Mase FM 50H User manual

FM 50H - FM 5.4H
FM 80H - FM 7.5H
REV.10 A.A. 19/05/2006
cod.41822
GRUPPO ELETTROGENO MANUALE DI USO E MANUTENZIONE I
Tipo modello
N° matricola
Codice
GENSET USE AND MAINTENANCE MANUAL GB
ELEKTROAGGREGAT GEBRAUCHSANWEISUNG UND
WARTUNGSVORSCHRIFTEN D

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 2
F
E
L
I
H
M
G
N
Fig.1
D
C
A
B
Fig.A

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 3
4
1
2
3
3
4
2
1
Fig.2
Fig.3
Fig.4

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 4
S.A.E
Service
Grade
-30 -20 -10 0 10 20 30 40
Ambient temperature (oC)
40
20W
20W40
20
30
5W
5W30
10W
10W30
FM 50 H
FM 80 HFM 5.4 H - FM 7.5 H
Fig.5 Fig.6
Fig.7 Fig.8
Fig.9 Fig.10
MAX
MIN

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 5
FM 5.4 H MECC.ALTE
Fig.11Cod. 45248
1
876
4 5
2
3
9
1514
11
1213

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 6
FM 7.5 H MECC.ALTE
Fig.12Cod. 45247
1
876
4 5
2
3
9
1514
11
1213

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 7
FM 80 H MECC.ALTE
Fig.13
Cod. 45236
1
8
7
4
5
6
9
10
11
3
12
13

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 8
FM 50 H MECC.ALTE
Fig.14Cod. 45235
1
87
5
2
3
9
11
12
10
6
13

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 9
FM 50 H Nuova Saccardo
Fig.15
Cod. 45631
1
87
6
5
3
2
14
12
11
10
9
13

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
- 10
FM 50 H Nuova Saccardo
Cod. 45629 Fig.16
1
87
6
5
3
2
14
12
11
10
9
13

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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PICTURES ............................................................... 2
WIRING DIAGRAM .................................................. 5
DEFINITIONS USED .............................................. 13
1 GENERAL INFORMATIONS .......................... 14
1.1 Conformuse .................................................. 14
1.2 Residual risks ................................................ 14
1.3 Symbology, definitions and manual informations 15
1.4 Reference documents ..................................... 16
1.5 Referenceregulations and legislativeprovisions . 16
1.6 Marking ......................................................... 16
1.7 Identification of the generator unit ..................... 16
1.8 Position of safety labels .................................. 17
1.8.1 Meaning of the safety labels ............................ 18
1.9 Generaldangerinformation .............................. 20
1.9.1 Dangerofentanglement .................................. 20
1.9.2 Dangerofburns ............................................. 20
1.9.3 Danger of harm to hearing ............................... 21
1.9.4 Danger of intoxication ..................................... 21
1.9.5 Danger of fire or explosion ............................... 21
1.9.6 Danger if failing to use personal
protectiondevices ........................................... 21
1.9.7 Danger caused by the engine starting .............. 22
1.9.8 Dangerofelectromagnetic radiation ................. 22
1.9.9 Dangerofelectrocution ................................... 22
1.9.10 Danger resulting from bad storage ................... 22
2 General characteristics ................................. 23
2.1 Table of technical characteristics ..................... 23
2.2 Noise emission .............................................. 24
2.3 Generator composition .................................... 25
2.4 Instrumentpanel ............................................ 25
3 INSTALLATION .............................................. 25
3.1 Positioningthe generator ................................ 25
4 USING THEGENERATOR ............................... 26
4.1 Starting ......................................................... 26
4.2 Protections ................................................... 26
4.3 Stopping ........................................................ 27
5 CAREANDMAINTENANCE ............................ 28
5.1 Preamble ....................................................... 28
5.2 Ordinaryengine maintenance .......................... 28
5.3 Engine oil change ........................................... 28
5.4 Spark plug maintenance ................................. 28
5.5 Airfilter cleaning/replacement .......................... 29
5.6 Period of inactivity .......................................... 29
5.7 Scheduledmaintenance table ......................... 30
5.8 Wiring diagram list ......................................... 30
6 ANOMALIES,CAUSESANDREMEDIES ......... 31
6.1 Parts list ........................................................ 31
6.2 Rules for ordering spare parts .......................... 31
7 TRANSPORT,STORAGE,LIFTING AND
HANDLING ................................................... 32
7.1 Transportand storage ..................................... 32
7.2 Liftingand handling ......................................... 32
8 GUARANTEEANDRESPONSIBILITY .............. 33
8.1 Guarantee ..................................................... 33
8.2 Limits of responsibility .................................... 33
9 DISPOSAL ..................................................... 33
9.1 Disposal of the waste materials deriving from
maintenanceandscrapping ............................ 33
10 SPARE PARTS ORDERFORM ....................... 34
INDEX

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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GB
GB
This manual has to be preserved for all through life of the
gen set to which ago reference
Thank you for having chosen a product MASE.
As a leading generator manufacturer, Mase Generators offers a wide range of generators with an output from 1 KVA
portable generators to 1600 KVA units for special applications.
Founded in 1970, the Cesena-based company extends over a area of 16,000 square meters, including a 9,000 sq. mtr.
manufacturingfacility.
Mase Generators began as a company producing 500 Watt, light and compact portable generators. These generators
made the Mase Generators name well known throughout the world. Mase Generators is a leader in high
quality,reliable products,and innovativeresearch performed by Research and Development Department.
The generator you have purchased is the fruit of years of experience in the sector and for the modern conception, the
strong sizing, the materials employees, the continuous updatings, constitutes an effective answer to the operators’
demands of the sector.
This Manual instructions will furnish you useful information and precious suggestions so you can fully exploit
all the possibilities that the generators offers you.
If any part of the manual resulted incomprehensible, please contact us.
In to renew our thanks we cordially greet you.
MASE GENERATORS SPA
MASE GENERATORS S.p.A. Via Tortona, 345
47023 Cesena (FC) Italy
Tel.[phone] Fax.[phone]
Technical data, informations, layouts of the texts and graphic preparations: edited by the Technical Office
Mase Generators
THE MASE GENERATORS SPA, RESERVES ALL THE RIGHTS ON THE MANUAL PRESENT. ANY TOTAL
OR PARTIAL REPRODUCTION IS PERMITTED WITHOUT WRITTEN AUTHORIZATION OF THE MASE
GENERATORS SPA.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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DEFINITIONS USED
The terms used are current technical terms and where considered necessary, the meaning is described
below.
- Generator
An assembly of an internal combustion piston engine and an alternate current, synchronous, 2-4 pole, self-excited
generator, joined together to create a station for self-production of electrical energy.
- User system
Composed of the power supply circuits of the user equipment, including the relevant sectioning, handling,
breaking, transformation, protection, etc. devices which do not form part of the production, transmission and
distribution systems.
- Category 1 electrical system
A system where the rated voltage is greater than 50 V and smaller than 1000 V including alternate current.
- Load
A set of numerical values of electrical and mechanical magnitudes which characterise the requirements imposed
on a rotary machine by an electrical circuit or by a mechanical device at a certain instant.
- Thermal switch
Main cut-out and breaking device made up of a switch which opens automatically by thermal effect.
- Differential switch
Main cut-out and breaking device made up of a switch which opens automatically by differential current effect.
- Skilled person
A person with technical know-how or sufficient experience to allow him to avoid the dangers inherent in electricity.
- MASE specialised personnel
A person able to evaluate the job assigned to him and recognise the possible dangers on the basis of training at
the MASE training centres, with professional experience and knowledge of the equipment in question and of the
possible dangers deriving in the event of negligent behaviour.
- Supplier
A body (e.g. manufacturer, agent, installer) which supplies the equipment or services relating to the machine.
- Control
Control action by which an output variable of the controlled system (controlled variable) is affected by an input
variable of the controlling system in order to achieve a certain goal.
- Manual control
Control where the change of a variable handled is produced by a person through manual intervention
- Automatic control
Control where the change of a variable handled is produced by a controlling device (automatic controller) without
the intervention of a person
- Danger
Source of possible harm or damage to health
- Protection
Guard or protection device as safety measure to protect persons from a present or potential danger.
- Casing
Part intended to assure protection of the equipment against specific outside influences and protection in every
sense against contacts.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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1 GENERAL INFORMATIONS
1.1 Conform use
The generator is suitable for independent production of electrical energy within the voltage and wattage limits
declared by the manufacturer.
Any other use outside the already stated field of use is prohibited: the generator is intended for non-industrial use.
The generator has been designed to operate independently (without operator) if not for sporadic checks.
The limits of use are:
-operating temperature: -5° +40°
-relative humidity: 30% - 90%
-the generator is suitable for operation outdoors provided that it is protected against rain; it may not be operated in
closed environments since the generator produces exhaust gas.
Inside installation is subject to approval by Mase or an installer authorised by Mase.
Arbitrary modifications to the machine are prohibited for safety reasons.
Original spare parts must be used on pain of losing machine conformity.
All the operations that require dismantling of special parts may only be carried out by technicians authorised by the
local dealer or the manufacturer.
Only Mase technicians or personnel trained by Mase have the necessary knowledge of the generator and the special
equipment as well as the experience to carry out any operation in the most economical and reliable way.
1.2 Residual risks
The generator has been designed taking into account the safety regulations set out in the EC directives and
standards; nonetheless, the following residual risks remain:The generator has been designed taking into account
the safety regulations set out in the EC directives and standards; nonetheless, the following residual risks remain:
- injury caused by contact with hot parts during maintenance.
- injury caused by electrocution during maintenance on the electric panel.
- risks connected with long periods of exposure to the noise of the generator.
- risks due to contact with the generator lubricants during maintenance.
- risks due to the fire hazard the fuel represents.
Because of the typical intrinsic danger of the Generators, you are reminded that, although the generator has been
designed, constructed and tested in accordance with the safety regulations, only proper and careful use can
guarantee full safety; to this end, the various precautions to be taken during use of the Generator are listed below.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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GB
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1.3 Symbology, definitions and manual informations
Those parts of the text not to be ignored are highlighted in bold type preceded by a symbol, as illustrated and
defined below.
Indicates that particular attention must be paid in order to prevent running serious risks
which could lead to death or possible harm to the health of personnel.
A condition which may occur during the lifetime of a product, system or plant considered
at risk regarding damage to persons, property, the environment or economic loss.
Indicates that particular attention must be paid in order to prevent serious consequences
which could result in damage to tangible goods, such as the resources or the product.
Instructions of particular importance.
Carefully consult this manual before using or carrying out any operation on the generator.
FAILURE TO RESPECT THE SPECIFICATIONS CONTAINED IN THIS USE AND MAINTENANCE MANUAL
WILL RESULT IN FORFEITURE OF THE GUARANTEE ON THE PRODUCT.
This manual was drawn up by the manufacturer and forms an integral part of the generator equipment, definition used
as indicated in Directive 98/37/ EC; the information contained in the manual is addressed to all the persons involved
in the operating life cycle of the generator, and is necessary to inform both those who effectively carry out the different
operations and those who coordinate the activities, to arrange the necessary logistics and to regulate access to the
place where the generator will be installed and operated.
This manual was drawn up by the manufacturer with the purpose of providing essential information and instructions
for proper use and maintenance in conditions of safety. It constitutes an integral part of the generator equipment and
must carefully be protected from any agent which may damage it for the entire life cycle of the generator. The manual
must accompany the generator if transferred to another user or owner.
The manual defines the purpose for which the generator was constructed and contains all the information necessary
to guarantee safe and proper use.
Constant observance of the instructions contained in this manual guarantees the safety of the operator, protection
against damage to persons or things, operating economy and a longer life of the generator.
The drawings are provided by way of example. Even if the generator in your possession differs from the illustrations
contained in this manual in elements of little significance, for example the colour, the safety of the generator and
the information provided are nevertheless guaranteed.
To facilitate consultation, it has been divided into sections identifying the main concepts; for a quick look at the
topics, consult the index.
Ongoing improvement and development of the product may have led to modifications to the generator which are not
included in this publication.
Whenever a problem concerning the generator or this publication arises, consult with Mase Generators
SPA for the latest information available.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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15
5
4
14
67
89
10 11
12
13
3
16
Fig.A
2
1
1.4 Referencedocuments
Theinstructionsforuseprovidedwitheachgeneratorare
made up of a collection of documents of which this
manual represents the General Part. The following
documentsarenormallyprovidedseparate.
aCEdeclarationofconformity.
bInstruction manual for use of the generators, (this
manual).
cEngineuseandmaintenancemanual.
dList of mase Service Centres.
e MaseWarrantycertificate.
fWarrantycard.
1.5 Reference regulations and legislative
provisions
The generator groups, built by mase, destined to the
countriesoftheEuropeanCommunity,areconformingto
theapplicableECdirectives,andtheyareprovidedofaEC
DeclarationofConformity.
98/37/ECandsubsequentamendments:
Essential machine requirements for safety and health
protection(“Machine”directive).
73/23/EC and subsequent amendments contained in
thedirective93/68/EC:Guaranteeofsafetyofelectrical
material intended for use within certain voltage limits,
(“LowVoltage”Directives).
1.6 Marking
The generator identification plate carries all the
identificationdatainaccordancewiththeprovisionsfor
ECmarkingforthosecaseswhererequired. Belowisa
facsimile of the identification plate fixed on the hull of
eachgenerator,(Fig.A).
1.7 Identification of the generator unit
See Fig.A
1 - Machinename
2 - Machinecode
3 - Serialnumber
4 - Ratedpower
5 - Declaredfrequency
6 - Ratedpowerfactor
7 - Ratedvoltage
8 - Ratedcurrent
9 - Degreeofprotection
10 - Class of isolation
11 - Temperaturemax.ofuse
12 - Altitude max. of use
13 - Performanceclass
14 - Yearofconstruction
15 - Manufacturer-Adress
16 - Weight
The machine code number, the serial number and
theyearofconstructionmustalwaysbeindicated
whencontactingthemanufacturerforinformation,
orderofspareparts,etc..

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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GB
cod. 42112
Fig.14
Cod. 42118
Cod.46106
STOP
Cod. 42350
Cod. 42346
Cod. 42348
Cod. 42349
1.8 Position of safety labels

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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STOP
1.8.1 Meaning of the safety labels
• These labels warn the user of any danger which may cause serious injury.
Carefully read the meaning and the precautions described in this manual.
• If the label detaches or becomes illegible, replace it with a new one which can be requested from an authorised Mase
dealer.
Danger Symbols Meaning
- Caution to avoid burns, do not touch during operation.
The exhaust manifold and the engine, pay attention to the labels on the generator.
- Leave the engine to cool down before storing it indoors.
- Read and understand the Use and Maintenance Manual before starting the generator.
- The Mase generator has been designed so as to guarantee safe and reliable operation
provided that the instructions are followed. Otherwise, personal injury or damage to the
equipment may result.
- The exhaust gases contain toxic carbon monoxide.
- Never operate the generator in a closed space.
- Provide for adequate ventilation. If installed indoors, scrupulously observe the ventilation
regulations.
- The fuels are highly flammable and in certain conditions also explosive.
- Fill up in a well-ventilated area with the engine off.
- Do not smoke or create sparks while filling up.
- Immediately clean off any fuel leaks.
- Danger of electric shock: consult the manual.
Obligation Symbols Meaning
- Obligation to connect the generator to earth.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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Prohibition Symbols Meaning
- The connections to an emergency electric network must be carried out by specialised
electricians in compliance with the relevant regulations in force. Improper connections
may cause current feedback from the generator to the electrical lines connected.
These current feedbacks may cause electroconduction to the people working for the
electricity company or who come into contact with the lines during the failure.
Moreover, once the line has been restored, the generator may explode, burn or cause
fires in the electrical system of the facility.
- No smoking or use of open flames.
- Do not clean, lubricate, repair or adjust moving parts.
- Do not extinguish fires with water, use homologated extinguishers.

FM 5.0 H - 5.4 H - 7.5 H - 8.0 H
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1.9 General danger information
• It is recommended to learn how to stop and operate all the controls.
• Do not allow unqualified personnel to use the generator.
• Even though the generator is protected, do not stand near it.
• Do not remove the labels for any reason and request replacement if necessary.
• Before starting the Generator or before starting any lubrication or maintenance operation, it is essential that the
personnel responsible has read and understood all the WARNINGS, CAUTION and DANGER notices in this
manual and in the additional technical documentation provided.
• Before any operation on the generator, ensure that the primary engine is not running and that no parts are moving,
and post a sign saying DO NOT SWITCH ON or similar at the start switch or the controls before carrying out the
maintenance or repair work on the generator.
• Nevertheless, the manufacturer cannot foresee all the possible circumstances which may lead to potential risks
in the effective conditions of use of the Generator.
Any operations and/or procedures for maintenance not expressly recommended or indicated in the user manuals
must always be notified to and approved by the manufacturer.
In the event that a procedure not specifically recommended needs to be applied, the user is responsible for assuring
that such procedure is safe and does not cause harm to persons.
• The manufacturer declines all responsibility for damage to persons or things deriving from inobservance of the
safety regulations.
• Carefully examine the safety warning plates on the generator and respect the relevant instructions.
1.9.1 Danger of entanglement
• Do not remove the original protections from any of the exposed rotating parts, hot surfaces, air intakes, belts and
live parts.
• Do not carry out any maintenance operation with the generator running.
• Do not wear flapping garments, such as scarves, foulards, bracelets, etc. and all garments must be tied with elastic
at the edges.
• Do not clean or carry out maintenance on moving parts
1.9.2 Danger of burns
• Do not permit unskilled persons or without adequate training to use the generator.
• Do not permit children or animals to approach the generator when it is in operation.
• Never touch the exhaust, the relevant protection or the engine body when the generator is running or still hot.
• Do not lean against or sit on the generator for any reason whatsoever.
• Identify the position of the fire extinguishers or other protection and emergency devices and learn their functioning.
• Identify any sources of danger such as fuel, engine oil or acid solution leaks, condensate in the drip caps, high
voltage, high pressure.