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INSTRUCTION MANUAL
2500W Inverter Generator
Model # HB5020C
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Website: www.powersmartusa.com
Toll free: 1-872-314-0005 Mon-Fri 9-5 EST
Email: support@amerisuninc.com / support@powersmartusa.com
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CONTENTS
TECHNICAL DATA ......................................................................................................................................................... 3 INTRODUCTION ............................................................................................................................................................. 4 SAFETYINFORMATION ................................................................................................................................................4 GENERAL SAFETY RULES ............................................................................................................................................5 IMPORTANT SAFETY INSTRUCTIONS ....................................................................................................................... 6 SYMBOLS ........................................................................................................................................................................ 7 KNOWING YOUR INVERTER GENERATOR .............................................................................................................. 8 GENERATOR PREPARATION .....................................................................................................................................11 GENERATOR OPERATION ......................................................................................................................................... 15 MAINTENANCE ............................................................................................................................................................ 18 TROUBLESHOOTING .................................................................................................................................................. 22 EXPLODED VIEW & PARTS LIST ..............................................................................................................................24 WARRANTY .................................................................................................................................................................. 28
TECHNICAL DATA
2500W inverter generator Engine type: air-cooling system Start type: Phase: Rated wattage: Surge wattage: Rated voltage: Rated current: Rated frequency: Displacement: Run time at 50% load: Spark plug gap: Fuel tank capacity: Engine oil capacity: USB output voltage: CO alarm: Noise rating: Package dimensions(L x W x H): Net weight:
Model#HB5020C 4 stroke, OHV, single cylinder with forced
Manual Single 1900 W 2500 W 120 V 15.8 A 60 Hz 80 cc 5.5 hour 0.6-0.7 mm (0.024-0.028 in.) 1.06 Gallon (4L) 12.3Fl.oz 5V Yes 69dB at 23 feet 20.5x12.8x20 inch 39.7 lb.
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INTRODUCTION
Thank You for Purchasing a PowerSmart® Product. This manual provides information regarding the safe operation and maintenance of this product. Every effort has been made to ensure the accuracy of the information in this manual. PowerSmart® reserves the right to change this product and specifications at any time without prior notice.
Please keep this manual available to all users during the entire life of the generator. This manual contains special messages to bring attention to potential safety concerns, generator damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage.
QUESTIONS? PROBLEMS? Please contact our Customer Service Dept. with any questions and/or comments, either by Email: support@amerisuninc.com / support@powersmartusa.com, or Toll Free at (872)314-0005. We are available Mon-Fri 9am-5pm EST to help solve any issues that you might encounter.
NOTICE REGARDING EMISSIONS Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst (if so equipped).
SAFETY INFORMATION
Before operating this generator, read and observe all warnings, cautions, and instructions on the generator and in this Owner's Manual.
NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. Read the entire Owner's Manual for safety and operating instructions. Failure to follow instructions and safety information could result in serious injury or death.
This safety alert symbol is used to identify safety information about hazards that can result in personal injury.
A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.
DANGER Indicates a hazard, which, if not avoided, will result in death or serious injury.
WARNING Indicates a hazard, which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazard, which, if not avoided, might result in minor or moderate injury.
CAUTION when used without the alert symbol, indicates a situation that could result in damage to the engine or generator.
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GENERAL SAFETY RULES
DANGER: CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING: The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if it isn't directly in contact with gasoline.
Do not operate near open flame.
Do not smoke near generator.
Always operate on a firm, level surface.
Always turn generator off before refueling. Allow generator to cool for at least 2 minutes before
removing fuel cap. Loosen cap slowly to relieve pressure in tank.
Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank.
Allow for expansion.
Always check for spilled fuel before operating.
Empty fuel tank before storing or transporting the generator.
WARNING: This generator produces powerful voltage, which can result in electrocution.
ALWAYS ground the generator before using it (see the "Generating set ground" portion of the
"GENERATOR PREPARATION" section).
Generator should only be plugged into electrical devices, either directly or with an extension cord.
NEVER connect to a building electrical system without a qualified electrician. Such connections must
comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result
in serious injury or death to utility workers.
Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or
steel work. GFCIs are available in-line with some extension cords.
Do not use in rainy conditions.
Do not touch bare wires or receptacles (outlets).
Do not allow children or non-qualified persons to operate.
WARNING: This generator produces heat when running. Temperatures near exhaust can exceed 150 (65).
Do not touch hot surfaces. Pay attention to warning labels on the generator identifying hot parts of the machine. 5
Allow generator to cool down after use before touching engine or areas of the generator that become hot during use.
CAUTION: Misuse of this generator can damage it or shorten its life.
Only use generator for its intended purposes. Operate only on dry, level surfaces. Allow generator to run for several minutes before connecting electrical devices. Shut off and disconnect any malfunctioning devices from generator. Do not exceed the wattage capacity of the generator by plugging in more electrical devices than the unit
can handle. Do not turn on electrical devices until after they are connected to the generator. Turn off all connected
electrical devices before stopping the generator. Turn the engine switch to "OFF" position when the engine is not running.
IMPORTANT SAFETY INSTRUCTIONS
Ensure that adequate ventilation is provided while the generator is in operation. The muffler is hot when the generator is running and just stopping. Be careful not to touch it. Under certain conditions, gasoline is extremely flammable and explosive. Be sure to add gasoline in a well-ventilated place. Turn off the engine and let it cool before filling. When refueling, keep away from the open fire. If there is oil spill while refueling, wipe the spilled gasoline immediately. Using should be prohibited in places with high fire risk. Do not connect the generator to the power system, or it may cause people to die from electric shock
when they come into contact with the wire; damage the generator or damage the home appliance. A pre-operation check must be performed before starting the engine to avoid accidents or equipment
damage. Generators must operate at least one meter away from the building and other equipment. Please put the generator on the horizontal ground. If the generator is tilted, it may cause gasoline
overflow. Be sure to master how to quickly shut off generators and understand the operation of all control
components. Children and pets must stay away from the operating area. While the engine is running, all personnel
must be away from its rotating parts. If the operation is not proper, there is a potential danger to the generator. Do not operate the generator
with a wet hand. Do not operate in the rain, snow, lest wet generator. Maintenance of generators to be operated by professionals. Generators vibrate in normal use. During and after the use of the generator, inspect both the generator as
well as extension and power supply cords for damage resulting from vibration. Have damaged items repaired or replaced as necessary. Do not use plugs or cords that show signs of damage such as broken or cracked insulation.
For power outages, permanently installed stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing of the components, possibly leading to a generator failure.
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SYMBOLS
Some of the following symbols may be used on this product. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the product better and safer.
SYMBOL NAME
DESIGNATION/EXPLANATION
V
Volts
A
Amperes
Hz
Hertz
W
Watts
MIN
Minutes
Voltage Current Frequency (cycles per second) Power Time
Safety Alert
Precautions that involve your safety.
Read the user's manual
To reduce the risk of injury, user must read and understand user's manual before using this product.
Carbon monoxide hazard
Never operate the generator in an enclosed area. Engine exhause contains carbon monoxide. Only operate the generator outside and away from windows, doors and vents.
Ground
Consult with local electrician to determine grounding requirements before operation.
Clearance
Electric shock alert
Fire/Explosion
Wet conditions alert
Keep all objects at least 5 feet (1.5m) from generator. Heat from the muffler and exhaust gas can ignite combustible objects.
Beware of electric shock hazard.
Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. Keep generator at least 5 feet (1.5m) from all objects to prevent combustion.
Do not expose to rain or use in damp locations.
Hot Surface
To reduce the risk of injury or damage, avoid contact with any hot surface.
Open Flame Alert
Fuel and its vapors are extremely flammable and explosive. Keep fuel away from smoking, open flames, sparks, pilot lights, heat, and other ignition sources.
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KNOWING YOUR INVERTER GENERATOR
Use the illustrations below to become familiar with the locations and functions of the various components and controls of this generator.
1 Carrying handle 2 Tank cap switch 3 Fuel tank cap
Control Panel
4 Engine switch 5 Recoil start handle 6 Control panel
7 Air filter and oil maintenance cover 8 Spark plug maintenance cover 9 Muffler exhaust exit
CO alarm light CO failure light Oil warning light Overload indicator light AC pilot light
DC reset ECO switch AC reset Parallel kit terminal USB port
12V DC port AC output receptacle Ground(earth)terminal
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CO Alarm Light(Red) When the concentration of CO exceeds the standard, the CO alarm light will turn on Red and the generator stops soon. CO Failure Light(Yellow) When the CO sensor is broken, the CO failure light will be on Yellow. Oil Warning Light (Yellow) The low oil level alarm system is designed to prevent engine damage due to insufficient oil in the crankcase. The low oil level alarm system automatically shuts down the engine before the engine oil in the crankshaft box is lowered to safety (the generator engine switch remains "ON"). NOTE: After the low oil level alarm system shuts down the engine, if you start the engine again, the low oil alarm indicator (yellow) lights up and the engine cannot run. If this happens, please fill in the oil and then restart the generator.
Overload Indicator (Red) When the overload indicatoris on, it indicates that the generating set is overload and then the AC protector works. It will stop the output of generating set to protect the electric equipment and the generating set itself. At this time, the overload indicator (red) will be on, but the engine is still in running state. We should disconnect the electrical equipment first.
If the overload indicator (red) is extinguished and the operation indication (green) is on, reconnect the electrical equipment, otherwise shut down the engine and check for malfunction. Running Indicator (Green) The output indicator lights up when generating set starts and has normal output.
Reset Button The reset button is used to restore output if an overload occurs. To restore output, reduce the loads and press the rest button. Grounding Terminal The grounding terminal is designed to prevent electric shock by connecting it to the grounding wire. The
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generating set must be properly grounded before operation. ECO switch When the energy-saving switch is in the energy-saving position, the generator is in the energy-saving state. When disconnecting or using low power, the engine automatically returns to a low speed state, thus reducing engine fuel consumption Full speed "full speed" means that the energy-saving state(ECO switch) is in OFF position and the engine is always at high speed, which is suitable for the situation where the load of electrical appliances varies greatly. When the energy-saving switch is in full-speed position, the engine will remain in a high speed state. In order to reduce the change of voltage, the energy saving switch should be in the position of "full
speed" when the electrical equipment needs a large instantaneous power, or when the generator is connected with the load of the high power apparatus at the same time. When using 12 V DC output, put the energy-saving switch in full-speed position.
WARNING: In the non-overload state, the output can not be restored by pressing the reset key. Each time the engine is started, the number of effective operation times of the protection cut-off switch is 5 times, or the engine needs to be restarted.
Fuel Tank Cap
Remove the fuel tank cap by rotating it anticlockwise to add fuel.
Parallel Operation
Make sure that the generating set is in a good running state before connecting it to other generating sets. The total power of electric devices should not exceed rated power of generating set. When electric motor starts, the overload indicator (red) will light up and normally it will stop within4 seconds. If it cannot stop, please call 1-872-314-0005 Mon-Fri 9-5 EST or email: support@powersmartusa.com & support@amerisuninc.com for customer service. During parallel operation, energy-saving switches of generating sets should be in the same position. To parallel operation, perform the following steps: 1. Connect one generating set to other generating set(s) in parallel. Use the parallel kit to make the parallel connection (the parallel kit needs to be purchased separately). 2. Start the engine in proper order and make sure that the running indicator (green) is normal. 3. Connect the plug of electric devices to the AC receptacle of parallel kit. 4. Run the electric devices.
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GENERATOR PREPARATION
The following section describes steps necessary to prepare the generator for use. If after reading this section, you are unsure about how to perform any of the steps please call (872) 314-0005 Mon-Fri 9-5 EST for customer service. Failure to perform these steps properly can damage the generator or shorten its lifespan.
Unpacking
Unpack the generator and all its parts. Do not discard the carton or any packaging until the generator is completely assembled.
Operating Location
Only use OUTSIDE and place the generating set in a well-ventilated area. Only operate the generating set on a flat, level surface and in a clean, dry operating environment. Allow two feet clearance on all side of the generating set while operating it outdoors. Operate in specified area, if any problem on applicable occasion, please consult the authorized local
dealers. In some areas, generating set must be registered with the local utility. Generating set used to construction sites may be subject to additional rules and regulations.
DANGER: The exhaust of the generating set contains carbon monoxide, using engine indoors CAN KILL YOU! NEVER use inside any building or any kind of enclosure, EVEN IF doors and windows are open. Place the generating set in a well-ventilated and clean area. Note the wind direction and air current when place the generating set.
High Altitude
This generating set may require a high altitude carburetor kit to ensure correct operation at high altitudes. Consult the authorized local dealer for high altitude kit information if you always operate your engine at altitudes above 5,000 feet (1,500 meters).
CAUTION: Even with carburetor modification, generating set horsepower will decrease about 3.5% for each 1,000 feet (300 meters) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.
Operation the engine at altitude below 5,000 feet (1,500 meters) with modified carburetor may cause the generating set to overheat and result in serious engine damage. Please restore factory specifications of the carburetor at the dealer when using the engine in a low altitude area.
Operating Condition
Check for loose or damaged parts, signs of oil or fuel leaks, and any other condition that may affect proper operation. Repair or replace all damaged or defective parts immediately.
Clean the dirt or foreign objects on the surface around exhaust and air intake of generator. DO NOT move or tip the generating set during operation. Use generating set only for intended uses. If you have questions about intended use, ask your local dealer.
Engine oil check
WARNING: This engine is not filed with oil before send out to the factory. User must add the proper amount of oil before operating the generator for the first time. Any attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil may result in
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engine damage and void your warranty. Engine Oil Recommendations Only use 4-stroke engine oil of SJ,SL or equivalent level which are in accordance with or higher than API standard. Check the API label on oil bottle or other container, and make sure the "SJ,SL" or equivalent level letter is in the label. SAE 10W-30 is recommended for general, all-temperature use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.
Ambient Temperature Add the engine oil 1. Remove two screws of the appearance cover. 2. Unscrew and remove the dipstick. 3. Add recommended oil to the upper limit(H). 4. Fully tighten the dipstick. 5. Install the appearance cover and tighten the screws. NOTE:The oil capacity (rated) of the engine crankcase is 12.3 fl. oz. Properly dispose of any used oil at an approved waste management facility.
CAUTION: Operate generator only on a level surfaces. Running the engine when the oil level is low can seriously damage the engine. The engine is equipped with a low oil sensor (applicable types) that will automatic stop the engine when the oil level falls below the safe limit. To avoid the inconvenient of an unexpected shutdown, fill to the upper limit and check the oil level regularly.
Generator Fuel Check
WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if not directly in contact with gasoline. With the engine stopped, check the fuel level. Refill the fuel tank if necessary. Use clean, fresh, regular unleaded gasoline with a minimum octane rating of 87. Do not mix oil with gasoline. Gasoline shall not overflow the tank (the oil level is lower than the red oil level indicator). After
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refueling, tighten the tank cover and wipe up any spilled fuel. Prevent dirt and water from entering the tank. Do not use gasoline containing more than 10% ethanol or gasoline containing methanol, otherwise the engine will be seriously damaged.
To add gasoline, follow these steps:
1. Make sure the generator stopped and it is on a level surface. 2. Unscrew fuel cap and set aside. NOTE: The fuel cap may be tight and hard to unscrew. 3. Slowly add unleaded gasoline to the fuel tank. Be sure not to fill above the upper limit mark. Always
allow room for fuel expansion. 4. The capacity of the fuel tank is 0.88gallon(4L).
NOTE: Do not fill the fuel tank to the very top. Gasoline will expand and spill over during use even with the fuel cap in place. Reinstall fuel cap and wipe clean any spilled gasoline with a dry cloth.
IMPORTANT: Do not fill tank indoors. Do not fill tank when the engine is running or hot. Never use an oil/gasoline mixture. Never use old gasoline. Avoid getting dirt or water into the fuel tank. Gasoline can age in the tank and make starting difficult. Never store generator for extended periods of time with fuel in the tank or the carburetor. Turn the fuel cock off and drain the fuel from the carburetor. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur. It is important to prevent gum deposits from forming in essential fuel system parts, such as the carburetor, fuel filter, fuel hose or tank during storage. Also, experience indicates that alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic fuel can damage the fuel system of the generating set while in storage. Be sure to review the instruction given in "Storage" section. Gasoline/ Alcohol Blends: up to 10% alcohol, 90% unleaded gasoline by volume is approved as a fuel. Other gasoline/alcohol blends are not approved. Effects of old, stale or contaminated fuel are not warrantable. Allow the generating set to cool for at least two minutes before removing fuel cap when adding fuel. Loose the fuel cap slowly to relieve any pressure in the tank.
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Generator Set Grounding
DANGER: Failure to properly ground the generator can result in electric shock. The generator must be properly connected to an appropriate ground. It helps prevent electrical shock if a ground fault condition exists in the generating set or in connected electrical devices, especially when the unit is equipped with a wheel kit. Proper grounding also helps dissipate static electricity, which often builds up in underground devices. A ground terminal has been provided on the generating set. For remote grounding, connect of a length of heavy gauge(4mm2 12 AWG minimum) copper wire between the generating set ground terminal and a copper rod driven into the ground. Local electrical codes may also require proper grounding of the unit. We strongly recommend that you consult with a qualified electrician for grounding requirements in your area. Neutral Floating* Neutral circuit IS NOT electrically connected to the engine crankcase/ground of the inverter generator. The generator (stator winding) is isolated from the engine crankcase and from the AC receptacle ground pin. Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional. Neutral Bonded to Frame* Neutral circuit IS electrically connected to the frame/ground of the generator. The generator system ground connects lower frame cross-member below the alternator. The system ground is connected to the AC neutral wire. * See your model's control panel for specified type of grounding.
Electrical Devices
Disconnect all electrical devices from the generator and switch off the AC circuit breaker before start the engine. The generator may be hard to start with electrical devices. The connected electrical equipment must not exceed the maximum limit of the generator. Please refer to the specification table for details. NOTE: After completing the above preparation, the generator is ready to be started.
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GENERATOR OPERATION
Generator Start
Disconnect the electrical equipment from the alternator's AC socket before starting the engine. For initial use (long unused, start after gasoline is used up), turn the engine switch knob to "ON"
position for 10 to 20 seconds before starting, so that gasoline can enter the engine carburetor. 1. Rotate the tank cap switch to "ON" position. NOTE: When the generator is being transported, the oil tank cover switch should be cranked to "OFF" position.
2. Turn the engine switch knob to the "CHOKE" position.
3. Grasp the recoil starter handle and pull slowly until resistance is felt, and then pull rapidly to avoid kickback. Firmly grasp the generator to avoid tumble of generator.
NOTE: Pay attention to pull the starting handle, the pull angle should not be too large, to prevent the handle from wearing the housing. Do not allow the starting handle to rebound and retract automatically to avoid damage to the shell. Slowly put the starting handle back. 4. When the engine is running, wait about 5 second, then turn the engine
switch to the "ON" position. 5. After all above operations, the engine can be normally loaded.
WARNING: Check starter cord conditions before operating. Have it replaced immediately by local authorized dealer if cord is frayed. WARNING: Do not connect device to the panel before generator start. The device should be in off position when it is connecting to the generator.
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Using The Generator
WARNING: It is prohibited to start or close the generating set when the output terminal of generating set is connected to an electric device is in "ON" state.
Connect to electrical devices Inspect power cord for damage before using. There is a hazard of electrical shock from crushing, cutting or heat damage. Make sure that the generating set has been properly grounded. If the electric devices require grounding, the generating set must ground. Make sure that the electric devices are in "OFF" position. Allow the engine to stabilize and warm up for a few minutes after starting. Connect and start the electric devices. Turn off all electric devices and disconnect them from the generating set. If the generating set supplies for several loads or electric devices, start the smallest one first and the largest one last.
DANGER: If connected devices overheat, turn them off and disconnect them from generating set.
Electrical Shock To reduce the risk of electrical shock, DO NOT use electrical cords that are worn, frayed, bare or otherwise damaged. DO NOT touch bare wires or receptacles. DO NOT handle generating set or electrical cords while standing in water, while barefoot, or while hands or feet are wet.
Loading Capacity
WARNING: Do not overload the generating set. Exceeding the generating set's capacity can damage the generating set and/or electric devices connected to it.
You must make sure your generating set can supply enough rated (running) and (starting) watts for the electrical devices at the same time. Follow these simple steps to calculate the running and starting watts necessary for your purposes. 1. Count the electrical devices you will power at the same time. 2. The amount of power you need to run with the devices is the total rated (running) watts of these items. 3. Starting power is the power needed shortly when electric devices start. Since not all devices start at the same time, starting power can be estimated by the maximum power of all devices plus the total power counted in step 2.
Wattage Reference Chart WARNING: It is necessary to equip with circuit protector or switch to isolate the generating set from the electric utility when the generating set is mainly used for backup. Failure to isolate the generating set from the power utility may result in injury or death to electric utility workers and damage to the generating set due to back feed of electrical energy.
When using AC power, you can use DC power at the same time. If using both AC and DC output sockets, note that the total power does not exceed the sum of AC and DC power.
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DC application The output voltage of DC socket is 15-20 V, for 12V DC load only. When AC power is used, DC power supply can be used. Overload of DC may make DC over protector act. Firstly, remove the DC load, wait for a few minutes,
and then reset the button of DC protector. AC application 1. Start the engine, make sure the AC output light (green) is on. 2. Turn off the power supply switch and plug the device into the generator's output socket. NOTE: In order to obtain the best operation effect and the maximum service life of the generator, the new generator should run for at least 20 hours under 50% load, so that the engine performance can be optimized.
Stop The Invert Generator
WARNING:Never stop the engine with electrical devices connected and with the connected devices in "ON" position. 1. Switch off the connected electrical appliances, and remove the connectors of all electric equipment from the generating set panel.
2. Turn the engine switch to "OFF" position.
3. After the engine has cooled down completely, turn the fuel tank cap switch counterclockwise to the "OFF" position.
WARNING: Be sure the fuel tank cap switch and Engine Switch locate the "OFF" position, when stopping, transporting and storing the generator.
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MAINTENANCE
The purpose of maintenance and periodic maintenance is to keep the generator in the best operating condition. WARNING: Improper maintenance or failure correct a problem before operation can cause a malfunction and result in property damage, serious injury or DEATH. lease use our original spare
parts or the same quality parts when replacing damaged parts.Improper maintenance will void your warranty.
DANGER: Accidental starts can cause severe injury or death. Remove the spark plug cap and ground generating set before performing any service. WARNING: The filter element may contains PAHs, PAHs are harmful for your health. Please wear gloves for protection during air filter maintenance.
Maintenance Schedule If the gasoline engine frequently works under high temperature or heavy load, change the oil every 25
hours. If the engine frequently work under dusty or other severe circumstances, clean the air filter element
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every 10 hours; If necessary, change the air filter element every 25 hours. If maintenance period and the exact time(hour), the one which comes first should govern. If you have missed the scheduled time to maintain your engine, do it as soon as possible.
Generator Maintenance
WARNING: Never clean the generator when it is running! Never use water to clean the generating set. Water can enter the generating set through the cooling slots and damage the generating set windings.
WARNING: Do not modify the generator in any way. Do not tamper with governed speed. Generator supplies correct rated frequency and voltage when running at factory set. Tampering with the factory set governor will void your warranty.
Make certain that the generator is kept clean and stored properly. Use a dry cloth to clean exterior surfaces of the generating set. Use a soft brush to clean the dirt and
oil. Use an air compressor (25 PSI) to clear dirt and debris from the generating set. Inspect all air vents and cooling slots to ensure that they are clean and unobstructed. Changing the oil
WARNING: Change the oil when the engine is warm form operation. The oil can reach up to 140under that condition. Careful operation should be taken to prevent burns.
1. Place the machine on a level surface which is about 300mm high away from the ground.
2. Loosen the cover screw and remove the cover as shown in the right figure.
3. Place the waste oil box on the ground. 4. Remove the oil dipstick, and tilt the machine to pour
the dirty oil as shown in the below figure. 5. Add recommended oil to the upper limit(H). 6. Fully tighten the dipstick. 7. Properly dispose of any used oil at an approved waste
management facility. 8. Reinstall the oil maintenance cover.
For conforming to the environment requirement, the used oil will be put into a sealed container and then be transported to the service station for recycle. Do not throw it into the trash or pour it on the ground.
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Air Filter Maintenance
WARNING: Do not run the engine without the air filter, or serious danger can result. A dirty Air Cleaner will restrict air flow into the carburetor. Please clean and maintain the air cleaner regularly to prevent carburetor from breaking down,If generators are often used in high dust areas, they need to be maintained more frequently.
1. Loosen the cover screw and remove the appearance cover. 2. Loose the filter fix clamp and remove the cover of the air filter. 3. Remove the foam filter element. 4. Wash in liquid detergent and warm water. 5. Squeeze thoroughly dry in a clean cloth. 6. Saturate in clean engine oil. 7. Squeeze in a clean absorbent cloth to remove all excess oil. 8. Assemble the filter element onto the filter unit. 9. Assemble the filter fix clamp. 10. Reinstall the air filter maintenance cover and the appearance
cover.
Spark Plug Maintenance
Spark plug gap : 0.6mm-0.7mm(0.024-0.028 in). Spark plug tighten torque: 12.5N.m
The spark plug is important for proper engine operation. A good spark plug should be intact, free of deposits, and properly gapped. Refer to Recommended Maintenance Schedule. To inspect the spark plug:
1. Remove the spark plug maintenance cover, and take off the spark plug cap
2. Using the spark plug spanner to loose and take off the spark plug.
3. Check the spark plug, if the spark plug insulator cracked or chipped, change a new one. Clean any dirt from the spark plug cap and spark plug base with wire brush if reuse it.
4. Measure the spark plug gap with a standard gauge. The normal value should be:0.6-0.7mm (0.024-0.028in), adjust if necessary.
5. Carefully thread the spark plug into the engine by hand. 6. After the spark plug is seated, use spark plug wrench to tighten the plug. 7. Attach the spark cap to the plug and connect the spark plug wire to the plug.
CAUTION: Only use recommended spark plug or equivalent. Do not use spark plugs that have improper heat range.
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Spark Collector Maintenance
WARNING: The spark collector must be maintained for every 100 hours of engine operation.
1. When the muffler is cooled, loosen the screws from the muffler outlet and take off the spark collector. 2. Use a brush to clean the carbon deposits on the spark collector. If the spark collector is damaged, and replace it. 3. Re-install the spark collector.Fuel Tank Filter Maintenance.
Fuel Tank Filter Maintenance
WARNING:Never use the gasoline while smoking or in the vicinity of an open flame.
1. Remove the fuel tank cap and filter. 2. Clean the filter with gasoline. 3. Wipe the filter and install it. 4. Install the fuel tank cap. NOTE: Be sure the fuel tank cap is tightened securely.
Transport And Storage
WARNING: Gasoline is highly flammable and extremely explosive. Empty the fuel tank and shut off fuel valve before storing or transporting this generating set.
To prevent fuel spillage when transporting or during temporary storage, the generating set should be secured upright in its normal operating position, with the engine switch OFF. The combination switch should be in the "stop" position and knob of the fuel cap should be turned to the "OFF" position.
When transporting Do not overfill the tank. Do not operate the generating set while it is on vehicle. Take the generating set off the vehicle and use it in a well-ventilated place. Avoid a place exposed to direct sunlight when putting the generating set on a vehicle. If the generating set is left in an enclosed vehicle for many hours, high temperature inside the vehicle could cause fuel to vaporize resulting in a possible explosion. The generator must not be transported a long time on rough road. If you have to drive on a road like this,drain off the gasoline and oil beforehand.
When storage for a long period The generating set should be started at least once every 2 weeks and allowed to run for at least 20 minutes. Follow the instructions below for longer term storage if the generating set will be out of service for 2 months or more. Allow the generating set to cool completely before storage. Clean the generating set according to instruction in maintenance section. Drain all fuel completely from the fuel tank, fuel hose and carburetor to prevent gum from forming. Turn off the fuel supply at the fuel valve. Change the oil. Reattach the spark plug. Remove the spark plug and pour about 15ml of oil into the cylinder.Crank the engine slowly to distribute the oil and lubricate the cylinder. Store the unit in a clean, dry area out of direct sunlight.
21
TROUBLESHOOTING
22
WIRING DIAGRAM
23
EXPLODED VIEW & PARTS LIST
Generator Exploded View
24
Generator Part List
Item Stock
1
H79i-TJDB000
2
91101-0612-00200
3
41130-G290022-00000
4
41130-G290021-00000
5
92201-0600-00100
6
41410-G290011-00000
7
92318-G290503-00000
8
36015-G65K502-H0200
9
91101-0612-00200
10
91202-0412-00200
11
36010-G660502-00000
12
92319-G290502-00000
13
41110-G290011-00000
14
41110-G290013-00000
15
41120-G290502-00000
16
41402-G290053-R2000
17
91116-G290011-00000
18
91705-G290505-00000
19
91202-0412-00200
20
91202-0416-00200
21
41440-G290021-H0400
22
41424-G290032-S2800
23
25221-G290011-00000
24
25220-G290021-00000
25
31430-G290506-00000
26
25160-G290502-00000
27
91206-4245-00200
28
91206-4232-00200
29
91101-0612-00100
30
93208-G290502-00000
31
23018-G290011-00000
32
23011-G290011-H0400
33
91705-G290506-00000
34
41402-G290052-R2000
Description
Qty
H79i powered
1
Hexagon flange bolt Small series
4
Frame shock-absorbing seat assembly
2
Frame shock-absorbing seat assembly
2
Hexagon flange nut
4
Baseplate assembly
1
Square nut
9
Controller plate
mounting 1
Hexagon flange bolt Small series
1
Cross recessed head screw
pan
2
Controller
1
Clip-on nut
12
Left shock-absorbing pad assembly
2
Left shock-absorbing pad assembly
1
Right shock-absorbing pad assembly
1
Decorative panel
1
Cross recessed hexagon head bolt
2
Hexagon step bolt
4
Cross recessed head screw
pan
1
Cross recessed head screw
pan
1
Knob assembly
1
Left housing
1
Rubber pad, window
Gauge
1
Gauge window
1
Starting assembly
switch 1
Fuel switch assembly 1
Cross recessed pan head tapping screw
2
Cross recessed pan head tapping screw
1
Hexagon flange bolt Small series
1
Retaining ring bearing clip
for 4
Air shroud, Muffler
1
Side cover, Muffler
1
Hexagon step bolt
12
Decorative panel
1
Item Stock
Description
Item
35
25130-G290021-000I0 Pipe
1
36
95206-E010010-00000 Clamp
2
37
95206-G290502-00000 Clamp
1
38 25190-G290032-00000 Fuel filter screen assembly 1
39 25108-G290011-00000 Rubber sleeve, Fuel tank
4
40 25140-G290503-H04J0 Fuel tank assembly
1
41 25190-G290031-00000 Fuel filter screen assembly 1
42 25109-G290011-H0400 Fixed nut, Fuel tank
1
43 26233-G290011-00000 Rubber sleeve, Filling port 1
44 25210-G290021-00000 Gauge assembly
1
45 25110-G290011-H0400 Fuel tank cap assembly
1
46 25214-G290503-00000 Gauge cover
1
47
91101-0610-00100
Hexagon flange bolt - Small series
2
48 41430-G290502-H0100 Right housing assembly
1
49 41404-G290011-00000 Rubber rope
1
50
92110-0500-00200
Nylon hexagon lock nut
1
51 41450-G290011-H0400 Baffle plate assembly
1
52 41403-G290021-H0400 Access door
1
53 41440-G290022-H0400 Knob assembly
1
54 41422-G290502-00000 Fastening rubber sleeve
2
55 41431-G290506-R2000 Right cover plate
1
56 91705-G290504-00000 Hexagon step bolt
2
57 41401-G290011-H0400 Decorative panel base
1
58 41402-G290051-H0400 Decorative panel
1
59 23158-G290507-H0400 Sound-absorbing sponge
1
60
36300-G290517-00000 Inverter
1
61
91202-0510-00100
Cross recessed pan head screw
1
62 36168-G290505-00000 Connection wire
1
63
91101-0608-00100
Hexagon flange bolt - Small series
1
64
91101-0612-00100
Hexagon flange bolt - Small series
2
65
31150-G220501-00000
Variable voltage rectifier assembly
1
66 36103-G290502-H0400 Panel assembly
1
67 36120-G320704-H0200 Control panel assembly
1
68
91202-0408-00200
Cross recessed pan head screw
4
25
Engine Exploded View 26
Engine Part List
Item Stock
Description
Qty
1
91101-0614-00100
Hexagon flange bolt - Small series
3
2
28110-E18001000001
Recoil starter assembly
1
3
28123-E180010
Handle, Rope
1
4
91101-0620-00100
Hexagon flange bolt - Small series
4
5
28140-E18050200000
Air shroud housing assembly 1
6
22132-E180501 Foam filter element
1
7
22115-E180010
Cap, Air filter
1
8
22008-E180010
Intake pipe
1
9
22004-E18001000000
Exhaust pipe
1
10
28001-E180010
Starter cup
1
11
26201-E180010
Cooling fan
1
12 33330-G290010 Magneto rotor assembly
1
13 33310-G290040 Magneto stator assembly
1
14
90001-E180010
Oil seal
1
15
31340-E180010
Trigger assembly
1
16
26231-E180010
Air shroud upper housing, Crankcase
1
17
91101-0612-00100
Hexagon flange bolt - Small series
2
18
31300-E180010
Ignition coil
1
19
91206-5013-00100
Cross recessed tapping screw
pan
head
2
20
13310-E180010
Crankcase assembly
1
21
26232-E180010
Air shroud lower housing, Crankcase
1
22
91101-0612-00100
Hexagon flange bolt - Small series
2
23 26236-E180010 Rubber sleeve, Engine oil port 1
24 19010-E180010 Oil dipstick assembly
1
25
94100-6204-P6300 Deep groove bearing
1
26
17021-E180010
Valve lifter
2
27
91710-E180010
Bolt,Connecting rod
2
28 15010-E180010 Connecting rod assembly
1
29
15122-E180010
Collar, Piston pin
2
30
15121-E180010
Piston pin
1
31
15100-E180010
Piston
1
32
15200-E180010
Piston ring
1
33 11131-E180010 Gasket,Cylinder head
1
34
11121-E180010
Intake valve
1
35
11122-E180010
Exhaust valve
1
36 91707-E180010 Double end bolt (Intake)
2
Item Stock
Description
Item
37
22002-E180010
38
22006-E180010
39
22007-E180010
40
25300-E180502
Gasket, Air intake
1
Heat shield, Carburetor
1
Gasket, shield
Carburetor
heat
1
Carburetor
1
41
92201-0600-00100 Hexagon flange nut
2
42
25317
43
25316
44
25318
Base, Stepmotor
1
Step motor
1
Enclosure, Step motor
1
45
11140-E180502
Cylinder head assembly
1
46
91718-E180010
47
31110-E180501
48
17010-E180010
49
17341-E180010
50
11101-E180010
51
17311-E180010
52
17312-E180010
Bolt, Cylinder head
4
Spark plug combination
1
Valve push rod assembly 2
Valve rocker arm shaft
1
Oil shield
1
Valve rocker arm
2
Lock nut, Valve
2
53
17315-E180010
Adjusting bolt, Valve
7
54
11401-E180010
Gasket, cover
Cylinder
head
1
55
11431-E180010
Cover, Breath groove
1
56
11432-E180010
Gasket, cover
Breath
groove
1
57
11410-E180010
Cylinder head assembly
cover 1
58
91101-0620-00100
Hexagon flange Small series
bolt
-
1
59
91708-V020501
Double end bolt (Exhaust) 7
60
23001-E180010
Gasket, Exhaust
1
61
23100-E180502
Muffler
1
62
91101-0612-00100
Hexagon flange Small series
bolt
-
1
63
92201-0600-00100 Hexagon flange nut
2
64
93404-E010010
Wood ruff key
1
65
15310-E180010
Crankshaft assembly
1
66
93100-E01L01000000
Washer
1
67
17210-E180010
Camshaft assembly
1
68
13001-E180501
Gasket, Crankcase
1
69
31080-E180010
Oil sensor assembly
1
70
13410-E180010
Crankcase cap assembly
1
71
91101-0622-00101
Hexagon flange Small series
bolt
-
7
27
TWO (2) YEARS LIMITED WARRANTY
PowerSmart® is committed to building tools that are dependable for years. Our warranties are consistent with our commitment and dedication to quality. TWO (2) YEARS LIMITED WARRANTY OF POWERSMART PRODUCTS FOR HOME USE. PowerSmart ("Seller") warrants to the original purchaser only, that all PowerSmart consumer power tools will be free from defects in material or workmanship for a period of two (2) years from date of purchase. Ninety (90) days for all PowerSmart Products, if the tool is used for professional or commercial use. SELLER'S SOLE OBLIGATION AND YOUR EXCLUSIVE REMEDY under this Two (2) Years Limited Warranty and, to the extent permitted by law, any warranty or condition implied by law, shall be the repair or replacement of parts, without charge, which are defective in material or workmanship and which have not been misused, carelessly handled, or misrepaired by persons other than Seller or Authorized Service Center. To make a claim under this Limited Warranty, you must return the entire power tool product; transportation prepaid, to PowerSmart Include a legible copy of the original receipt, which lists the date of purchase (month and year) and the name of the company purchased from. THIS LIMITED WARRANTY DOES NOT APPLY TO ANY ACCESSORY ITEMS INCLUDED WITH THE TOOL SUCH AS CIRCULAR SAW BLADES OTHER RELATED ITEMS OR TO ANY REPLACEMENT PARTS LISTED UNDER MAINTENANCE. ANY IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO TWO (2) YEARS FROM DATE OF PURCHASE. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS) ARISING FROM THE SALE OR USE OF THIS PRODUCT. SOME STATES IN THE U.S. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE IN THE U.S., PROVINCE TO PROVINCE IN CANADA AND FROM COUNTRY TO COUNTRY. For questions / comments, technical assistance or repair parts Please call toll free at: 1-872-314-0005 (M-F 9am 5pm EST) Email: support@amerisuninc.com / support@powersmartusa.com
SAVE YOUR RECEIPTS. THIS WARRANTY IS VOID WITHOUT THEM.
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WPS 文字