Powersmart PS48 User Manual

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INSTRUCTION MANUAL

7500W Portable Generator

Model # PS48

Have product questions or need technical support? Please feel free to contact us!

Website: www.Amerisuninc.com Toll free: 1-800-791-9458 Mon-Fri 9-5 EST

Email: support@amerisuninc.com

CONTENTS

Technical data…...………………………………………………………... 3 Introduction………………………………………………………………. 4 Safety information…….………………………………………………... 4

General safety procedures ……....……………………………………… 5

Important safety instructions……………………………………………. 6 Knowing your generator………………………………………………… 7 Generator preparation…………………………………………………... 8 Step 1 Setup wheel kit…………………………………………. 8 Step 2 Add oil…………………………………………………… 8 Step 3 Add gasoline……………………………………………… 9 Step 4 Ground the generator……………………………………. 10 Step 5 Connect the battery…………………………………… 10

Starting the generator………....………………………………………… 11

Stopping the generator…………………………………………………. 13 Using the generator……………………………………………………... 13 Maintenance……………………………………………………………... 15 Storage & transport procedures…………………………………………. 20 Troubleshooting…………………………………………………………. 20 Wiring diagram…………………………………………………………. 21 Exploded view & parts list……………………………………………… 22 Warranty………………………………………………………………… 26

TECHNICAL DATA

7500W Generator Model # PS48 Engine type: 4 stroke, OHV, single cylinder with forced air cooling system Spark plug: F6TC Spark plug gap: 0.7-0.8 mm (0.028-0.031 in) Spark plug torque: 1/2-3/4 turn after gasket contacts base or 15 ft.lb Displacement: 420 cc Fuel tank capacity: 7.4 gallons / 87 octane minimum Oil capacity: 37 fl.oz Lubrication system: Splash lubrication Rated wattage: 7000W Surge wattage: 7500W Rated voltage: 120V/ 240V Rated amperage: 58.3A/29.2A Frequency: 60Hz Phase: Single Battery: 12VDC, 14Ah Dimensions (L x W x H): 29.1x21.9x24.4 inches Run time on 50% load: 9.5 hours Noise rating: 78 dB at 23 feet Weight: 206 lb.

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?

In order to answer questions and solve problems in the most efficient and speedy manner, contact Customer Service at (800) 791-9458, Mon-Fri 9am-5pm EST or email: support@amerisuninc.com.

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.

GENERAL SAFETY PROCEDURES

For any questions regarding the hazard and safety notices listed in this manual or on the product, please call (800) 791-9458 Mon-Fri 9-5 EST before using the generator.

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.

WARNING: This generator produces heat when running. Temperatures near exhaust can exceed 1500F (650 C).

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® 3500W 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.

KNOWING YOUR GENERATOR

Use the illustrations below to become familiar with the locations and functions of the various components and controls of this generator.

1 Handle

Recoil starter

2 Muffler

30A 120V/240V Receptacle

3 Wheel

10 Circuit breaker

4 Air cleaner

11 Grounding nut

5 Front foot

12 Fuel tank cap

6 Engine switch

13 Fuel tank

7 20A Duplex Receptacle

13 12

4 5 6 7 8

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 (800) 791-9458 Mon-Fri 9-5 EST for customer service. Failure to perform these steps properly can damage the generator or shorten its life.

Step 1 - SETUP WHEEL KIT

WARNING: This generator is heavy. Assembly procedures may require lifting equipment or

two people.

ATTACH FRONT FOOT

To attach the feet to the generator, perform the following steps:

1. Find a wooden block or a similarly sturdy item that is at

least three inches thick. Stack the end of the generator with the recoil starter onto the wooden block.

2. Setup front foot as attached picture.

ATTACH WHEELS

To attach the wheels to the generator, perform the following steps:

1. Rest the exhaust end of the generator on

the same wooden block used for attaching the front foot.

2. Slide the wheel onto the axle.

3. Slide the wheel shaft with the cotter pin hole inward through the frame.

Secure using the cotter pin.

4. Repeat steps 2 and 3 for the other wheel.

Step 2 - ADD OIL

The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time. The oil capacity of the engine crankcase is 37 fl. oz. For general use (above 40° F), we recommend 30W, 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

To add oil, follow these steps:

1. Make sure the generator is on a level surface. Tilting the generator to assist in filling will cause oil to

flow into engine areas and will cause damage. Keep generator level!

2. Remove the dipstick from the engine.

3. Add oil slowly as to not overflow the unit.

4. To check the oil level, wipe the dipstick with a clean rag. Insert the dipstick into the oil fill opening

without screwing it in. Remove the dipstick to check the oil mark.

5. Slowly add more oil and repeat step 4 until the oil mark reaches to the top of the dipstick. Do not

overfill the crankcase. The generator is equipped with a low-oil sensor and will not start if the amount of oil is insufficient.

6. Check for oil leaks. Tighten dipstick firmly.

Step 3 - 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 fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. Do not mix oil with gasoline.

To add gasoline, follow these steps:

1. Make sure the generator 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 7.4 gallons. 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:

• 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.

Oil Dipstick

Step 4 - GROUND THE GENERATOR

WARNING: Failure to properly ground the generator can

result in electrocution.

Ground the generator by tightening the grounding nut on the front control panel against a grounding wire. A generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper wire. This grounding wire should be connected at the other end to a copper, brass, or steel-grounding rod that is driven into the earth. Wire and grounding rods are not included in generator contents. Grounding codes can vary by location. Contact a local electrician to check the area codes.

Step 5 – CONNECT THE BATTERY

WARNING: Battery gives off explosive hydrogen gas.

Keep battery away from spark, flame, or cigarette. Do not connect or disconnect battery while generator is running. Service or use battery only in well ventilated areas.

WARNING: Battery contains sulfuric acid. Battery acid is poisonous. Tilting the generator with the battery installed can cause battery acid to spill.

Wear protective clothing and eyewear when servicing battery. Keep out of reach of children. Do not tilt generator with battery installed. If battery acid gets on your skin, wash with water immediately. If battery acid gets in your eyes, flush with water for at least 15 minutes and call a doctor immediately. If battery acid is swallowed, drink a large amount of water or milk. Then drink milk of magnesia or vegetable oil. Call a doctor immediately.

The generator comes with the battery disconnected for safety. To use the electric start, the battery needs to be connected. To connect the battery:

1. Remove the protective covering from the free end of the negative battery cable. This cable is

connected to the generator on the other end and is located in the vicinity of the battery.

2. Attach the free end of the negative cable to the battery and secure the connection. NOTE: If you do not plan to use the generator for a long period of time, it is a good idea to disconnect the negative battery cable from the battery for storage. After disconnecting the cable, cover the free end with an insulator such as electrical tape.

NOTE: After completing the above preparation, the generator is ready to be started.

Grounding Nut

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 (800) 791-9458 Mon-Fri 9-5 EST 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.

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.

• 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.

MANUAL START THE ENGINE

To manual start the generator, perform the following steps:

1. Unplug all electrical devices from the generator during ignition. Otherwise

it will be difficult for the engine to start.

2. Check that the generator is properly grounded (Refer to “GROUND THE

GENERATOR”).

3. Check the oil and fuel levels.

4. Turn the fuel valve to the “ON” position.

5. Move the choke lever to the “CLOSE” position.

6. Set the ON/OFF Switch to the “ON” position.

7. Pull on the recoil starter handle slowly until a slight

resistance is felt, then pull quickly to start the engine. Return cord gently into the recoil starter. Never allow the cord to snap back.

8. If engine fails to start, repeat step 7. NOTE: After

repeated failed attempts to start the engine, please consult the troubleshooting guide before attempting again. If problems persist, please call (800) 791-9458 M-F 9am-5pm EST.

9. Once the engine has started, slowly return the choke lever all the

way to the “OPEN” position.

10. Allow the engine to run for several minutes before attempting to

connect any electrical devices. This allows the generator to stabilize its speed and temperature.

ELECTRIC START THE ENGINE

To start the generator using the electric start function, perform the following steps:

1. Make sure no electrical devices are connected to the generator. Such devices can make it difficult for

the engine to start.

2. Check that the generator is properly grounded (Refer to “Ground the Generator”).

3. Check the oil and gas levels.

4. Turn the fuel valve to the “ON” position.

5. Move the choke lever to the “Start” position.

6. Set the engine switch to the “ON” position.

7. Press the engine switch to the “START” position for 2-3 seconds or until the engine starts. NOTE: If

the engine does not start after 2-3 seconds, release the switch from the start position. Keeping the switch in the START position too long can damage the starter.

8. If engine fails to start, wait 10 seconds, then repeat step 7. NOTE: After repeated attempts to start the

engine, please consult the troubleshooting guide before attempting again. If problems persist please call (800) 791-9458 Mon-Fri 9-5 EST.

9. Once the engine has started. Slowly move the choke lever all the way to the “Run” position. Allow

the generator to run for several minutes before attempting to connect any electrical devices.

Engine Switch

STOPPING THE GENERATOR

TO STOP THE GENERATOR

1. Turn off all electrical devices prior to unplugging them from the generator. Unplugging running

devices can cause damage to the generator.

2. Turn the “ON/OFF” switch to the “OFF” position.

3. Turn the fuel valve to the “OFF” (horizontal) position.

WARNING: Allow the generator to cool for several minutes before touching areas that become hot during use.

CAUTION: Allowing gasoline to sit in the fuel tank for long periods of time can make it difficult to start the generator in the future. Never store the generator for extended periods of time with fuel in the fuel tank. Refer to Generator Storage Section.

USING THE GENERATOR

WARNING: When this generator is used on 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 other than the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.

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 the machine’s components, possibly leading to a generator failure.

Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output.

CAUTION: Become familiar with the markings on the panel before connecting electrical devices.

Connect electrical devices running on AC current according to their wattage requirements. The chart below shows the rated and surge wattage of the generator.

Model

Rated Wattage

Surge Wattage

PS48

7000W

7500W

The rated (running) wattage is the wattage the generator can produce on a continuous basis.

The surge wattage is the maximum amount of power the generator can produce for an extremely short

period of time (seconds). Many electrical devices such as refrigerators require short bursts of extra power in addition to the rated wattage listed by the device to start their motors. The surge wattage ability of the generator covers this extra power requirement.

The total running wattage requirement of the electrical devices connected to the generator should not exceed the rated wattage of the generator itself. To calculate the total wattage requirement of the electrical devices you plan to connect, find the rated (or running) wattage of each device. This number

should be listed somewhere on the device or in its instruction manual. If this wattage cannot be found, calculate it by multiplying the Voltage requirement by the Amperage drawn:

Watts = Volts x Amperes

If these specifications are not available, estimate the wattages requirement of the device by using the chart in next page.

When the rated wattage requirement of each electrical device has been determined, add these numbers to find the total rated wattage needed. If this number exceeds the rated wattage of the generator, DO NOT connect all these devices. Select a combination of electrical devices, which have a total rated wattage lower than or equal to the rated wattage of the generator.

CAUTION: The generator can run at its surge wattage capacity for only a short time. Connect electrical devices requiring a rated (running) wattage equal to or less than the rated wattage of the generator. Never connect devices requiring a rated wattage equal to the surge wattage of the generator. This can trip the circuit protectors (circuit breakers).

Tool or appliance

Rated watts

Additional surge watts

Electric water heater (40 Gal)

4000

Hot plate

2500

Radial arm saw

2000

Electric stove (each element)

1500-2800

Circular saw

1500

Air compressor (1 HP)

1500

3000

Window air conditioner

1200

1800

Miter saw

1200

Microwave

1000

Well water pump

1000

Reciprocating saw

960

1040

Sump pump

800

1200

Refrigerator freezer

800

1200

Furnace blower

800

1300

Computer

800

Electric drill

600

900

Television

500

Deep freezer

500

Garage door opener

480

Stereo

400

Box fan

300

600

Clock radio

300

Security system

180

DVD player

100

Common light bulb

Estimated wattage requirements of common electrical devices

Note: The above wattage figures are estimates. Check the wattage listed on the electrical device before consulting this chart. Once the electrical devices that will be powered by the generator have been determined, connect these devices.

CAUTION: Do not connect 50Hz loads to the generator.

SOME NOTES ABOUT POWER CORDS Long or thin cords can drain the power provided to an electrical device by the generator. When using such cords, allow for a slightly higher rated wattage requirement by the electrical device. See below for recommended cords based on the power requirement of the electrical device.

Ampere Rating

Total Length of Cord in feet

More Than

Not More Than

100

150 0 6

14 6 10

Not Recommended

Maximum extension cord lengths by power requirement

If an overload occurs, shut down the generator. Unplug all electrical devices and wait five minutes. Then, start the unit back up again to get power back.

MAINTENANCE

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.

Recommended maintenance schedule

Each 8 hours or daily

First 8 hours

Every 25 hours

Every 3 months or 50 hours

Every 6 months or 100 hours

Every year

As necessary

Engine oil

Check lever

Replace

x x*

Air cleaner

Check x x

Clean x

Spark plug

Check /Clean

Change

x x

Fuel tank

Check lever

*Clean/change more often under dusty conditions or operating under heavy load.

Recommended maintenance schedule

CLEANING THE GENERATOR

Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water can get inside the working parts of the generator and cause a short circuit or corrosion. Always try to use the generator in a cool, dry place. If the generator becomes dirty, clean the exterior with a damp cloth, a soft brush, a vacuum or pressurized air.

CHECKING THE OIL

The oil capacity of the engine crankcase is 37 fl. oz.

Check the oil level of the generator according to the Recommended Maintenance Schedule above. The generator is equipped with an automatic shutoff to protect it from running on low oil. This is a critical step for proper engine starting. To check the oil level:

1. Make sure the generator is on a level surface.

2. Clean around oil fill. Remove dipstick and wipe the

dipstick with a clean rag. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark. Add oil if the oil mark covers less than one half of the dipstick.

3. Slowly add more oil and repeat step 2 until the oil mark

reaches to the top of dipstick. Do not over fill the crankcase.

4. Reinstall oil dipstick.

CHANGING/ADDING OIL

Change the oil according to the Recommended Maintenance Schedule. Change the oil when the engine is warm. This will allow for complete drainage. Change oil more often if operating under heavy load or high ambient temperatures. It is also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. The oil capacity of the generator engine is 37 fl.oz. Add oil when the oil level is low. For proper type and weight of oil refer to “add oil” portion of the “Generator Preparation” section.

To drain oil, follow these steps:

1. Place a container underneath the engine to catch oil as it

drains.

2. Using a wrench, unscrew the oil drain bolt. Allow all the

oil to drain from the engine.

3. Reinstall the oil drain bolt and tighten with a wrench.

To refill the crankcase with oil, follow these steps:

1. Make sure the generator is on a level surface. Tilting the generator to assist in filling will cause oil to

flow into engine areas and will cause damage. Keep generator level!

2. Remove the dipstick from the engine.

3. Using a funnel or appropriate dispenser, add the correct amount of oil (37 fl.oz) into the crankcase.

The engine is equipped with a low oil sensor and will not start if the amount of oil is insufficient.

4. Reinstall dipstick.

NOTE: Never dispose of used motor oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange oil disposal.

AIR CLEANER MAINTENANCE

Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor. Occasionally check that the air cleaner is free of excessive dirt. Refer to Recommended Maintenance Schedule page

15. For air cleaner detail:

1. Unhinge the clasps at the top and bottom of the air cleaner cover.

Drain Bolt

2. Remove the sponge-like element from the casing.

3. Wipe the dirt from inside the empty air cleaner casing.

4. Wash the sponge -like element in household detergent and warm water. Small amount of oil in the element is normal and necessary for the engine to work properly.

5. Reinstall the sponge-like element in the air cleaner casing and reinstall the cover.

CAUTION: running the engine with dirty, damaged or missing air cleaner elemen t will cause the engine to wear out prematurely.

FUEL VALVE CUP CLEANING

The fuel valve cup is a small well underneath the fuel valve. It helps to trap dirt and water that may be in the fuel tank before it can enter the engine. To clean the fuel valve cup:

1. Turn the fuel valve to the “OFF” position.

2. Unscrew the fuel valve cup from the fuel valve using a wrench. Turn the valve toward you and unscrew.

3. Clean the cup of all sediments using a rag or brush.

4. Reinstall the fuel valve cup.

SPARK PLUG MAINTENANCE

Spark plug: F6TC

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 spark plug boot. Be careful not to tear insulation or wire.

2. Unscrew the spark plug from the engine using the spark plug wrench provided. There is limited space for the wrench to turn. Use both rows of holes in the spark plug wrench to gain leverage to loosen the plug.

3. Visually inspect the spark plug for cracks or excessive electrode wear. Replace as necessary.

4. Measure the plug gap with a wire gauge. The gap should be 0.7 to 0.8 mm (0.028-0.031 in).

5. If re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base then re-gap the spark plug.

6. Screw the spark plug back into the spark plug hole using the spark plug wrench. Do not over-tighten spark plug. Recommended tightening of spark plug is 1/2 to 3/4 of a turn after spark plug gasket contacts spark plug hole. Reinstall the spark plug boot.

Air Cleaner Cover

DRAINING THE FUEL TANK

Clean fuel tank each year or before storing the generator for extended periods of time. To drain the fuel tank and carburetor:

1. Turn the fuel valve to the “OFF” position.

2. Remove the fuel line between the fuel valve and carburetor. Caution: A small amount of fuel may

leak from the hose during removal.

3. Attach a fuel line (not included with the generator) to the exposed end of the fuel valve.

4. Position fuel line into an appropriate container and open the fuel valve allowing fuel to flow into the

container.

5. Once fuel is drained, shut off the fuel valve.

6. Start and run the engine until fuel runs out.

7. Remove the fuel valve cup (See “FUEL VALVE CUP CLEANING”).

8. Empty the fuel valve cup of any fuel and clean.

9. Reinstall the fuel valve cup.

10. Store the emptied gasoline in a suitable place.

CAUTION: Do not store fuel for more than 3 months.

HIGH ALTITUDE OPERATION ABOVE 3000 FEET

The fuel system on this generator may be influenced by operation at higher altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 feet above sea level. At elevations above 8000 feet, the engine may experience decrease performance, even with the proper main jet. Operating this generator without the proper altitude kit installed may increase the engine’s emissions and decrease fuel economy and performance. The kit should be installed by a qualified mechanic.

WARNING! To prevent serious injury from fire: Follow kit procedures in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before proceeding.

Notice: Warranty Void if necessary adjustments are not made for high altitude use.

The altitude kit (PS48-115) includes below parts: bolt seal, fuel cup seal and main jet.

High Altitude Kit Installation Instructions

1. Turn off the engine.

2. Close the fuel valve.

3. Place a bowl under the fuel cup to catch any spilled fuel.

4. Unthread the bolt holding the fuel cup. Caution! Carburetor bowl may have gas in it which will leak upon removing the bolt.

5. Remove the bolt, bolt seal, fuel cup, fuel cup seal and main jet from

the body of the carburetor assembly.

6. Replace the main jet with the replacement jet needed for your

altitude range.

Note: The fuel cup seal and bolt seal may be damaged during removal and should be replaced with the new ones from the kit.

7. Replace the Fuel Cup Seal, fuel cup, Bolt seal and bolt. Tighten in

place.

8. Wipe up any spilled fuel and allow excess to evaporate before starting engine. To prevent FIRE, do

not start the engine while the smell of fuel hangs in the air.

STORAGE & TRANSPORT PROCEDURES

CAUTION: Never place any type of storage cover on the generator while it is still hot.

If the generator is being stored for short periods of time (30 to 60 days), add stabilized fuel to the fuel tank until full. NOTE: Filling the tank reduces the amount of air in the tank and helps reduce deterioration of fuel. Run the engine for 2 – 3 minutes allowing stabilized fuel mixture to circulate through the carburetor. When storing the generator for extended periods of time:

• Drain the fuel tank (see “Draining the Fuel Tank” in the “Maintenance” section).

• Change oil.

• Do not obstruct any ventilation openings.

• Keep the generator in a cool dry area.

When transporting generator:

• Tighten fuel cap and vacuum relief valve. Drain the fuel tank if possible (see “Draining the Fuel

Tank” in the “Maintenance” section).

• Keep the generator upright. Never place the generator side down. Doing so will make it difficult to

start.

TROUBLESHOOTING

Problem

Cause

Solution

Engine will not start.

Engine switch is set to "OFF".

Set engine switch to "ON".

Fuel valve is turned to "OFF".

Turn fuel valve to "ON" position.

Choke is open.

Close the choke.

Engine is out of gas.

Add gasoline.

Engine is filled with contaminated or old gas.

Change the gas in the tank. Drain the gas in the carburetor.

Spark plug is dirty.

Clean spark plug.

Spark plug is broken.

Replace spark plug.

Generator is not on level surface.

Move generator to a level surface to prevent low oil shutdown from triggering.

Oil is low.

Add or replace oil.

Air cleaner is dirty.

Clean or replace air cleaner element.

Engine runs but there is no output.

Circuit breaker button is off.

Wait for 2 minutes and move the circuit breaker button to the "ON" position.

Bad connecting wires/cables.

If you are using an extension cord, try a different one.

Bad electrical device connected to generator.

Try connecting a different device.

Generator runs but doesn’t support all electrical devices connected.

Generator is overloaded.

Perform these steps:

1. Turn off all electrical devices.

2. Unplug all electrical devices.

3. Turn off generator.

4. Wait several minutes.

5. Restart generator.

6. Try to connect fewer electrical loads

to the generator.

Short in one of the connected devices.

Try disconnecting any faulty or short-circuited electrical loads.

Air cleaner is dirty.

Clean or replace air cleaner.

WIRING DIAGRAM

EXPLODED VIEW AND PARTS LIST

Engine exploded view

Engine parts list

Item

Stock #

Description

Qty Item

Stock #

Description

Qty

PS48-001

Bolt M6×16

5 57

PS48-057

Cotter Pin

1 2 PS48-002

Cylinder Head Cover

1 58

PS48-058

Bolt M6×16

PS48-003

Breather Hose

1 59

PS48-059

Camshaft

PS48-004

Nut M6

2 60

PS48-060

Washer

1 5 PS48-005

Rocker Arm Assembly

1 61

PS48-061

Bearing 6202

2 6 PS48-006

Rocker Arm Assembly

1 62

PS48-062

Balance Shaft

1 7 PS48-007

Rocker Arm Shaft

1 63

PS48-063

Pin 9×12

1 8 PS48-008

Rocker Arm Base

1 64

PS48-064

Crankcase Cover

PS48-009

Bolt 2

PS48-065

Bolt M8×38

PS48-010

Rocker Arm Base

1 66

PS48-066

Bolt M8×45

PS48-011

Bolt M6×12

6 67

PS48-067

Oil Seal

PS48-012

Shroud

1 68

PS48-068

Dipstick

PS48-013

Head Cover Gasket

1 71

PS48-071

Pin, φ7×14

PS48-014

Valve Spring Seat

2 72

PS48-072

Governor Gear

PS48-015

Valve Locker

4 73

PS48-073

Crankcase Gasket

PS48-016

Valve Spring

2 74

PS48-074

Washer

PS48-017

Valve Seal

2 75

PS48-075

Bearing TM6207E

PS48-018

Valve Seat

2 76

PS48-076

Crankshaft

PS48-019

Stud M8×35

2 77

PS48-077

Bolt 2 20

PS48-020

Muffler Gasket

1 78

PS48-078

Starter Motor

PS48-021

Nut M8

2 79

PS48-079

Bolt M6×16

PS48-022

Exhaust Pipe

1 80

PS48-080

Cylinder Head Baffle

PS48-023

Stud M6×104

2 81

PS48-081

Throttle Linkage

PS48-024

Carburetor Insulator Gasket

1 82

PS48-082

Governor Spring

PS48-025

Insulator

1 83

PS48-083

Idle Spring

PS48-026

Carburetor Gasket

1 84

PS48-084

Governor Lever

PS48-027

Carburetor

1 85

PS48-085

Bolt M8×14

PS48-028

Air Filter Gasket

1 86

PS48-086

Governor Gear Bracket

PS48-029

Air Filter Assembly

1 87

PS48-087

Fuel Hose

PS48-030

Air Filter Base

1 88

PS48-088

Fuel Hose 4×10×565

PS48-031

Air Filter Clip

2 89

PS48-089

Fiberglass Tube 10×390

PS48-032

Air Filter Seal

1 90

PS48-090

Clamp

PS48-033

Air Filter Baffle

1 91

PS48-091

Crankcase

PS48-034

Air Filter Element

1 92

PS48-092

Clip 1 35

PS48-035

Air Filter Cover

1 93

PS48-093

Oil Seal 35×52×7

PS48-036

Nut M6

2 94

PS48-094

Bush 1 37

PS48-037

Bolt M10×1.25×87

3 95

PS48-095

Charging Coil

PS48-038

Cylinder Head

1 96

PS48-096

Bolt M6×30

PS48-039

Spark Plug

1 97

PS48-097

Flywheel

PS48-040

Bolt M10×1.25×65

1 98

PS48-098

Wire Board

PS48-041

Cylinder Head Gasket

1 99

PS48-099

Bolt M6×8

PS48-042

Pin 12×20

2 100

PS48-100

Cooling Fan

PS48-043

Exhaust Valve

1 101

PS48-101

Starter Cup

PS48-044

Intake Valve

1 102

PS48-102

Nut M16×1.5

PS48-045

Piston Ring Set

1 103

PS48-103

Drain Bolt

PS48-046

Push Rod

2 104

PS48-104

Washer

PS48-047

Tappet

2 105

PS48-105

Shroud

PS48-048

Piston

1 106

PS48-106

Ignition Coil

PS48-049

Piston Pin

1 107

PS48-107

Bolt M6×28

PS48-050

Circlip

2 108

PS48-108

Clip

PS48-051

Connecting Rod Assembly

1 110

PS48-110

Nut M6

PS48-052

Oil Sensor

1 111

PS48-111

Blower Housing

PS48-053

Governor Gear Shaft

1 112

PS48-112

Recoil Starter

PS48-054

Shroud

1 113

PS48-113

Washer

PS48-055

Washer

1 114

PS48-114

Bolt M6×10

PS48-056

Oil Seal

1 115

PS48-115

Altitude Kit

Generator exploded view

Generator parts list

Item

Stock #

Description

Qty

Item

Stock #

Description

Qty

PS48-201

Bolt M6×25

PS48-235

Voltage Regulator

1 2 PS48-202

Washer

PS48-236

Washer 6

PS48-203

Fuel Tank Cap

PS48-237

Spring Washer 6

PS48-204

Fuel Tank

PS48-238

Bolt M6×194

4 5 PS48-205

Screw M6×20

PS48-239

End Cover

1 6 PS48-206

Bolt 6 40

PS48-240

Bolt M8×16

2 7 PS48-207

Circlip

PS48-241

Muffler

1 8 PS48-208

Fuel Valve

PS48-242

Muffler Gasket

PS48-209

Nut M6

PS48-243

Spring Washer 8

PS48-210

Clamp

PS48-244

Bolt M8×32

PS48-211

Panel Shroud

PS48-245

Circlip

PS48-212

Bolt M6×18

PS48-246

Handle

PS48-213

Control Panel

PS48-247

Nylon Washer

PS48-214

Engine

PS48-248

Pin 10×75

PS48-215

Clip 1 49

PS48-249

Nut M10×1.25

PS48-216

Positive Cable

PS48-250

Damping Pad A

PS48-217

Air Filter Bracket

PS48-251

Nut, M8

PS48-218

Plug 1 52

PS48-252

Pin 1 19

PS48-219

Alternator

PS48-253

Damping Pad B

PS48-220

Nut 2 54

PS48-254

Bolt M10×1.25×40

PS48-221

Spring Washer 5

PS48-255

Bolt

PS48-222

Washer 5

PS48-256

Binder Plate

PS48-223

Bolt M5×229

PS48-257

14Ah Battery

PS48-224

Washer 10

PS48-258

wheel Shaft

PS48-225

Spring Washer 10

PS48-259

Washer

PS48-226

Ground Wire

PS48-260

Wheel

PS48-227

Rear Bracket Support

PS48-261

Cotter Pin

PS48-228

Bolt M10×1.25×280

PS48-262

Washer

PS48-229

Cable Tie

PS48-263

Frame Assembly

PS48-230

Bolt M5×14

PS48-264

Nut M8

PS48-231

Rear Bracket

PS48-266

Front Foot

PS48-232

Negative Cable

PS48-267

Rubber Foot

PS48-233

Bolt M6×12

PS48-268

Bolt M6×18

PS48-234

Carbon Brush

PS48-269

Bolt M8×16

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 POWER SMART 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: 1-800-791-9458 (M-F 9am – 5pm CST)

Email: support@amerisuninc.com

SAVE YOUR RECEIPTS. THIS WARRANTY IS VOID WITHOUT THEM.

Powersmart PS48 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual