0
CONTENTS:
1. GENERAL SAFETY PRECAUTIONS…………………………………….2-3
2. ELECTRICAL SAFETY PRECAUTIONS…………………………………3-4
3. SAFETY STICKERS AND EXPLANATIONS………………………….....4-5
4. SPECIFICATIONS…………………………………………………………….6
5. COMPONENTS……………………………………………………………......7
6. PRE OPERATION CHECKS………………………………………… …..8-11
7. OPERATING PROCEEDURES…………………………………………12-17
8. WATTAGE INFORMATION……………………………………………….....18
9. MAINTENANCE SCHEDULE……………………………………………19-21
10. HOW-TO MAINTENANCE …………………………………………….....22-24
11. TRANSPORTING AND STORAGE………………………………………24-25
12. TROUBLE SHOOTING……………………………………………………26-27
13. WIRING DIAGRAM…………………………………………………….…..28-29
1
IMPORTANT:
Thank you for purchasing a Power Master Gasoline Generating Set (hereinafter referred to as
the “generator”).
This manual will assist you in operating and maintaining your generator. This manual is the
latest version. With the continuous improvement and upgrading of this product, the
manufacturer reserves the right to modify this manual without notice. The manufacturer shall
assume no liability for incorrect information contained in this manual.
This manual is an integral part of the generator. When the generator is transferred to others,
this manual should be handed over to the new owner.
Some important information in this manual will be indicated in the following way ,please see
below). The users should pay special attention to these instructions.
The range of POWER MASTER GENERATORS is safe and reliable, but
incorrect use of these products may cause personal injury and or damage
to your machine. Please read this manual thoroughly before operation as
this product is required to operate strictly in accordance with this manual.
IMPORTANT NOTICES:
PLEASE PAY SPECIAL ATTENTION TO STATEMENTS PRECEDED BY
THE FOLLOWING WORDS:
Danger
DANGER
This indicates a hazardous situation, which, if not avoided, will result in death or
serious injury.
Warning
WARNING:
This indicates a hazardous situation, which, if not avoided, could result in death
or serious injury.
Caution
CAUTION:
This indicates a hazardous situation, which, if not avoided, could result in injury.
2
1. GENERAL SAFETY PRECAUTIONS:
Danger
Warning
Caution
1.1. A “LAYMAN” and or “CHILDREN” may
not recognize the possible dangers of
operating a generator. We recommend that
only competent persons should operate the
generator.
1.2. Fuel is combustible and easily ignited.
Do not refuel during operation.
1.3. Do not refuel whilst smoking or near
naked flames. Do not overfill or spill fuel. If
this happens clean the fuel on and around
the generator properly before operating.
1.4. Only use the specified fuel when
operating the generator
1.5. Some parts of the internal-combustion
engine are hot and might cause burns. Pay
attention to the warning signs on the
generating set.
1.6. Engine exhaust gases are toxic. Do not
operate the generator in an unventilated
room. When installed in a ventilated room,
additional requirements for fire and
explosion protection must be observed.
1.7. Regularly check that the bolts and nuts
are properly tightened as they may become
lose due to vibration of the generator whilst
in use.
1.8. Before using the generator ensure that
you have checked the periodic maintenance
schedule in the operator’s manual.
1.9. Pay attention to the wiring or extension
cords from the generator to the connected
device. If the wire is under the generator or
in contact with a vibrating part, it may break
and possibly cause a fire, generator burnout,
or electric shock hazard. Replace damaged
or worn cords immediately.
1.10. Do not operate in rain, wet or damp
conditions, or with wet hands. The operator
may suffer severe electric shock if the
generator is wet.
1.11. If wet, wipe and dry it well before
starting. Do not pour water directly over the
generator, nor was hit with water.
1.12. Be extremely careful that all necessary
electrical grounding procedures are followed
during each and every use. Failure to do so
can be fatal.
1.13. Do not connect the generator to a
commercial power line. Connecting to a
commercial power line may short circuit the
generator. We strongly recommend the use
of a Transfer Switch for connecting to a
domestic circuit.
1.14. Do not smoke when handling the
battery. The battery emits flammable
hydrogen gas, which can explode if exposed
to cigarettes and or naked flames. Keep the
area well-ventilated and keep naked flames/
sparks away when handling the battery.
1.15. Keep children and all bystanders at a
safe distance from the genertor whislt in use.
3
1.16. It is absolutely essential that you know
and understand the safe and proper use of
the power tool or appliance that you intend
to connect to the generator. All operators
must read, understand and follow the tool/
appliance operators maunal. The tool and
appliance applications and limitations must
be understood. Keep all instruction manuals
and in a safe place for future reference.
1.17. Always switch off the circuit breaker on
the generator when not in use.
2. ELECTRICAL SAFETY INFORMATION:
2.1. Electrical equipment including cable, cords and plug connection must not be defective.
Please check before using.
2.2. Do not plug the generator directly into a wall socket-outlet.
2.3. The generator should not be connected to other sources such as the power company
supply mains. In special cases where stand-by connection to existing electrical systems
or integration therewith is intended, note that it is a legal requirement that such
connections or integration may only be performed by a competent person.
2.4. Protection against electrical shock depends on circuit-breakers that are specially
matched to the generator. If a circuit breaker requires replacement, it shall be replaced
by a circuit breaker that has identical ratings and performance characteristics.
2.5. Due to high mechanical stresses only tough rubber-sheathed flexible cable should be
used.
2.6. If the generator is of CLASS II construction then earthing of the generator is not required.
2.7. Cord Extension Sets:
2.7.1. A 1mm2 flexible cable can draw a maximum of 10A provided that the cable is not
longer than 25m.
2.7.2. A 1.5mm2 flexible cable can draw a maximum of 10a provided that the cable is not
longer than 35m
2.7.3. A 1.5mm2 flexible cable can draw a maximum of 16a provided that the cable is not
longer than 20m
2.7.4. A 2.5mm2 flexible cable can draw a maximum of 10a provided the cable is not
longer than 65m
2.7.5. A 2.5mm2 flexible cable can draw a maximum of 16a provided that the cable is not
longer than 45m
2.7.6. A 4mm2 flexible cable can draw a maximum of 10a provided that the cable is not
longer than 100m
4
2.7.7. A 4mm2 flexible cable can draw a maximum of 16a provided that the cable is not
longer than 65m
2.8. DROP IN ELECTRIC EXTENSION CORDS:
When a long electric extension cord is used to connect an appliance or tool to the generator, a
certain amount of voltage drop or loss occurs in the extension cord which reduces the effective
voltage available for the appliance or tool.
The chart below has been prepared to illustrate the approximate voltage loss when an extension
cord of 300 feet (approx.100 meters) is used to connect an appliance or tool to the generator.
Nominal
cross
section
A.W.G.
Allowable
current
No. of
strands/
strands
dia.
Resistance
Current Amp.
mm2
No.
A
No./mm
/100m
1A
3A
5A
8A
10A
12A
15A
Voltage drop
0.75
18 7 30/0.18
2.477
2.5V
8V
12.5V
1.27
16
12
50/0.16
1.486
1.5V
5V
7.5V
12V
15V
18V
2
14
17
37/0.26
0.952
1V
3V
5V
8V
10V
12V
15V
3.5
12 to10
23
45/0.32
0.517
1.5V
2.5V
4V
5V
6.5V
7.5V
5.5
10 to 8
35
70/0.32
0.332
1V
2V
2.5v
3.5V
4V
5V
3. SAFETY STICKERS AND EXPLANATIONS:
5
6
4. SPECIFICATIONS:
Item
1KVA
2.2KVA
2.8KVA
5.5KVA
6.5KVA
7.5KVA
ENGINE
ENGINE MODEL
SR156F
SR170F
SR170FE
SR188F/E
SR190F/E
SR192F/E
ENGINE TYPE
OHV, 25 tilt, Single Cylinder, Forced Air Cooling, 4-Stroke
BORE STROKE (MM)
56X40
70X54
70X54
88X64
90X66
92X57
DISPLACEMENT (ML)
98
208
208
389
420
445
LUBRICATING TYPE
SAE 10W – 30W/40/S
IGNITION SYSTEM
T.C.L.
GENERATOR SPECIFICATION
STARTING SYSTEM
Recoil Start
Electric Start
RATED VOLTAGE (V)
230V
RATED FREQUENCY
(Hz)
50
RATED OUTPUT (KW)
0.85 2 2.5
5 6 7
RATED CURRENT (A)
3.7
8.7
10.7
21.7
26
30
MAXIMUM OUTPUT
(KW)
1
2.2
2.8
5.5
6.5
7.5
POWER FACTOR
(COS)
1
PHASE
Single
FUEL TANK
CAPACITY(L)
6
15
15
25
25
25
OIL CAPACITY(L)
0.35
0.6
0.6
1.1
FUEL LOAD
CONSUMPTION(L/H)
1.2
1.7
1.7
3.1
3.5
3.5
FUEL LOAD
CONTINUOUS RUN
TIME(H)
8 9 9 8 7
7
NOISE LEVEL {Db(A)}
≤ 92
≤94
≤94
≤96
≤96
≤96
REGULATING
SYSTEM
Advanced Automatic Voltage Regulator(AVR)
PACKAGE
DIMESNIONS
(L*W*H)(mm)
475X385X440
605X460X465
605X460X465
715X640x595
715X640X585
CONTAINER
LOADING QTY
(20/40/40H)
360/720/864
225/475/475
225/485/485
108/216/216
108/216/216
N.W(Kg)
27
41
47
78
81
87
G.W(Kg)
29
44
49
81
84
90
Specifications are subject to change without notice.
ELECTRIC START MODEL:
7
5. COMPONENTS:
(1) FUEL COCK
(2) FUEL TANK COVER
(3) AIR CLEANER
(4) RECOIL STARTER
(5) TOLLEY WHEEL
(6) FRAME
(7) SOCKET
(8) CONTRAL PANEL
(9) BATTERY
(10) OIL DIPSTICK
8
6. PRE-OPERATION CHECKS:
6.1. CHECKING THE ENGINE OIL:
6.1.1. Ensure that the generator is on a flat and level surface before adding oil.
6.1.2. Remove the oil cap and check the level of the oil
6.1.3. Add oil to the generator if the oil is below the indicator line
6.1.4. Always ensure that your engine oil is clean.
6.2. OIL CAPACTIY FOR THE VARIOUS GENERATOR MODELS:
6.2.1. 1KVA - 0.35L
6.2.2. 2.2KVA - 0.6L
6.2.3. 2.8KVA - 0.6L
6.2.4. 5.5KVA - 1.1L
6.2.5. 6.5KVA - 1.1L
6.2.6. 7.5KVA - 1.1L
6.3. RECOMMENDED ENGINE OIL:
6.3.1. Only use 4-stroke automotive oil (API or
SE) alternatively you can use a higher
grade (SG, SH or SJ). SAE 10W -30 or
10W-40 is recommended for general
all-temperature use. If single viscosity oil is
used, select the appropriate viscosity for
the average temperature in your area
9
6.4. CHECKING THE ENGINE FUEL:
Do not refuel while smoking or near an open flame or other potential fire hazards.
6.4.1. Use the fuel gauge to check the fuel level.
6.4.2. If the fuel level is too low, only refuel with
unleaded fuel
6.4.3. Ensure that you use the fuel filter screen on the
fuel filter
6.5. FUEL CAPACITY FOR THE VARIOUS
GENERATOR MODELS:
6.5.1. 1KVA – 6L
6.5.2. 2.2KVA - 15L
6.5.3. 2.8KVA – 15L
6.5.4. 5.5KVA – 25L
6.5.5. 6.5KVA – 25L
6.5.6. 7.5KVA – 25L
6.6. CHECKING COMPONENT PARTS:
Before starting the generator please check the following::
6.6.1. Check for any fuel leaking from any part of the generator.
6.6.2. Check that all the nuts and bolts are securely tightened on the generator.
WARNING:
Make sure you review each warning in order to prevent fire hazards. Do not refill the fuel tank whilst
the engine is running or hot. Please ensure that the fuel cock is closed before refueling. Be careful
not to contaminate the fuel with any dust, dirt, water or other foreign liquids/objects. Please lean all
spilt fuel thoroughly before starting the generator.
Ensure that the generator is clear from any open flames. Do not smoke whist refueling the
generator.
WARNING:
10
6.6.3. Check for any visible damaged components on the generator.
6.6.4. Check that the generator is not resting on or adjacent to any electrical wiring.
6.7. CHECK THE GENERATOR SURROUNDINGS:
6.8. BATTERY INSTALLATION (ELECTRIC STARTER MODEL)
The recommended battery capacity is 12V -24AH.
WARNING:
Make sure you review each warning in order to prevent fire hazards. Keep the surrounding area
clear of flammables or other hazardous materials. Keep the generator at least 3 feet (1 meter)
away from all buildings and or other structures. Only operate the generator in a dry, well-ventilated
area. Keep the exhaust pipe clear of all foreign objects. Keep the generator away from open
flames. Do not smoke in close proximity to the generator. Keep the generator on a flat and level
surface.
Do not attempt to block the generator air vents with any paper or other material/objects.
WARNING
Follow the instructions very carefully failing to do so may result in injury and or death. Only use
the recommended battery capacity. Ensure that the KEY/SWITCH is in the “STOP” position prior
to connecting or disconnecting the battery. Always check to ensure that the terminals are
connected correctly. Positive (+) Cable to Positive (+) Terminal, Negative (-) Cable to Negative
(-) terminal.
RED CABLE: Positive (+) Terminal BLACK CABLE: Negative (-) Terminal
Please note that the generator will not start if the connection of the battery is done incorrectly.
Ensure that you securely tighten the nuts and bolts on the battery terminals. Disconnect the
battery cables from the terminals when charging the battery. Please note that when charging the
battery we recommend a “TRICKLE/SLOW” charge. This will pro long the life of the battery.
11
6.9. GROUNDING THE GENERATOR:
6.9.1. When grounding the generator connect the grounding lug of the generator to the
grounding spike.
6.9.2. If such grounding conductor or ground electrode is unavailable, connect the
grounding lug of the generator to the grounding terminal of the electric tool or
appliance.
12
7. OPERATING PROCEDURES:
7.1. STARTING THE GENERATOR ENGINE:
7.1.1. Turn the engine “KEY” to the “ON/START” position.
(For manual start
Generators there will be a Switch and not a Key).
7.1.2. Turn the circuit breaker to the “OFF” position.
7.1.3. Open the fuel cock.
7.1.4. Turn the choke lever to “CLOSED” position if the generator engine is cold.
7.1.5. For manual start machines pull the recoil starter until resistance is felt.
7.1.6. This is the “compression” point. Return the handle to its original position, and then
pull swiftly.
7.1.7. If the generator engine fails to start after several attempts, repeat above the
procedures with the choke knob returned to the “OPEN” position.
7.1.8. Do not pull the rope of the recoil starter out completely.
7.1.9. After starting the generator allow the starter handle to return to its original position
whilst still holding on to the handle.
For the 1KVA generator model please refer to Figure 1.
For the 2.2KVA, 2.8KVA, 5.5KVA, 6.5KVA, 7.5KVA generator models please refer to
Figure 2.
CAUTION
Every time before starting the generator please
ensure that you check the oil level
13
7.10. For Electric/Key Start Machines insert the key in
to the ignition and turn the key
clockwise to the “RUN” position.
7.11. Then turn the key 1 (one) turn further in a
clockwise position to the “START” position.
This will engage the starter motor and this will start the generator.
NOTE: If you are starting the generator for the first time we recommend that you use the
recoil starter.
7.12. After the engine has started, please return the choke lever
to the “OPEN” position.
For the 1KVA generator model please refer to Figure 1.
For the 2.2KVA, 2.8KVA, 5.5KVA, 6.5KVA, 7.5KVA generator
models please refer to Figure 2.
7.13. Always let the generator engine warm up sufficiently
7.2. USING ELECTRIC POWER:
CAUTION:
Do not attempt to run the starter motor for more than 5 seconds continuously. If the
generator engine fails to start, return the key to the “RUN” position and wait about 10
seconds before attempting to start it again. Do not turn the key switch to the “START”
position when the generator engine is running as this could damage the starter motor. When
attempting to start the generator engine using the recoil starter ensure that the key is in the
“ON” position before pulling the recoil starter handle.
WARNING:
Make sure that the appliance is switched OFF before connecting it to the generator.
Do not move the generator while it is running.
14
7.2.1. AC APPLICATION:
7.2.2. Check the volt meter for sufficient voltage.
7.2.3. This generator is properly tested and adjusted and set at the factory.
7.2.4. If the generator does not produce the specified voltage please contact GENTECH
INDUSTRIES, the OFFICIAL SERVICE AGENTS COUNTRYWIDE for all models
of POWER MASTER GENRATORS.
7.2.5. Turn off the switch (es) of the electrical appliance(s) before connecting to the
generator.
7.2.6. Insert the plug(s) of the electrical appliance(s) into the
receptacle.
7.2.7. Check the amperage of the receptacles used making
reference to the TABLE on page 4 and be careful not to
take a current exceeding the specified amperage.
7.2.8. Check that the total wattage of all appliances that is being
connected to the generator does not exceed the rated
output of the generator.
7.2.9. Turn on the appliance switch.
NOTE: If the circuit breaker “TRIPS” during opera tion the
generator is overloaded or the appliance is defective. Stop the
generator immediately and check the appliance and /or generator
for overloading.
15
7.3. CONNECTING TO DOMESTIC CIRCUITS (HOUSE WIRING)
7.3.1. When connecting the generator to the house wiring the generator output power must be
taken from the 220V receptacle.
7.3.2. A transfer switch must be installed to transfer the load from the commercial power
source to the generator. This switch is necessary to prevent accidents caused by the
recovery from power outages. Use a transfer switch of the correct capacity. Install the
transfer switch between the meter and the fuse or AC Breaker Box.
WARNING:
If a generator is to be connected to residential or commercial power lines for stand-by power
during power outage- all connections must be made by a competent person/ licensed electrician.
Connection failure, or improper connection, may result in death, personal injury, damage to the
generator, damage to the appliances, damage to the building’s wiring, or even result in a fire.
CAUTION:
If the neutral wire of the house wiring is earthed, be sure to earth the ground terminal of
the generator. An electric shock may result if this procedure is not followed.
16
7.4. CHARGING THE BATTERY:
NOTE: It may be necessary to charge the battery
directly after purchase. It is recommended to fully
charge the battery with a battery charger on the first
charge on a slow/trickle charge.
7.4.1. DC APPLICATION:
7.4.1.1. Connect the positive (red) terminal on the generator to the positive (+) terminal on the
battery.
7.4.1.2. Connect the negative (black) terminal on the generator to the negative(-) terminal on
battery.
7.4.1.3. Use the recoil starter to start the generator the battery will then begin to charge as the
generator runs.
Note: Both AC and DC outputs can be used at the same time providing that the total output
is within the rated output of the generator.
7.4.2. BATTERY CHARGER:
7.4.2.1. Disconnect the battery cables before/during charging the battery
7.4.2.2. Ensure that the battery charger is connected correctly.
7.4.2.3. Please note that we recommend a trickle/ slow charge.
7.4.2.4. Once the battery is fully charged reconnect the battery to the generator (see page 9).
7.4.3. SAFETY PRECAUTIONS WHILE CHARGING:
7.4.3.1. An explosive hydrogen gas is discharged through vent holes in the battery during the
charging process.
7.4.3.2. Electrolyte fluid can burn your eyes and clothing. Be extremely careful and avoid
contact. If contact occurs wash the affected area immediately with large quantities of
water or milk and consult a doctor for treatment.
7.4.3.3. When charging a large capacity battery or totally discharging a battery excessive
current may force the DC breaker to turn off. In such cases use a battery charger to
charge a large battery with an AC output.
17
7.4.3.4. Battery defects may cause the DC breaker to turn off. Check the battery before
replacing the DC breaker.
7.5. STOPPING THE GENERATOR:
7.5.1. Turn off the power switch of the electric equipment and unplug the cord from the
receptacle of the generator.
7.5.2. Turn the circuit breaker to the “OFF” position.
7.5.3. Allow the engine to cool down for about three minutes with no load prior to switching it
off.
7.5.4. For recoil starter models turn the switch to the “OFF” position
7.5.5. Electric starter models turn the key to the “STOP” position.
7.5.6. Close the fuel cock.
7.6. OIL SENSOR:
7.6.1. The oil sensor detects a drop in the oil level in the crank case and automatically stops
the engine when oil level drops below a predetermined level.
7.6.2. When engine has stops automatically switch off the generator’s circuit breaker and
check the oil level. Refill with engine oil to the upper level as instructed on page 6, and
then restart the engine.
7.6.3. If the engine does not start please re check the oil level.
CAUTION:
Do not remove the OIL SENSOR PROBE when
refilling with oil. Remove the oil filler cap on the
opposite side of carburetor.
18
8. WATTAGE INFORMATION:
8.1. Some appliances need a “surge” of energy when starting. This is commonly known as a
“LAGGING” Load.
8.2. This means that the amount of electrical power needed to start the appliance may exceed
the amount needed to maintain its use.
8.3. Electrical appliances and tools normally come with a label indicating voltage, cycles/Hz,
amperage (amps) and electrical power needed to run the appliance or tool.
8.4. Check with your nearest branch with questions regarding power surges of certain
appliances or power tools.
8.5. Electrical loads such as incandescent lamps and hot plates require the same wattage to
start as is needed to maintain their use. This is commonly known as a “LEADING” Load
8.6. Loads such as fluorescent lamps require1.5 to 2 times the indicated wattage during
start-up.
8.7. Electrical motors require a large starting current. Power requirements depend on the type
of motor and its use. Once enough “power” is attained to start the motor, the appliance will
require only +-50% of the wattage in order to continue running.
8.8. Most electrical tools require 1.5 to 3 times their wattage for running under load during use.
Loads such as submersible pumps and air compressors require a very large force to start.
They need 3 to 5 times the normal running wattage in order to start.
NOTE: PLEASE REFER TO THE CONSUMPTION CHART AND LOAD
CALCULATOR IN THE QUICK REFERENCE GUIDE BOOKLET.
19
9. MAINTENANCE SCHEDULE:
FOR ALL YOUR SERVICE, MAINTENANCE AND WARRANTY QUERIES PLEASE CONTACT
GENTECH INDUSTRIES. PLEASE REFER TO THE BACK PAGE FOR ALL CONTACT
DETAILS.
9.1. DAILY INSPECTION:
Before staring the generator please check the following service items:
20
9.2. PERIODIC MAINTENANCE:
Periodic maintenance is vital for the safe and efficient operation of the generator. Check the table
below for periodic maintenance intervals.
IT IS ALSO NECESSARY FOR THE UESER OT THIS GENERATOR TO CONDUCT THE
MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-RELATED PARTS LISTED BELOW
TO KEEP THE EMISSION CONTROL SYSTEM EFFECTIVE.
The emission control system consists of the following parts:
(1) Carburetor and internal parts
(2) Cold start enrichment system, (if applicable)
(3) Intake manifold, (if applicable)
(4) Air cleaner elements
(5) Spark plug
(6) Magneto or electronic ignition system
(7) Spark advance/retard system, (if applicable)
(8) Exhaust manifold, (if applicable)
(9) Hoses, belts, connectors and assemblies
The maintenance schedule indicated in the table is based on normal generator operation. Should
the generator be operated in extremely dusty conditions or in heavier loading conditions, the
maintenance intervals must be shortened. This will dependent on the contamination of oil,
clogging of filter elements and the wear and tear of parts.
21
9.2.1. PERIODIC MAINTENANCE TABLE:
MAINTENANCE ITEMS
EVERY 8
HOURS
(DAILY)
EVERY
20
HOURS
EVERY
100
HOURS
(WEEKLY)
EVERY 200
HOURS
(MONTHLY)
EVERY
500
HOURS
EVERY
1000
HOURS
CLEAN GENERTOR AND
CHECK BOLTS AND NUTS
CHECK AND REFILL ENGINE
OIL
REPLACE ENGINE OIL
Init ia l
EVERY 100 HOURS
CLEAN SPARK PLUG
CLEAN AIR FILTER
REPLACE AIR FILTER
ELEMENT
CLEAN FUEL STRAINER
CLEAN AND ADJUST SPARK
PLUG AND ELECTRODES
REPLACE SPARK PLUG
REMOVE CARBON FROM
CYLINDER HEAD(*note2)
CLEAN AND ADJUST VALVE
CLERANCE(*note2)
CLEAN AND ADJUST
CARBURETOR(*note2)
CLEAN AND REPLACE
CARBON BRUSHES
REPLACE FUEL LINES
OVERHAUL ENGINE*note 2)
IF AND WHEN REQUIRED
*Note: 1.The initial oil change should be performed after the first twenty (20) hours of
operation thereafter only change the oil every one hundred (100) hours.
9.2.2. Before changing the oil, please try to look for a suitable way to dispose of old oil.
9.2.3. Do not pour it down drains, onto garden soil or into open streams. Your local zoning
or environment instructions on proper disposal.
22
10. “HOW – TO” MAINT ENANCE
10.1. ENGINE OIL CHANGE:
We recommend that you change the engine oil
every 100 hours. (For a new engine please change
the engine oil after the first 20 hours.)
10.1.1. Drain the oil by removing the drain plug
and the oil filler cap while the engine is
still warm.
10.1.2. Once the oil has completely drained out reinstall the drain plug and fill the engine with oil
until it reaches the upper level on the oil filler cap. DO NOT OVER FILL.
10.1.3. Only use clean high quality lubricating oil. Do not use old or dirty oil as this will affect the
performance and longevity of the generator. This generator is fitted with an OIL ALERT
SENSOR and will NOT start if there is insufficient oil in the sump/engine.
10.2. CLEANING AIR FILTER:
A dirty air filter element will make the starting of the
generator difficult. It will also cause the generator to
under- perform and may cause permanent damage.
Always keep the air filter element clean.
10.2.1. The urethane foam element must be washed
with a cleaning detergent. After cleaning it
ensure that it is dried properly before
reinstalling. Please clean every 100 hours.
10.2.2. Clean the paper element by tapping and blowing it gently to remove dirt and dust. Never
use oil to clean the paper element. Please clean every 50 hours and replace every 200
hours.
Please clean the air filter elements more often when operating in dusty environments.
OIL CAPACITY:
1.0KVA :0.35L
2.2KVA/2.8KVA: 0.6L
5.5KVA/6.5KVA/7.5KVA: 1.1L
CAUTION
Do not wash the elements with kerosene, gasoline or oil.
23
10.3. CLEANING AND ADUSTING SPARK PLUG:
10.3.1. If the spark plug is clogged with carbon please clean it using a plug cleaner or wire brush.
10.3.2. Always check electrode gap after cleaning.
Adjust gap to 0.03 inches (0.7mm to 0.8mm).
MODEL
SPARK PLUG TYPE
1KVA
E6TC
2.2KVA
FTC
2.8KVA
F7TC
5.5KVA
F7TC
6.5KVA
F7TC
7.5KVA
F7TC
10.4. CLEANING FUEL STRAINER:
Please note that dirt and water in the fuel are removed by
the fuel strainer.
10.4.1. Remove the strainer cup and clean it properly by removing
the water and dirt collected.
10.4.2. Clean the screen and strainer cup with gasoline.
10.4.3. Fasten the cup tightly to the main body and ensure that
there are no fuel leaks.
10.5. FUEL HOSE REPLACEMENT:
WARNING
Please take extreme caution when replacing the fuel hose as gasoline is
extremely flammable and dangerous. DO NOT SMOKE OR EXPOSE TO OPEN
FLAMES whilst doing this.
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10.5.1. Please ensure that the fuel hose is replaced every 500 hours. Do not attempt to do this
whilst there fuel cock is open.
10.5.2. Please replace the fuel hose immediately should a leak develop or if the fuel hose is
perished.
10.6. CHECKING CARBON BRUSH:
10.6.1. When the brush becomes excessively worn its contact
pressure with the slip ring changes and causes a rough
surface on the slip ring resulting in irregular generator
performance.
10.6.2. Check the carbon brush every 500 hours or if the
generator performance is irregular.
10.6.3. If the brush is 0.2 inches (5mm) or less please replace
it with a new one immediately.
10.6.4. Remove the brush cover and disconnect the wire
before removing the carbon brush.
10.6.5. Carefully note the carbon brush direction and relative
position with the slip ring when installing a new brush.
11. TRANSPORTING AND STORAGE:
11.1. Before tran sporting the generator please ensure that the fuel cock i s in the “OFF”
position.
Caution
Contact with a hot engine or exhaust system can cause severe burns and or fires, always
allow for the engine to cool down prior to transporting and or storing.
Always ensure that the generator is transported and or stored in a flat horizontal position.
Tilting of the unit may cause fuel spillage which may result in a fire.
11.2. Before storing the generator for an extended period of time please ensure that the
area of storage is free from excessive water, dust and humidity. Please follow the
table below:
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NEVER STORE THE GENERATOR INSIDE A HOUSE OR OFFICE. DO NOT STORE THE GENERATOR
WHERE IT IS SUSEPTABLE TO RAIN OR WATER.
STORAGE TIME
RECOMMENDED MAINTENANCE
0 – 1 MONTH
NO PREPARATION REQUIRED
1 – 2 MONTHS
DRAIN OUT ORIGINAL FUEL IN THE
FUEL TANK AND REPLACE WITH
CLEAN FUEL
2 – 12 MONTHS
DRAIN OUT ORIGINAL FUEL IN THE
FUEL TANK AND REPLACE WITH
CLEAN FUEL
EMPTY ALL FUEL FROM THE
CARBURETOR
EMPTY FUEL FROM THE FUEL
SEDIMENT CUP
>12 MONTHS
DRAIN OUT ORIGINAL FUEL IN THE
FUEL TANK AND REPLACE WITH
CLEAN FUEL
EMPTY ALL FUEL FROM THE
CARBURETOR
EMPTY FUEL FROM THE FUEL
SEDIMENT CUP
REMOVE THE SPARK PLUG AND POR
A TEASPOON OF 4 STROKE ENGINE
OIL INTO THE CYLINER. TURN THE
ENGINE SLOWLY BY PULLING ON
THE RECOIL STARTER. REINSTALL
THE SPARK PLUG
DRAIN THE OLD OIL AND REPLACE
WITH CLEAN OIL
AFTER REMOVAL FROM STORAGE,
DRAIN THE STORED FUEL INTO A
SUITABLE CONTINER AND REPLACE
WITH FRSH FUEL BEFORE STARTING
DRAIN THE CARBURETOR BY LOOSENING THE DRAIN SCREW. DRAAIN THE FUEL INTO
A SUITABLE CONTAINER. REINSTALL THE DRAIN PLUG.
HAVING SWITCHED THE FUEL COCK OFF, REMOVE THE SEDIMENT CUP, EMPTY THE
FUEL, THEN REINSTALL THE CUP AND SECURE IT PROPERLY.
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12. TROUBLESHOOTING:
If the generator engine fails to start after several attempts and if there is no electricity available at
the output socket then please check the chart below. If the generator still fails to start or generate
electricity the please contact GENTECH INDUSTRIES (see the back page of this manual for the
contact details).
WHEN THE ENGINE FAILS TO START:
Check if chock lever is in its proper
position
Check if fuel cock is open.
Check the fuel level.
Check if engine switch is in the
“OFF” position.
Check to make sure that the
generator is not connected to an
appliance.
Check the spark plug in case the
spark plug cap is loose.
Check spark plug for carbon build
up.
Set the choke lever to the “CLOSED”
position
If it is closed then open it.
If empty then refill the fuel. Be careful
not to overfill
Turn engine switch to the “ON”
position
If it is connected to an appliance then
turn off the power switch on the
appliance and unplug it.
If it is loose then push the spark plug
cap back tightly onto the spark plug.
Remove the spark plug and clean the
electrode or replace the park plug
with a new one.
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WHEN THERE IS NO ELECTRICITY AT THE RECEPTACLE:
Check to make sure that the circuit
breaker is in the “ON” position.
Check AC and DC terminal for a
possible loose connection.
Check to see if any appliance is
connected whilst trying to start the
generator.
Low and or irregular power from
the generator
After making sure that the total wattage
of the electrical appliance is within
permissible limits and there are no
defects in the appliances turn the circuit
breaker to the “ON” position. If the
circuit breakers continue to trip then
please contact GENTECH INDUSTRIES.
Secure the connection if necessary.
Turn off the switch on the appliance and
disconnect the appliance cable/plug
from the receptacle. Reconnect only
after the generator has started and is
running smoothly.
Check if the carbon brushes are
excessively worn and replace if
necessary.
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13. WIRING DIAGRAM:
29
PLEASE NOTE THAT THIS MANUAL HAS BEEN DESIGNED FOR THE 1KVA,
2.8KVA, 5.5KVA, 6.5KVA AND 7.5KVA GENERATORS:
FOR ALL WARRANTY INFORMATION PLEASE READ
THROUGH YOUR LIMITED WARRANTY POLICY
BOOKLET
2.2KVA,
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