Mase IS 8 User manual

mase
GENERATORS
MANUALE USO E MANUTENZIONE
USAGE AND MAINTANCE MANUAL
MANUEL D’INSTRUCTIONS ET D’ENTRETIEN
GEBRAUCHSANWEISUNG UND WARTUNGSVORSCHRIFTEN
MANUAL USO Y MANTENIMENTO
GEBRUIKS- EN ONDERHOUDSHANDLEIDING
IS 8
IS 9.5
50 Hz
60 Hz
IS 9
IS 10.2
50 Hz
60 Hz
REV.4 M.C. 23-01-02 cod.41637

IS 8 - 9.5 9.2 - 10.2
2
mase
MASE GENERATORS S.p.A.
Tel.[phone]
Fax [phone] (commercial dept.)
Fax [phone] (service dept.)
Fax [phone] -Tlx 550397
NR.000000
DICHIARAZIONE CE DI CONFORMITA'
EC DECLARATION OF CONFORMITY
Fabbr cante/Manufacturer: MASE GENERATORS S.p.A.
Ind r zzo /Address : V a Tortona 345, P evesest na (FO)
Il sottoscr tto Lu g Forest n qual tà d d rettore generale della MASE GENERATORS S.p.A., d ch ara sotto la
propr a responsab l tà che l gruppo elettrogeno modello ......... :
The unders gned Lu g Forest as MASE GENERATORS S.p.A. general manager declares, under h s sole
responsab l ty, that the generators model s..................:
Cod ce / Code Descr z one / Model Matr cola / Ser al N.
E' conforme alle d spos z on delle D rett ve d segu to elencate :
CEE 89/392 (come emendata delle D rett ve CEE 91/368 e CEE 93/44)
CEE 89/336 (come emendata delle D rett ve CEE 92/31)
CEE 73/23 mod f cata da CEE 93/68.
Corresponds to the requ rements of the follow ng EEC D rect ves :
89/392/EEC (as amended by the D rect ve 91/368/EEC and 93/44/EEC)
89/336/EEC (as amended by the D rect ve 92/31/EEC )
73/23//EEC as amended by 93/68/EEC.
Cesena, / / ......................................................
D rettore Tecn co
Techn cal D rector
GENERATORS
MASE GENERATORS S.p.A. Sede legale ed Amm.: 47023 CESENA (FO) ITALY - Via To tona, 345 - C.F./P.I. 00687150409 Cap. Soc. milioni
1250 inte amente ve sato - Regist o Società T ibunale Fo l' n. 6818 - CCIAA Fo l' n.164063 - c.c.p. n. 11541471 - EXPORT FO n. 006368
1

IS 8 - 9.5 9.2 - 10.2
mase
3
10
2
1
2
3
5
6
7
8
9
4

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mase
3
1
2
3
4
5
6
7
8
9
10 11 12
13 141516
18
17
19 20
21
22
23
24

IS 8 - 9.5 9.2 - 10.2
mase
5
12
9
8
7
6
10
4
5
12 3 4 5
11
1
3
2
2
45

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mase
1
1
TAB "A"
6
2
7
3
2
S.A.E
S
ervice
Grade
-30 -20 -10 0 10 20 30 4
0
Ambient temperature (
o
C)

:
:


:
:
:
:
8

IS 8 - 9.5 9.2 - 10.2
mase
7
9
10
1
2
3

IS 8 - 9.5 9.2 - 10.2
8
mase
11
12
1
2
3

IS 8 - 9.5 9.2 - 10.2
mase
9
13
IS 8-9.5
IS 9.2-10.2

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10
mase
14
IS 8-9.5 P.I
IS 9.2-10.2 P.I

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11

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INDEX
THE GUARANTEE OF THE PRODUCT BECOMES VOID
IF THE SPECIFICATIONS CONTAINED IN THE
FOLLOWING INSTALLATION MANUAL ARE NOT
RESPECTED
Pictures .................................................................. 2
Wiring diagram ................................................ 9-10
1 General information ................................... 24
1.1 Purpose of the manual ................................... 24
1.2 Attached documentat on ................................ 25
1.3 Mach ne dent f cat on .................................... 25
1.4 Instrument panel ............................................ 25
1.5 Safety regulat ons .......................................... 25
2 Generator description ................................. 26
2.1 General .......................................................... 26
2.2 Cool ng system .............................................. 26
2.3 Control panel ................................................. 26
3 Using the generator .................................... 26
3.1 Prel m nary checks ........................................ 26
3.2 Bleed ng the fuel system ............................... 27
3.3 Start ng .......................................................... 27
3.4 Stopp ng ........................................................ 27
4 Protections ................................................... 27
4.1 Low o l pressure protect on ............................ 27
4.2 H gh water temperature protect on ................. 27
4.3 Alternator overheat ng protect on .................... 27
4.4 Alternator overheat ng protect on .................... 28
4.5 Protect on aga nst short-c rcu t of the low-voltage
electr c system .............................................. 28
5 Maintenance ................................................ 28
5.1 Ord nary eng ne ma ntenance ........................ 28
5.2 Eng ne o l and o l f lter change ....................... 28
5.3 A r f lter clean ng ............................................ 28
5.4 Fuel f lter replacement ................................... 29
5.5 Coolant check................................................ 29
5.6 V-belt tens on check ...................................... 29
5.7 Empty ng the cool ng system ........................ 29
5.8 Coolant replacement ...................................... 30
5.9 Z nc anode replacement ................................. 30
5.10 Seawater pump ma ntenance ........................ 30
5.11 Alternator ma ntenance .................................. 30
5.12 Battery ma ntenance ......................................30
5.13 Per ods of nact v ty ........................................ 30
5.14 Summary table of scheduled ma ntenance .... 31
5.15 Troubleshoot ng ............................................. 31
6 Technical characteristics ........................... 32
References for the wiring diagram .................... 33

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1. GENERAL INFORMATION
Carefully consult this manual before proceeding with any operation on the generator.
1.1 PURPOSE OF THE MANUAL
Thank you for choos ng a MASE product.
Th s manual has been drawn up by the manufacturer and const tutes an ntegral part of the generator equ pment. It must
be kept safely, protected from hum d ty and from any agent wh ch m ght damage t, and must accompany the generator
f transferred to another user or to a new owner.
The nformat on conta ned n the manual s addressed to all those persons nvolved n the operat ng l fe cycle of the
generator, and s useful for nformat on for both those who effect vely carry out the d fferent operat ons and those who
coord nate the act v t es, arrange the necessary log st cs and regulate access to the place of nstallat on.
The manual def nes the purpose for wh ch the generator was constructed and conta ns all the nformat on necessary
to guarantee safe and proper use.
Constant observance of the nstruct ons conta ned n th s manual guarantees the safety of the operator, operat ng
economy and a longer l fe of the generator.
To fac l tate consultat on, t has been d v ded nto sect ons dent fy ng the ma n concepts. For a qu ck look at the top cs,
consult the ndex on Page 23.
Symbols
Those parts of the text not to be gnored are h ghl ghted n bold type preceded by a symbol, as llustrated and def ned
below:
Ind cates that part cular attent on must be pa d n order to prevent runn ng nto ser ous danger wh ch
could lead to death of personnel or poss ble hazards to health.
A cond t on wh ch may occur dur ng the l fet me of a product, system or plant cons dered at r sk
regard ng damage to persons, property, the env ronment or econom c loss.
Ind cates that part cular attent on must be pa d n order to prevent ser ous consequences wh ch
could result n damage to tang ble goods, such as the resources or the product.
Instruct ons of part cular mportance.
The draw ngs are prov ded by way of example. Even f the generator n your possess on d ffers cons derably from the
llustrat ons conta ned n th s manual, the safety of the generator and the nformat on prov ded are nevertheless
guaranteed.
The manufacturer in his pursuit of a policy of constant development and upgrading of the product may make any
modifications without prior notice.

IS 8 - 9.5 9 - 10.2
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1.2 Attached documentation
The follow ng documentat on forms an ntegral part of
th s manual:
- EEC declarat on of conform ty (F g. 1)
- Eng ne use and ma ntenance manual
- Serv ce logbook
- Cert f cate of guarantee
- Guarantee card
1.3 Machine identification
See Fig. 2
1  Mach ne code
2  Year of construct on
3  Power factor
4 - Declared frequency
5 - Cont nuous power
6  Rated voltage
7  Current
8  We ght
9  Performance class
10  Ser al number
The data dent fy ng the mach ne code number, the ser al
number and the year of construct on must always be
spec f ed when contact ng the manufacturer for nformat on
or for requests for spare parts.
See Fig. 3
1- Soundproof cas ng
2- Top access door
3- S de access door
4- Instrument panel
5- Anchor ng brackets
6- Exhaust and cool ng water p pe f tt ng
7- Seawater ntake connect on p pe f tt ng
8- Connect on p pe f tt ngs to fuel tank
9- Connect on term nals to battery
10- Eng ne a r f lter
11- Coolant expans on tank
12- Eng ne o l extract on pump
13- D esel fuel f lter cartr dge
14- Seawater pump
15- Fuel pump
16- O l f lter cartr dge
17- O l f llercap
18- Electr c l ne connect on box
19- Battery charger alternator
20- Coolant tank
21- Water/a r heat exchanger
22- Exhaust man fold
23- Starter motor
1.4 Instrument panel
Legend Fig. 4
1- Hour counter
2- Magnetothermal sw tch
3- DC current thermal sw tch
4- START/STOP button
5- Eng ne protect on module
6- RUN l ght  eng ne runn ng
7- OIL l ght  low o l pressure
8- ºC l ght  h gh eng ne temperature
9- BATT l ght  battery charger operat ng
10- ºC l ght  h gh alternator temperature
11- Glow plugs (not present)
12- Fuel leak (vers on RINA)
1.5 Safety regulations
Carefully read all the nformat on conta ned n th s manual
and the nstallat on manual as t s fundamental for proper
nstallat on and use of the generator and for t mely
ntervent on n case of necess ty.
The manufacturer decl nes all respons b l ty for damage
to persons or th ngs der v ng from nobservance of the
safety regulat ons.
Carefully exam ne the safety warn ng plates on the
mach ne and respect the relevant nstruct ons.
- Do not perm t ncompetent persons or w thout
adequate tra n ng to use the generator.
- Do not perm t ch ldren or an mals to approach the
generator when t s n operat on.
- Do not access the generator or the control panel w th
wet hands, s nce t s a potent al source of electr c
shock f mproperly used.
- Any nspect ons of the generator must be carr ed out
w th the eng ne off. Inspect ons w th the eng ne on are
to be carr ed out by spec al sed personnel only.
- Do not nhale the combust on smoke s nce t conta ns
substances hazardous to health.
- Use the generator w th the access doors closed.
- Never touch the eng ne or alternator body w th the
hands when the generator s runn ng or st ll hot.
In the event of oil or fuel leaks, clean off thoroughly
to prevent creating fire ha ard conditions.
In the event of fire, do not use water, but fire
extinguishers.
Should any problem arise or should you have any
questions, please contact the Mase SERVICE
department.

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2. GENERATOR DESCRIPTION
2.1 General
The IS 8 and IS 9.5 generators were des gned for easy
nstallat on on boats.
The soundproof cas ng, obta ned w th nsulated, pa nted
mar ne alum n um panels, allows easy access to the
eng ne and the alternator for ma ntenance and nspect on
operat ons, and at the same t me strongly reduces no se.
The 4-stroke, d rect- nject on, d esel eng ne, bu lt by
Yanmar, s extremely rel able and robust. Exhaust
em ss on s n conform ty w th CARB regulat ons.
The synchronous-type, 4-pole, brushless alternator has
an electron c voltage regulator (SR7) wh ch guarantees
stab l ty to + 5% w th respect to the nom nal value. The
h gh p ckup capac ty of the alternator makes the generator
part cularly su table for the power supply of electr c
motors of a r cond t oners, desal nat on plants,
compressors, etc.
The generator has a local control panel [F g. 3 Ref. 4] on
wh ch the controls and control nstruments are housed.
2.2 Cooling system
The generator eng ne s cooled by closed-c rcu t c rculat on
of coolant wh ch y elds heat to the seawater by means of
a heat exchanger [F g. 3, Ref. 20].
Th s heat exchanger bu lt of cupron ckel was spec ally
des gned by mase to make the eng ne su table for use at
sea.
A second heat exchanger cools the a r ns de the soundproof
cas ng and the a r necessary for alternator vent lat on.
At the t me of nstallat on a seawater feed c rcu t for
cool ng must be nstalled and an exhaust system to
convey the combust on gas and the water used for cool ng
to the outs de.
2.3 Control panel
A control panel s pos t oned on the generator for runn ng
checks and to start and stop the generator. An eng ne
protect on module [F g. 4 Ref. 5] controls the generator
protect ons, stopp ng the eng ne n case of a fault and
s gnall ng the fault detected by means of spec al warn ng
l ghts.
-Green RUN p lot l ght [F g. 4 Ref. 6], when on,
nd cates that the generator s runn ng and no operat ng
fault has been detected.
-Red BATT p lot l ght [F g. 4 Ref. 9), when on,
nd cates that the alternator battery charger s faulty.
-Red OIL p lot l ght [F g. 4 Ref. 7], when on, nd cates
that the eng ne o l pressure s nsuff c ent.
-Red [F g. 4 Ref. 10] p lot l ght, when on, nd cates that
the temperature of the coolant or the water c rculat ng
n the heat exchangers s too h gh.
-Red [F g. 4 Ref. 8] p lot l ght, when on, nd cates that
the alternator w nd ngs have reached too h gh
temperatures.
The follow ng may also be found on the control panel:
-A b polar magnetothermal sw tch [F g. 4 Ref. 2] wh ch
cuts the power n case of an overload or short-c rcu t.
-A thermal sw tch (F g. 4 Ref. 3] to protect the low-
voltage electr c system aga nst short-c rcu t.
-An hour counter (F g. 4 Ref. 1].
-The generator start/stop button [F g. 4 Ref. 4].
The generator can be connected w th a connector to the
remote start ng panel, suppl ed by mase as an opt onal,
and can be nstalled on the dashboard.
Two d fferent remote start ng panels are ava lable as
shown n F g. 5.
The most s mple vers on has a start/stop button [F g. 5
Ref. 1] and a green p lot l ght [F g. 5 Ref. 2] wh ch, when
on, nd cates that the generator s runn ng.
The second vers on of the remote start ng panel [F g. 5
Ref. 3] has, n add t on to the start/stop button, an
nstrument wh ch nd cates the eng ne o l pressure value
(F g. 5 Ref. 4] and an nstrument wh ch nd cates the
coolant temperature value [F g. 5, Ref. 5].
When carrying out maintenance operations on the
generator, disconnect the negative pole of the starter
battery to prevent accidental starting.
3. USING THE GENERATOR
3.1 Preliminary checks
At f rst start ng of the generator, or after hav ng done any
type of ma ntenance work, t s always good pract ce to
check:
-the o l level by means of the d pst ck [F g. 7 Ref. 2]
(see table A for recommended o ls [F g. 8]).
-that all the anchor ng po nts of the generator are
properly t ghtened.
-that all the electr cal ut l t es are off to prevent start ng
the generator on load
-that the water and fuel p pes are properly connected
-that all the electr cal connect ons have properly been
carr ed out and that there are no electr cal connect ons
n a bad state.
-that the water cock s open [F g. 6 Ref. 2]
-that the sect on of the water c rcu t from the pump to
the valves has been f lled manually f a non-return
valve has been mounted on the sea ntake (as
recommended n the nstallat on manual) [F g. 4 Ref.
1].

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3.2 Bleeding the fuel system
The presence of a r bubbles n the fuel system s caused
by rregular funct on ng of the eng ne or the ncapac ty to
reach the nom nal number of revolut ons. A r m ght enter
the fuel c rcu t through a not perfectly t ght seal (p pes,
f lters, tank) or when the fuel n the tank s at m n mum
level. The fuel system has been des gned n such a way
as to autonomously el m nate a r bubbles that have
penetrated the c rcu t. Automat c bleed ng s obta ned by
act vat ng the fuel pump for a few m nutes before start ng
the eng ne.
The fuel pump s act vated by press ng the START button
for a second.
Should the eng ne st ll funct on rregularly after th s
operat on, consult a techn c an for a thorough nspect on
of the fuel system.
3.3 Starting
Before start ng the generator, ensure that the prel m nary
checks descr bed n paragraph 3.1 have been carr ed out.
Start the generator by press ng the START button located
on the control panel [F g. 4 Ref. 4] and release t only when
the generator has started, tak ng care not to exceed 15
sec. for each attempt and respect ng an nterval of at least
30 sec. All the warn ng l ghts of the eng ne protect on
module [F g. 4, Ref. 5] w ll come on for a few seconds, and
f there are no eng ne or generator faults, only the green
RUN l ght [F g. 4 Ref. 6] w ll rema n on to nd cate that the
generator has been started and that funct on ng s regular.
Repeated attempts at starting with negative 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 having closed the sea intake cock
[Fig. 6 Ref. 2].
3.4 Stopping
The generator s stopped by press ng the OFF button on
the control panel.
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.
4. PROTECTIONS
The IS 8 and IS 9.5 generators are equ pped w th a ser es
of protect ons wh ch safeguard them aga nst mproper
use and operat ng problems.
When the generator stops because a protect on has
ntervened, on the eng ne protect on module [F g. 5, Ref.
5] of the control panel the warn ng l ght relat ve to the fault
w ll come on.
4.1 Low oil pressure protection
Intervenes sw tch ng off the generator when the eng ne o l
pressure s nsuff c ent. Its ntervent on s s gnalled by the
OIL l ght [F g., 4, Ref. 7] com ng on. Normally t s
suff c ent to top up w th the lack ng quant ty of o l to be
able to restart the generator.
The low oil pressure protection does not give an
indication of the level of engine oil in the sump.
Therefore, check this level 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 transverse axis. If the engine is
operated at a greater inclination, the risk is insufficient
lubrication or aspiration of engine oil through the
air filter.
4.2 High water temperature protection
Intervenes sw tch ng off the generator when the eng ne
coolant temperature s too h gh or there s no c rculat on
of seawater.
Its ntervent on s s gnalled by the ºC l ght [F g. 4, Ref.
10] com ng on.
Only restart the generator after the cause of the fault has
been dent f ed and removed.
4.3 Alternator overheating protection
Intervenes sw tch ng off the generator when there s a
thermal overload on the alternator.
Its ntervent on s s gnalled by the ºC l ght [F g. 4, Ref.
8] com ng on. The generator can be restarted after a few
m nutes when the temperature of the alternator w nd ngs
has returned to normal values. It s, however, recommended
to f nd and remove the causes of the ntervent on.
In the event of one of the above described
protections intervening, after ascertaining and
removing the cause of the intervention, press the
STOP button to reset the control panel (otherwise
the signal would remain in memory preventing the
engine from starting).

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4.4 Protection against short-circuit and overload
The generator s protected aga nst short-c rcu t and
overload. A b polar magnetothermal sw tch [F g. 4 Ref. 2]
cuts the supply of electr c current when a short-c rcu t
occurs or when the electr c current del vered exceeds the
nom nal value.
Before restor ng the contact by l ft ng the lever of the
magnetothermal sw tch, d sconnect the ut l t es.
4.5 Protection against short-circuit of the low-
voltage electric system
In the event of a short-c rcu t n the low-voltage electr c
system, a thermal sw tch [F g. 4, Ref. 3] breaks the c rcu t
stopp ng the generator. In th s case the warn ng l ghts of
the eng ne protect on module w ll all be off and t w ll not
be poss ble to re-attempt start ng.
Before restor ng the electr c c rcu t by press ng the button
located on the thermal sw tch [F g. 4 Ref. 3], have a
spec al sed techn c an f nd and remove the cause of the
short-c rcu t.
5. MAINTENANCE
Any maintenance operation on the generator must
be carried out with the engine off after letting it cool
down sufficiently, and must be carried out by
authorised personnel.
Before accessing the generator, disconnect one
pole of the starter battery in order to prevent
accidental starting.
5.1 Ordinary engine maintenance
The per od c ma ntenance to be carr ed out on the eng ne
s l sted n TABLE B.
For more deta led nformat on consult the manual prov ded
w th each generator by the eng ne manufacturer.
Check the oil level by means of the graduated
dipstick [Fig. 7, Ref. 2]. The level must always be
between the MAX and MIN notches on the dipstick
[Fig. 7 Ref. 1].
5.2 Engine oil and oil filter change
The eng ne o l sump capac ty s 3.6 l tres.
Top-ups and f ll ng w th eng ne o l s carr ed out through
the hole [F g. 3, Ref. 17].
To change the o l n the o l sump, remove the d pst ck [F g.
7, Ref. 2] and operate the spec al extract on pump [F g.
3, Ref. 12] after hav ng removed the screw wh ch
funct ons as plug.
It s recommended to dra n the o l when t s st ll suff c ently
warm to flow eas ly.
For recommended o ls see table A, F g. 8.
The first engine oil change must be carried out after
50 hours of generator operation. For the second and
subsequent oil changes, every 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.
Avoid contact of engine oil with the skin. During
maintenance operations use gloves and protective
glasses.
In case of contact with engine oil, immediately and
thoroughly wash the affected part with soap and
water.
To replace the eng ne o l f lter cartr dge [F g. 3, Ref. ?],
unscrew t from ts support, us ng su table tools normally
found on the market. Repos t on the new cartr dge, tak ng
care to lubr cate the rubber r ng gasket.
The f rst replacement must be carr ed out after 50 hours
of generator operat on. For the second and subsequent
replacements, respect an nterval of 400 hours.
For further nformat on consult the eng ne use and
ma ntenance 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.
5.3 Air filter cleaning
The generators of the IS ser es have a dry a r f lter wh ch
prevents fore gn bod es from enter ng the combust on
chamber. For ts ma ntenance t s suff c ent to clean the
f lter ng mass w th d esel fuel once a year to remove nay
mpur t es.

IS 8 - 9.5 9 - 10.2
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Dispose of the liquids used for air filter washing in an
appropriate manner. Take them to special collection
centres.
Any maintenance operation on the generator must
be carried out with the engine off after letting it cool
down sufficiently, and must be carried out by
authorised personnel.
Before accessing the generator, disconnect the
negative pole of the starter battery to prevent
accidental starting of the generator.
5.4 Fuel filter replacement
To guarantee long l fe and proper funct on ng of the
eng ne, t s extremely mportant to per od cally replace
the fuel f lter cartr dge, respect ng the frequency nd cated
by the eng ne manufacturer as l sted n the table n
Paragraph 5.12.
Th s operat on s carr ed out n the follow ng steps:
-Close the fuel cock [F g. 3, Ref. 24]
-Completely unscrew the r ng nut of the support [F g.
3, Ref. 13]
-Remove the old cartr dge and pos t on the new one.
-For remount ng repeat the operat ons n reverse
order.
When the f lter has been replaced, bleed the fuel system
carry ng out the operat ons descr bed n Paragraph 3.2.
Avoid contact of the fuel oil with the skin. During
maintenance operations use gloves and protective
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.
5.5 Coolant check
Per od cally check the coolant level n the closed-c rcu t
cool ng system. The reference ndex for th s check s
pr nted on the expans on tank [F g. 3, Ref. 11]. If the level
s nsuff c ent, pour coolant nto the expans on tank,
tak ng care not to exceed the max mum level ndex.
Never open the cap of the expansion tank [Fig. 3,
Ref. 11] or coolant tank [Fig. 3, Ref. 20] when the
engine is hot to prevent dangerous coolant leaks.
5.6 V-belt tension check
A V-belt s used to transm t the rotary mot on from the
dr ve shaft pulley to that of the seawater pump [F g. 9 Ref.
1].
Excess ve belt tens on accelerates wear, wh le a slack
belt makes the pulleys dle and does not allow suff c ent
water c rculat on.
Adjust the belt tens on as follows:
Loosen the two adjust ng screws [F g. 9, Ref. 2] and move
the seawater pump outwards to ncrease the tens on or
nwards to decrease t. Lock the screws and check the
tens on.
The correct belt tens on s such as to allow a y eld of about
5 mm [F g. 9] under a thrust force of 8 kg.
A second belt s used to transm t the rotary mot on from
the dr ve shaft pulley to that of the closed-c rcu t coolant
pump and the battery charger DC alternator [F g. 9 Ref.
3].
Adjust the belt tens on as follows:
Loosen the adjust ng screw [F g. 9 Ref. 4] and move the
battery charger DC alternator [F g. 9, Ref. 5] outwards to
ncrease the tens on and nwards to decrease t.
The correct belt tens on s such as to allow a y eld of about
10 mm [F g. 9] under a thrust force of 8 kg.
To prevent the belt from slipping, do not dirty it with
oil. Clean the belt with petrol if any oil is spilled.
Keep hands away from the V-belt or the pulleys
when the engine is running.
5.7 Emptying the cooling system
To carry out ma ntenance on the water/a r exchanger or
on the cool ng system the seawater must be dra ned from
the ntake c rcu t. Th s operat on s carr ed out as follows:
-Close the sea ntake cock [F g. 6, Ref. 2]
-Open the dra n tap [F g. 6, Ref. 3] unt l all the water
has run out
-Close the dra n tap.
Reopen the seawater intake cock before starting the
generator.

IS 8 - 9.5 9 - 10.2
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31
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5.8 Coolant replacement
Yearly change the coolant n the closed-c rcu t cool ng
system.
Connect a 20-30 cm long rubber tube [F g. 10, Ref. 2] to
the dra n tap [F g. 10, Ref. 1] located on the eng ne base
to fac l tate collect on of the used coolant n a collect on
receptacle [F g. 10, Ref. 3]. Open the tap and completely
dra n the closed-c rcu t cool ng system.
When the operat on has been completed, close the tap
and f ll the c rcu t w th new coolant.
Dispose of the used coolant in an appropriate manner
as it is a polluting product.
Take the used coolant to special collection centres
responsible for disposal.
5.9 Zinc anode replacement
To protect the water/a r heat exchanger [F g. 11, Ref. 1]
and the water/coolant heat exchanger [F g. 11, Ref. 2]
aga nst galvan c current, two sacr f c al z nc anodes [F g.
11, Ref. 4] have been nserted ns de them. Per od cally
check the r state of wear and, f necessary, replace them
n order to prevent that the galvan c current rreparably
corrodes the heat exchanger. It s recommended to
check the z nc anodes at least once a month when the
generator s new to check how fast consumpt on s, to
then be able to act accord ngly.
It s, however, opportune to replace the z nc anodes at
least once a year.
F g. 11 shows the po nts where the z nc anodes are
pos t oned.
5.10 Seawater pump maintenance
At least once a year check the ntegr ty of the rubber rotor
of the seawater pump [F g. 12, Ref. 1].
Before open ng the seawater pump to nspect the rotor,
dra n the seawater from the cool ng system as descr bed
n Paragraph 5.7.
To access the rotor, remove the cover [F g. 12, Ref. 2] and
w th the a d of a pa r of pl ers extract the rotor pull ng t out
w th force. To remount a new rotor, repeat the operat ons
descr bed above n reverse order.
5.11 Alternator maintenance
The alternator used on th s model of generator s type
synchronous, self-energ sed, w th electron c voltage
regulat on. Th s model alternator, w thout man fold and
brushes, does not requ re part cular ma ntenance
operat ons. The per od c checks and ma ntenance are
l m ted to remov ng any traces of damp and ox dat on
wh ch m ght damage t.
5.12 Battery maintenance
For start ng all the generator models, t s recommended
to use an 80 A/h battery for amb ent temperatures
exceed ng 0ºC, and 100 A/h for lower temperatures.
Before nstall ng a new battery t s mportant that t
undergoes a full charg ng cycle.
At least once a month check the level of the electrolyte
and, f necessary, top up w th d st lled water. If the
generator s not to be used for a long per od, t s
recommended to d sconnect the battery and store t n a
dry place at a temperature over 10ºC and to carry out a full
charg ng cycle once a month.
If the battery is left completely flat for long periods,
there is a risk of irreparably damaging it.
The pos t ve term nal of the battery must be protected w th
Vasel ne to prevent corros on and the format on of ox de.
For top-ups with sulphuric acid, ready solutions
must be used.
The battery top-up operations with distilled water or
with acid must be carried out with rubber gloves and
protective glasses to prevent accidental contact of
the sulphuric acid with the skin.
In the event of accidental contact, thoroughly wash
the part affected with soap and water and consult a
doctor.
Before recharging the battery check the level of the
electrolyte and, if necessary, fill up with distilled
water. This operation must be repeated when the
recharging cycle has been completed.
5.13 Periods of inactivity
Start up the generator at least once a month. If the
generator s not to be used for a long t me, the follow ng
operat ons must be carr ed out:
-Change the eng ne o l
-Replace the o l f lter cartr dge (see par. 5.2)
-Replace the fuel f lter cartr dge (see par. 5.4)
-Remove the njectors and pour 2 cc eng ne o l nto
each cyl nder and let the eng ne turn over a few t mes,
manually operat ng the dr ve shaft pulley. Remount
the njectors.
-Replace the z nc anodes (see par. 5.9)
-Through the seawater ntake p pe asp rate some ant -
freeze whose funct on s to protect the heat
exchangers aga nst low temperatures and to lubr cate

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the seawater pump rotor and the metall c parts n the
cool ng system.
-D sconnect the starter battery and store t n a dry
place (see par. 5.12)
-D sconnect the sea exhaust p pe from the eng ne
man fold.
-Clean the seawater f lter.
-Close the seawater ntake cock.
-Dra n the seawater from the exhaust.
-Clean and lubr cate the ant s phon valve, f nstalled
(s phon break).
5.14 Summary table of scheduled maintenance
OPERATION HOURS
Check engine oil level .................................... 10
Check coolant .................................................. 10
Check for oil leaks ........................................... 20
Check for fuel leaks......................................... 20
Check for coolant leaks .................................. 20
Adjust V-belt tension ...................................... 100
Check battery charger.................................... 100
Clean fuel filter ............................................... 200
Adjust belt tension .......................................... 200
*Change engine oil ........................................ 200
Check seawater pump rotor .......................... 400
Check engine rpm .......................................... 400
Check integrity of electrical connections ..... 400
Replace fuel filter ........................................... 400
* Replace oil filter........................................... 400
Check injectors ............................................... 400
Check injector timing ..................................... 400
Adjust play on intake/exhaust valve ............. 400
Check the fuel injection pump ..................... 1000
Check battery electrolyte level ................. monthly
Clean and deoxidise the metallic parts...... yearly
Clean air filter ............................................... yearly
Replace coolant completely ........................ yearly
Replace inc anodes .................................... yearly
Carry out the f rst ma ntenance operat on after 50
hours, subsequently accord ng the requ red ntervals.
5.15 Troubleshooting
The starter motor turns but the main engine does not
start
-Check that there s fuel n the tank (f ll up)
-Check f the stop electromagnet s n the f r ng pos t on
(consult Serv ce Centre)
-Bleed the a r bubbles from the fuel c rcu t (see par. 3.2)
The engine protection module is not activated when
the START button is pressed
-battery, and the electr cal connect ons (reconnect).
-Check ntegr ty of the battery (recharge or replace).
The generator switches off during the operating
period
-Check f a protect on has been act vated w th the
relevant l ght com ng on (remove the cause and retry
start ng).
-Check f there s fuel n the tank (f ll up).
There is a high grade of smoke at the engine
exhaust
-Check that the o l level n the sump does not exceed
the MAX ndex (restore level).
-Check that the generator s not n overload.
-Check cal brat on of the njectors (consult Serv ce
Centre).
The engine runs irregularly
-Check the fuel f lters (replace).
-Bleed the a r bubbles from the fuel c rcu t (see par.
3.2).
The alternator voltage is too low
-Correct the voltage value act ng on the electron c
regulator.
-Check the eng ne rpm (1560 rpm w thout ut l t es
connected).
-Voltage regulator broken (replace).
Starter battery flat
-Check the electrolyte level n the battery (restore the
level).
-Check funct on ng of the DC alternator.
-Check ntegr ty of the battery.
The generator does not deliver power
-Check that the magnetothermal sw tch [F g. 4, Ref.
2] s n the ON pos t on. If not, contact an author sed
Serv ce Centre.
TABLE B