masemarine is25 new2 · is 2.5 13 3 alternator the generators of the is 2.5, series are equipped...
TRANSCRIPT
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GE
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TO
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WORKSHOP MANUAL
IS. 2.5 50 Hz
IS 2.5
2
Index1 Machine identification........................51.1 Generators composition .......................... 5
2 TOOL TABLE .......................................... 9
3 ALTERNATOR ..................................... 133.1 Stator .................................................... 153.1.1 Power windings ..................................... 153.1.2 Excitation windings ............................... 173.1.3 Alternator thermostat ............................ 173.1.4 Battery charger windings ................ 193.2 Rotor ..................................................... 213.2.1 Rotor winding (n°2) ............................... 213.2.2 Rotor diodes (n°2) ................................. 233.2.3 Rotor varistors (n°2) ............................ 233.3 Capacitors ............................................ 25
4 ENGINE ................................................ 274.1 Technical features ................................. 254.2 Maintenance ......................................... 284.3 Trouble-shooting ................................... 304.4 Fuel ...................................................... 354.5 Electric diesel fuel pump ...................... 374.6 Lubrication ............................................ 39
5 SENSORS ............................................ 415.1 Closed-circuit engine thermal switch .... 415.2 Open-circuit engine thermostat (sea) .... 435.3 Oil pressure switch ............................... 45
6 SEA WATER COOLING ....................... 476.1 Seawater/closed-circuit system ............ 476.2 Water pump .......................................... 496.3 Water pump belt ................................... 516.4 Water/air heat exchanger ...................... 53
7 ADJUSTMENTS ................................... 557.1 Rpm adjustment ................................... 557.2 Closing cover motor ............................. 577.3 Engine air filter cleaning ...................... 597.4 Level oil check ..................................... 617.5 Engine oil filter cleaning ...................... 61
8 ELECTRICAL SYSTEM ........................ 638.1 Command circuit .................................. 638.1.1 Multicore cable ..................................... 698.2 Stop solenoid........................................ 718.3 Thermal switch (AC circuit breaker) ........... 738.4 Engine wiring ........................................ 758.5 Battery charger ..................................... 778.6 Fuse ..................................................... 798.7 Starter motor ........................................ 818.8 Battery .................................................. 83
9 DISASSEMBLY .................................... 859.1 Removing the casing ............................. 859.2 Removing the alternator ........................ 899.3 Removing the alternator cover
on the bearing side ............................... 919.4 Removing the stator .............................. 939.5 Removing the rotor ................................ 959.6 Removing the rotor bearing ................... 95
IS 2.5
3
I
SCREW SHUT ..................................... 95
SPARE PARTS .................................... 96ENGINE-ALTERNATOR...................... 96FRAME ................................................ 98
WIRING DIAGRAM ............................... 101
IS 2.5
4
1
123
56789
4
10
SERIAL No.
2
1
3
5
46
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 - Weight10 - Serial number
The machine code number, the serial numberand the year of construction must always bequoted when contacting the manufacturer forinformation, requests for spare parts, etc.
1.1 Generators composition
The generators are essentially composed ofthe following components (Fig.1-2):
1- Soundproof casing2- Top access door3- Motor side access door4- Anchoring brackets5- Exhaust and cooling water pipe fitting6- Seawater intake connection pipe fitting7- Connection pipe fittings to fuel tank
IS 2.5
6
2
12
8A
11
9
1918
21
16
14 13
1510
20
8B
17
23
22
IS 2.5
7
8A-Connection to battery +8B-Connection to battery -9- RPM adjusting screw of engine10- Engine air filter11- Staff oil level12- Seawater pump13- Fuel pump14- Oil filter cartridge15- Oil fillercap16- Electric line connection box17- Battery charger regolator18- Water/air heat exchanger19- Exhaust manifold20- Starter motor21- Remote control panel connector22- Capacitor23- Fuse
IS 2.5
8
3
IS 2.5
9
2 TOOL TABLE
Denomination: Torque spanner
Use: To tighten the nuts and bolts to theprescribed torque
Denomination: Battery tester
Use: To check the electrolyte level of the battery
Denomination: Digital thermometer
Use: Measures the temperature of thecomponents
Denomination: Contact tachometer
Use: Measures the rpm of the rotary shaft bybringing the indicator tip in contact with thecentral hole of the shaft.
Denomination: Photocell tachometer
Use: Allows measuring the rpm of the rotaryshaft 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 pulsesystem not taking into account the centre of therotary shaft and the circumference of the rotatingobject.
IS 2.5
10
4
IS 2.5
11
Denomination: Tester
Use: Measures the AC/DC voltage, the resistorsand the diodes
Denomination: Amperometric caliper
Use: Measures the AC voltage, frequency(engine rpm) and AC current.The power drawn from the generator can thusbe measured.
Denomination:Ammeter
Use: Measures the line current connecting it inseries
Denomination:Frequency meter
Use: Measures the frequency (engine rpm)connecting it in parallel to the 230-115V line ofthe generator.
Denomination: Extractor
Use: Used to extract the alternator bearingcover and the rotor bearing.
IS 2.5
12
5
IS 2.5
13
3 ALTERNATOR
The generators of the IS 2.5, series are equippedwith a brushless, synchronous, 2-pole, self-regulating, self-excited alternator with 1 capacitor(Fig. 2 Ref. 22) connected to the auxiliary windingfor stator excitation. The alternator generatesalternate voltage available at the terminals at afrequency of 50/60 Hz (corresponding to the speedof the prime mover of 3000/3600 rpm) according tothe principle described below.Upon starting, the rotor magnetism (residualmagnetism of the nucleus) induces a voltage in theauxiliary excitation windings.This voltage is applied to the capacitor, and makesa capacitive current circulate in the closed circuitcomposed of the capacitor and the auxiliary winding.This current produces a magnetic field whichstrengthens the rotor magnetism generating avoltage inside it which, rectified by the diodes,makes a continuous current circulate in the rotorfield windings.The rotating magnetic field due to circulation of thiscurrent in its turn generates in the primary windingthe rated voltage to the generator terminals.
TESTS
All the resistance measurements are made withthe alternator cold, ambient temperature 10 - 30°C, and with instrumentation such as to allowreading the values indicated.The tolerance with respect to the values listed isapproximately ± 10%.Approximate readings made with instruments withinadequate range, can only indicate continuity ofthe winding but do not give an indication of anyshort-circuits.
N.B.Apart from the failure possibilities indicated below,there might be one or more earth windings. It istherefore recommended to test these possibilities,checking with a tester that there is no continuitybetween the various windings (identified in thefollowing paragraphs) to earth and between them.
IS 2.5
14
6
1 4 43 3
20 102 0
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 wirescoming from the stator, marked by the letters P1 F1P2 F2 .- Verify that the resistance values between the twopairs of wire terminals P1 F1 and P2 F2 are within thelimits as reported in the table above.N.B. The total resistance value for power winding(220 V 240 V) is measured connecting F1 and P2.the resistance value measured between P1 and F2is double of that indicated in the table above.
REMEDY: Replace the stator
WARNING: The windings have been treatedwith resin and paint for humid-saline climates. Ifthese treatments have deteriorated, replace !
IS 2.5
16
3 AL
TERN
ATO
RE
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) comingfrom the stator from the capacitor (Fig. 7 Ref.2).- Check that the resistance between the ends ofthe cables falls within the values indicated in thetable.
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 boardarea (Fig. 8).-Disconnect the 1.0 mm2 red (or white) wiresfrom the 17 and 18 terminal board.-Check continuity between the two ends of thecables.
REMEDY: Replace the stator
N.B.: The alternator thermostat may intervenebecause of an overload or overtemperature.Therefore, check if necessary, the applied loadsand the operating temperature of the generatorwith particular attention to its installation.
n° colore IS 3,5 n° colore IS 4,00 Rosso-Red 0 Rosso-Red 50 Nero-black 60 Bianco-WhiteECCITAZIONE 2,76 2,29
50Hz 60HzColore / 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. 9Ref.1) from the regulator (the correspondingsymbols “~” “~” on the regulator) and check thatthe resistance falls within the values indicated inthe table.- Check that the resistance between each cableand the black wire (2.5 mm2 cross-sectionmarked + Fig. 9 Ref.2 ) is half the valueindicated in the table.
IS 3,5 IS 4,05 Blù-Blue 6 Verde-Green5 Blù-Blue 6 Verde-Green
CARICABATTERIA 0,13 0,11
n° colore n° colore50Hz 60Hz
0,162 0,127
IS 2.5
20
3 AL
TERN
ATO
RE
10
1
IS 2.5
21
3 AL
TERN
ATO
R3.2 Rotor
3.2.1 Rotor winding (n°2)
Features:
Test method:-Check that the resistance between the twoends of the diodes falls within the valuesindicated. (Fig.10).
REMEDY: Replace the rotor
IMPORTANTFailed output voltage may exceptionally be causedby absence or insufficiency of residual rotormagnetism.As first operation, it is recommended, with thegenerator running, to briefly connect a 12V batteryto the capacitor terminals or to the power output.That way the rotor is instantaneously magnetised.
Rotore- Rotor25micrF
IS 3,5 4,050 / 60HZ
2,37Condensatore - Capacitor
2,5
2,11
IS 2.5
22
A K
3 AL
TERN
ATO
RE
11
A K AK
IS 2.5
23
3 AL
TERN
ATO
R3.2.2 Rotor diodes (n°2)
Characteristics : SKR 26/16
Test method:-Disconnect the cables at end A of the 2 diodes(Fig. 11)-Check with a tester with the + prod on A and the- prod on K if there is continuity.-Check that when inverting the tester prods thereis no continuity.
REMEDY: Replace the faulty diode.
3.2.3 Rotor varistors (n. 2)
Characteristics : V420 K10
Test method:- Disconnect the rheophores of each varistorfrom the rotor windings.- Check that there are no burn marks.- With a tester check that there is nocontinuity.
REMEDY: Replace both varistors.
IS 2.5
24
12
IS 2.5
25
3.3 Capacitor
Characteristics - 25 uF 450V 50 Hz:
Test method:-Disconnect the cables from the capacitor.-Check that the resistance at their ends is notless than 200K Ohm.
N.B.: This test is done to check that the capacitoris not in short-circuit.Reduced capacitance results in reduced no-loadvoltage and is difficult to evaluate.In this case, check for other possible causes. It isrecommended to replace the capacitor.
REMEDY: Replace the capacitor
IS 2.5
26
4 M
OTO
RE
13
IS 2.5
27
Unit
-
mm
c.cRpm 3000 3600
Continuous power PSMaximum power PS 6.1 6.7
----
-----
Max. head fuel pump cm.Fuel consumption at full power (l/h) 1.3 1.5
(l/min) 400 480degrees
Model L 70 AEType 4-stroke, vertical, air-cooled diesel engine
directNo. of cylinders - Bore x Stroke 1\78X62Cylinder block material AlluminiumDisplacement 296Rotation speed
Power* Direction of rotation Anticlockwise (flywheel view)
20:1Compression ratioRecommended diesel fuel ISO 8217 DMA, BS 2869 A1 or A2 (Cetane number: min. 45)Lubrication system Forced lubrication with trochoid pumpEngine oil tank capacityMax/effective lt 1.1Recommended engine oil API quality, Class CC or higherRegulator Mechanical centrifuge regulator (all speeds)Ignition system ElectricEngine stopping system Solenoid / 12VFuel pump Electric / 12V
70
Combustion air volumeMax. operating inclination 30
40
1/70x55
4,2 4,7
0,7 0,8280 340
IS 2.5
29
4.2 Maintenance
For long life and proper functioning of the generator, the checking and maintenance schedule indicatedin the following table must be respected.How to execute these operations is described, for the part relating to the engine, in the use andmaintenance handbook or in the workshop manual of the engine manufacturer.During normal maintenance operations (assembly/disassembly) some general rules must be followed
- respect the tightening torques.- use suitable grease, oils, and thread-locking fluid.- do not wash the windings or electrical parts with acid or corrosive substances.- spray deoxidiser on the electrical contacts- respect the cable numbering.If necessary note down the numbering and the position.
OPERATION ................................................................. HOURS
Engine oil level check ..........................................................10Check that there are no oil leaks ........................................20Check that there are no fuel leaks ......................................20V-belt tension adjustment ..................................................100Battery charger check ........................................................100Clean the fuel filter .............................................................200* Engine oil change .............................................................200Check the seawater pump rotor ........................................400Check the engine rpm ........................................................400Check integrity of the electrical connections. .................400Fuel filter replacement .......................................................400* Oil filter replacement........................................................400Check the injector ..............................................................400Check the injecting timing .................................................400Intake/exhaust valve play adjustment ..............................400Check the fuel injection pump ........................................1.000Battery electrolyte level check .................................. monthlyClean and deoxidise the metallic parts ....................... yearlyAir filter cleaning ............................................................ yearlyZinc anode replacement ............................................... yearly
* Carry out the first operation after 50 hours, subsequently according to the fixed intervals.
Engine life cycleHours
Average time elapsing between one fault and the next 500*First partial overhaul 700*Total overhaul 2000
*unship the generator
IS 2.5
30
IS 2.5
31
GB
IS 2.5
32
4 M
OTO
RE4.3 Trouble-shooting
CO
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NT
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OVERHEATING
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COOLING SYSTEM
THE ENGINE DOES NOT START
THE
ENG
INE
STAR
TS
BUT
THEN
STO
PS
IMM
EDIA
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INTAKE SYSTEM EXHAUST GASFUEL / FEED SYSTEMLUBRICATION
SYSTEMENGINE
F
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IN IDLE
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IN
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EXCESSIVE CONSUMPTION
MIXED WITH DIESEL FUEL
MIXED WITH WATER
ENG
INE
OIL
IN OPERATION
ADJU
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PLA
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TEMPERATURE INCREASE AT EXHAUST
REM
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S
IS 2.5
33
GB4.3 Trouble-shooting
4 EN
GIN
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FAU
LT
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GEN
ERAT
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PM A
ND
SET
TO
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ATED
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EL P
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EL P
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ELECTRICAL SYSTEM
STAR
TIN
G A
ND
STO
PPIN
G P
RO
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MS
VOLT
AGE
DEL
IVER
Y PR
OB
LEM
S
ALTERNATOR
IS 2.5
34
Fuel system diagram
4 M
OTO
RE
14
IS 2.5
35
4.4 fuel
1. Proper use of diesel fuel
Use diesel fuel of a quality equivalent to or higherthan ISO 8217 DMA, BS 2869 Part 1 Class A1 orPart 2 Class A2. (cetane number: min. 45) Providethe customers with adequate instructions on properuse of diesel fuel in order to prevent the followingproblems from arising:
(1) Deposits on the exhaust valve.
Deposits on the exhaust valve cause exhaust ofunburnt gas, erosion of the valve seat as well aspoor compression, imperfect combustion andexcessive fuel consumption, etc.
(2) Deposits in the piston ring housing.
Deposits in the piston ring housing cause:gas blow-by; poor lubrication; imperfectcombustion; excessive fuel consumption; engineoil contamination; premature wear, etc. of thecylinder barrel and the piston ring.
(3) Obstruction or corrosion of the fuel nozzlehole.
Imperfect combustion causes wear and corrosionof the injection mechanism and obstruction of thefuel nozzle hole.
IS 2.5
36
4 M
OTO
RE
15
2
1
IS 2.5
37
4.5 Electric diesel fuel pump
Characteristics : 12V
Test method:
- Check that the filter (Fig.15 Ref.1) is not dirty.-Disconnect the cables.-Check functioning with a 12V battery connectingthe (+) of the battery to the (+) of the pump andthe (-) of the battery to the (-) of the pump.
REMEDY: Clean the filter (Fig.15 Ref.2) withcompressed air / replace the pump.
WARNING:Pump cooling is assured by passage of thediesel fuel. To prevent damaging it, do not run itdry.
IS 2.5
38
Lubrication system diagram
Ambient temperature (°C) at which the engine is usedRecommended SAE gradations
16
IS 2.5
39
4.6 Lubrication
1. Proper use of engine oil
Proper use of engine oil guarantees:
(1) Adequate protection of the engine partssubject to friction against engine friction andwear.
(2) Protection of the engine parts against rustand corrosion.
(3) Efficient cooling of the parts which reach hightemperatures.
(4) Protection of the engine against combustiongas leaks.
(5) Protection of the engine parts against sludgedeposits.
For the above reasons it is recommended to useengine oil API Service Class CC or higher.Inform the customers that the engine oil mustinitially be changed after 50 hours and atintervals of 250 hours . Select the engine oilviscosity on the basis of the ambienttemperature in which the engine will be used,according to the SAE gradation indicated below.
IS 2.5
40
5 SE
NSO
RI
17
1
IS 2.5
41
5 SE
NSO
RS
5 Sensors
5.1 Closed-circuit engine thermal switch
Characteristics: 115° C n.o. contact.
Test method
- Immerse the thermostat in a container of antifreezefluid or oil.- Heat the fluid and measure the temperature. If thetester shows continuity values at a temperature of112-118°C, the thermal switch is in good condition.(Fig.17, ref.1)
REMEDY: replace the thermostat.
N.B. Its intervention is associated to thealphanumeric code E-82 and to the red led(fig.26, ref.8).
IS 2.5
42
5 SE
NSO
RI
18
IS 2.5
43
5.2 Open-circuit engine thermostat (sea)
Characteristics: 70°C N.O. contact
Test method
- Immerse the thermostat in a container of water.- Heat the fluid and measure the temperature. - Ifthe tester shows continuity values at a temperatureof 65-75°C, the thermostat is in good condition.
REMEDY: replace the thermostat
N.B. Its intervention is associated to thealphanumeric code E-82 and to the red led(fig.26, ref.8).
IS 2.5
44
5 SE
NSO
RI
19
IS 2.5
45
5.3 Oil pressure switch
Characteristics:n.c.= normally closed (motore in stopped)n.o.= normally open (motore in run)
Test method:
-Start the engine.-Remove the cable from the pressure switch andmove the tester probes towards the terminal of theswitch and the cylinder block. If the tester indicatescontinuity it means that the pressure switch isfaulty. (fig.19)
Remedy: replace the pressure switch.
N.B. Its intervention is associated to thealphanumeric code E-81 and to the red led(fig.26, ref.7).
IS 2.5
46
Circuit/seawater cooling system diagram
6 RA
FFRE
DDAM
ENTO
20
IS 2.5
47
6 SE
AWAT
ER C
OO
LING
6 SEA WATER COOLING
6.1 "Seawater/circuit" system
Characteristics: open-circuit liquid withseawater.
Seawater pump flow rate 25 l/min.
IS 2.5
48
6 RA
FFRE
DDAM
ENTO
21
2
1
1
IS 2.5
49
6 SE
AWAT
ER C
OO
LING
6.2 Water pump
Characteristics: type Johnson (F35B-8)
Test method:-Visual-Remove the screws (Fig.21 Ref.1) and removethe pump cover (Fig.21 Ref.2).-Remove the rotor.
REMEDY: If damaged, replace the rotor
N.B.For proper functioning of the generator, thischeck must be carried out every 300 hours orafter one year.
WARNING: After severe overheating of the rotor,check that no rubber particles have entered thecircuit.
IS 2.5
50
22
12
3
4
IS 2.5
51
6.3 Water pump belt
Test method:
-Press on the belt with about 10 kg and checkthat flexure does not exceed 0.5cm (Fig.22Ref.1).
REMEDY: Tighten the belt, loosen the waterpump retaining bolts (Fig.22 Ref.2).-Pull on the belt acting on the pump adjustingscrew (Fig.22 Ref.3).-Align the two pulleys with the aid of a ruler orsquare (Fig.22 Ref.4).-Retighten the retaining bolts, restoring thewhole assembly (Fig.22 Ref.2).
N.B. For proper functioning of the water pump,carry out these operations every 200 hours.
WARNING : be careful when aligning the pulleys
IS 2.5
52
6 RA
FFRE
DDAM
ENTO
23
1
IS 2.5
53
6.4 Water/air heat exchanger
Characteristics: tube bundle / radiant mass
Test method- Check that there is no sedimentation or foreignbodies in the tubes (Fig.23) .- Check that the zinc pad(Fig.23 Ref.2) is notworn
REMEDY
- Unscrew the zinc pad-holder cap (Fig.23Ref.1) ; if the pad is worn, replace it
- Immerse the tube bundle in a solution of water(90%) and hydrochloric acid (10%).
IS 2.5
54
7 RE
GO
LAZI
ONI
24
12
IS 2.5
55
7 ADJUSTMENTS
7.1 Rpm adjustment
Since the alternator is type four-pole thefollowing correspondence is valid:
Hz RPM1 60
50 300060 3600
Test method:
-Check the output frequency of the power terminalswith a suitable instrument (vibrating-reed frequencymeter or digital or with revolution counter).
For accurate reading of the voltage and amperagevalues use only instruments that show the trueeffective value(R.S.M.)
REMEDY: Loosen the counternut and the screw(Fig.24 Ref.1/2).-Turn the brackets until reaching the no. ofrevolutions, then lock the screws.
N.B. Since the voltage generated by the unit isproportional to the frequency, check the number ofengine revolutions as possible cause of voltageanomalies.
IMPORTANT:Since the number of engine revolutions is calibratedand locked during testing,it is recommended, in general, to adjust thecalibration.The indications given here refer to the bareessentials, and must be followed up by testingthe engine. As an indication of the possible causesof poor engine efficiency, it is recommended tocheck whether the air filter or fuel filter is clogged,or if the injectors are defective or blocked.
Hz giri/min. - RPM Volta vuoto - in idle 52,5/53 3150/3180 225/250-112/125
a carico - at full power 50/51 3000/3060 220/250-110/125a vuoto - in idle 62,5/63 3750/3780 115/130-230/260
a carico - at full power 60/61 3600/3660 115/130-230/260
50 Hz
60Hz
IS 2.5
56
IS 2.5
57
7.2 Closing cover motor
Control's method:
- To verify that the cover is closed in correctway without too mobility towards the box.
IS 2.5
58
26
1
1
IS 2.5
59
7.3 Engine air filter cleaning
Test method:
- Check periodically the air filter condition.
REMEDY
- Remove the screws (Fig. 26 Ref. 1)- Remove the filtering element.- Wash with diesel fuel and dry with compressed air.
An inefficient filter may cause loss of engine powerand excessive smoke at the exhaust.
IS 2.5
60
27
4
21
6
5
6
IS 2.5
61
7.4 Oil level check.
Test method:
- Check the oil level
REMEDY
To change the engine oil use the special manual pump(Fig. 27 Ref 4).It is recommended to drain the oil when it is stillsufficiently warm to floweasily.
The level must always be between the MAX and MINnotches on the dipstick (Fig.27 Ref. 2).
Oil sump capacity:
IS 2.5 lt 1,1
7.5 Engine oil filter engine.
Test method:
- Check the oil filter condition.
REMEDY- Remove the screw (fig.27, rif.5).- Remove the filter (fig.27, rif.6).- Wash with diesel fluel and dry with compressed air.
IS 2.5
62
8 IM
PIAN
TO E
LETT
RICO
28
IS 2.5
63
8 ELECTRICAL SYSTEM
8.1 Command circuit
Every generator group has a command tomicroprocessor for the commands and thecontrols.The command to microprocessor converses withthe card relay of edge car which performs thefunctions of command in power.This is the center of control of the generator, onwhich the component followings are found:
1) HOURSMETER2) OFF BUTTON3) START BUTTON4) BUTTON ON5) PANEL ON LED (GREEN)6) GENERATOR OUTPUT LED (GREEN)7) OIL PRESSURE LED (RED)8) ENGINE TEMPERATURE LED (RED)9) GENERATOR TEMPERATURE LED (RED)10) CABLE MOLTIPLE POLAR
When the unit stops because a circuit breaker trips, theoperating time indication disappears from the control paneldisplay and an alphanumeric code appears to indicatethe cause of the generator stop. In the table below all thecodes 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 hasstopped because of no voltage = 0 Volt. When this codeappears, it means:
- that the control panel is unable to measure the alternatorvoltage for cut-off of an electrical connection;
- that the alternator is damaged.
IS 2.5
64
IS 2.5
65
GB
Code E - 81 This code indicates that the unit has stopped because the motor lubrication system pressure is insufficient.
Code E - 82 This code indicates that the unit has stopped because the motor has reached too high temperatures.
Code E - 83 This code indicates that the unit has stopped because the alternator has reached too high temperatures.
Code E - 85 This code indicates that the unit has stopped because the voltage has dropped to below 70%
Code E - 87 This code indicates that the unit has stopped because the generator voltage has not reached 80% of thenominal value 30 seconds after starting. This could be caused by insufficient motor RPM or a broken alternator.
Code 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 latterswitches off completely after one minute, stopping the unit. of the nominal value for longer than 15 seconds.
IS 2.5
66
8 IM
PIAN
TO E
LETT
RICO
29
1 2
IS 2.5
67
COLOR FUNCTION
2 black - batt 12v 83 pink electrov./pum
p6
4 / /5 yellow start 76 / /7 / /8 / /9 green High engine
temp.5
10 grey Low oil press.
4
11 blù High altern. temp.
3
12 / /13 / /14 / /15 Braid Cable
shieldingT
FS1 brown 115 / 120 a.c.
1
FS2 white 115 / 120 a.c.
2
9
REL
AY B
OAR
D T
ERM
INAL
PIN
S
MULTIPOLAR CABLE
CO
NTR
OL
CIR
CU
IT C
ON
NEC
TOR
PIN
S
1 red + batt12v
Test method:- Disassemble the circuit from its box (Fig. 29)- Check that the connector is securely in place andcheck the integrity of the cables connected inside it(Fig.29, Ref.1).- Check that there are no evident signs of burning,oxidation or water.- With the generator off, check with a tester that thereis 12V battery voltage on the red/black wires, beingextremely careful not to short-circuit the two prods
N.B. If there is no battery voltage, look for the causeelsewhere- With the generator on, check with a tester that thereis 115VAC/120VAC on the brown/white wires .(Fig.29, Ref.2)N.B. If there is no voltage, look for the causeelsewhere
REMEDY: Before replacing the control circuit, it isrecommended to carry out further tests on theconnection cable and the relay board.
IS 2.5
68
30
4
1
6
3
2
3
IS 2.5
69
I GB
8.1.1 Multicore cable
Characteristics : 7x0.35mm2 + 2x0.35mm2multicore cable with double-shielding
Test method:- Detach the connector from the control circuit anddisconnect the cables from the relay board.- Check that there is no continuity between each ofthe 9 wires and also towards the metal shieldingbraid.- Jumper two cables (e.g. red/black) and check on theconnector that there is continuity between them.REPEAT THE OPERATION FOR ALL 9 CABLES.
REMEDY: Replace the cable
8.2.2 Relay board (Fig.30)
Characteristics :- Ref.1 Self-resetting fuse- Ref.2 Solenoid valve/fuel pump relay:
12V 30A relay- Ref.3 Start relay: 12V 30A relay- Ref.4 Diodes: 1N4004- Ref.5 Diode: P 600- Ref.6 Voltage selection bridge
Test method:Self-resetting fuse (Fig.30, Ref.1)
- Check that the rheophores are securely soldered onthe component.- Disconnect the wires of the control circuit.- Check that there is 12V between terminal 10 (+batt.) and 11 (- batt.).- Check that there is 12V between terminal 10 (+batt.) and 8 (- batt.). No voltage indicates that thefuse has blown. Find the cause of the overload andremove it
REMEDY: Replace the relay board
N.B. Intervenes due to overcurrent, cutting thenegative battery line to the control circuit (the controlcircuit does not come on). It resets automaticallyupon cessation of the cause of the overcurrent. Itsintervention may be caused by problems on thecontrol circuit line and cable or on the coils of the 2relays and their associated diodes.
IS 2.5
70
31
32
2
1
IS 2.5
71
GB
“Solenoid valve/fuel pump start” relay (Fig.31)- Detach the relay from its socket.- Check that there is continuity between the
points 85-86 (12V coil).- check that, powering the points 85-86 with a
12V battery, the contact 30-87 closes andvice versa.
- Remedy: replace the faulty relay.N.B. The two relays are powered by the control circuitclosing the coil towards the - batt, therefore an overallfunctional test can be carried out:
- Disconnect the cables of the control circuitfrom the relay board.
- START RELAY LINE TEST (Fig.30, Ref.3)Jumper the terminals 7 - 8; the starter motormust turn, but the generator does not start.Ifnecessary, check with a tester that there is12V power supply on the starter motor.
- SOLENOID VALVE/FUEL PUMP RELAYLINE TEST (Fig.30, Ref.2) Jumper theterminals 6 - 8; the solenoid valve and the fuelpump must be powered; check with a testerthat there is 12V power supply on thesolenoid valve and the fuel pump.
If the two tests are successful, look for the causeelsewhere.
Diodes P 600 (Fig.32, Ref.1)- Disconnect cable 14 from the relay terminal
board.- Check with a tester with the + prod on A and
the – prod on K that there is continuity.- Check that when inverting the tester prods
there is no continuity.Remedy: replace the diode or the relay board.N.B. Separates the fuel pump power supply from thesolenoid valve.
Voltage selection bridge- Check that the retaining screws are tight.- Ensure that the bridge/bridges are properly
remounted.N.B. Used to connect the stator windings in series(230/240V) or in parallel (115/120).
Diodes 1N4004 (Fig.32, Ref.2)- Detach the two relays from the socket.- Disconnect the cables from the relay terminal
board.- Check with a tester with the + prod on A and
the - prod on K that there is continuity.- Check that when inverting the tester prods
there is no continuity.Remedy: Replace the diodes or the relay board.N.B. If damaged, they might break the pilot channel ofthe control circuit.
IS 2.5
72
33
34
2
1
1
IS 2.5
73
Characteristics:12V, normally closed, coil resistance 18.3 ohm
Testing method:-Disconnect the fast-on terminal (Fig.33 Ref.1).Verify that the resistance value between points1 and 2 - Fig.33 is as reported above.
REMEDY: Replace the fuel solenoid
8.2 Stop solenoid
8.3 Thermal switch (AC circuit breaker)
Characteristics: 2-pole 14A
- Disconnect the cables.- Check that with the thermal switch switch deactivated(OFF) there is no continuity on the ends of each pole.- Check that with the magnetohydraulic switch activated(ON) there is continuity at the ends of each pole.(Fig.34, ref1)
Remedy: Replace the thermal switch
IS 2.5
74
8 IM
PIAN
TO E
LETT
RICO
35
(PROBES TEMPERATURE)
SONDE
TEMPERATURA
1111 1
(GROUND
C.B.)
++
IS 2.5
75
8.4 Engine wiring
Test method- Check that the cables and the junctions are notoxidised or flayed, in particular near the cornersand edges of the underbody and near theseawater pipe joints.- Check that the Faston terminals are securelytightened on the components.- Check that the black 2.5mm2 cable whichconnects the battery charger casing to thegenerator is present and securely tightened.(Fig.35, Ref.1)- Check that the cables connected on the relayboard do not accidentally touch each other.
Remedy: Repair or replace the cables.
IS 2.5
76
36
+BATT. 12V
~ ~
~AVV.C.B.
-
11111
2
CO
MM
ON
IS 2.5
77
~
~
8.5 Battery charger
Characteristics: 12V - after charging 14/14.3V
Operation:The battery charger is powered by two identicalwindings, with a central common point, whichgenerate alternate current. The two ends of thewindings are connected directly to the pins ~(Fig.36 Ref.2) on the battery charger, while thecommon is connected to the + battery (underthe fuse) and the casing to the - battery.When the battery charger receives the + batteryon the pin (Fig. 36 Ref.1), it starts chargingharnessing a half-wave, first from one winding(between one end and the common) and thenfrom the other; from this pin ( ) the batterycharger also processes the end-of-chargingsignal.
N.B. The current delivered by the batterycharger increases (with equal battery voltage)increasing the load on the generator. When thegenerator is turned on to recharge the battery, itis recommended to load it with 1/2 its power.
Test method- Start the generator- Apply a load on the 115V or 230V line of about1/2 the machine power.- Check that there is alternate current on thepins ~ (Ref. 2 Fig. 36).- Check that there is battery voltage between thebattery charger casing (- batt.) and the pin(Ref.1, Fig. 34).- Check that the battery voltage rises to above13.0V.
Remedy: Replace the battery charger.
IS 2.5
78
37
38
IS 2.5
79
8.6 FUSE
30A lamellar fuse characteristics
Test method:
- Extract the fuse.- Check the integrity of the blade.- With a tester check the continuity of the fuse.
Remedy: replace the fuse.
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80
8 IM
PIAN
TO E
LETT
RICO
39
1
-
+
IS 2.5
81
8.7 Starter motor
Characteristics:12V 0.8 KW
Test method:
-Disconnect the 2.5mm2 white cable. (with femaleFaston) (rif.1, fig.39).
-Use a 12V battery connecting the (+) of the batteryto the screw terminal and the (-) to the ground(starter motor casing) (fig.39)..
-Check that the motor turns by placing a jumperbetween the screw terminal (+ starter motor) andthe adjacent Faston (fig.39, rif.1).
Remedy: Replace the starter motor. 8 EL
ECTR
ICAL
SY
STEM
IS 2.5
82
8 IM
PIAN
TO E
LETT
RICO Terminal Cap
Cover
Cathode plate
Separator
Felt
Anode plate
Battery body
Grease
Maximumlevel
Minimumlevel
Acceptable Insufficient Excessive
Fluid level
Battery tester
Measuring the battery charge with the tester
40
IS 2.5
83
8.8 Battery
Characteristics: Least capacity 70 Ah, 12V
Test method:
(1) Electrolyte level
Check the electrolyte level in each cell. If insufficient,add deionised water until reaching the MAX level asshown in the figure.
(2) Battery charge.
Use a battery tester or a densimeter to check thebattery condition. If it is flat, recharge it. O Using thebattery tester. To check the battery using thetester, firmly fix the red terminal to the positiveterminal of the battery and the black one to thenegative terminal. Check the battery charge on theindicator:Green sector - normalYellow sector - partially dischargedRed sector - discharges incorrectly or excessively
REMEDY: recharge the battery or replace.
8 EL
ECTR
ICAL
SY
STEM
IS 2.5
84
9 SM
ONT
AGG
IO
41
IS 2.5
85
9 DISASSEMBLY
9.1 Removing the casing
- Remove the top door and the top panel
IS 2.5
86
9 SM
ONT
AGG
IO
42
IS 2.5
87
-- Remove the screws and then the panel
IS 2.5
88
9 SM
ONT
AGG
IO
43
3
1
2
3
IS 2.5
89
Remove the clamp (Fig.43, Ref.1) and then theexchanger (Fig.43, Ref.2).
9.2 Removing the alternator.
Disconnect all the cables from the relay board andthe termal switch.Remove the cover (Fig.43 Ref.3). 9
DISA
SSEM
BLY
IS 2.5
90
9 SM
ONT
AGG
IO
47
1
2
3
2
3
IS 2.5
91
9.3 Removing the alternator cover on thebearing side (Fig.47 Ref.1)
- Remove the retaining screws of the alternatorcover on the bearing side (Fig.47 Ref.2)
- With the aid of an extractor, remove the cover(Fig.47 Ref.3)
9 DI
SASS
EMBL
Y
Componente Diametro filettatura x passo Coppie di serraggio (Nm)Component screw Diameter Shut (Nm)
Viti fissaggio coperchio alternatoreScrew fixing cover alternator M8x1,25 3~3,2M6X1 15
IS 2.5
92
48
1
2
IS 2.5
93
9.4 Removing the stator (Fig.48 Ref.1)
- With one screwdriver prise in the positionindicated in Fig.48 Ref.2.
- Remove the stator, taking care not to damagethe rotor windings.
IS 2.5
94
9 SM
ONT
AGG
IO
49
1 2
43
1
4
IS 2.5
95
9 DI
SASS
EMBL
Y
SCREW SHUT
9.5 Removing the rotor. (Fig. 49 Ref. 1, 2, 3)
- Undo the nut (Fig.49, Ref.1)- Hit the bearing with a wooden batten. If therotor is not released at the first attempt, repeatthe operation turning the rotor 180°.
9.6 Removing the rotor bearing (Fig. 49,Ref.4)
- Use an extractor of adequate dimensions.
Component screw Diameter Shut (Nm)
Screw fixing cover alternator M8x1,25 3~3,2
Component screw Diameter Shut (Nm)
M6x1 10~12M8x1,25 22~28M10x1,5 44~54M12x1,75 78~98
Nut with hexagonal head
M6X1 15
Component screw Diameter Shut (Nm)
Screw fixing rotor M8x1,25 28-30
I
IS 2.5
96
10 T
AVO
LA R
ICAM
BI Rev. / Rel.FIG. 1 /2IS 2.5 engine / alternator
motore / alternatore
3566
61
69
63
59
67
68
Rif. Cod. Qty. Descrizione Description1 70821 1 Asta livello olio Oil dipstick2 90905 1 Scatola filtro Air filter box3 70812 1 Massa filtrante Sponge4 10807 1 Portagomma Nipple5 61156 1 Collettore filtro aria Manifold6 8584 1 Bocchettone carico olio Filler7 10808 1 Sede asta olio Fitting8 30647 1 Elettrovalvola Fuel solenoid9 70822 1 Tappo carico olio Oil cap
10 10822 1 Curva scarico Fitting11 70543 cm 30 Tubo gasolio Pipe12 70442 cm 25 Tubo acqua d.15 Pipe13 70237 cm 25 Tubo gasolio Pipe14 10812 1 Portagomma Nipple15 10813 1 Raccordo Fitting16 61157 1 Gomito miscelatore Exhaust manifold17 30253 1 Sonda temp. acqua 70 °C Thermostat18 80120 1 Sonda temp. cilindro Thermostat19 31001 1 Pompa acqua mare Sea water pump
IS 2.5
97
GB
10 S
PARE
PAR
TSRev. / Rel.FIG. 1/2IS 2.5
Rif. Cod. Qty. Descrizione Description20 50257 1 Puleggia pompa 50 Hz Pulley20 50260 1 Puleggia pompa 60 Hz Pulley21 70823 1 Manicotto carico olio Oil pipe22 70824 1 Manicotto acqua Water pipe23 10814 1 Gomito ottone Fitting24 10614 2 Portagomma Nipple25 10615 1 Puleggia Pulley26 70807 1 Cinghia 50 Hz Belt26 70863 1 Cinghia 60 Hz Belt27 03767 1 Coperchio alternatore Cover28 10610 1 Tirante centrale Central tie rod29 013093 1 Rotore Rotor30 910589 2 Diodo rotore Diode31 20521 2 Varistore Varistor32 013049 1 Statore 115/230V 50Hz Stator 115/230V 50Hz32 04262 1 Statore 120/240V 60Hz Stator 120/240V 60Hz33 70647 1 Passacavo Cable guide34 81103 1 Cuscinetto Bearing35 71169 2 Tubo carburante Fuel Pipe36 012806 1 Coperchio alternatore Cover37 10284 4 Tirante alternatore Tie rod38 10464 1 Rondella con guida Washer39 31004 1 Pompa gasolio Diesel pump40 07050 1 Cablaggio motore Electrical assy41 61158 1 Staffa antivibranti Bracket42 61159 1 Staffa antivibranti Bracket43 61162 1 Supporto pompa Pump bracket44 61163 1 Piastrina supporto pompa Plate45 07166 1 Staffa elettrovalvola Bracket46 013145 1 Protezione alternatore Protection47 70634 4 Antivibrante 30x30 Shock absorber48 70808 1 Cuffia in gomma Rubber cover49 70802 1 Cuffia in gomma Rubber cover50 70616 cm70 Guarnizione adesiva 10x15 Gasket51 70629 cm25 Tubo d.25 Pipe52 10823 7 Dado Oteco Nut53 10794 2 Fascetta 30x60 Clamp54 10825 6 Fascetta 16x25 Clamp55 90906 1 Parete divisoria Panel56 97539 1 Raccordo elettrovalvola Fitting57 71151 1 Guarnizione OR Or gasket58 10842 2 Fascetta 10x15 Clamp59 92623 1 Girante pompa Jota Impeller for Jota pump59 80161 1 Girante pompa Jhonson Impeller Jhonson pump60 97537 1 Pressostato olio Oil pressure switch61 11374 2 Portagomma nafta Fuel Nipple62 70185 1 Guarniz. OR O-Ring gasket63 92456 1 Guarniz. pompa acqua Jota Jota pump O-Ring63 93312 1 Guarniz. pompa Johnson Johnson pump gasket64 97601 1 Guarnizione scarico Gasket 65 10166 1 Vite Screw66 10791 2 Fascetta Clamp67 012485 1 Staffa supporto termico Bracket68 71228 1 Cappuccio Cover69 32714 1 Interruttore termico 2P 10 A Thermal switch 2P 10 A70 03757 1 Motore Yanmar L48 50Hz Yanmar L48 Engine 50Hz70 011774 1 Motore Yanmar L48 60Hz Yanmar L48 Engine 60Hz
engine / alternatormotore / alternatore
I
IS 2.5
98
Rev. / Rel.FIG. 2/2IS 2.5 frame
cassa
b
c
a
d
29
30
31
28
32
10 T
AVO
LA R
ICAM
BI
IS 2.5
99
GBRev. / Rel.
FIG. 2/2IS 2.5 framecassa
Rif. Cod. Qty. Descrizione Description1 80542 1 Regolatore carica batt. Batt. charger regulator 2 31188 1 Condensatore Capacitor3 31002 1 Fusibile lamellare 20 A Fuse 20 A4 30925 1 Portafusibile Fuse carrier5 30926 1 Piastrina portafusibili Fuse holder terminal6 32690 1 Scheda relè Relay board7 61181 1 Radiatore acqua/aria Water/Air intercooler8a 90902 1 Coperchio cassa sup. Soundproof box cover8b 90903 1 Coperchio cassa post. Soundproof box cover8c 12759 1 Fondo cassa Soundproof box bottom8d 70881 1 Scatola scheda relè Relay box cover9 611160 2 Staffa fondo cassa Bracket10 07529 1 Supporto scambiatore Water/Air intercooler support11 70733 8 Elastomero Shock absorber12 10780 4 Distanziale Spacer13 70739 2.7 mt Profilato in gomma Gasket14 70809 1 Serie spugne Sponge get15 10567 1 Passacavo DG48 Cable guide16 10566 2 Passacavo DG29 Cable guide17 70799 2 Pressacavo PG 13,5 Cable guide18 07337 2 Staffa fissaggio cofani Plate19 10823 7 Dado oteco MUT 986 M6Nut
21 70800 2 Dado per PG 13,5 Nut22 80162 1 Zinco Scambiatore Zinc anode23 04306 4 Cinghietta in gomma Strap24 10815 4 Fermo cinghietta Plate2526 31678 2 Relè Relay27 70878 1 Paratia lato motore Bulkhead28 91034 1 Circuito stampato Printed circuit29 70786 40 cm Guarnizione Gasket30 70854 1 Scatola pannello comandPrinted circuit box31 70634 4 Antivibrante 30x30 Shock absorber 30x3032 07664 1 Comando a distanza Remote control panel
10 S
PARE
PAR
TS
IS 2.5
100
Mat
ricol
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ATO
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orto
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*NO
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ly if
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* Pa
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us le
s ro
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tilic
en c
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de
la fi
cha.
IS 2.5
101
WIRING DIAGRAMSCHEMA ELETTRICO
59
1 4 43 3
20 102
P1
P21F
F2
1817
16151413121110
78
9
123456789
5
11
13
12
14T
19 18T P
17 16EV P
15 M-
50 3012V+
0
19
21
50(60)
5(6)5(6)
+
1PF2
IS 2.5
102
1 ROTOR2 STATOR3 DIODE 3A4 VARISTOR5 PRINTED CIRCUIT RELAY6 POWER TERMINAL BOARD7 RELAY CIRCUIT TERMINAL BOARD8 CONTROL PANEL TERMINAL BOARD9 FUSE 1A10 CAPACITOR11 BATTERY CHARGER REGULATOR12 FUSE13 STARTER14 BATTERY15 FUEL PUMP16 FUEL SOLENOID17 OIL PRESSURE SWITCH18 OVERHEAD ENGINE THERMOSTAT19 WATER TERMOSTAT20 ALTERNATOR THERMOSTAT21 THERMAL SWITCH