Home

maspower series 1 w 703 controller

1. Fig 2 L ka Diagram of reverse side of 703 N 154 Panel Cut out 149 x 109 ka Lig Fig 3 l ALTERNATOR Dimensions mm N O TYPICAL CONNECTIONS F2A Terminals suitable for 22 16 awg 0 8mm 1 3mm field wiring Tightening Torque 0 8N m 7Ib in CONTROLLER Start o p Auxiliary Outputs Supply f 3 f Auxiliary Alarm control ler Inputs 10 11 NY O 4 O Engine temp switch O D Remote start Q Ol pressure switch U Battery L Battery negative must be grounded Na Solid state outputs Nol External Automotive or Plug in type relays Deep Sea Electronics p Highfield House Humanby Industrial Estate North Yorkshire YO14 OPH England Tel 44 0 172 389 0099 Fax 44 0 172 389 3303 E mail sales deepseaplc com Function Pre heat Timer Start Delay Stop Delay Energise to Stop Timer 703 Installation Value MasPower Defaults in Grey 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds 0 Seconds 5 Seconds 10 Seconds
2. No load can be imposed output drop Con d Poor fitting of the intake exhaust valve Overhaul the cylinder head seat gas blowing by or poor combustion due to a drop in compression pressure Poor combustion due to contaminants Overhaul the head in the piston top recess Malfunctioning head gasket gas Replace the head gasket blowing by Piston seized worn or stuck ring Measure the compression pressure scratched or worn cylinder or wear gas blowing by Poor combustion due to a Overhaul the piston drop in compression pressure Poor spray condition of fuel injection Check and clean valve Poor combustion due to contaminants Overhaul the head in the piston top recess Air intake silencer clogged insufficient Clean or replace the element air quantity Exhaust mixing elbow and or exhaust Check and clean pipe stained or clogged increase back pressure Intake air temperature too high Measure the intake air temperature insufficient air quantity ane Check and clean the air inlet and air outlet check the ventilation Check and clean the fresh water cooler check the sea water flow No intake exhaust valve clearance gas Adjust the valve clearance to specified blowing by or poor combustion due toa value drop in the compression pressure Exhaust gas color Black smoke Poor fitting of the intake exhaust valve Overhaul the cylinder head seat gas blowing by or poor c
3. 15 Seconds 20 Seconds 30 Seconds 60 Seconds Ojo 0 0000 0 0 600000000 0060 6000000000000 0000 180 Seconds O Nominal Frequency 50 Hz O S 14 Overshoot 24 60 Hz O S 14 Overshoot 24 Nominal DC Voltage Crank disconnect on Oil Pressure Underspeed detection O O O O O O G O O 0 i O o O O O O O O O O Auxiliary Input 1 Function Auxiliary Input 2 Function Auxiliary Output 1 Function Auxiliary Output 2 Function o O 12V DC CF 8V OO0O OO0 00DOO OOOO 6 0086001601088 OOI e 0086 OO 24V DC CF 16V Close on Fault OJOO O Y Open on Fault O Close on Fault Open on Fault Disabled OJO OOJO O Enabled 2 second delay Disabled OJO OJO Enabled U S 20 Immediate Warning Close on Fault Immediate Warning Open on Fault Immediate Shutdown Close on Fault Immediate Shutdown Open on Fault Delayed Warning Close on Fault Delayed Warning Open on Fault Delayed Shutdown Close on Fault Delayed Shutdown Open on Fault Immediate Warning Close on Fault Immediate Warning Open on Fault Immediate Shutdown Close on Fault Immediate Shutdown Open on Fault Delayed Warning Close on Fault Delayed Warning Open on Fault Delayed Shutdown Close on Fault Delayed Shutdown Open on Fault Not Used Pre heat Engine Run
4. START OP Table 3 1 Gauge Operating Ranges Gauge Normal Operating Range GEMERATOR COR T HOO Water temperature 170 195F 77 91 C Figure 3 9 Remote Panel Controller digital DC voltmeter 12 14 volts 0 o d KR i HOURS ALARM PRE HEAT START Figure 3 10 Remote Start Panel with Hourmeter and Indicator Lights 3 6 Operation Chapter 4 Scheduled Maintenance 4 2 Routine Maintenance Refer to the Table 4 1 Maintenance Schedule and Before performing any maintenance procedures i ony 5 the hourmeter located on the generator set refer to the Safety Precautions and information at the front of this manual controller to determine when to schedule routine service 4 1 General NOTE Generator sets that are subject to extreme weather or dusty or dirty conditions should be ser Most of the scheduled maintenance deals with ser viced more frequently Dry compressed air should vicing the engine Under normal conditions the be used at frequent intervals to blow the dust and generator portion of the Series I generator set does dirt out of the generator portion not require service on a regular basis Table 4 1 Maintenance Schedule Before Every Every300 Every Service to be Performed indicated by y Starting 150 Hr Hr 600 Hr LUBRICATION SYSTEM Check the crankcase oil level and add oil as necessary NA ee ee First Replace the lube oil filter element E FUEL SYSTEM INTAKE EXHAUST SYSTEM C
5. To fill the system with fresh water coolant use the following procedure 1 Check that the two fresh water drain cocks are tightened firmly The drain cocks are color coded red One is located on the exhaust mani fold and the other is on the service side of the engine block see Figure 2 1 Remove the fresh water pressure cap by turning it counterclock wise 1 3 of a turn see Figure 3 5 Fill the fresh water long life coolant LLC mix ture up to the lip of the filler port 3 2 Controller Operation 3 2 1 Controls and Indicators mame Raman Start Stop Switch AC Circuit Breaker standard Ensure main power switch is on Press yellow manual button to start at generator Press yellow auto switch to activate remote start The circuit breaker trips when a fault occurs in the output circuit During maintenance of craft or generator set wiring the circuit breaker dis connects the generator set Place the circuit breaker s in the ON posi tion to close the circuit breaker Fresh Water Fill Cap DC Circuit Breaker or Fuses The circuit breaker or fuses fail when a fault occurs in the controller circuit After a fault correction check fuses in the control box D Plate Fresh Water Expansion Sl Tank y E Y gt Full A connector on the controller s back panel allows the connection of optional remote start kits Remote Start Connector Hourmeter The meter records total generator set o
6. aged if the starter switch is operated with the fly wheel still moving Engines with a safety relay in the circuit can t be restarted unless the starter switch has been turned off once the starter motor is running 3 4 Operation 3 3 1 Cautions During Engine Operation During engine operation check the following items 1 Exhaust Color Black exhaust indicates that the engine is under strain Continued operation will shorten the lives of the engine Stop engine operation when black exhaust is emitted 2 Water and Oil Leakage Check that there are no water oil or combustion gas leaks loose bolts and abnormal noise overheating and excessive vibrations If any abnormality is found stop the engine and contact your nearest Yanmar dealer 3 Alarm Lamps e Low Oil Pressure Alarm Lamp OIL If the low oil pressure alarm lamp illuminates or is lit while the engine is running check whether the lube oil is too low If not there is an abnormality in the lube oil circuit Contin ued operation will cause engine seizure Stop the engine as soon as possible and consult your nearest Yanmar dealer NOTE To check the lube oil level stop the engine and wait for at least 3 minutes e Charge Alarm Lamp CHG If the charge lamp illuminates while the engine is running there is a fault in the charg ing circuit or with the fan belt slippage or damage Stop the engine and check If the fan belt condition is sat
7. Any exces sive tension may cause damage to the bearings of the alternator or water pump 4 7 Electrical System 4 7 1 Checking the Battery customer supplied 1 Check the electrolyte level and replenish dis tilled water if the electrolyte level is too low 2 If it is hard to start the engine when the elec trolyte level is normal recharge the battery 4 7 2 Checking the Alarm Lamps Check the correct functioning of the alarm lamps If there is any abnormality immediately stop the engine and contact your nearest Yanmar dealer The following lamps will illuminate only when there is a fault e Low oil pressure e High temperature e Engine overspeed e Engine underspeed e Low battery voltage 4 8 Engine 4 8 1 Adjusting the Engine Speed The governor maintains constant engine speed by adjusting the fuel supplied to the engine The gov ernor is factory adjusted and generally needs no further service or adjustment To adjust the speed setting perform the following 1 Loosen the locking nut on the speed adjusting screw see Figure 4 11 2 Turn the screw clockwise to increase the speed and frequency 3 To decrease speed turn screw counterclock wise 4 Tighten the locking nut at the new speed setting ocking Nut Speed Adjustment Screw Figure 4 11 Governor Adjustment Screw 4 8 2 Storing the Generator Set When storing the engine for a long time without using it maintain the engine for futu
8. Check for water leakage 2 Stop the engine Wait for the cooling water to cool down and check the water level in the expansion tank Replenish cooling water as necessary 3 Finally tighten the cap of the expansion tank securely 4 6 7 Alternator Water Pump Belt V Belt 1 If the belt tension is loose the belt will slip to cause poor battery charging and insufficient flow rate of the water pumps resulting in engine overheat Check and adjust the V belt tension as described in the procedure below see Figures 4 9 and 4 10 Scheduled Maintenance 4 7 Adjustment Figure 4 9 Alternator Water Pump Belt 2 Make a visual check If the V belt is scratched cracked or worn replace it with a new one 3 Apply a force of approximately 98 N 10 kgf to the center of the V belt with fingers or using a belt tension gauge to check the deflection of the V belt Deflection should be 3 8 5 8 in 10 15 mm Fresh Water Pump Alternator Apply Force 98 N 10 kgf Deflection 3 8 5 8 in 10 15 mm Figure 4 10 Adjusting Belt Tension 4 Adjust the V belt tension as required Loosen the bolt and nut see Figure 4 9 to move the alternator outward and make an adjustment On completion of adjustment tighten the bolt and nut securely NOTE Avoid damage to the alternator During adjustment take care not to damage the stator coil or the through bolt 4 8 Scheduled Maintenance NOTE Avoid excessive V belt tension
9. Mixing Elbow Min 14 inches above waterline Exhaust outlet 4 inches above the waterline Installation Below the Waterline Exhaust outlet Siphon 4 inches above break the waterline Gi Te Min 14 inches above waterline Waterline Silencer customer supplied Figure 6 2 Exhaust System Installations Installation 6 3 Figure 6 3 Extra Fuel Filter with Water Trap 6 5 Cooling Systems The following features are necessary in any marine cooling system Intake thru hull strainer Do not align the sea water intake for the gen set in relation to direc tion of travel with propulsion engine intake and screen Flush mount is recommended for the thru hull strainer Install strainers with slotted holes with slots parallel to direction of vessel movement The area of the strainer opening s must be equal to or greater than the inside diame ter of the water line hose to seawater pump Mount seacock to hull attach it to intake and ensure it is accessible for operation NOTE Mount seacock according to manufac turer s specifications If using caulking to seal seacock do not apply an excessive amount Excess caulk causes incorrect water flow and in some cases develops a barrier which forces water upward past seawater pump and into engine cylinders This condition is possible when vessel is moving and generator set is shut down Mount seawater strainer of sufficient capacity to seacock or permanent struc
10. from a location remote of the generator set Supplied with 15 ft 4 6 m connection harness Overall mounting dimensions are 4 1 16 in 103 mm by 2 1 4 in 57 mm see Figure 8 2 for dimensions 8 2 Replacement Parts and Accessories a 6 75 in 3 171 4 mm Part number PB4719 Figure 8 2 Remote Instrument 4 Meter Panel analog Part number PB4720 4 6 75 in gt 171 4 mm Figure 8 3 Remote Panel Controller digital e Remote Start Panel allows starting and stop ping from a remote location see Figure 8 4 for dimensions ALARM PRE HEAT START Part numbers MPO001 without hourmeter MP001H with hourmeter Figure 8 4 Remote Start Panel e Plug in Extension Wiring Harnesses provide additional wiring between all remote panels and controller connector in 5 10 20 50 and 100 ft increments One required for each remote meter panel kit Replacement Parts and Accessories 8 3 Appendix A Glossary ITEM AC AISI AM amp ANSI API A R A S ASA ASME ASTM aux AWG AWM BHP bmep Btu C CC CCA CEC cfh cfm CID cm cmm CPVC CSA CT Cu in CWC cyl dB dBA DC DCR EIA EMI EPA F fl oz FM ft ft Ibs DESCRIPTION alternating current American Iron and Steel Institute amplitude modification ampere American National Standards Institute American Petroleum Institute as required as requested as supplied as stated as suggested Am
11. long with the Replenish lube oil up to the upper limit oil in the oil pan at a low level of the oil level gauge Lube oil temperature too high cooling Lower the cooling water temperature water temperature too high see the cooling water temperature rise problem Oil shortage in the oil plan below the Check for oil leakage Lube oil filter clogged Trouble with the oil pressure switch Trouble with the lube oil pressure regulating valve and or oil pump There is an increase Cooling water shortage in the water Check and replenish in the cooling water cooler trapped air causes insufficient Y The lube oil deteriorates too early Lube oil pressure too low the alarm lamp lights up lower limit of the oil level gauge temperature the cooling alarm lamp lights up 5 4 Troubleshooting Table 5 1 Basic Troubleshooting Chart Continued Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ENGINE FAILS TO START Continued There is an increase Fresh water and or sea water pump Check and adjust in the cooling water drive belt loose temperature the alarm lamp lights Insufficient sea water flow Check and replace up Conta Trouble with the thermostat no water Sea water pump impeller damaged flows on the fresh water side and or sea water path clogged Fresh water and or sea water path Clean the cooling water passage MN stained Trou
12. n tach temp turbo UHF UL US USA USCG vac vdc VHF DESCRIPTION potentiometer parts per million pounds per square inch pint pints polyvinyl chloride quart quarts quantity reference radio frequency interference round head machine screw root means square revolutions per minute room temperature vulcanization Society of Automotive Engineers silicon controlled rectifier second seconds specification square square centimeter s square inch es tachometer temperature turbocharger ultrahigh frequency Underwriter s Laboratories Inc United States United States of America United States Coast Guard volt volts volts alternating current volts direct current very high frequency watt watts Appendix B Related Publications Observe the regulations and standards below when installing marine generator sets U S Coast Guard Code of Federal Regulations Title 33 Subpart I Electrical Systems Subpart J Fuel Systems Title 46 Subchapter F Marine Engineering Part 58 Main and Auxiliary Machinery and Related Systems Order the above publications from Superintendent of Documents U S Government Printing Office Washington DC 20402 Phone 1 202 783 8238 Boating Safety Circular Commandant G BC Boating Statistics G BP 1 Order the above documents from U S Coast Guard Headquarters 2100 Second Street S W Washington DC 20593 0001 Boating Safety Hotline 1 800 368 5647 Underwri
13. rode or block the cooling passages affecting the engine durability 4 6 2 Long Life Coolant Select a good quality long life coolant The use of fresh water without LLC will cause rust or water scale to form in the water passage such as the cylinder jacket affecting the cooling perfor mance In addition an increase in thermal load may cause early wear on the engine s moving parts affecting the engine durability During cold weather the cooling water may freeze damaging parts in the cooling water passages 4 6 3 Mixing Ratio of Cooling Fresh Water and LLC Determine the mixing ratio of the fresh water and LLC according to the ambient temperature by fol lowing the coolant manufacturer s specifications If the water to LLC ratio is insufficient the rust preventive effect will diminish Conversely an excessive amount of LLC will adversely affect the engine s cooling performance and an increase in thermal load will cause damage to the moving parts 4 6 4 Procedures for Checking the Cooling Water Check the water level of the expansion tank on a daily basis The water level when the engine is cold should be between the upper and lower limits see Figure 4 7 If it is low replenish with a mix ture of fresh water and LLC Check for any change in the water level before and after operation Under normal conditions the water level fluctuates as follows Before operation cold state lower level
14. 81 1000 11 77 1200 4TNE98 Scheduled Maintenance 4 5 4 5 1 Checking the Air Intake Silencer Check the air intake silencer according to the rec ommended intervals on the maintenance schedule using the following procedure NOTE If operating in areas that are particularly dirty or dusty check the silencer more frequently 1 Release the spring clips to remove the silencer cover and check the element see Figure 4 6 2 If the element is dirty rusty or damaged replace it 3 Clean the cover and reattach the spring clips Silencer Cover Filter Element Figure 4 6 Cleaning the Intake Silencer 4 5 2 Checking the Mixing Elbow The mixing elbow combines high temperature exhaust and cool seawater In an improperly maintained exhaust system this mixture can cause rapid deterioration and failure due to engine vibration 1 Check for carbon accumulation or corrosion inside the mixing elbow 2 Use a wire brush to clean off any carbon accumulation 3 Check the exhaust manifold mounting threads for the presence of corrosion or cracks 4 6 Scheduled Maintenance 4 If the mixing elbow or any exhaust compo nents are damaged replace them to prevent carbon monoxide leakage in the engine 4 6 Cooling System 4 6 1 Cooling Fresh Water Use clean water distilled is recommended and be sure to add long life coolant LLC to prevent rust buildup and freezing NOTE The use of hard or dirty water may cor
15. A OT 4 8 O OS 4 8 481 Aduse the Engine gt Peed acars iia 4 8 As 862 Storing the AG CNEL ATOR ri Rs 4 9 3 TROUDICSHOOUING il ais 5 1 Instalati Menora a AA a 6 1 B a UIC FLO EE EEEE A AE AE O EE NAE S EE TEE E A EA E A E EE 6 1 e MON a o o EN 6 1 O Ventilador 6 1 Gah a A NN 6 1 OAT Bue EO 6 1 6 42 Puel Eines and Pl SAA AAA 6 1 643 Extra Fuel Piker with Water TraPrsacinir aa 6 2 Ged CODES ia 6 4 Go A ate eautueatddadiaaddnneineuaeiaume 6 4 661 TS Ta Break aia 6 5 Gil NCCC A oy TTT 6 5 6 01 ACV e CONS Ctl Sata 6 5 A THT 6 5 e Na THT 6 5 67 4 Remotestart Switcm SORA OO A 6 5 Ta Wirmo Diagrams adn 7 1 8 Replacement Parts and Accessories caia 8 1 Sk or sI O 8 1 82 Ordering Replacement Parts sm caed dana 8 1 Bo e e ETT 8 2 Appendix A Glossary sai don A 1 Appendix B Related PUD NCAtlONs aid B 1 Appendix E Service LOG aci C 1 Appendix D Emissions Regulations si A a D 1 2 Table of Contents Chapter 1 Introduction This Operation Manual describes how to operate maintain and service MasPower Series 1 Models MPS 5M and MP8M marine generator sets Please read the manual thoroughly before using the generator set to ensure proper handling and operation After you have read the manual keep it safely stored and accessible Pay particular attention to the section on Safety Precautions see pages 111 v1 To maintain your generator set in the best running condition follow all instructions
16. Immediately after stop warm state higher level NOTE If the water levels in the expansion tank before and after operation are the same check the following points 1 With the engine cool open the pressure cap of the main tank and check the amount of water 2 Check the hose connected between the main tank and the expansion tank Ensure that the hose clips are tight and the hoses are free of cracks 3 Check the water leakage from the periphery of the engine 4 If the cause of the problem is still not clear contact your local dealer Fresh Water E Expansion E Tank R ia Full bee Indicator Low Indicator ee Main Tank Figure 4 7 Fresh Water Cooling Tank 4 6 5 Changing the Fresh Water Coolant The fresh water coolant should be changed only after the engine has sufficiently cooled 1 Prepare a drain can 2 Remove the cap of the expansion tank 3 Remove the pressure cap of the fresh water drain tank 4 Open the red drain cock see Figure 4 8 Drain the cooling water from the expansion tank Finally tighten the drain cock Replenish the fresh water coolant in the main tank and the expansion tank to the proper levels Figure 4 8 Drain Location for Fresh Water 4 6 6 Fresh Water Coolant Level and Water Leakage Checks 1 On completion of the change of cooling water be sure to run the engine until the water tem perature increases to a proper value 76 185 F 80 85 C
17. MASRIWER Operation and Instruction Manual Series I Marine Generator Sets Model Numbers MP5 5M MP8M 19 May 2004 Revision 1 Information in this publication represents data available at the time of print MasPower reserves the right to change this publication and the products represented without notice and without any obligation or liability O 2004 MasPower Inc All rights reserved Safety Precautions Important information on safe and efficient operation Read this information before installation operation or maintenance of your equipment To protect yourself and others from hazards and to prevent accidents be aware of potential danger and act with caution Read follow and save these safety instructions The levels of hazards that may result from equipment mishandling are classified and explained in the following table Classification HAZARD LEVEL A DANGER A hazard is present that will cause severe personal injury death or substantial property damage A hazard is present that can cause severe personal injury death or substantial property damage A CAUTION A hazard is present that will or can cause minor personal injury or property damage Accidental Start of Generator Fuel and Exhaust System Set Vapors Generator can be started by remote control Explosive fuel and gasoline vapors can cause severe injury or death Use extreme care when handling Accidental start of the generator ca
18. a level 2 4 Alternator Alternator specifications are listed in the following Chart Models Description MP5 5 MP8M Generator Type Four Pole Rotating Field Coupling Type Flexible Disc Excitation Type Brushless Exciter 1500 1800 VR 2 4 Voltage Regulator Model Voltage Regulation 3 Frequency Regulation 4 Voltage connection and derate factors determine actual generator set output kW kVA 2 5 Controller 2 5 1 Controller Features For a description of how the controls and indicators for the Series I generator set operate refer to Chap ter 3 The following is a list of controller features e Start Stop switch e Starter interlock prevents reengagement of starter whenever engine is running e Hourmeter for scheduling maintenance e Safety shutdowns Over speed Under speed High exhaust temperature High head temperature High coolant temperature Low oil pressure e Plugs receptacle controller connections e Terminal connections Clearly identified Corrosion resistant e Quick disconnect wiring harness e Adjustable voltage regulator Specifications 2 3 2 6 Engine e Electric fuel pump with 1 4 NPT fuel inlet A e Full flow cooling system thermostat bypass 2 6 1 Engine Features e Glow plugs for cold start The engine used in Series I generator sets is manu factured by Yanmar Features of the engine are as follows e High water temperature and high exhaus
19. aat ih F gt Oil Filler Cap MA Gear Case Al at oe SD AAA TA a q F Figure 4 3 Oil Fill Cap Locations 5 Using a funnel fill the engine to the proper level with the proper oil type and viscosity 6 Replace the oil fill cap 4 3 4 Changing the Lube Oil Filter To change the filter use the following procedure see Figure 4 4 1 Loosen the oil filter by turning it counterclock wise with a filter wrench Clean up any spilled oil 2 Clean the contact surface of the oil filter seat Rotate Filter Counter clockwise Figure 4 4 Oil Filter Replacement 4 4 Scheduled Maintenance 3 Lightly lubricate the O ring surface of the new filter with fresh oil Thread the filter on until the O ring makes contact then hand tighten an additional one half turn 4 Start the generator and check for oil leaks Stop the generator Remove the dipstick and wipe it clean Reinsert the dipstick then remove it to check the oil level Add oil as nec essary to bring the level up to the MAX mark on the dipstick 4 4 Fuel System Be sure to use the diesel fuel ISO 8217 DMA BS 2869 A1 or A2 Cetane No 45 min most suit able for engine performance 4 4 1 Selecting the Proper Fuel Oil In cold weather select the fuel oil of appropriate properties according to the ambient temperature Use of low quality or non specified fuel oil can cause the following e start up trouble insufficient output or exce
20. ank cock closed Open the cock fully The starter rotates but the engine does not start No fuel oil in the fuel tank Replenish fuel oil Air trapped in the fuel oil system Bleed Fuel oil filter clogged Replace the fuel filter Check the electrical circuit Check and replace the engine stop solenoid Table 5 1 Basic Troubleshooting Chart Continued Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ENGINE FAILS TO START Continued The starter rotates In cold weather Replace with cold weather fuel oil but the engine does Fuel oil viscosity too high for fuel to flow a Lib In cold weather 1 Warm the fuel tank fuel filter and Fuel oil system frozen fuel pipe and drain the fuel oil from them 2 Replace with the fuel oil for cold weather Trouble with governor lever Check and adjust No intake exhaust valve clearance gas Readjust the valve clearance to leakage causing insufficient specified value compression Poor fitting of intake exhaust valve Overhaul the cylinder head seat gas leakage causing insufficient compression Flaws on cylinder worn or seized ring Overhaul the piston Y resulting in poor compression engine speed does not increase Fuel filter clogged Replace the fuel filter Intake silencer clogged insufficient air Clean or replace the element quantity Trouble with the governor lever Check and adjust Y Engine speed is Tr
21. ble with the ventilating passage Check and clean the air inlet and air ventilation outlet ventilation Too much cooling Check the cooling fresh water passage using a cap tester for water leakage fresh water is consumed Cooling water rubber hose damaged or Check and replace hardened Hose clip is too lose Retighten the clip ee Trouble with the pressure cap water Check and replace does not return to the fresh water cooler from the sub tank Rubber hose between the sub tank and Check and replace or retighten fresh water cooler damaged hose clip loose poor airtight nessO Engine mounting bolts loose Check and retighten Un uniformity combustion between Check and adjust the fuel valve cylinders injection pressure and injection spray conditions Severe engine vibration Check and adjust the intake exhaust valve clearance Major moving parts such as cylinder Overhaul the engine crank pin metal and crankshaft metal worn to cause an excessive clearance Oil leakage from the Blow by gas passage blocked resulting Check and clean the blow by gas crankshaft oil seal in an excessive increase in pressure in passage the crankcase Oil seal lip worn abnormally Replace the oil seal Troubleshooting 5 5 Table 5 1 Basic Troubleshooting Chart Continued Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ABNORMAL SOUND IS HEARD High knocking is Fue
22. carefully For your convenience we have included a Mainte nance Schedule chart that lists the items that should be inspected or checked on a regular basis and whether the necessary maintenance or repair is simple enough to be performed by the owner or must be handled by an authorized service center Also included is a Service Log where you can keep track of the cumulative operating hours of your generator set and enter the dates of service If you require information regarding government regulations or industry standards that relate to installation or use of marine generator sets refer to the Related Publications section in the Appen dix You will also find a glossary of terms and abbreviations in the Appendix All information included in this Operation Manual is current as of the date of publication Because we are constantly working to improve the perfor mance and quality of our products the product described in this manual may differ slightly from your product We reserve the right to change the content and or product shown as we deem neces sary without incurring any obligation The MasPower Series 1 Generator Set is designed to give safe and dependable service provided it is operated and maintained according to instructions Therefore if you have any questions or concerns do not hesitate to contact your nearest authorized dealer Introduction 1 1 1 2 Introduction Chapter 2 Specifications 2 1 Service Views F
23. ceptable Use flexible exhaust hose conforming to UL Standard 1129 for engine wet exhaust com ponents between mixing elbow and exhaust outlet Independently mount the silencer to eliminate any stress on exhaust system and exhaust manifold mixing elbow See Chapter 2 Specifications for mixing elbow water line hose size See Figure 6 4 for exhaust connection to mixer elbow Siphon Break Connection Point Mixing Elbow Figure 6 4 Mixing Elbow Connection Install siphon break hose between heat exchangers and raw water outlet and exhaust elbows raw water inlet Minimum Exhaust Hose Size I D mm in Maximum Allowable Exhaust Back Pressure kPa mm H20 MP5 5M 9 81 1000 51 2 0 6 6 1 Siphon Break A siphon break is installed to prevent seawater from entering the generator s engine It is required if the exhaust manifold outlet is less than 9 inches above the waterline at any time Install siphon break according to manufacturer s instructions NOTE A siphon break that is installed improperly will cause engine damage and may void the warranty 6 7 Electrical Systems 6 7 1 AC Voltage Connections Make AC connections to generator set inside the controller box The generator set is usually con nected to a ship to shore transfer switch which allows the use of shore power when docked or generator set power when docked or at sea The wiring is then connected to a main circuit breaker box panel board which d
24. e delivery back to the fuel injec tors Incoming fuel cools the injectors and achieves maximum engine efficiency by supplying cool fuel to the engine Fuel tank capacity and amount of fuel will affect cooling capability 6 4 2 Fuel Lines and Filters Use 5 16 in 7 9 mm ID size customer supplied fuel lines to connect to the fuel pump and fuel return Fuel lines and fuel line supports must com ply with USCG Regulations Installation 6 1 Fresh Control Panel Battery Storage Mounting Base AD Extra Fuel Filter with Water Trap Water Expansion AN Tank e Seawater Strainer Seacock Figure 6 1 Typical Location and Mounting of the Generator Set 6 4 3 Extra Fuel Filter with Water Trap The engine is provided with an element type fuel filter but in order to eliminate water and dirt com pletely use an extra fuel filter with a water trap To attach extra fuel filter and water trap select a suitable position in the piping between the fuel feed pump and the fuel oil tank The position must be free of vibrations and facilitate filter inspection and replacement see Figure 6 3 NOTE Do not attach the extra fuel filter to the engine 6 2 Installation Required capacity for extra fuel filter PowerSource Required Flow Rating Model GPH L H MP5 5M 3 6 16 3 Use a filter element with a 30 micron rating Installation Above the Waterline Lift improves Silencer customer silencing supplied
25. e generator set output leads from the transfer switch and heavily taping the ends of the leads Observe the following precautions when per forming voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the electrical enclosure or components inside the enclosure Battery Acid and Gases Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Always wear splash proof safety goggles rubber gloves and boots when servicing the battery Also be sure to remove all jewelry Do not open a sealed battery or mutilate the battery case Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging e Do not dispose of a battery in a fire e Turn the battery charger off before connecting the battery e To avoid sparks do not disturb the battery charger connections while the battery is charging e Ventilate the compartments containing batteries to prevent accumulation of explosive gases e Disconnect the battery before generator set installation or maintenance e Remove the negative lead first when discon necting the battery reconnect the negative lead last when reconnecting the battery Never connect the negative bat
26. erican Standards Association formerly ANSI American Society of Mechanical Engineers American Society for Testing Materials auxiliary American Wire Gauge appliance wiring material brake horsepower brake mean effective power British thermal unit Celsius degree cubic centimeter cold cranking amps Canadian Electrical Code cubic feet per hour cubic feet per minute cubic inch displacement centimeter centimeters cubic meters per minute chloropoly vinyl chloride Canadian Standards Association current transformer cubic inch es city water cooled cylinder decibel decibels A weighted direct current direct current resistance Electronic Industries Association electromagnetic interference Environmental Protection Agency Fahrenheit degree fluid ounce s frequency modulation foot feet foot pound s ITEM fs ga gal gals gph gpm gr grd Hg H2O in Ibs int ext ISO J kg kg cm kgm kJ km kPa kph kV kVA kW kWH LED s Ib Ibs L hr L min LOP LP LWT m3 max MHz DESCRIPTION full scale gauge meters wire size gallon gallons gallons per hour gallons per minute grade ground mercury element water horsepower hour hours high water temperature hertz cycles per second inside diameter Institute of Electrical and Electronic Engineers inch inches inch pounds internal external International Standards Organization joule joules kilogra
27. ersburg FL 33710 Sales 727 522 9471 1 800 545 4574 Service 727 521 4661 To ensure supply of correct parts or information make note of the following identification numbers in the spaces provided Series Generator Set Engine unit serial numbers are found on the name plate attached to the generator set Series Generator R MER MODEL MP8M SPECIFICATIONS Output E 60Hz 8KW 50Hz 6KW Unit No 8M Output Ph Eng S N Voltage 120 240 Amperage Phase 120 240V 66 7 33 33 PF 1 Horsepower 1800 RPM 12 9 Horsepower 1500 RPM 10 7 Amb Temp 50 C Gen S N Manufactured by Mas Power oe 1 800 545 4574 Sample Nameplate Generator Set Accessories An alternate nameplate inside the junction box identifies factory installed generator set accessories Accessory Nos 8 2 Ordering Replacement Parts Use genuine parts and specified lube oil and fuel oil Failure to do so may cause an accident or affect equipment durability NOTE When replacing hardware do not substi tute with inferior grade hardware Screws and nuts are available in different hardness ratings Ameri can Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness Check markings on bolt head and nuts for identification NOTE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example ABC or 3AC ceramic Do not substitute clear glass ty
28. ession Close the sea cock during this procedure Open seacock after bleeding procedure is complete 3 1 3 Oil Check Check the oil in the crankcase daily or before each startup to ensure the level is in the safe range Refer to Figure 3 2 to locate the dipstick Dipstick Fuel Filter Hose Figure 3 2 Oil Dipstick Location To check the oil remove the dipstick yellow han dle and wipe the end clean reinsert it as far as possible and remove Maintain the oil level between the MIN and MAX marks on the dipstick see Figure 3 3 NOTE Do not operate the generator set if the oil level is below the MIN mark or above the MAX mark 3 2 Operation Dipstick Oil Max Level Oil MIN Level Figure 3 3 Dipstick Oil Level Check 3 1 4 Replenishing the Lube Oil Level the generator set and fill the oil pan with the recommended lube oil Oil Filler Cap Valve Cover Oil Filler Cap Gear Case Figure 3 4 Filling the Lube Oil 1 Remove the filler cap from the filler port on the top of the valve cover or at the gear case and fill the lube oil using a funnel see Figure 3 4 2 Fill the lube oil up to the max level mark on the dipstick 3 After the lube oil is replenished reinsert the dipstick into its original position and tighten the filler cap in the filler port NOTE After replenishing the lube oil be sure to thoroughly clean up any spills 3 1 5 Filling the Fresh Water Cooling System
29. etc e Check cooling water systems for leaks blockages etc DIESEL www maspowerproducts com 7177 30th Ave North St Petersburg Florida 33710 Tel 727 522 9471 Fax 727 381 3235 For Georgia Alabama 229 347 8394 Toll Free 800 545 4574 703 Installation Instructions Configuration Mode is selected by operation of a small switch on the rear left hand edge of the PCB This is partially hidden to prevent accidental operation See figs 1 and 2 Once Configuration Mode is selected the Auto LED will commence rapid flashing When in Configuration Mode all normal operation is suspended The Stop push button can be used to select the LED code that corresponds to the required function The 5 left hand LED s will form the code The Manual push button will allow the user to change the function parameters The 3 right hand LED s inform the user of the current setting for the chosen function When the required parameters are displayed pressing the Auto button will save the new setting The process is repeated for each function change When configuration is complete the Configuration Mode Selector Switch should be returned to the Normal position A key to all configuration options is provided overleaf on the Functions and Parameters table NES O O G O O a O lt O OOO ja ce N 12 13 14 15 109 125 114 123 45 6 7 8 9 10 11
30. h Water Coolins Systems il 3 3 22 GComtroller pera sa a 3 3 zl Controls and R Ee r ES ii 3 3 id Stats me Erin ai rodas 3 3 91 Cautions D rme Engine E T h Le alcala ciacasoaRiASS 3 4 S Starine the Gener Onis cdo ds 3 5 39 UO p pin the Eneas don 3 5 Be I Proc cdta ads 3 5 5 6 Remote Panel Controller ran aia 3 5 20l Remote c e TTT 3 5 2o o AA A A NEA 3 6 4 SCNEGUIEC Mamtenancea HT 4 1 A A E O CO DON PO serait Gasadanineaaeaties 4 1 A2 ROUNE IAEA T TT 4 1 AS Fb rican Stemi lic 4 3 Al SPEAR 4 3 Ae Checking the ube Ol Ll A 4 3 Ae aati AA as dao E AEN tavounsinavebed eesanars 4 3 hot Changing the Lube Oil lero 4 4 Ate PE id sicda 4 4 Adal Selecting the Proper Fuel Ollas 4 4 AAD Replacing the Puel Putre 4 4 443 Checking tor Oil leakage nec 4 5 AAA Bleeding the Fuel yt ica od 4 5 Table of Contents 1 AO Intake T Stma od 4 5 Al Checkine the Air Intake MEET At 4 6 40 2 Checla e the IMT x 11 ElDoOWs aaa 4 6 46 Coolmod is 4 6 c al A cagaanianonenseamaesuein asaua suasmindanea AO 4 6 AN A O N 4 6 4653 Mixing Ratio 0ft Go line Fresh Water and LEC sauneis n aN E EE 4 6 4 6 4 Procedures for Checking the Cooling Water 4 6 456 5 Chanemo tie Presi Water Coolant enirn E 4 7 4 6 6 Fresh Water Coolant Level and Water Leakage Checks sse 4 7 AoT Alternator Water Pump belt VW Bella 4 7 AT MEIC A O Saa E deena 4 8 A dl Checkins the Batey oranan a E A A 4 8 472 Checking the Alar Lamps serae E T E O E
31. heck the exhaust gas condition If the exhaust is blue Y or black contact your local distributor dealer During operation Scheduled Maintenance 4 1 Table 4 1 Maintenance Schedule Continued Every 50 Hrs Before or Every Every300 Every Service to be Performed indicated by y Starting 1 Month 150 Hr Hr 600 Hr A AS SOLA Inspect the exhaust water mixing elbow NA esencial A A A O O e e ARA O SO LES COOLING SYSTEM AA T H HH H K e HT T R O O A A tension if applicable KL O MU A O Check replace the seawater pump impeller V v Check Replace Check replace zinc anode Y Y Check Replace ELECTRICAL SYSTEM Check battery electrolyte level pf Adjust the alternator driving belt tension ae nae Check and tighten the electrical connections Clean the battery cables ENGINE AND MOUNTING Check for water fuel coolant and oil leakage ee operation aeaa o A a v A GENERATOR Test run the generator set AT Keep generator free of dust A MI 4 2 Scheduled Maintenance 4 3 Lubrication System 4 3 1 Specifications We recommend the following lubricating oil e Use Class CD or better Service Classification of API STD e Select a viscosity index according to the atmo spheric temperature see Figure 4 1 e Lube oil with 15W 40 can be used throughout the year Selection of viscosity SAE Service Grade 20 10 0 20 40 60 80 Atmospheric Temperature Figure 4 1 Oil Viscosit
32. ide Can cause severe nausea fainting or death The exhaust system must be leak proof Routinely inspect the system for leaks Carbon monoxide is an odorless colorless taste less nonirritating gas that can cause death if inhaled for even a short time Use the following precautions when installing and operating the generator set e Do not install the exhaust outlet where exhaust can be drawn in through portholes vents or air conditioners If the generator set exhaust dis charge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust e Never operate the generator set without a func tioning carbon monoxide detector Be especially careful when anchored and operating the gener ator set under calm conditions because gases may accumulate e When operating the generator set dockside ensure that your exhaust is directed away from other boats and buildings e Inspect the exhaust system and carbon monox ide detector on a regular basis iv Safety Precautions Hazardous Voltage Electric Shock Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Ground electrical equipment Before servicing the equipment open the main circuit breakers of all power sources Disconnect the generator set from the load by opening the line circuit breaker or by discon necting th
33. il ter outlet Fill the hose and pump with clean water then reconnect hose and open seacock On startup observe water discharge from the exhaust outlet to verify pump operation 3 1 1 Filling the Fuel Tank Fill the fuel tank with the specified fuel oil The fuel oil tank should be about 90 full and should not be over filled 3 1 2 Bleeding the Fuel System To prevent starting problems or erratic operation bleed the fuel system if the following conditions are present the generator has run out of fuel air leaks have developed in the system s suction side or the fuel filter water separator has been replaced NOTE Connect the battery during the priming procedure to provide power to the fuel pump switch 1 Loosen the vent screw see Figure 3 1 Figure 3 1 Bleeding the Fuel System Operation 3 1 2 Locate the small momentary push button on the side of the generator set electrical box see Figure 2 1 3 Press and hold the button to run the fuel pump 4 Run the pump until air bubbles stop appearing at the bleeder fitting 5 Tighten the fitting before running the engine NOTE After bleeding the fuel system be sure to clean up any diesel fuel spills NOTE If the fuel system has been completely emptied it may be necessary to loosen the injec tor line compression nut on top of the injectors 1 2 turn then crank the engine over briefly until air stops coming out around the fuel line Then tighten the compr
34. isfactory contact your nearest Yanmar dealer e Do not check the coolant level while the engine is still hot Steam or hot water may burst out if the radiator cap is removed too soon after the engine is stopped Before removing the pressure cap stop the gen erator set and allow it to cool then proceed When removing the coolant cap turn your face well away and cover the cap with a cloth Turn the cap slowly to gently release the pressure inside the radiator e Cooling Water Temp Alarm Lamp WATER If the cooling water temperature alarm lamp illuminates during load operation of the engine the engine is overheated Stop the engine immediately and check the fan belt tension and the cooling water level If both are satisfactory contact your nearest Yanmar dealer If shutdown occurs because of any of the above failures the alarm lamp will remain illuminated 3 4 Starting the Generator With an operator present once each week operate the generator set under load for one hour The operator should perform all of the prestart checks before starting the generator Start the gen erator set according to the procedure in the Con troller section of this manual While the generator is operating under load listen for a smooth run ning engine and visually inspect the generator set for fluid or exhaust leaks 3 5 Stopping the Engine 3 5 1 Procedure e Before stopping the engine run the engine under no load for appro
35. istributes branch cir cuits throughout the craft See Chapter 7 Wiring Diagrams for reconnection of generator set 6 7 2 Battery Batteries and installations must conform to USCG Regulation 183 420 Generator sets should use separate battery ies from propulsion engines whenever possible Both generator set and propul sion engines starting charging systems must have a common negative ground See Table 6 1 6 7 3 Wiring Use stranded copper for all wiring Wire gauges and insulation conductor temperature ratings sheath stripping conductor support and protec tion conductor terminals and splices and over current protection circuit breakers fuses must conform to USCG Regulations 183 425 through 18 460 Use rubber grommets and cable ties as necessary to protect and secure wiring from sharp objects exhaust system and any moving parts Table 6 1 Gauge Operating Ranges Distance Between Generator Set and Battery Cable Size AWG At 75 F m 18 C 0 C 24 C CINTO o fe a er o 6 7 4 Remote Start Switch Connection MasPower offers several remote panels for connec tion to the generator set Refer to Chapter 8 Replacement Parts and Accessories for further detailed descriptions Installation 6 5 Chapter 8 Replacement Parts and Accessories 8 1 Customer Service For further information or questions contact the company directly at MasPower Inc 2801 Anvil Street North St Pet
36. ither 50 Hz or 60 Hz operation PP l Turtle Light Means Under speed Check e Engine Speed e Generator over load e Controller program or speed signal e No generator output Fix e Adjust engine up to correct speed e Disconnect high load devices e Program controller for proper speed setting check for voltage to controller speed input e Check generator voltage regulator exciter coil or windings repair or replace as needed Battery Light Means Charging system not operating Check e Belt Tension e Dynamo or alternator have no output Fix e Tighten or replace belt e Bench test for shorts bad windings worn bearings etc Check connections on charging circuit Check for output on exciter wire On dynamo systems make sure the regulator body is grounded to engine A f Da BD i i HE E ee B b a ory Y WA Win ee x aay T TT s y R Y Y aa KT www maspowerproducts com a A 7177 30th Ave North St Petersburg Florida 33710 PAR Tel 727 522 9471 Fax 727 381 3235 For Georgia Alabama 229 347 8394 Toll Free 800 545 4574 Light Means Check Light Means Check Fix Light Not used Fail to start Generator attempted three times to start but did not e Fuel system and filters e Check for AC output Head temp or exhaust overheat e Loss of coolant or cooling water flow e Check coolant system for leaks bas hoses bad coolant pump
37. l injection timing too early Check and adjust to specified value heard Valve hitting noise is Intake exhaust clearance too large Check and adjust to specified value Y heard High gear noise is Improper gear backlash Overhaul Y heard High intake spittingis No intake exhaust value clearance Check and adjust to specified value heard 5 6 Troubleshooting Chapter 6 6 1 Introduction We recommend that you contact your local dealer for installation of the Series I marine generator set To handle the installation process use this section as a guide then refer to the operation section for specific service instructions Reliable and safe gen erator set operation depends largely upon proper installation Marine generator set installations must comply with all applicable regulations and standards See Appendix B Reference Material for governing agencies Follow guidelines presented here in plan ning and making installations Use specifications given only in initial planning Use current dimen sion drawings and wiring diagrams 6 2 Location Refer to Figure 6 1 When selecting an appropriate location for the generator set consider the following e Ensure there is adequate space for ventilation cooling exhaust and fuel system installation Also allow for service access to the unit e Available structural members must provide ade quate support for the generator unit e The compartment must be sealed to preve
38. m kilograms kilograms per square centimeter kilogram meter s kilojoules btu cal kilometer kilometers kiloPascal kiloPascals kilometers per hour kilovolt kilovolt amperes kilowatt kilowatts kilowatt hour liter liters light emitting diode s pound pounds liter per hour liters per hour liter s per minute low oil pressure liquefied petroleum low water temperature meter meters cubic meter cubic meters maximum megahertz mile miles Appendix A A 1 ITEM mil min min my MJ m min MPa mpg mph MS mW MW N A NBS NEC NEMA NFPA Nm NPT N R OC OD OEM OS O S OSHA OV OZ PF PMG A 2 Appendix A DESCRIPTION one one thousandth of an inch minute minimum milli joule s mega joule s millimeter cubic meters per minute megaPascal miles per gallon miles per hour military standard milliwatt s megawatt s not available National Bureau of Standards National Electrical Code National Electrical Manufacturers Association National Fire Protection Association Newton meter s National Standard taper pipe thread per general use not required overcrank outside diameter original equipment manufacturer overspeed oversize Occupational Safety and Health Act overvoltage ounce ounces power factor permanent magnet generator ITEM pot ppm psi pt pts PVC qt qts qty ref RFI r h m rms RPM RTV SAE SCR sec spec specs sq sq cm sq
39. met the challenge by obtaining Certificates of Compliance issued by the authorities Yanmar is compliant with worldwide exhaust emissions regulations Appendix D D 1 DSE 703 Troubleshooting Lights y Oil Can Light Means Loss of oil pressure Check e Oil level e Oil pressure switch e Engine Oil pressure with pressure gauge Fix e Add oil check for leaks e Replace oil pressure switch v R amp R engine bearings oil pump etc Thermometer Light Means High Coolant Temp Check e Coolant level e Coolant leaks in exhaust manifold hoses amp engine e Coolant pump amp belt e Loss of cooling water Fix e Add coolant Dexcool 50 50 e Repair any leaks Replace any hoses or hose clamps as needed e Tighten or replace belt check coolant pump and repair replace as needed e Check raw water system for leaks or blockages check heat exchanger for leaks or blockages check that water supply is not blocked check raw water pump for prime worn impeller etc DIESEL WA N T T A d w A S y d y pl b www maspowerproducts com A 7177 30th Ave North St Petersburg Florida 33710 A Tel 727 522 9471 Fax 727 381 3235 For Georgia amp Alabama 229 347 8394 Toll Free 800 545 4574 L gt l Rabbit Light Means Over speed Check e Engine Speed e Controller programming Fix e Adjust engine speed to proper level 50 Hz sets 53 Hz No load 60 Hz sets 63 Hz No load e Program controller for e
40. n cause severe injury or death storing and using fuels some generator sets may be equipped with the Vaporized fuels are highly explosive Use extreme automatic start feature Before attempting any care when handling and storing fuels Before repair perform the following steps to disable the starting the generator set operate the blower 4 min generator set and prevent an automatic start utes and check the engine compartment for fuel 1 Place the generator set start stop switch in Nepas the STOP position e Store fuels in a well ventilated area away from 2 Disconnect the power to the battery charger spark producing equipment and out of the if equipped reach of children 3 Remove the battery cables negative lead e Never add fuel to the tank while the engine is first Reconnect the negative lead last running because spilled fuel may ignite on con when reconnecting the battery tact with hot parts or from sparks Safety Precautions iii e Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors e Keep the fuel lines and connections tight and in good condition e Use pipe sealant on threaded fittings to prevent fuel leakage e Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation e Use a container to catch fuel when draining the fuel system and wipe up spilled fuel Carbon monox
41. ng often require knowledge of electrical and electronic circuits To avoid additional prob lems caused by improper repairs contact an authorized service distributor dealer for service Table 5 1 Basic Troubleshooting Chart Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ENGINE FAILS TO START The starter fails to Check the battery electrolyte level run or its speed is too low Drop in the battery voltage battery discharge Charge or replace the battery Check the electric circuit leak Battery terminal disconnected Clean Retighten loosened or corroded Poor grounding of the battery Check and repair loosened terminal break Battery switch not turned on Turn on the switch Check the cables between the alternator and battery Poor alternator charging alarm lamp turned on Check the alternator for trouble Trouble with the starter switch Engine stop solenoid malfunctioning fuel oil shut off Check and replace Check and replace a Y Trouble with the starter Replace with oil having viscosity index suitable for ambient temperature Oil s viscosity index too high Viscosity increased due to lube oil Check and replace deterioration Remove the load from the machine to unload the engine Load imposed on the engine Completely disassemble and service the engine Major moving parts such as piston and metal seized Fuel t
42. ning Common Warning Common Shutdown System in Auto Common Alarm Energise to Stop Not Used Pre heat Engine Running Common Warning Common Shutdown System in Auto Common Alarm 00 0 0 eee e O00o0jl e 6000000000 0 0 0 0 OO 00 8 6 0000 O0O0O0Oj e 00e ee OOI 0086 OO 000000000 00 00 00 00000000960 Oje OE OE Oee 010 OJO Oj OO VA OPA OO O O Oe 0j e OE O Oee OO OE Oe Oe OO OE Oee Oeo Energise to Stop Chapter 7 Wiring Diagrams Head Exhaust Temp Temp Brown 16 Fuel Pump EIA White 14 s0 eJ9U95 gt ier F DU D 5 ME y N x MS amp gt ajans L B Wh Yel la BE Orange16 HET Sender o EA A S a pr ee RB S R Sete E r eNe N IA D PE rt lt AS Yellow El Gene ls 15 Ka f l IEA s B E Fuel Prime Switch 02 Hre BE ll RAE Figure 7 1 Wiring Diagram Schematic MP703 Wiring Diagrams 7 1 Hourmeter Terminal Block Color Guage Grey 14 20 Purple 14 Blue 14 Black Red White Red Orange 16 Yellow 16 Hourmeter Remote Purple 16 Brown 14 Purple 16 Green 14 c gt 2 a Green 14 Red 14 9 O gt O 2 O O G Q ca Terminal Figure 7 3 Four Gauge Remote Panel Hookup Figure 7 4 Standard Panel Hookup Terminal Block Color Guage 23 O
43. noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operat Ing generator set Safety Precautions Hazardous Waste Materials Disposal of waste materials Failure to properly dispose of waste materials will cause environmental pollution When disposing of hazardous waste materials fol low the instructions below 1 Be sure to contain waste liquids such as lube oil and coolant in a suitable receptacle Take the necessary precautions to prevent the waste liquids from spilling on the ground Do not dump waste liquids into sewer river soil or sea water Dispose of hazardous wastes such as lube oil coolants solvents various filters and batteries according to environmental laws and regulations Table of Contents Sale Precauciones iii t ANTOAUCUIO Wii 1 1 Z SL a 1 La ON Siria ii 2 1 o AL 2 1 Did General peca cOn 2 2 E MC O tada 2 3 Zo ll GencralDes cipal aa 2 3 Di Dies CMe ALOE IN AUIS ME TE tee sec ONR E AE A A eueeane canes 2 3 E AMM e OI sas sre e PO O uo tie cin eiamaraneaseuae euuencoNs 2 3 23 Controller a aaa 2 3 ZS lll Controller Feature nidad 2 3 ZO SETT 2 4 A Mi A AA E A EE Siadswcsebeancaeesedaeee 2 4 210 2 EINEM PEC ONS aaa 2 4 3 Operaio PO A E 3 1 Sale Prestare Checa ta 3 1 SI Fme ile A 3 1 SL Bkedinothe Fuck tdi di airis 3 1 E A ves serena TA erent Taree tre Teer et ry 3 2 ILA Replenish tube ia 3 2 S L Filino the Fres
44. nt exhaust gases and fuel vapors from entering cabins Diesel generator sets are not ignition protected 183 410 requires ignition USCG Regulation protected devices only in gasoline gaseous fueled environments 6 3 Ventilation Proper ventilation of fumes and gases must be con sidered during installation Ventilation provisions must comply with the United States Coast Guard USCG regulations governing vent sizes and oper ator requirements Installation 1 As a general rule the inlet and outlet vent sizes should be 2 sq in per ft 1 3 sq cm 30 5 cm of the craft s beam If any screening of vents is used then the opening measurements should be doubled For continuous operation ambient air temperature must not exceed 140 F 60 C 2 Vent ducts should extend to the bilges to expel heavier than air fumes 3 If the generator is to be mounted in the engine compartment the airflow to the compartment should be increased to accommodate the gener ator s requirements 4 Sniffer devices should be installed to generate alarms or engine shutdown should dangerous fumes be detected 6 4 Fuel Systems Refer to Safety Section for precautions regarding fuel systems 6 4 1 Fuel Supply Do not modify the tank or gen set engine fuel sys tem Tank and installation must conform to USCG Regulations Locate the fuel return line as far as practical from the fuel pickup This allows tank fuel to cool return fuel befor
45. ombustion due to a drop in the compression pressure Troubleshooting 5 3 Table 5 1 Basic Troubleshooting Chart Continued Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ENGINE FAILS TO START Continued Exhaust gas color Piston seized worn or stuck ring Overhaul the piston Contd scratched or worn cylinder gas Black smoke blowing by White smoke Piston seized worn or stuck ring Overhaul the piston scratched or worn cylinder excessive Oil Up allowing the oil to burn Flaws in the intake exhaust valve stem Y scratched or worn valve guide or seal malfunctioning stem seal excessive Oil Down allowing the oil to burn Too much lube oil is Too much oil in the oil pan Drain the oil until the oil level is below consumed the upper limit of the oil level gauge Piston seized worn or stuck ring Overhaul the piston scratched or worn cylinder excessive Oil Up allowing the oil to burn Flaws in the intake exhaust valve stem Replace the intake exhaust valve stem Y scratched or worn valve guide or seal malfunctioning stem seal excessive i Oil Down allowing the oil to burn Overhaul the cylinder head Y Improper lube oil used Replace with the specified lube oil Piston seized worn or stuck ring Overhaul the piston scratched or worn cylinder too much gas blowing by gas allowing it to enter the lube oil Operation performed too
46. ouble with the governor lever Check and adjust MO abnormal too high l l or too low or Trouble with the fuel valve governor Adjust and repair fluctuating and or fuel pump The engine does not Engine stop solenoid malfunctioning Check and repair the electric circuit of Y stop the engine fails the fuel oil cannot be shut off the engine stop solenoid to stop even when l the starter switch is Check and replace the engine stop used solenoid No load can be Fuel tank cock not opened fully Open the cock fully 4 imposed output Fuel filter clogged Replace the fuel filter drop Air intake silencer clogged insufficient Clean or replace the element air quantity Check and clean Exhaust mixing elbow and or exhaust pipe stained or clogged increase in exhaust back pressure Trouble with the governor lever Check and adjust Poor injection of the fuel valve Check and adjust 5 2 Troubleshooting Table 5 1 Basic Troubleshooting Chart Continued Contact Authorized Dealer for Problem Possible Cause Corrective Action Servicing ENGINE FAILS TO START Continued Excessive wear on the fuel pump Overhaul the fuel pump Y plunger insufficient fuel supply Trouble with the fuel feed pump Check and overhaul S insufficient fuel supply No intake exhaust valve clearance gas Adjust the valve clearance to specified S blowing by or poor combustion due to value a drop in the compression pressure
47. pe fuses for ceramic fuses If ampere rating is unknown or questionable see wiring diagram These are the most common replacement parts 1 Lube oil filter cartridge type Applicable Engine Part Number All 129150 35151 2 Fuel oil filter cartridge type Applicable Engine Part Number All 124550 55700 3 Sea water pump impeller Applicable Engine Part Number All 18653 0001 4 Fresh water pump and charging alternator driv ing belt Applicable Engine Part Number MP 5 5 M 10451 4 42780 Replacement Parts and Accessories 8 1 5 Air filter element Applicable Engine Part Number 8 3 Accessories Several optional accessories are available to finalize the installation or to add convenience to operation and service Contact MasPower at 727 522 9471 to obtain the most current information and to find a dealer nearest you Accessories available at the time of print of this publication are as follows e Super Quiet Sound Shield provides for highly effective silencing ease of access for engine generator servicing low maintenance excellent durability and safety see Figure 8 1 for dimensions Depth 21 75 in 442 mm 32 in p 836 mm Figure 8 1 Optional Sound Enclosure Model MP8M e Siphon Break is required to prevent seawater entry into the engine when generator set is installed at or below water line e Remote Start Stop and Hourmeter Instru ment Panel allows starting stopping
48. perating hours for reference in maintenance scheduling Indicator RR Low Indicator 3 3 Starting the Engine Before operating the engine check that the rota tional parts are free from obstructions Figure 3 5 Fresh Water Coolant Filling Levels NOTE Pour the coolant slowly using a funnel in 1 Turn the fuel cock to OPEN see Figure 3 6 such a manner that no bubbles are formed 3 Replace and tighten the cap by turning it 1 3 clockwise 4 Remove the water filler cap of the expansion tank and add the fresh water LLC mixture up to the upper marking Full see Figure 3 5 After filling replace the cap lt w kg wd Fuel Cock Figure 3 6 Opening the Fuel Cock Operation 3 3 2 Make sure Main DC Power Switch is on 3 Press yellow Manual Button to START at the generator see Figure 3 7 4 Press yellow AUTO to activate Remote Start 5 There will be a few seconds starting delay for pre heat 00001 7 h Hi Mebanizmi At Generator Activate Remote Start Start Button Stop Button Figure 3 7 Starter Switch PROTECTING THE BATTERY Do not run the starter motor for more than 15 sec onds at a time If the engine can t be started wait for approximately 30 seconds before using the starter again ENGINE RESTARTING Be sure to check that the flywheel has come to a standstill before turning the starter switch to START e The starter motor of flywheel gear may be dam
49. ption U S Total Fuel Flow Supply and Return for Filter Sizing Notes 1 Intermittent angular operation can be as much as 30 degrees for 3 minutes or less 2 Fuel consumption may very slightly 2 2 Specifications 2 3 Generator 2 3 1 General Description The generator used in the Series 1 generator set is a self exciting synchronous brushless type machine Generator features include the following e Rotor is compactly constructed with an integral damper cage and field winding section conduc tor directly wound on the rotor e Special interpole fixation combined with the mechanical compactness of the winding ensures high operational reliability e The generator is manufactured and tested according to NEMA standards ISO standards and IEC recommendation e The exciter is a 4 pole synchronous generator with salient poles on the stator and cylindrical armature on the rotor e The system is excited automatically by means of residual magnetism of the magnetic circuits of the generator and exciter stabilized by the per manent magnet in one of the exciter poles e Mounted on a stainless steel drip pan e Standard SAE housing with a coupling disc 2 3 2 Generator Ratings 77 F Model 25 C Series Voltage kW kVA MP5 5M 120 240 60 50 45 8 22 9 5 5 5 5 EN MPSM 120 240 60 50 66 7 33 3 NINOS NOTE All units are rated 1 0 power factor Rat ings are based on an altitude of 500 ft 150 m above se
50. range 16 14 Red 14 24 Yellow 16 15 Green 14 Blue 14 Grey 14 oa 1204 ale E ele 21 Black Yellow 120 22 White Yellow 240 1 9 Black Red White Red Purple Remote Figure 7 5 Multigen Remote Wiring Diagrams 7 3 Multitek
51. re use 1 Finish the periodic check and maintenance before storage if the date of it is approaching Start the generator and run it until it reaches operating temperature Stop the generator and drain the oil from the crankcase while the engine is still warm Change the oil filter and the fuel filter Fresh Water Drain red plug 10 11 Refill the crankcase with the specified weight oil Wait until the engine has cooled down before extracting cooling water from the engine Be sure to drain water from the fresh water cooling system if anti freeze is not used see Figure 4 12 Drain all the seawater from the cooling system and leave open Shut before operations Drain the seawater from the stainer and the seawater pump Block air and exhaust ports Remove the batteries from the engine and charge them fully before storage Charge the batteries every month during storage because they run down naturally self discharge Cover entire unit with dust cover NOTE If water is not drained it may freeze and damage major parts of the water cooling system fresh water cooler oil cooler water pumps etc Fresh Water Drain red plug S Figure 4 12 Location of Fresh Water Drains Scheduled Maintenance 4 9 4 10 Scheduled Maintenance Chapter 5 Troubleshooting If a problem in encountered during operation refer to Table 5 1 and take proper measures Corrective action and testi
52. rge entire contents of gaseous porta ble fire extinguisher through the access port or other provision Do not smoke or permit flames or sparks near the fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Do not operate the generator set with the air cleaner silencer removed Keep the compartment and the generator set clean and free of debris to minimize the risk of fire Wipe spilled fuels and engine oil Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Before checking the engine allow it to cool Remove the cap after pressure has been com pletely released and the engine has cooled To release pressure cover the pressure cap with a Safety Precautions v thick cloth and then slowly turn the cap coun terclockwise to the first stop Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Hazardous Noise vi Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Generator sets not equipped with sound enclo sures can produce noise levels greater than 105 dBA Prolonged exposure to
53. ront of this manual Check or inspect the following items before startup and at the intervals specified in the service schedule see the Maintenance section on page 4 1 e Air Cleaner check that the element is installed and clean to allow clean air to flow through the engine e Air Inlets keep clean and free from obstructions e Air Shrouding keep tight and in position e Battery check electrolyte level and make sure battery connections are tight For additional care and maintenance refer to the battery man ufacturer s instructions e Coolant check the coolant level if necessary add fresh coolant until level is just below the overflow tube opening or mark e Alternator Belt check belt condition and ten sion of the alternator belt e Exhaust System check for any leaks and keep the exhaust outlet free from obstruction Check that the silencer and piping are tight and in good condition e Fuel Level check fuel level and keep tank s full to ensure adequate fuel supply e Oil Level do not overfill Keep the oil level at or near the full mark on the dipstick e Operating Area check that the air intake area is kept clean and that the flow of cool air is unobstructed Make sure that the area sur rounding the generator set is clean and free from tools rags debris etc e Seawater Pump Priming cbefore initial startup prime the seawater pump Close the seacock and remove the hose from the water f
54. s sive smoke e an increase in thermal load due to poor com bustion or excessive wear on the engine s moving parts due to foreign matter e fuel oil can freeze and no output will be produced 4 4 2 Replacing the Fuel Filter Clean or replace the fuel filter as described in the procedure below see Figure 4 5 1 Close the fuel cock on the pipe line 2 Remove the collar from the fuel filter adapter while holding the filter bowl in place 3 Remove the filter bowl and filter element Fuel Cock Fuel Filter Collar Figure 4 5 Fuel Filter Replacement If the filter element is damaged replace it Wipe off all the parts with a clean rag Inspect all mating surfaces and threads for damage replace as necessary 6 Place the fuel filter element into the fuel filter bowl and lubricate the rubber seal with fresh fuel oil Do not use gasoline to clean the element 7 Slide the collar against the bowl flange posi tion the fuel filter up against the adapter and hand tighten the collar 8 Open the fuel cock NOTE Bleed the fuel system after replacing the filter and run the engine to check for fuel oil leakage 4 4 3 Checking for Oil Leakage When the lube oil and filter have been replaced be sure to run the engine to check for leaks at the lube oil drain plug and filter connection Also check the oil level 15 20 minutes after the engine is stopped and replenish oil if necessary 4 4 4 Bleeding the Fuel S
55. t tem perature cutout e 12V fuel pump e Low oil pressure cutout e Battery charging alternator e Oil drain valve and hose e One side serviceability of fuel system lubrica e Belt guard tion system seawater pump and air cleaner e Disposable oil and fuel filters Vibration isol e Vibration isolators 2 6 2 Engine Specifications Generator Set Model EI AO OI e DE O CI CN Numerics AA Cylinder Block Material Cylinder Head Material Piston Rings Bore Stroke Displacement Compression Ratio Horsepower 60 50 Hz RPM 60 50 Hz Direction of Rotation as viewed from generator end Lubrication System Lube Oil Capacity w filter Oil Recommendation API Engine Firing Order 1 cylinder nearest to flywheel Combustion System Battery Voltage Fuel Pump Priming Max Recommended Fuel Pump Lift Coolant Capacity U S approx Recommended Coolant Ratio Thermostat 2 4 Specifications Ooo UCI Caton a 2 Compression 1 Oil mem feere soroa mew fesa EC 784 1006 2 2 Compression 1 Oil in mm in mm CID CC 47 84 784 61 39 1006 hp qt L foce R R Ep Ooo pe o o he o Oo fee CS INN E E ARIANE 3 2 3 5 5 5 Electric Electric ft m qt L 3 5 1 067 3 2 84 3 5 3 31 50 50 80 0 3 5 1 067 Chapter 3 Operation 3 1 Prestart Checklist Before performing any prestart checks or inspec tions refer to the Safety Precautions and informa tion at the f
56. ters Laboratories Inc UL Publications Stock 333 Pfingsten Road Northbrook IL 60062 Marine Department Phone 1 919 549 1400 NFPA 302 National Fire Protection Association Batterymarch Park Quincy MA 02269 Society of Automotive Engineers SAE Customer Service 400 Commonwealth Drive Warrendale PA 15086 Phone 1 412 776 4970 American Boat and Yacht Council Inc ABYC 3069 Solomon s Island Road Edgewater MD 21037 Phone 1 410 956 1050 Phone 1 410 974 8112 Fax 1 410 956 2737 IEEE 45 The Institute of Electrical and Electronics Engineers Inc 345 East 47th Street New York NY 10017 Appendix B B 1 Appendix C Service Log Use the log below to keep a cumulative record of operating hours on your Series I generator set and the dates required services were performed Enter hours to the nearest quarter hour OPERATING HOURS HOURS RECORD OF SERVICE eee DATE OF DATE HOURS SERVICE SERVICE PERFORMED Appendix C C 1 Appendix D Emissions Regulations CALIFORNIA PROPOSITION 65 Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm Diesel Engine Exhaust Exhaust emissions regulations for diesel engines have been evolving worldwide by authorities such as the US EPA Calif ARB European EU amp EC IMO under the auspices of the UN the Ministry of Construction in Japan and so on In all cases Yanmar has
57. tery cable to the positive connection terminal of the starter solenoid e Do not test the condition of the battery by shorting the terminals together Moving Parts Rotating parts Can cause severe injury or death Do not operate the generator set unless all guards screens and covers are in place e Keep hands feet hair clothing and test leads away from the belts and pulleys when the gener ator set is running Do not operate the generator set with the belt guard removed e The generator set must be operating in order to perform some scheduled maintenance proce dures Be especially careful if the sound shield has been removed leaving the belts and pulleys exposed sound shield equipped models only e Before working on the generator set or equip ment connected to the set disable the generator set as follows 1 Place the generator set start stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Fire Hazards Hot Parts Fire Can cause severe injury or death In case of fire do not open the sound shield or compartment To avoid serious injury or death from fire shut down engines generator sets and blowers Imme diately discha
58. ture at a point not higher than seawater pump Strainer should be accessible for servicing NOTE Some seawater strainers include seacock and intake thru hull strainer Water lines from seacock to engine driven sea water pump are usually flexible hose Reference ABYC Standard P 1 for acceptable exhaust hose materials If using non flexible water line a flexi 6 4 Installation ble section of hose is necessary to allow vibrational motion of the generator set during operation Sup port nonflexible water lines within 4 in 102 mm of their connection to the flexible section Keep piping straight and as short as possible If the pipe is too long water draw problems may occur To remedy some problems with long pipe runs usually over 15 ft 4 6 m increase the hose size to the next standard pipe diameter Example substitute 3 4 in 19 mm for 5 8 in 15 9 mm See Chapter 2 Specifications for inlet water line hose size 6 6 Exhaust Systems There are two types of exhaust system installa tions silencer above the waterline and silencer below the waterline see Figure 6 2 Use water cooled exhaust lines in all marine instal lations Keep lines as short and straight as possi ble ABYC Safety Standard P 1 6 i recommends using two corrosion resistant hose clamps with a minimum width of 1 2 in 13 mm on each end of flexible exhaust hose connections A pitch of at least 1 2 in 13 mm per running foot 30 5 cm is ac
59. uel Prime Switch Air Intake Silencer Oil Fill Cap Control Panel o o gt l 7 n A Fresh Water Circuit Breaker 2 Bee Expansion Tank Main pe lt N Fuel Bleed Screw Power Switch Y Governor Adjustment B Z ay pi Cap Oil Filter Fresh Water Drain Heat Exchanger Fuel In Out gt S 1 K i L Sea Water Drain h i gt and Zinc i a A Seawater Input Oil Drain Fitting Oil Drain Valve Fuel Flow Cock and Fuel Filter Fresh Water Coolant Tank Pressure Cap Mixing Elbow Bia S 3 d A l Belt SS L da Y Remote Harness Hook Up l pe i pp Engine Harness z rter Solenoi Alternator UN Starter Solenoid Fresh Water Drain Figure 2 1 Typical Service Views NOTE Consult an authorized distributor dealer or the service manual for items not shown Specifications 2 1 Fire Extinguisher Inlet Service Access Remote Harness Hook Up Oil Drain EP Fuel In Out Figure 2 2 Generator Set shown with Optional Sound Enclosure 2 2 General Specifications Description Units mPssm_ mPem Dimensions 21 75 552 45 Dimensions w sound enclosure 0 1016 Weight wet Weight w sound shield wet Angular Operation max in all directions Minimum clearances for vibration and cooling top front 1 5 38 1 1 5 38 1 rear and sides without optional sound shield Air Requirements CFM L min 29 12 825 Fuel Consum
60. ximately 5 minutes e After stopping the engine close the fuel cock e Wipe off and clean the engine e Turn off the battery switch if your engine has one EMERGENCY STOP If the engine can t be stopped with the engine stop lever or the speed control lever or the engine speed can t be lowered by the speed control lever stop the engine as follows Block off the air supply Shut off the fuel cock Loosen all the nuts on either the fuel injection pump side or the fuel injection nozzle side This cuts off the fuel supply and the engine stops In such cases contact your nearest Yanmar dealer to locate the causes and have them repair the engine 3 6 Remote Panel Controllers 3 6 1 Remote Start The remote start options allow starting and stop ping from a location removed from the location of the generator set The illuminated gauges include the engine oil pressure gauge and water tempera ture gauge Standard Series I generator sets come equipped with a connector on the controller for to connect the panel kit Refer to Figures 3 8 3 9 and 3 10 Figure 3 8 Remote Four Meter Panel Controller analog Operation 3 5 3 6 2 Remote Panel Gauge Operation optional If the generator set has an optional remote panel MASPOWER with gauges observe the gauges upon engine start i up see Table 3 1 If gauge readings are not within the ranges specified contact an authorized service distributor dealer nm my
61. y Chart 4 3 2 Checking the Lube Oil Level Use the lube oil specified in this manual Using a low quality lube oil will cause early wear on the engine s moving parts and adversely affect the durability of the engine Do not fill the lube oil over the specified level Overfilling may cause the following problems e The engine speed may increase excessively under no load resulting in engine break down e Foreign matter carbon etc may adhere to the piston causing damage to the cylinder or causing the piston rings to get stuck The oil may also leak Level the engine before checking or replenishing the lube oil A proper check cannot be made if the engine is tilted Over filling or under filling the lube oil may cause damage to the engine 4 3 3 Changing the Lube Oil To replace the lube oil use the following proce dure NOTE The lube oil can be drained quickly and easily when the engine is still warm after running 1 To drain the oil turn the yellow drain valve handle to the open position see Figure 4 2 Oil Drain Valve Handle yellow Figure 4 2 Oil Drain Valve Handle Location 2 Drain the oil into a waste oil can Allow ample time for oil to drain After com pleting the draining process turn the oil drain lever to the fully closed position 4 Remove one of the two oil fill caps see Figure 4 3 Scheduled Maintenance 4 3 Oil Filler Cap ABRA Bonnet Pa b ah F i L E L 4 AN k
62. ystem Refer to Section 3 1 2 for the proper procedure to bleed the fuel system 4 5 Intake System In the intake and exhaust systems resistances to intake air flow and exhaust gas flow are generated The limits shown in the tables below must be observed to ensure engine performance The initial upper limits here refer to allowable resistances when the parts in the intake and exhaust systems are new As the engine is used the resistances increase due to deposits in the air cleaner and muffler The upper limits for air cleaner replacement and exhaust system cleaning including the exhaust tube and muffler are the limit values for operation See Tables 4 2 and 4 3 for intake and exhaust specifications Table 4 2 Allowable Depression at Engine Allowable Depression at Engine Manifold lt kPa mm H O Upper Limit Manifold for Air Cleaner Replacement 6 23 635 Applicable Initial Model Upper Limit All TNE series 2 45 250 9 5 in H20 Table 4 3 Allowable Exhaust Back Pressure Allowable Exhaust Back Pressure lt kPa mm H O Upper Limit for Exhaust Applicable Initial System Model Upper Limit Cleaning 2TNE68 N 5 88 600 7 06 720 2TNE68 3TNE66 N 9 81 1000 11 77 1200 3TNE68 N 3TNE68 3TNE72 N 3TNE74 N 11 77 1200 14 12 1440 3TNE74 3TNE78A 9 81 1000 11 77 1200 3TNE82A 3TNE84 3TNE88 4TNE84 6 37 650 7 65 780 4TNE88 3TNE84 T 4 90 500 5 88 600 4TNE84 T 4TNE94 9

maspower series 1 w 703 controller

Contents

Download Pdf Manuals

Related Search

Related Contents