Full Text Searchable PDF User Manual
IS 2.5
USAGE AND MAINTENANCE MANUAL
Rev.2 M.C. 27-11-2001
Cod. 41977
masemasemasemasemase
GENERA
T
ORS
IS 2.5
2
GENERATORS
NR.000000
mase
GENERATORS S.p.A.
Tel. +39 (0) 547 354311
Fax +39 (0) 547 317555
DICHIARAZIONE CE DI CONFORMITÀ
EC DECLARATION OF CONFORMITY
Fabbricante/Manufacturer:
mase
GENERATORS S.p.A.
Indirizzo /Address : Via Tortona 345, Pievesestina (FC)
Il sottoscritto Luigi Foresti in qualità di direttore tecnico 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. technical manager declares, under his sole
responsability, that the generator model................:
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.
mase
GENERATORS S.p.A.
Sede legale ed Amm.: 47023 CESENA (FC) ITALY - Via Tortona, 345 - C.F./P.I. 00687150409 Cap. Soc. milioni 2000
di cui 949 versati - Registro Società Tribunale Forl' n. 6818 - CCIAA Forl' n.164063 - c.c.p. n. 11541471 - EXPORT FO n. 006368
Cesena, / /
......................................................
Direttore Tecnico
Technical Director
3
GENERATORS
IS 2.5
1
2
A
APERTO
OPEN
OUVERT
GEÖFNET
ABIERO
OPEN
3
TAB "A"
IS 2.5
4
GENERATORS
4
5
6
7
5
GENERATORS
IS 2.5
SCHEMA ELETTRICO-WIRING DIAGRAM-SCHEMA ELECTRIQUE-SCHALTPLAN-ESQUEMA ELE'CTRICO
ELEKTRISCH SCHEMA
1
4
4
3
3
20
10
2
P
1
P
2
1
F
F
2
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
T
P
17
16
EV
P
15
M
-
50 30
12V
+
0
19
21
50(60)
5(6)
5(6)
+
1
P
F
2
6
8
IS 2.5
6
GENERATORS
MOTORE-ALTERNATORE - MOTEUR-ALTERNATEUR - ENGINE-ALTERNATOR - MOTOR-GENERATOR
5LI &RG
4W\ 'HVFUL]LRQH
'HVFULSWLRQ
1 70821
1
Asta livello olio
Oil dipstick
2 90905
1
Scatola filtro
Air filter box
3 70812
1
Massa filtrante
Sponge
4 10807
1
Portagomma
Nipple
5 61156
1
Collettore filtro aria
Manifold
6 8584
1
Bocchettone carico olio
Filler
7 10808
1
Sede asta olio
Fitting
8 30647
1
Elettrovalvola
Fuel solenoid
9 70822
1
Tappo carico olio
Oil cap
10 10822
1
Curva scarico
Fitting
11 70543
cm 30 Tubo gasolio
Pipe
12 70442
cm 25 Tubo acqua d.15
Pipe
13 70237
cm 25 Tubo gasolio
Pipe
14 10812
1
Portagomma
Nipple
15 10813
1
Raccordo
Fitting
16 61157
1
Gomito miscelatore
Exhaust manifold
17 30253
1
Sonda temp. acqua 70 °C
Thermostat
18 80120
1
Sonda temp. cilindro
Thermostat
19 31001
1
Pompa acqua mare
Sea water pump
7
GENERATORS
IS 2.5
Rif. Cod.
Qty. Descrizione
Description
20 50257
1
Puleggia pompa 50 Hz
Pulley
20 50260
1
Puleggia pompa 60 Hz
Pulley
21 70823
1
Manicotto carico olio
Oil pipe
22 70824
1
Manicotto acqua
Water pipe
23 10814
1
Gomito ottone
Fitting
24 10614
2
Portagomma
Nipple
25 10615
1
Puleggia
Pulley
26 70807
1
Cinghia 50 Hz
Belt
26 70863
1
Cinghia 60 Hz
Belt
27 03767
1
Coperchio alternatore
Cover
28 10610
1
Tirante centrale
Central tie rod
29 013093
1
Rotore
Rotor
30 910589
2
Diodo rotore
Diode
31
20521
2 Varistore Varistor
32 013049
1
Statore 115/230V 50Hz
Stator 115/230V 50Hz
32 04262
1
Statore 120/240V 60Hz
Stator 120/240V 60Hz
33 70647
1
Passacavo
Cable guide
34 81103
1
Cuscinetto
Bearing
35 71169
2
Tubo carburante
Fuel Pipe
36 012806
1
Coperchio alternatore
Cover
37 10284
4
Tirante alternatore
Tie rod
38 10464
1
Rondella con guida
Washer
39 31004
1
Pompa gasolio
Diesel pump
40 07050
1
Cablaggio motore
Electrical assy
41 61158
1
Staffa antivibranti
Bracket
42 61159
1
Staffa antivibranti
Bracket
43 61162
1
Supporto pompa
Pump bracket
44 61163
1
Piastrina supporto pompa
Plate
45 07166
1
Staffa elettrovalvola
Bracket
46 013145
1
Protezione alternatore
Protection
47 70634
4
Antivibrante 30x30
Shock absorber
48 70808
1
Cuffia in gomma
Rubber cover
49 70802
1
Cuffia in gomma
Rubber cover
50 70616
cm70 Guarnizione adesiva 10x15
Gasket
51 70629
cm25 Tubo d.25
Pipe
52 10823
7
Dado Oteco
Nut
53 10794
2
Fascetta 30x60
Clamp
54 10825
6
Fascetta 16x25
Clamp
55 90906
1
Parete divisoria
Panel
56 97539
1
Raccordo elettrovalvola
Fitting
57 71151
1
Guarnizione OR
Or gasket
58 10842
2
Fascetta 10x15
Clamp
59 92623
1
Girante pompa Jota
Impeller for Jota pump
59 80161
1
Girante pompa Jhonson
Impeller Jhonson pump
60 97537
1
Pressostato olio
Oil pressure switch
61 11374
2
Portagomma nafta
Fuel Nipple
62 70185
1
Guarniz. OR
O-Ring gasket
63 92456
1
Guarniz. pompa acqua Jota
Jota pump O-Ring
63 93312
1
Guarniz. pompa Johnson
Johnson pump gasket
64 97601
1
Guarnizione scarico
Gasket
65 10166
1
Vite
Screw
66 10791
2
Fascetta
Clamp
67 012485
1
Staffa supporto termico
Bracket
68 71228
1
Cappuccio
Cover
69 32714
1
Interruttore termico 2P 10 A
Thermal switch 2P 10 A
70 03757
1
Motore Yanmar L48 50Hz
Yanmar L48 Engine 50Hz
70 011774
1
Motore Yanmar L48 60Hz
Yanmar L48 Engine 60Hz
IS 2.5
8
GENERATORS
CASSA INSONORIZZANTE
CHASSIS
FRAME
RAHMEN
b
c
a
d
29
30
31
28
32
5LI &RG 4W\ 'HVFUL]LRQH
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1
80542
1
Regolatore carica batt.
Batt. charger regulator
2
31188
1
Condensatore
Capacitor
3
31002
1
Fusibile lamellare 20 A
Fuse 20 A
4
30925
1
Portafusibile
Fuse carrier
5
30926
1
Piastrina portafusibili
Fuse holder terminal
6
32690
1
Scheda relè
Relay board
7
61181
1
Radiatore acqua/aria
Water/Air intercooler
8a
90902
1
Coperchio cassa sup.
Soundproof box cover
8b
90903
1
Coperchio cassa post.
Soundproof box cover
8c
12759
1
Fondo cassa
Soundproof box bottom
8d
70881
1
Scatola scheda relè
Relay box cover
9
611160
2
Staffa fondo cassa
Bracket
10
07529
1
Supporto scambiatore
Water/Air intercooler support
11
70733
8
Elastomero
Shock absorber
12
10780
4
Distanziale
Spacer
13
70739
2.7 mt Profilato in gomma
Gasket
14
70809
1
Serie spugne
Sponge get
15
10567
1
Passacavo DG48
Cable guide
5LI &RG 4W\ 'HVFUL]LRQH
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16
10566
2
Passacavo DG29
Cable guide
17
70799
2
Pressacavo PG 13,5
Cable guide
18
07337
2
Staffa fissaggio cofani
Plate
19
10823
7
Dado oteco MUT 986 M6Nut
21
70800
2
Dado per PG 13,5
Nut
22
80162
1
Zinco Scambiatore
Zinc anode
23
04306
4
Cinghietta in gomma
Strap
24
10815
4
Fermo cinghietta
Plate
25
26
31678
2
Relè
Relay
27
70878
1
Paratia lato motore
Bulkhead
28
91034
1
Circuito stampato
Printed circuit
29
70786
40 cm Guarnizione
Gasket
30
70854
1
Scatola pannello comandPrinted circuit box
31
70634
4
Antivibrante 30x30
Shock absorber 30x30
32
07664
1
Comando a distanza
Remote control panel
IS 2.5
14
GENERATORS
CONTENTS
FIGURESpag.2
TAB."A" TABLE SUGGESTED OILS
pag.2
WIRING DIAGRAM
pag.4
1
SAFETY REGULATIONS
pag.20
2
PRELIMINARY CHECKSpag.20
3
GENERATOR USE
pag.20
Starting
Generator Stop
4
SAFETY DEVICES
pag.20
Low oil pressure device
Warning
High temperature device
Alternator overload/over temperature device
Important
5
MAINTENANCE
pag.21
Important
Engine maintenance
Important
6
INACTIVE PERIOD
pag.21
7
CONTROL PANEL
pag.21
8
PROTECTION FUSE
pag.22
9
DIMENSION AND WEIGHT
pag.22
10
DESCRIPTION WIRING DIAGRAM
pag.22
11
TROUBLE MAINTENANCE
pag.22
12
TROUBLE SHOOTIN
pag.22
13
TECHNICAL FEATURESpag.23
DANGER
WARNING
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.
Important information.
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.
CAUTION
INFORMATION
GB
15
GENERATORS
IS 2.5
CONGRATULATIONS ON HAVING CHOSEN A MASE
PRODUCT
This manual contains all the necessary information for
proper installation and use of the generator. Its essential,
either for the customers 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 customers 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
nearest MASE SERVICE CENTER, theyll be pleased to
help you at any time.
MASE reserve the right to introduce changes without prior
notice. No part or illustration contained in this handbook
can be reproduced without previous approval by MASE
MASE GENERATORS S.p.A.
1 SAFETY REGULATIONS
- Read carefully all the instructions given in this handbook
and in the installation manual; they are of the utmost
importance for correct installation and use of the unit and
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.
- Do not handle the generator or the remote control panel
with wet hands; any misuse may cause electric shocks.
- Any testing of the unit is to be carried out only when the
engine is stopped. Possible checks on the generator
when its running have to be performed only by skilled
workers.
2 PRELIMINARY CHECKS
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.
- The generator is well secured to the soundproofing box
by means of the proper bolts.
- The electric loads are disconnected so as to avoid
starting the generator on load.
- Every connection (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)
- If anon-return valve is used, the cooling circuit from the
valve up to the pump has been manually filled (ref. 1
fig. 2)
3 GENERATOR USE
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 the pilot and warning lamps will glow for 5 sec. 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,the safety devices of the generator are automaticily
activated (see item. 4).
Generator Stop
The generator can be stopped ushing the <<OFF>>
button on the control panel (fig. 3 ref 2).
4 SAFETY 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 intervention is shown by the 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:
it causes generator shut-down in case of high temperatu-
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.
Its intervention is shown bythe relative warning light going
on (fig. 3 ref. 9). Wait until the temperature of the alternator
windings goes back to the normal values. Its however
recommended to look forand eliminate the causes of the
intervention before starting the generator again.
If one of the above safety devices intervenes, look for and
eliminate the causes of the intervention, then push the <<
STOP >> button to avoid that signal keeps stored.
WARNING
WARNING
GB
IS 2.5
16
GENERATORS
INFORMATION
In case of the two fuses (ref.1/2 Fig.4) got burnt,
a protectio inserts and does not allows the generator to
start.
5 MAINTENANCE
Any servicing is to be carried out with the engine 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:
l. 0.8
Oil topping up and replacement can be carried out through
the hole. (fig. 5 ref. 2).
For changing oil, remove the levelstick and replace oil with
the special pipe. (fig. 5, ref. 3).
We suggest to carry out the draining when the oil is still
warm enough, to allow an easy flowing out.
Beore executing the maintenance on the water-air
exchanger (rif. 3 fig. 6), it is necessary to empty the water
intake circuit throught the special cock.(ref. 3 fig. 2)
6 INACTIVE PERIOD
Should the unit remain unused for a long time, its
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
indispensable to drain the engine cooling circuit using the
lever cock (ref. 3 fig. 2)
- Lubrificate the water pump impeller.
CAUTION
INFORMATION
WARNING
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)
ENGINE TEMPERATURE 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.
GB
17
GENERATORS
IS 2.5
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.
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)
RELAY CIRCUIT FUSE
2)
BATTERY CHARGER FUSE
9 DIMENSIONS AND WEIGHT( fig. 7 )
IS 2500
a)
Lenght
mm.580
b)
Width
mm.430
c)
Height
mm.430
Weight
Kg. 80
10 DESCRIPTION WIRING DIAGRAM (fig. 8 )
1
ROTOR
2
STATOR
3
DIODE 3A
4
VARISTOR
5
PRINTED CIRCUIT RELAY
6
POWER TERMINAL BOARD
7
RELAY CIRCUIT TERMINAL BOARD
8
CONTROL PANEL TERMINAL BOARD
9
FUSE 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
MAGNETOTERMIC SWITCH
11 TROUBLE MAINTENANCE
12 TROUBLE SHOOTING
INFORMATION
WARNING
GB
COMPLAINT
PROBABLE REASON
Defective starting buttons
l
Defective fuel solenoid
l
l
Defective battery Battery
cable section
l
Defective starting motor
l
Piping fuel filter choked
l
l
12V circuit fuse
l
Avv./Ev.relay
l
Too much oil in crankcase
l
l
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
l
l
l
Defective feeding pump
l
l
BLAC
K SM
OC
KE
ST
AR
T
AN
D
ST
OP
U
N
S
T
ABLE
RUNNING
DO
E
S
NO
T
ST
AR
T
W
H
IT
E SM
OC
KE
IS 2.5
18
GENERATORS
GB
211cc.
70 X 55
3000 3600
230 240
DIESEL
ELECTRIC
0,8 lt.
20°
1700W 1900W
1
F
50 60
1cylinder,4 stroke,internal combustion
air-cooled diesel
Displacement
Model
R.P.M.
Bore for stroke
Power Hp
Fuel consumption g./Hp.h
Starting system
Oil capacity
Max inclination
ALTERNATOR
Continuous output
Power factor
Insulation class
Frequecy Hz
ENGINE
3,8/4,2 4,2/4,7
YANMAR
Fuel
Synchronous,self-excited,single
phase, 2 poles, brushless
13 TECHNICAL FEATURES
L48 AE