Powersmart PS5040 User manual

INSTRUCTION MANUAL
4400W Open Frame Inverter Generator
Model # PS5040
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Website:www.powersmartusa.com
Toll free: 1-800-791-9458 M-F 9-5 EST
Email: [e-mail]
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CONTENTS
Technical data…….………………………………………………......... 3
Introduction…….………………………………………………………. 4
Safety information…….………………………………………………... 4
General safety rules ……....…………………………………………… 5
Important safety instructions……………………………………………. 6
Symbols………………………………………………………………… 7
Knowing your generator………………………………………………… 8
Generator preparation…………………………………………………... 10
Starting the generator………....………………………………………… 13
Using the generator……………………………………………………... 15
Stopping the generator…………………………………………………. 17
Maintenance……………………………………………………………... 17
Storage & transport procedures…………………………………………. 20
Troubleshooting…………………………………………………………. 21
Wiring diagram…………………………………………………………. 22
Exploded view & parts list……………………………………………… 23
Warranty statement……………………………………………………… 28
TECHNICAL DATA
4400W Open Frame Inverter Generator
Engine type:
Spark plug gap:
Displacement:
Fuel tank capacity:
Oil capacity:
Rated wattage:
Starting wattage:
Rated voltage:
Rated current:
Frequency:
Phase:
USB output voltage:
Dimensions (L x W x H):
Noise rating:
Weight:
Model # PS5040
4 stroke, OHV, single cylinder with forced
air-cooling system
0.6-0.8 mm (0.024-0.031 in.)
224 cc
2.54 gallons
20.3 fl.oz
3500W
4400W
120V
29.2A
60Hz
Single
5V
20.9 x 13.8 x 19.3 inches
68 dB at 23Feet
72.8 lbs.

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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:
[e-mail], or Toll Free at [phone]. 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
For any questions regarding the hazard and safety notices listed in this manual or on the product, please
call [phone] Mon-Fri 9-5 EST before using the generator. Please read and understand the
instructions in this manual before starting the engine or attempting to operate this unit.
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 “Ground the Generator” 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.

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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.
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
SAVE THESE INSTRUCTIONS – This manual contains important instructions for the PowerSmart®
4400W generator that should be followed during installation and maintenance of the generator.
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.
WARNING: If this generator is used as a supply for a building’s wiring system, the generator
must be installed by a qualified electrician and connected to a transfer switch as a separately
derived system in accordance with the National Electrical Code, NFPA 70. The generator
shall be connected to a transfer switch that switches all conductors excluding the equipment grounding
conductor. The frame of the generator shall be connected to an approved grounding electrode.

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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 Voltage
A
Amperes
Current
Hz
Hertz
Frequency (cycles per second)
W
Watts
Power
MIN
Minutes
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 Keep all objects at least 5 feet (1.5m) from generator. Heat from
the muffler and exhaust gas can ignite combustible objects.
Electric shock alert Beware of electric shock hazard.
Fire/Explosion 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.
Wet conditions
alert
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 GENERATOR
Use the illustrations below to become familiar with the locations and functions of the various components
and controls of this generator.

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Parallel kit terminal
It used for parallel operation with another inverter (parallel kit sold separately)
Running indicator (green)
The running indicator lights up when generating set starts and has normal output.
Overload indicator (red)
When the overload indicator is on, it indicates that the generating set is overload and it may cause
overheat of frequency converter, or increase of AC voltage. 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
running indicator (green) is off and the overload indicator (red) is on, but the engine is still in running
state.
When the generating set has no output and the overload indicator is on, please take the following steps:
1. Lower the total power of the connected electric devices to the rated output range of generating set.
2. Check the air intake for impurities and check the control parts for abnormal situation. Handle
immediately if necessary.
3. Press the reset button.
Oil alarm lamp (yellow)
When the oil level drops below the lower limit, the oil protection system will stop the engine
automatically and oil alarming lamp will blink by pulling the recoil starter. The engine will not run until
the oil has been filled to the proper level.
Note: If engine flames out or fails to start, please adjust Engine switch to “ON” position and then pull the
recoil starter. If the oil alarming lamp lights up, it shows lack of oil. Please add appropriate oil and restart
the engine.

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Energy-saving switch
When the energy-saving switch is in “ON” position, the energy saving equipment controls the engine
rotate speed according to the connected loads. There will be good fuel consumption and low noise.
When the energy-saving switch is in“OFF”position, the engine will always run in rated rotate speed no
matter it is connected to the loads or not (See the parameter table for details).
Note: Please set the energy-saving switch to “OFF” position when connect to air compressor, sinking
pump etc. because these equipments need large starting current.
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 [phone] 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.
Step 1 - ADD OIL
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 engine damage and void your warranty.
The oil capacity of the engine crankcase is 20.3 fl. oz. For general use (above 40° F), we recommend
10W-30, 4-stroke engine oil.
ENGINE OIL RECOMMENDATIONS
Select good quality detergent oil bearing the American Petroleum Institute (API) service classifications
SJ, SL, or SM (synthetic oils may be used). Use the ASE viscosity grade of oil from the following chart
that matches the starting temperature anticipated before the next oil changes.
Engine Oil Temperature Recommendations

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To add oil, follow these steps:
1. Place the engine on a level surface with engine stopped.
2. Remove the dipstick (See fig.1) and wipe it clean.
3. Reinstall dipstick into tube, rest on oil fill neck, DO NOT thread cap
into tube.
Remove the dipstick again and check oil level. Level should be at top
of indicator on dipstick.
4. Fill to the upper limit (marked with “H”) of the dipstick with
the recommended oil if the oil level is low (See fig.2).
5. Reinstall and fully tighten the dipstick.
CAUTION: Operate generator only on a level surfaces. 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.
Step 2 - ADD GASOLINE
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.
Use clean, fresh, regular unleaded gasoline with a minimum octane rating of 87. Do not mix oil with
gasoline. Always wipe up any spilled fuel.
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 careful not to overfill.
The capacity of the fuel tank is 2.54 gallons (See fig.3).
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.
4. 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.
Fig.3
Fig.1
Fig.2

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NOTICE:
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.
Step 3 - GROUND THE GENERATOR
WARNING: Failure to properly ground the generator can result in electrocution.
The generator must be properly connected to an appropriate ground. It helps prevent electrical shock if
ground fault condition exists in the generator 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 ungrounded devices.
A ground terminal on the frame of the generator has been provided on the generator end. For remote
grounding, connect of a length of heavy gauge(4mm2) copper wire between the generator
ground terminal and a copper rod driven into the ground.
The National Electrical Code requires that the frame and external electrically conductive parts of this
generator be properly connected to an approved earth 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.
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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STARTING THE GENERATOR
Before starting the generator, make sure you have read and performed the steps in the “Generator
Preparation” section of this manual. If you are unsure about how to perform any of the steps in this
manual, please call [phone] Mon-Fri 9-5 EST or email: [e-mail] for
customer service.
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. Even if you cannot smell the exhaust, you may 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: This generator produces powerful voltage, which can result in electrocution.
ALWAYS ground the generator before using it (see the “Ground the Generator” 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 or wet conditions.
Do not touch bare wires or receptacles (outlets).
Do not allow children or non-qualified persons to operate.
CAUTION: Disconnect all electrical loads from the generator before attempting to start.

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STARTING THE ENGINE
To start the generator, perform the following steps:
1. Turn the fuel valve to the “ON”position (See fig.4).
2. Pull the choke valve switch to “OFF”position (See fig.5).
When in cold engine status, turn the choke valve to “ON” position, or turn it to “half -open” position
When in hot engine status. When fail to start the engine for twice, fully open the choke then operate
switch or recoil.
CAUTION: Choke plate should be setting in different width due to temperature and other factors.
3. Turn the switch to “ON” position. The switch button according to the open position, and then seize
the starter handle and slow pulling until there is a sense of resistance so far,and quickly pull to start
(See fig.6).
WARNING: Rapid retraction of the starter cord will pull hand and arm towards the engine
faster than you can let go.
Unintentional startup can result in entanglement, traumatic amputation or laceration. Broken
bones, fractures, bruises or sprains.
4. When starting, slowly turn choke lever to “ON” position as temperature rises. If engine runs unstable
(with shake), shift the lever to “half-open” position until the engine runs stable before rest the lever
to “ON” position (See fig.7).
Fig.4
Fig.5
Fig.7
Fig.6

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WARNING: During the engine warm up, partly open for the choke is necessary until the
temperature to a certain level.
5. The generator may be normally loaded.
WARNING: Connect the output terminal of the generator with the electric equipment. Do
not start or stop the engine when the electric equipment is in “ON” status.
USING THE GENERATOR
CONNECT TO ELECTRICAL DEVICES
1. Inspect power cord for damage before using. There is a hazard of electrical shock from crushing,
cutting or heat damage.
2. Allow the engine to stabilize and warm up for a few minutes after starting.
3. Make sure that the generating set has been properly grounded. If the electric devices require
grounding, the generating set must ground.
4. Make sure that the electric devices are in “OFF” position. And the load current is not higher than
the maximum withstanding current of single socket.
5. Connect and start the electric devices.
6. Turn off all electric devices and disconnect them from the generating set.
7. If the generating set supplies for several loads or electric devices, start the smallest one first and
the largest one last.
DANGER: 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 all the devices is
the total rated (running) watts of these items.
3. Identify how many surge (starting) watts you will need.
Surge wattage is the short burst of power needed to start
electric motor-driven tools or appliances such as a
circular saw or refrigerator.
Because not all motors start at the same time, total surge
Watts can be estimated by adding only the electrical Wattage Reference Chart

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device(s) with the highest additional surge watts to the total rated watts from step 2.
WARNING: You must isolate the generator from electric utility by opening the electrical
system’s main circuit breaker or main switch if the generator is used for backup power.
Failure to isolate the generator from the power utility may result in injury or death to electric
utility workers and damage to the generator due to backfeed of electrical energy.
CAUTION: When the overload indicator is on (See fig.8),
it
indicates that the generating set is overload and it may cause
overheat of frequency converter, or increase of AC voltage.
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 running indicator(green) is off and the overload
indicator(red) is on, but the engine is still in running set.
When the generating set has no output and the overload indicator is on, please take the following steps:
1. Lower the total power of connected electric devices to the rated
output range of generating set.
2. Check the air intake for impurities and check the control parts
for abnormal situation. Handle immediately if necessary.
3. Press the reset button (See fig.9).
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 within
4 seconds. If it cannot stop, please call [phone] Mon-Fri 9-5 EST or
email: [e-mail] 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.
CAUTION: When overload too much, overload indicator (red) blinks continuously,
and the generating set may be damaged. When overload a little, overload
indicator (red) lights up continuously, it may shorten the service life of generating set.
When continuously operating the generating set, power cannot exceed the rated power
of generating set.
The total power of electric devices cannot exceed the rated power of generating set. The manufacturers of
electric devices or tools always list the rated power of similar models or serial number.
Fig.8
Overload Indicator
Reset button
Fig.9

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STOPPING THE GENERATOR
WARNING:Never stop the engine with electrical devices connected and with the connected
devices turn “ON”.
1. Remove all the load on generator.
2. Allow the generator run at no load for a few minutes to stabilize internal temperatures of the engine
and generator.
3. Turn the engine switch to “OFF” position.(See fig.10)
4. Turn the fuel valve to “OFF” position (See fig.11).
5. Remove the plug of all electric equipment from the generator panel (See fig.12).
MAINTENANCE
WARNING: Accidental starts can cause severe injury or death. Remove and ground spark
plug
wire 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.
Fig.11
Fig.12
Fig.10

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Proper routine maintenance of the generator will help prolong the life of the machine. Please perform
maintenance checks and operations according to the schedule in below chart.
NOTE:
Note1: Applicable types (if available).
Note2: Before each season and after then (whichever comes first).
Note3: Service more frequently under severe , dusty, dirty conditions.
Note4: To be performed by knowledgeable, experienced owners or the authorized dealer.
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 damp 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.

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ENGINE MAINTENANCE
Checking the oil
The oil capacity of the engine crankcase is 20.3 fl. oz.
1. Place the engine on a level surface with engine stopped. Check the engine oil level. Remove the oil
maintenance cover. Remove the dipstick and wipe it clean.
2. Reinstall dipstick into hole, rest on oil fill neck, DO NOT thread cap into hole.
3. Remove the dipstick again and check oil level. Level should be between the upper and lower limit.
Fill to the upper limit of the dipstick with the recommended oil if the oil level is too low.
4. Reinstall and fully tighten the dipstick.
Changing the oil
WARNING: Change the oil when in hot engine state. The oil can reach up to 140℃under
that condition. Careful operation should be taken to prevent burns.
1. Place the engine on a level surface.
2. Clean area around dipstick and drain plug.
3. Remove the oil dipstick (See fig.13).
4. Remove the oil drain plug and allow the oil to drain completely.
5. Unscrew the oil gauge after tightening the drain bolts.
6. Add recommended oil to the upper limit (see add oil instruction above).
7. Reinstall and fully tighten the dipstick.
Dispose of used oil at an an approved waste management facility.
AIR FILTER
Routine maintenance of the air cleaner helps maintain proper airflow
to the carburetor. Occasionally check that the air cleaner is free of
excessive dirt.
1. Loosen the filter fix bolt and and remove the cover of the air filter
(See fig.14).
2. Remove the foam filter element.
3. Wash in liquid detergent and warm water.
4. Squeeze thoroughly dry in a clean cloth.
5. Saturate in clean engine oil.
6. Squeeze in a clean , absorbent cloth to remove all excess oil.
7. Place the filter in the assembly.
8. Fasten the air filter cover with the fix bolt, and the mounting it back
to the air filter body.
WARNING: Do not run the engine without the air filter,
or serious danger can result.
Fig.13
Fig.14

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SPARK PLUG
Spark plug gap : 0.6mm-0.8mm(0.024-0.031 in).
Spark plug tighten torque: 15-20N.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. Clean any dirt from the spark plug cap and spark plug base.
2. Remove the spark plug cap.
3. Using socket wrench to loose and remove the spark plug.
4. Inspect the spark plug and spark plug washer, if it was broken or worn,
replace with a new one.Clean the spark plug with wire brush if reuse it.
5. Check spark plug gap. Carefully bend side electrode to adjust the gap if
necessary.
6. Carefully thread the plug into the engine by hand.
7. After the spark plug is seated, use spark plug wrench to tighten the plug.
8. 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.
SPARK ARRESTER
1. Allow the generating set to cool completely before servicing the spark arrester.
2. Remove the two bolt holding the cover plate which retains the end of the
spark arrester to the muffler.
3. Remove the spark arrester screen.
4. Carefully remove the carbon deposits from the spark arrester screen with a
wire brush (See fig.16).
5. Replace the spark arrester if it is damaged.
6. Reinstall the spark arrester in the muffler and attach with the two screws.
STORAGE & TRANSPORT PROCEDURES
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.
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.
Fig.15
Fig.16