEI 17-13/1): Assembled protection and
manoeuvring equipment for low voltage (low-voltage panels).
EN 50081-1/2 (Electromagnetic compatibility): General
regulation on emission
- Part 1: Residential, commercial and light-industry
environments.
- Part 2: Industrial environment.
EN 50082-1/2 (Electromagnetic compatibility): General
regulation on immunity.
- Part 1: Residential, commercial and light-industry
environments.
- Part 2: Industrial environment.
89/392/EEC and subsequent amendments contained in
the Directives 91/368/EEC, 93/44/EEC and 93/68/EEC:
Essential machine requirements for safety and health
protection (Machine directive).
73/23/EEC and subsequent amendments contained in the
Directive 93/68/EEC: Guarantee of safety of electrical
material intended for use within certain voltage limits (Low
Voltage directives).
1.6 Machine identification
See Fig.2
1 - Machine name
2 - Machine code
3 - Serial number
4 - Rated power
5 - Declared frequency
6 - Rated power factor
- Rated voltage
8 - Rated current
9 - Degree of protection
10 - Class of isolation
11 - Temperature max. of use
12 - Altitude max. of use
13 - Noise level
14 - Performance class
15 - Year of construction
16 - Manufacturer - Adress
1 - Weight
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.

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1.7 Generetors conposition
See Fig.3
The generators are essentially composed of the following
components:
1 - Soundproof casing
2 - Top access door
3 - Side access door
4 - Instrument panel
5 - Anchoring brackets
6 - Exhaust and cooling water pipe fitting
- Seawater intake connection pipe fitting
8 - Connection pipe fittings to fuel tank
9 - Connection terminals to battery
10 - Engine air filter
11- Coolant expansion tank
12 - Engine oil extraction pump
13 - Diesel fuel filter cartridge
14 - Seawater pump
15- Fuel pump
16 - Oil filter cartridge
1 - Oil fillercap
18 - Electric line connection box
19 - Battery charger alternator
20 - Collector cooled to water
21 - Water/air heat exchanger
22 - Exhaust manifold
23 - Starter motor
24 - Remote control panel connector
25 - RPM adjusting screw of engine
26 - Water/Air intercooler
1.8 Instrument panel
See Fig.4
Each generators is fitted with an instrument panel for the
controls with the following components
1 - Hour counter
2 - Magnetothermal switch
3 - DC current thermal switch
4 - START/STOP-Preheat button
5 - Engine protection module
6 - RUN light  engine running
- OIL light  low oil pressure
8 - ºC light  high engine temperature
9 - BATT light  battery charger operating
10 - ºC light  high alternator temperature
11 - Preheat ligh - (not present)
12 - Fuel leak (version RINA)

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15
1
2
5
4
14
6
7
8
9
10
11
12
13
3
16
Fig.A
2 GENERAL INF RMATI N
2.1 Reference documents
The instructions for use provided with each generator are
made up of a collection of documents of which this
manual represents the General Part. The following
documents are normally provided separate.
aCE declaration of conformity.
bInstruction manual for use of the generators, (this
manual).
cEngine use and maintenance manual.
dList of mase Service Centres.
e Mase Warranty certificate.
fWarranty card.
2.2 Reference regulations and legislative
provisions
All the mase generators are designed and manufactured
in compliance with the legislation in force.
The generator and its components are constructed in
accordance with the following applicable regulations and
directives.
98/37/EC and subsequent amendments:
Essential machine requirements for safety and health
protection (Machine directive).
73/23/EC and subsequent amendments contained in
the directive 93/68/EC : Guarantee of safety of
electrical material intended for use within certain
voltage limits, (Low Voltage Directives).
2.3 Marking
The generator identification plate carries all the
identification data in accordance with the provisions for
EEC marking for those cases where required. Below is
a facsimile of the identification plate fixed on the hull of
each generator, (Fig.1).
2.4 Identification of the generator unit
See Fig.A
1 - Machine name
2 - Machine code
3 - Serial number
4 - Rated power
5 - Declared frequency
6 - Rated power factor
- Rated voltage
8 - Rated current
9 - Degree of protection
10 - Class of isolation
11 - Temperature max. of use
12 - Altitude max. of use
13 - Performance class
14 - Year of construction
15 - Manufacturer - Adress
16 - Weight
The machine code number, the serial number and
the year of construction must always be indicated
when contacting the manufacturer for information,
order of spare parts, etc..

IS 25T - IS30T - IS34T 50 Hz
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3. GENERAT R CARACTERISTIC
3.1 General caracteristic
The IS generators were designed for easy installation on
boats.
The soundproof casing, obtained with insulated, painted
marine aluminium panels, allows easy access to the
engine and the alternator for maintenance and inspection
operations, and at the same time strongly reduces noise.
The 4-stroke, direct-injection, diesel engine, built by Yanmar,
is extremely reliable and robust. Exhaust emission is in
conformity with CARB regulations.
The synchronous-type, 4-pole, brushless alternator has an
electronic voltage regulator (SR ) which guarantees stability
to + 5% with respect to the nominal value. The high pickup
capacity of the alternator makes the generator particularly
suitable for the power supply of electric motors of air
conditioners, desalination plants, compressors, etc.
The generator has a local control panel [Fig. 3 Ref. 4] on
which the controls and control instruments are housed.
3.2 Cooling system
The generator engine is cooled by closed-circuit circulation
of coolant which yields heat to the seawater by means of
a heat exchanger [Fig. 3, Ref. 26].
This heat exchanger was specially designed by mase to
make the engine suitable for use at sea.
A second heat exchanger cools the air inside the soundproof
casing and the air necessary for alternator ventilation.
At the time of installation a seawater feed circuit for cooling
must be installed and an exhaust system to convey the
combustion gas and the water used for cooling to the
outside, as indicate in the installation manual.
3.3 Control panel
A control panel is positioned on the generator for running
checks and to start and stop the generator. An engine
protection module [Fig. 4 Ref. 5] controls the generator
protections, stopping the engine in case of a fault and
signalling the fault detected by means of special warning
lights.
- Green RUN pilot light [Fig. 4 Ref. 6], when on,
indicates that the generator is running and no operating
fault has been detected.
- Red BATT pilot light [Fig. 4 Ref. 9), when on,
indicates that the alternator battery charger is faulty.
- Red  IL pilot light [Fig. 4 Ref. 7], when on, indicates
that the engine oil pressure is insufficient.
- Red "°C" [Fig. 4 Ref. 10] pilot light, when on, indicates
that the temperature of the coolant or the water circulating
in the heat exchangers is too high.
- Red "°C" [Fig. 4 Ref. 8] pilot light, when on, indicates
that the alternator windings have reached too high
temperatures.
- Yellow [Fig.4, Ref.11]
When on it signals that the pre-heating glow plugs have
been activated.
The glow plugs are turned on before starting by turning the
ignition key from the STOP to the ON position; once the
operating temperature has been reached, they
automatically go off and the engine can be started.
- Red [Fig.4, Ref.12]
When on it signals that the emergency stop button has
been pressed. Turn it to reset it.
The following may also be found on the control panel:
- A bipolar magnetothermal switch [Fig. 4 Ref. 2]
which cuts the power in case of an overload or short-
circuit.
- A thermal switch (Fig. 4 Ref. 3] to protect the low-
voltage electric system against short-circuit.
- An hour counter (Fig. 4 Ref. 1].
- The generator start/stop button [Fig. 4 Ref. 4].
The generator can be connected with a connector to the
remote starting panel, [Fig. 3 Ref. 24] supplied by mase a s
an optional, and can be installed on the dashboard.
Two different remote starting panels are available as shown
in Fig. 5.
The most simple version has a start/stop button [Fig. 5 Ref.
1] and a green pilot light [Fig. 5 Ref. 2] which, when on,
indicates that the generator is running.
The second version of the remote starting panel [Fig. 5 Ref.
3] has, in addition to the start/stop button, an instrument
which indicates the engine oil pressure value (Fig. 5 Ref. 4]
and an instrument which indicates the coolant temperature
value [Fig. 5, Ref. 5].
When carrying out maintenance
operations on the generator, disconnect the negati e
pole of the starter battery to pre ent accidental starting.

IS 25T - IS30T - IS34T 50 Hz
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3.3.1 Data sheet IS 25
(QJLQH
50 Hz
Model Yanmar 4TNE94
Type Diesel 4 stroke
Cylinders (nr.) 4
Cylinder block material Cast iron
Bore (mm. - in.) 94
Stroke (mm.- in.) 100
Displacement (cc. - CID) 2776
Power (hp) 39
RPM 1500
Compression ratio 18:1
Combustion system Direct injection
Engine head material Cast iron
Speed governor Centrifugal mechanical
Lubrication system Forced
Oil sump capacity with filter(l -gl) 10.2 - 2.24
Engine stop system Stop solenoid
Fuel pump Mechanical
Prevalence max pomp fuel 80
Fuel consuption (l/h - gl/h) 7,2
Air intake (l/h - gl/h) 1900
Starting battery (Ah - V) 80 - 12
Battery charger (A-V) 40 - 12
Starter (kW-V) 2.3 - 12
Max. inclination 30°
Water pump flow (l/min. - gl/min.) 40 - 8.8
$OWHUQDWRU
50 Hz
Type Synchronous, 4-poles,
brush less self-excited
Regulation Electronic
Cooling Air/water ( Intercooler W/A )
Voltage (V) 400
Frequency (Hz) 50
Amps 40,4
Max. power (kW / KVA) 22,4 / 28
Continuous power (kW / KVA) 20 / 25
Power factor (cos ø) 1 - 0,8
Insulating class H
Voltage stability ±2%
Frequency stability ±5%
3.3.2 Data sheet IS 30
(QJLQH
50 Hz
Model Yanmar 4TNE94
Type Diesel 4 stroke
Cylinders (nr.) 4
Cylinder block material Cast iron
Bore (mm. - in.) 94
Stroke (mm.- in.) 100
Displacement (cc. - CID) 2776
Power (hp) 39
RPM 1500
Compression ratio 18:1
Combustion system Direct injection
Engine head material Cast iron
Speed governor Centrifugal mechanical
Lubrication system Forced
Oil sump capacity with filter(l -gl) 10.2 - 2.24
Engine stop system Stop solenoid
Fuel pump Mechanical
Prevalence max pomp fuel 80
Fuel consuption (l/h - gl/h) 7,2
Air intake (l/h - gl/h) 1900
Starting battery (Ah - V) 80 - 12
Battery charger (A-V) 40 - 12
Starter (kW-V) 2.3 - 12
Max. inclination 30°
Water pump flow (l/min. - gl/min.) 40 - 8.8
$OWHUQDWRU
50 Hz
Type Synchronous, 4-poles,
brush less self-excited
Regulation Electronic
Cooling Air/water ( Intercooler W/A )
Voltage (V) 400
Frequency (Hz) 50
Amps 44,8
Max. power (kW / KVA) 24,8 / 31
Continuous power (kW / KVA) 22,4 / 28
Power factor (cos ø) 1 - 0,8
Insulating class H
Voltage stability ±2%
Frequency stability ±5%

IS 25T - IS30T - IS34T 50 Hz
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3.3.3 Data sheet IS 34
(QJLQH
50 Hz
Model Yanmar 4TNE98
Type Diesel 4 stroke
Cylinders (nr.) 4
Cylinder block material Cast iron
Bore (mm. - in.) 98
Stroke (mm.- in.) 110
Displacement (cc. - CID) 2776
Power (hp) 39
RPM 1500
Compression ratio 18:1
Combustion system Direct injection
Engine head material Cast iron
Speed governor Centrifugal mechanical
Lubrication system Forced
Oil sump capacity with filter(l -gl) 10.2
Engine stop system Stop solenoid
Fuel pump Mechanical
Prevalence max pomp fuel 80
Fuel consuption (l/h - gl/h) 10,8
Air intake (l/h - gl/h) 2500
Starting battery (Ah - V) 80 - 12
Battery charger (A-V) 40 - 12
Starter (kW-V) 2.3 - 12
Max. inclination 30°
Water pump flow (l/min. - gl/min.) 40
$OWHUQDWRU
50 Hz
Type Synchronous, 4-poles,
brush less self-excited
Regulation Electronic
Cooling Air/water ( Intercooler W/A )
Voltage (V) 400
Frequency (Hz) 50
Amps 52,3
Max. power (kW / KVA) 28,96 / 36,2
Continuous power (kW / KVA) 26,96 / 33,7
Power factor (cos ø) 1 - 0,8
Insulating class H
Voltage stability ±2%
Frequency stability ±5%
4 SAFETY REGULATI NS
4.1 General precautions
Before starting the generator and before starting any
lubrication or maintenance operation, it is indispensable for
the staff responsible to read and understand all the
WARNINGS and all the CAUTION and DANGER indications
listed in this manual and in the supplementary documentation
furnished.
Nevertheless, the manufacturer cannot foresee all the
possible circumstances which may lead to potential risks
in the effective conditions of use of the generator.
Any operations and/or procedures for maintenance not
expressly recommended or indicated in the user manuals
must always be notified to and approved by the manufacturer.
In the event that a procedure not specifically recommended
needs to be applied, the user is responsible for assuring
that such procedure is safe and does not cause harm to
persons or things.
The manufacturer declines all responsibility for damage to
persons or things deriving from inobservance of the safety
regulations.
Carefully examine the safety warning plates on the machine
and respect the relevant instructions.
- Do not permit incompetent persons or without adequate
training to use the generator.
- Do not permit children or animals to approach the
generator when it is in operation.
- Do not access the generator with wet hands, since it is
a potential source of electric shock if improperly used.
- Any inspections of the generator must be carried out with
the engine off. Inspections with the engine on are to be
carried out by specialised personnel only.
- Do not inhale the combustion smoke since it contains
substances hazardous to health.
- Use the generator with the access doors closed.
- Never touch the engine or alternator body with the hands
when the generator is running or still hot.
- When carrying out maintenance operations on the
generator, disconnect the negati e pole of the starter
battery to pre ent accidental starting.
- In the e ent of oil or fuel leaks, clean off thoroughly
to pre ent creating fire hazard conditions.
- In the e ent of fire, use a homologated fire extinguisher
 ne er use water.
- Do not allow access to persons wearing a pacemaker
because of possible electromagnetic interference
with the de ice.
Should any problem arise or should
you ha e any questions, please contact the Mase
SERVICE department.

IS 25T - IS30T - IS34T 50 Hz
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When using the generator always
bear in mind that in wet or ery humid places and in
confined conduction spaces it is obligatory to comply
with articles 313 and 318 of Presidential Decree No. 547
27/04/55, as well as Chap. 11 Section IV of the CEI 64-8
regulation.
4.2 Prescriptions for safety during installation
and setup
- The personnel in charge of installation and starting of
the generator must always wear a protecti e helmet,
safety shoes and o eralls.
- Use protecti e glo es.
- Do not lea e disassembled parts, tools or anything
else not forming part of the system on or near the
engine.
- Ne er lea e inflammable liquids or cloths soaked in
inflammable liquids in proximity of the generator,
near electric equipment (including lamps) or parts of
the electrical system.
- Take the necessary precautions to pre ent the danger
of electrocution.
- Check that the earthing system has been installed
and constructed in accordance with regulations.
5 USING THE GENERAT R
5.1 Preliminary checks
Before beginning with any starting procedure, it is extremely
important to become familiar with the generator and its
controls. Furthermore, a visual inspection must be carried
out on the machine and the installation.
Any source of potential or real danger must be eliminated
before proceeding.
· Identify the position of the emergency stop buttons,
switches and other emergency systems on the generator.
· Learn the special emergency procedures relative to the
installation in question.
- the oil level by means of the dipstick [Fig. Ref. 2] (see
table A for recommended oils [Fig. 8]).
- that all the anchoring points of the generator are properly
tightened.
- that all the electrical utilities are off to prevent starting the
generator on load
- that the water and fuel pipes are properly connected
- that all the electrical connections have properly been
carried out and that there are no electrical connections in
a bad state.
- that the water cock is open [Fig. 6 Ref. 2]
- that the section of the water circuit from the pump to the
valves has been filled manually if a non-return valve has
been mounted on the sea intake (as recommended in the
installation manual) [Fig. 4 Ref. 1].
5.2 Bleeding the fuel system
The presence of air bubbles in the fuel system is caused by
irregular functioning of the engine or the incapacity to reach
the nominal number of revolutions. Air might enter the fuel
circuit through a not perfectly tight seal (pipes, filters, tank)
or when the fuel in the tank is at minimum level. The fuel
system has been designed in such a way as to
autonomously eliminate air bubbles that have penetrated
the circuit.
To eliminate the air bubbles, first of all eliminate the cause
and carry out the following operations:
1 - Adjust the fuel pump lever manually [fig. , ref.3] until
all the air in the supply system has been released.
2 - Repeat the operations described above if engine
operation is still irregular.
For more detailed information,
consult the manual supplied by the engine manufacturer
that accompanies each generator .
5.3 Starting
Before starting the generator, ensure that the preliminary
checks described in paragraph 5.1 have been carried out.
Start the generator by pressing the START button located
on the control panel [Fig. 4 Ref. 4] and release it only when
the generator has started, taking care not to exceed 15 sec.
for each attempt and respecting an interval of at least 30
sec. All the warning lights of the engine protection module
[Fig. 4, Ref. 5] will come on for a few seconds, and if there
are no engine or generator faults, only the green RUN light
[Fig. 4 Ref. 6] will remain on to indicate that the generator
has been started and that functioning is regular.
Repeated attempts at starting with
negati e outcome may cause excess accumulation of
water in the exhaust system with possible serious
damage to the engine.
If it is difficult to start the engine, do not insist for too
long without first ha ing closed the sea intake cock
[Fig. 6 Ref. 2].
5.4 Stopping
The generator is stopped by pressing the button [Fig.4,
Ref.4] on the control panel in "STOP"position.
Before stopping the generator it is
recommended to let it run for a few minutes without
drawing electric current, in order to allow the engine
and the alternator to cool down.

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6 PR TECTI NS
The generators are equipped with a series of protections
which safeguard it against improper use and faults which
may compromise integrity.
When the generator stops because a protection has
tripped, on the engine protection module [Fig. 4, Ref. 5] of
the control panel the warning light relative to the fault will
come on.
6.1 Low oil pressure protection
Intervenes switching off the generator when the engine oil
pressure is insufficient. Its intervention is signalled by the
OIL light [Fig., 4, Ref. ] coming on. Normally it is sufficient
to top up with the lacking quantity of oil to be able to restart
the generator.
- The low oil pressure protection does not gi e an
indication of the le el of engine oil in the sump.
Therefore, check this le el daily.
- The engine functions properly if it does not exceed an
inclination of maximum 30º for less than 3 minutes,
25º without time limit, both on the longitudinal and
the trans erse axis. If the engine is operated at a
greater inclination, the risk is insufficient lubrication
or aspiration of engine oil through the air filter.
6.2 High water temperature protection
Intervenes switching off the generator when the engine
coolant temperature is too high or there is no circulation of
seawater.
Its intervention is signalled by the ºC light [Fig. 4, Ref. 10]
coming on.
Only restart the generator after the cause of the fault has
been identified and removed.
6.3 Alternator overheating protection
Intervenes switching off the generator when there is a
thermal overload on the alternator.
Its intervention is signalled by the ºC light [Fig. 4, Ref. 8]
coming on. The generator can be restarted after a few
minutes when the temperature of the alternator windings
has returned to normal values. It is, however, recommended
to find and remove the causes of the intervention.
In the e ent of one of the abo e
described protections inter ening, after ascertaining
and remo ing the cause of the inter ention, press the
STOP button to reset the control panel (otherwise the
signal would remain in memory pre enting the engine
from starting).
6.4 Protection against short-circuit and overload
The generator is protected against short-circuit and overload.
A bipolar magnetothermal switch [Fig. 4 Ref. 2] cuts the
supply of electric current when a short-circuit occurs or
when the electric current delivered exceeds the nominal
value.
Before restoring the contact by lifting the lever of the
magnetothermal switch, disconnect the utilities.
6.5 Protection against short-circuit of the
low-voltage electric system
In the event of a short-circuit in the low-voltage electric
system, a thermal switch [Fig. 4, Ref. 3] breaks the circuit
stopping the generator. In this case the warning lights of the
engine protection module will all be off and it will not be
possible to re-attempt starting.
Before restoring the electric circuit by pressing the button
located on the thermal switch [Fig. 4 Ref. 3], have a
specialised technician find and remove the cause of the
short-circuit.
7 MAINTENANCE
7.1 Preamble
Any maintenance operation on the
generator must be carried out with the engine off and
lea ing it to cool down sufficiently, and must only be
carried out by authorised and suitably trained personnel.
It is recommended to scrupulously follow the instructions
in the manual provided by the engine Manufacturer with
each generator.
It is important to regularly inspect and carry out maintenance
on the generator. The frequency of maintenance should be
decided on the basis of the number of hours of operation.
To proceed with maintenance the side and top doors must
be removed.
Before accessing the generator,
disconnect one pole of the starter battery in order to
pre ent accidental starting.
7.2 rdinary engine maintenance
The periodic maintenance to be carried out on the engine
is listed in TABLE B at the paragraph .15.
For more detailed information consult the manual provided
with each generator by the engine manufacturer.
Check the oil le el by means of the
graduated dipstick [Fig. 7, Ref. 2]. The le el must always
be between the MAX and MIN notches on the dipstick
[Fig. 7 Ref. 1].

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7.3 Engine oil and oil filter change
The engine oil sump capacity is 10.2 litres.
Top-ups and filling with engine oil is carried out through the
hole [Fig. 3, Ref. 1 ].
To change the oil in the oil sump, remove the dipstick [Fig.
, Ref. 2] and operate the special extraction pump [Fig. ,
Ref. ] after having removed the screw which functions as
plug.
It is recommended to drain the oil when it is still sufficiently
warm to flow easily.
For recommended oils see table A, Fig. 8.
- The first engine oil change must be carried out after 50
hours of generator operation. For the second and
subsequent oil changes, e ery 200 hours is sufficient.
- For more detailed information on engine lubrication,
consult the engine use and maintenance manual
attached to the generator.
- Dispose of the used oil or fuel in an appropriate manner
as they are polluting products.
Take the used engine oil to special collection centres
responsible for disposal.
A oid contact of engine oil with the
skin. During maintenance operations use glo es and
protecti e glasses.
In case of contact with engine oil, immediately and
thoroughly wash the affected part with soap and water.
To replace the engine oil filter cartridge [Fig. 3, Ref.16],
unscrew it from its support, using suitable tools normally
found on the market. Reposition the new cartridge, taking
care to lubricate the rubber ring gasket.
The first replacement must be carried out after 50 hours of
generator operation. For the second and subsequent
replacements, respect an interval of 400 hours.
For further information consult the engine use and maintenance
manual.
For the safety of the engine, use only
original spare parts.
When the operation has been
completed, thoroughly wipe off all oil and fuel from the
engine parts.
7.4 Air filter cleaning
The generators of the IS series have a dry air filter which
prevents foreign bodies from entering the combustion chamber.
For its maintenance it is sufficient to clean the filtering mass
with diesel fuel once a year to remove nay impurities.
Dispose of the liquids used for air
filter washing in an appropriate manner. Take them to
special collection centres.
7.5 Fuel filter replacement
To guarantee long life and proper functioning of the engine,
it is extremely important to periodically replace the fuel filter
cartridge, respecting the frequency indicated by the engine
manufacturer as listed in the table in Paragraph .15.
This operation is carried out in the following steps:
- Completely unscrew the ring nut of the support [Fig. 3,
Ref. 13]
- Remove the old cartridge and position the new one.
- For remounting repeat the operations in reverse order.
When the filter has been replaced, bleed the fuel system
carrying out the operations described in Paragraph 5.2.
A oid contact of the fuel oil with the
skin. During maintenance operations use glo es and
protecti e glasses.
In case of contact with fuel, immediately and thoroughly
wash the affected part with soap and water.
When the operation has been
completed, thoroughly wipe off all traces of fuel and
take the used cloths to special collection centres.
7.6 Coolant check
Periodically check the coolant level in the closed-circuit
cooling system. The reference index for this check is
printed on the expansion tank [Fig. 3, Ref. 11]. If the level
is insufficient, pour coolant into the expansion tank, taking
care not to exceed the maximum level index.
Ne er open the cap of the expansion
tank [Fig. 3, Ref. 11] or coolant tank [Fig. 3, Ref. 26]
when the engine is hot to pre ent dangerous coolant
leaks.
7.7 V-belt tension check
A V-belt is used to transmit the rotary motion from the drive
shaft pulley to that of the seawater pump [Fig. 9 Ref. 1].
Excessive belt tension accelerates wear, while a slack belt
makes the pulleys idle and does not allow sufficient water
circulation.
Adjust the belt tension as follows:
Loosen the two adjusting screws [Fig. 9, Ref. 2] and move
the seawater pump outwards to increase the tension or
inwards to decrease it. Lock the screws and check the
tension.
The correct belt tension is such as to allow a yield of about
5 mm [Fig. 9] under a thrust force of 8 kg.