Powermaster PM-3500 User manual

0

1

C O N T E N T S:

1. GENERAL SAFETY PRECAUTIONS………………………………………………3-4

2. ELECTRICAL SAFETY PRECAUTIONS……………………………………………4-5

3. SAFETY INFORMATION………………………………………………6-7

4. CONTROL FUNCTION……………………………………………8-11

5. PRE-OPERATION CHECK……………………………………………11-12

6. OPERATION…………………………………………………………13-16

7. PERIODIC MAINTENANCE…………………………………………17-20

8. TROUBLE SHOOTING………………………………………………20-21

9. STORAGE…………………………………………………………21

10. SPECIFICATIONS…………………………………………………22

11. WIRING DIAGRAM…………………………………………………23-26

2

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:

3

This indicates a hazardous situation, which, if not avoided, could result in injury.

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 connect 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

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

4

applications and limitations must be understood. Keep all instruction manuals 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

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.

5

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.

6

! WARNING ──────────────────────────────────

PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE

MACHINE.

────────────────────────────────────────

3．SAFETY INFORMATION

1）EXHAUST FUMES ARE POISONOUS

z Never operate the generator in a closed area or it may lead to possible unconsciousness and or death.

Only operate the generator in a well ventilated area.

2）FUEL IS HIGHLY FLAMMABLE AND POISONOUS

z Always turn off the generator when refueling

z Never refuel while smoking or in the vicinity of an open flame.

z Do not spill any fuel on the engine or muffler when refueling.

z If you swallow any fuel, inhale fuel vapor, or allow any to get in to your eyes please consult your doctor

immediately. If any fuel spills on your skin or clothing please wash with soap and water and change your

clothes immediately

z When operating or transporting the generator please ensure that it is kept upright. If it tilts fuel may leak

from the carburetor or fuel tank.

3）ENGINE AND MUFFLER MAY BE HOT

z Place the generator in a place where children are not likely to touch the machine.

z Avoid placing any flammable materials near the exhaust outlet during operation.

z Keep the generator at least 1m (3 ft) from buildings or other equipment or the generator may overheat.

z Avoid operating the generator with a dust cover.

z Be sure to carry the generator only by its carry handle.

z Place the generator on a flat surface to ensure that the generator

can eliminate heat freely.

4）ELECTRIC SHOCK PREVENTION

z Never operate the generator in a wet environment. Keep out of

the rain

z Never touch the generator with wet hands as this may result in

an electric shock.

z Be sure to ground (earth) the generator.

NOTE: ───────────────

hot

cool air

7

Use ground (earth) lead of sufficient current capacity.

Diameter: 0.12mm (0.005 in)/ampere

EX: 10 Ampere --1.2mm (0.055 in)

──────────────────

5）CONNECTION NOTES

z Do not connect the generator directly to the Utility Power Source.

z Do not connect the generator in parallel with any other generator.

8

4．CONTROL FUNCTION

DESCRIPTION

(1) Fuel tank (2) Fuel tank cap (3) Fuel filter

(

4

)

Carr

y

in

g

handl

e

(

5

)

Muffle

r

(

6

)

Spark plu

g

(7) Choke lever (8) Recoil starter (9) Fuel cock

(10) Brake lever (11) Wheel (12) Oil filler cap

(

13

)

Air filter

(

14

)

Fuel pum

p

(

15

)

En

g

ine switch

(16) AC pilot light (17) Overload indicator light (18) Oil warning light

(19) Economy control switch (20) Voltmeter (21) DC protector

(

22

)

DC receptacle

(

23

)

Ground

(

earth

)

terminal

(

24

)

AC receptacle

(25) AC receptacle L5-30R (26) AC receptacle 5-20R (27)

Parallel connection control socket

(28) Parallel connection socket (29)

Frequency Transfer Switch

AC 230VAC 230V

AC 120V AC 120V

-

3

0

L

5

0

3

V

5

2

1

A

R

123

45 6789

10 11 16 17 18 12 13 14

19

20

21 24

22 23 25 26

27

28

29

V

A

KW

HZ

MODE

V

A

KW

HZ

MODE

15

9

(

1

)

Fuel tank

(

2

)

Fuel tank ca

p

(

3

)

Fuel fil

t

e

r

(4) Carrying handle (5) Muffler (6) Spark plug

(7) Choke lever (8) Recoil starter (9) Fuel cock

(

10

)

Brake lever

(

11

)

Wheel

(

12

)

Oil filler ca

p

(13) Air filter (14) Fuel pump (15) Battery

(16) Engine switch (17) AC pilot light (18) Overload indicator light

(

19

)

Oil warnin

g

li

g

h

t

(

20

)

Voltmete

r

(

21

)

Econom

y

control switch

(22) DC protector (23) DC receptacle (24) Ground (earth) terminal

(25) AC receptacle (26) AC receptacle L5-30R (27) AC receptacle 5-20R

(28)Parallel connection control

socket

(29)Parallel connection socket (30)

Frequency Transfer Switch

(31)Remote control

AC 230VAC 230V

AC 120V AC 120V

-

3

0

L

5

0

3

V

5

2

1

A

R

15

16 17 18

19

20

21

22

25

23 24 26 27

28

29

30

V

A

KW

HZ

MODE

V

A

KW

HZ

MODE

123 45 6789

10 11 12 13 14

31

10

1）OIL WARNING SYSTEM

When the oil level falls below the lower level the generator will stop

automatically. Unless you refill with oil the generator will not start again.

2）ENGINE SWITCH

The engine switch controls the ignition system.

① “ON” (run)

Ignition circuit is switched on. The engine can be started.

② “STOP”

Ignition circuit is switched off. The engine will not run.

③ “START”

Starting circuit is switched on. The starter motor starts.

3）ECONOMY CONTROL SWITCH

When the economy control switch is turned “ON”, the economy control

unit controls the engine speed according to the connected load. This

may result in better fuel efficiency and less noise.

4）DC CIRCUIT PROTECTOR

The DC circuit protector turns off automatically when the load exceeds

the generator rated output.

CAUTION: ──────────────────────

z If the DC circuit protector turns off then reduce the load to within the

specified generator rated output.

───────────────────────────

5）FUEL TANK CAP AIR VENT KNOB

The fuel tank cap is provided with an air vent knob to stop fuel flow.

The air vent knob must be turned once clockwise from the closed

position. This will allow fuel to flow to the carburetor and the generator

to run.

When the generator is not in use tighten the air vent knob

counterclockwise until it is finger-tight to stop fuel flow.

6）FUEL COCK

The fuel cock is used to supply fuel from the tank to the carburetor.

OPEN CLOSED

ON OFF

2

1

3

2

1

11

7）REMOTE CONTROL SWITCH

The remote control switch controls the ignition system

① “ON”

The starter motor starts.

② “OFF”

The engine will not run.

8）BRAKE LEVER

The function of brake lever is to prevent generator moving.

If the break lever is on the wheel will be in the locked position and this

will stop the generator from moving.

5. PRE-OPERATION CHECK

NOTE: ────────────────────────

z Add at least 5 liters of fuel when using the generator for the first

time

z Pre-operation checks should be made each time the generator is

used.

───────────────────────────

1）CHECK ENGINE FUEL

z Make sure there is sufficient fuel in the tank.

z If the fuel is low refill with clean unleaded gasoline.

z Be sure to use the fuel filter screen on the fuel filter neck when

refilling the generator

z Unleaded fuel is recommended for this generator

z Fuel tank capacity: (see page 17)

WARNING: ──────────────────────

z Do not refill the tank whilst the generator is running or hot.

z Close fuel cock before refueling with fuel.

z Keep the fuel free from dirt, dust, water and other foreign objects.

z Do not overfill when refilling the generator.

z Wipe off spilt fuel thoroughly before starting the generator.

UPPER

LEVEL

① ②

12

z Keep away from fire.

──────────────────────────

2）CHECK ENGINE OIL

Make sure that the engine oil is at the upper level of the oil filler hole. Add

oil as necessary.

z Remove oil filler cap and check the engine oil level.

z If oil level is below the lower level line then refill with suitable oil to

upper level line. Do not screw in the oil filler cap when checking oil

level.

z Change the oil if contaminated.

Oil capacity: (see page 17)

z Recommended engine oil:

API Service “SJ”

3）GROUND (Earth)

Please ensure that the generator is properly earthed/grounded.

4）CONNECT BATTERY (for electric starting system)

z Loosen the screw and remove the battery cover.

z Clamp the red wire to the positive (+) terminal and the black wire

to the negative (-) terminal of the battery. Do not reverse these

positions.

z Be sure the battery is installed on the battery mount tray securely.

z Install the cover and tighten the screw.

NOTE: ───────────

z Recommended battery: 12V6AH

───────────────

32°FF

80°

25° CC

0°

or 10W-30

SAE #30

or 10W-40

SAE #20

or 10W-30

or 10W-40or 10W-40

or 10W-30

SAE 10W

13

6. OPERATION

NOTE: ───────────────────────

z The generator has been shipped without engine oil. Fill with oil or it

will not start.

z Do not tilt the generator when adding engine oil. This could result in

overfilling and damage to the engine

───────────────────────────

1）STARTING THE ENGINE

NOTE: ─────────────────────

z Only connect the electrical appliances after you have started the

generator.

─────────────────────────

A Recoil start

1. Open the fuel tank air vent to the “OPEN” position.

2. Turn the fuel cock lever to the “ON” position.

3. Turn the engine switch to the “ON” or “RUN” position.

4. Turn the choke lever to the “│ │”position. Not necessary if the

engine is electric type.

5. Pull the starter handle slowly until resistance is felt. This is the

“Compression” point. Return the handle to its original position and

pull swiftly. Do not fully pull out the rope. After starting, allow the

starter handle to return to its original position while still holding the

handle. Grasp the carrying handle firmly to prevent the generator

from falling over when pulling the recoil starter.

6. Warm up the engine.

7. Turn the choke lever back to the operating position. Not necessary

if the engine is electric type.

8. Always warm up the engine without a load for a few minutes.

B Electric Start

1. Open the fuel tank air vent to the “OPEN” position.

2. Turn the fuel cock lever to the “ON” position.

3. Turn the engine switch to the “START” position.

OPEN

ON

STOP

ENGINE

SWITCH

ENGINE

SWITCH

14

4. Turn the engine switch to the “RUN” position

5. Warm up the engine without a load for a few minutes.

C Remote start

1. Open the fuel tank air vent to the “OPEN” position.

2. Turn the fuel cock lever to the “ON” position.

3. Turn the engine switch to the “RUN” position.

4. Click remote switch to the “ON” position.

5. Warm up the engine without a load for a few minutes.

2）USING ELECTRIC POWER

1. AC APPLICATION

(a) Check the AC pilot lamp for the correct voltage reading.

(b) Turn off the switch(es) of the electrical appliance(s) before connecting

to the generator.

(c) Insert the plug(s) of the electrical appliance(s) into the receptacle.

CAUTION: ─────────────────────

z Make sure that the electrical appliances are turned off before

plugging in.

z Make sure that the total load is within generator rated output.

z Make sure that the socket load current is within socket rated

current.

z The economy control switch must be turned to “OFF” when using

electrical appliances that require a large starting current such as compressors, fridges and freezes.

──────────────────────────

2．OVERLOAD INDICATOR LIGHT

The overload indicator light will come on when an overload of a

connected electrical appliance is detected, or if the inverter unit

overheats and if the AC output voltage rises. The electronic circuit

breaker will then activate stopping power to the generator in order to

protect the generator and any connected electrical appliances. The output pilot light (green) will flicker and the

overload indicator light (red) will turn on and then the engine will stop running. If so please follow the following

ENGINE

SWITCH

ENGINE

SWITCH

ENGINE

SWITCH

15

steps:

(a) Turn off any electrical appliance that is connected to the generator

and stop the engine immediately.

(b) Reduce the total wattage of any electrical appliances connected

to the generator to within the application range.

(c) Check for blockages in the cooling air inlet and around the control

unit. If any blockages are found please remove.

(d) After checking please restart the generator.

CAUTION: ─────────────────────────────────────

z Please note that the generator AC output automatically resets when the engine is stopped and then

restarted.

z The overload indicator light may come on for a few seconds at first when connecting electrical devices that

require a large starting current such as a compressors, fridges and freezers. Please note that this is not a

malfunction.

──────────────────────────────────────────

3. DC APPLICATION (option)

This usage is applicable to 12V battery charging only.

(a) Charging instruction for battery

z Disconnect the battery terminals.

z Loosen the battery fluid filler cap completely.

z Fill distilled water to the upper limit if the battery fluid level is low.

z Measure the specific gravity for the battery fluid by using a

hydrometer. Calculate the charging time in accordance with the

table shown on the right.

z The specific gravity for a fully charged battery should be within 1.26

to 1.28. We recommend that this is checked regularly.

(b) Connect from the DC output socket and the battery using proper charging leads. Make sure that the

polarity is correct when connecting. IE (+) to positive and (-) to negative.

(c) After checking the connection please set the DC circuit protector to the “ON” position.

CAUTION: ──────────────────────

z Make sure that the economy control switch is turned off whilst charging the battery.

───────────────────────────

3

2

1

CSpecific gravity 20°

3. 47AH 20HR

2. 35AH 20HR

1. 30AH 20HR

Battery capacity

chargong time Hr

810

4620

1.06

1.14

1.10

1.22

1.18

1.26

1.30

Aim for specific gravity and charging time

16

3）STOPPING THE ENGINE

1. Turn off the power switch or disconnect the electrical appliance.

2. Turn off the engine switch by turning the switch to the “STOP”

position.

Click the remote switch to the “OFF” position.

3. Turn the fuel cock lever by turning it to the “OFF” position.

4. Turn the fuel tank cap air vent knob counterclockwise to the

“CLOSED” position.

.

CLOSED

ON

STOP

ENGINE

SWITCH

ENGINE

SWITCH

OFF

17

7. PERIODIC MAINTENANCE

1) MAINTENANCE CHART

Regular maintenance is most important for the best performance and safe operation.

Item Remarks

Pre-operation

check

(

dail

y)

Initial

1 months

or 20 H

r

Every

3 months

or 50Hr

Every

6 months

or100Hr

Every

12 months

or 300Hr

Spark

Plug

Check condition adjust gap

and clean. Replace if

necessary.

z

Engine

Oil

Check oil level z

Replace z z

Oil filter Clean oil filter z

Air Filter Clean. Replace if necessary. z

Fuel

Filter

Clean fuel cock filter. Replace

if necessary z

Choke Check choke operation z

Valve

Clearance

Check and adjust when

engine is cold. z

Fuel Line Check fuel hose for crack or

damage. Replace if

necessary.

z

Exhaust

System

Check for leakage. Retighten

or replace gasket if

necessary

z

Check muffler screen.

Clean / replace if necessary. z

Carbureto

r

Check choke operation z

Cooling

system

Check fan damage. z

Starting

system

Check recoil starter

operation.

z

Idle speed

Check and adjust engine idl

e

speed

z

18

Fittings /

Fastener

s

Check all fittings and

fasteners correct if

necessary.

z

Crankcase

breather

Check breather hose for

cracks or damage. Replace if

necessary

z

Generator Check the pilot light comes on z

2）ENGINE OIL REPLACEMENT

1. Place the generator on a flat level surface and warm up the engine

for several minutes. Then stop the engine and turn the fuel cock

knob to the “OFF” position. Turn the fuel tank cap air vent knob

clockwise.

2. Loosen the screw and remove the cover.

3. Remove the oil filler cap

4. Place an oil pan under the engine and tilt the generator to drain the

oil completely.

5. Once the oil has drained return the generator to the upright position.

6. Add engine oil until it reaches the “upper level” indicator.

7. Replace the oil filler cap properly.

8. Replace the cover properly and tighten the screw.

z Recommended engine oil: (see page 17)

API Service “SJ”

CAUTION: ──────────────────────

z Make sure that no foreign material falls into the crankcase.

z Do not tilt the generator when adding engine oil as this could result in overfilling and could cause damage

to the engine

z Make sure that you clean the oil filter every 100 hours.

───────────────────────────

3）AIR FILTER

Maintaining an air filter in proper condition is very important. Dirt that is

induced through improperly installed, improperly serviced, or inadequate

elements damages and wears out engines. Always keep the air filter

OIL FILTER



UPPER

LEVEL

19

element clean.

1. Remove the side cover.

2. Remove the air filter cover and element.

3. Wash the element in a solvent and dry properly.

4. Oil the element and squeeze out all excess oil. The element should

be wet but not dripping.

5. Insert the element into the air filter.

6. Replace the side cover.

CAUTION: ──────────────────────

The engine should never run without the air filter element as this may

result in excessive piston and or cylinder wear.

───────────────────────────

4）CLEANING AND ADJUSTING SPARK PLUG

1. Remove the side cover.

2. Check for discoloration and remove the carbon build up.

3. Check that the correct spark plug is being used and gap.

4. Replace the spark plug if necessary.

5. Replace the side cover once completed.

5）FUEL TANK FILTER

1. Remove the fuel tank cap and filter.

2. Clean the filter with solvent. If damaged, replace.

3. Wipe the filter and insert it.

WARNING

Make sure that the tank cap is tightened securely.

─────────────────

Standard electrode color: Tan Color

Standard Spark Plug: CR4HSB (NGK)

Spark Plug Gap: 0.6-0.7 mm (0.024-0.028 in)

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Powermaster PM-3500 User manual

Powermaster PM-3500 User manual

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