Yanmar Mase Marine Generators IS 2.5 Workshop Manual

mase mase mase mase mase GENERATORS WORKSHOP MANUAL IS. 2.5 50 Hz

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

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

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

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

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

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

IS 2.5 8 3

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

IS 2.5 10 4

Yanmar Mase Marine Generators IS 2.5 Workshop Manual

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