home diesel power HDP-3500, Owner'S Manual

Page 1: ...Owners Manual 3500W WWW HOMEDIESELPOWER COM HOME DIESEL POWER ...

Page 2: ...23 Inspection Cleaning and Maintenance 27 Compliance 28 Limited Warranty 29 WARNING READ AND UNDERSTAND ALL SAFETY PRECAUTIONS IN THIS MANUAL BEFORE OPERATING FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PERSONAL INJURY PROPERTY DAMAGE AND OR VOIDING OF YOUR WARRANTY ALL POWER AMERICA WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS ...

Page 3: ...tions Be sure to retain them for future use WARNING WARNINGS INDICATE A CERTAINTY OR STRONG POSSIBILITY OF PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED CAUTION CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED Note Notes give helpful information WARNING IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMA...

Page 4: ...res Always have multiple ABC class fire extinguishers nearby z Keep the generator and surrounding area clean at all times z Fuel or oil spills must be cleaned up immediately Dispose of fluids and cleaning materials as per any local state or federal codes and regulations Store oily rags in a covered metal container z Never store fuel or other flammable materials near the generator WARNING FAILURE T...

Page 5: ...r hot engine shutdown If this occurs open exhaust system drain plugs if equipped and allow the gases to dissipate before attempting to restart the generator z Use only engine manufacturer recommended fuel and oil Hot Components Power Output This generator is not designed to power sensitive electronic equipment including computers and medical devices without the addition of an approved line conditi...

Page 6: ...arized plug where one blade is wider than the other This plug fits in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system z Avo...

Page 7: ...the electrical characteristics and rated capacities of the generator z Before servicing equipment powered by the generator disconnect the equipment from its power input z Keep all electrical equipment clean and dry Replace any wiring where the insulation is cracked cut abraded or otherwise degraded Replace terminals that are worn discolored or corroded Keep terminals clean and tight z Insulate all...

Page 8: ... turn it on or off Any generator that cannot be controlled with the power switch is dangerous and must be replaced Generator Use and Care z Make sure the power switch is in its OFF position and disconnect the spark plug wire before making any adjustment changing accessories or storing the generator Such preventive safety measures reduce the risk of starting the generator accidentally z Store idle ...

Page 9: ... contractor z All electrical work including the earth ground connection should be completed by a licensed electrician z Any separate fuel storage or generator supply facility must be built or installed in full compliance with all relevant local state and federal regulations z It is recommended to use the generator only in well ventilated outdoor areas A running gasoline engine will generate carbon...

Page 10: ...f the generator frame at its low side z For trailer installation the generator should be mounted on the center point of the trailer over the wheels The trailer must be capable of supporting the weight of the generator and all contents tools etc z Install sound and weather proofing only when it is not raining or snowing to avoid trapping moisture within the generator s area Mechanical z Always make...

Page 11: ...es safety eye goggles and safety hat z Do not alter or adjust any part of the generator that is assembled and supplied by the manufacturer z Always follow and complete scheduled engine and geenerator maintenance Chemicals z Avoid contact with hot fuel oil exhaust fumes and hot solid surfaces z Avoid body contact with fuels oils and lubricants used in the generator If swallowed seek medical treatme...

Page 12: ...ion cord not included is used make sure to use only UL approved cords having the correct gauge and length according to the following table Nameplate Amps full load Cord Lengths 0 50 50 100 100 150 150 200 0 5 16 16 12 12 5 1 8 16 14 10 8 1 12 14 12 12 1 15 12 10 15 20 10 10 ...

Page 13: ...120 VAC 3 prong grounded DC electrical Current output 12VDC 10A Gasoline engine Horsepower 6 5 Type 4 cycle OHV air cooled recoil start Displacement 196cc Oil capacity 0 63 quart 0 6 liter EPA approved yes Fuel Type unleaded gasoline Capacity 3 96 gallons 15 liters Running time 7 8 hours approx Fuel gauge included Weight Approximate weight 112 lbs ...

Page 14: ...eral Parts Listing This list is provided for reference purposes only All repairs and part replacement should be performed by a qualified technician Some parts may not be available as single replacements 4 1 2 13 12 25 23 24 ...

Page 15: ...0 4 6 Outlet 2 24 Connection Board 1 7 DC Terminal 2 25 Nut M5 4 8 Ground Connector 1 26 Stator 1 9 DC Fuse 1 27 Rotor 1 10 Pilot Light 1 28 Cooling Fan 1 11 Shock Absorber 4 29 Insulation Board 1 12 Shock Absorber Foot 4 30 Fuel Tank 1 13 Lock Washer Nut 4 31 Fuel Filter 1 14 Stator Cover 1 32 Seal Ring 1 15 Alternator Back Cover 1 33 Fuel Tank cap 1 16 Capacitor 1 34 Fuel Gauge 1 17 Bolt M5x16 4...

Page 16: ...3 5KW Generator 16 General Parts Listing cont d Item Qty Item Qty 37 Spacer 4 41 Frame 1 38 Rub Washer 4 42 Switch Box Cover 1 39 Bushing 4 43 Engine 1 40 Fuel Valve 1 ...

Page 17: ... Engine Parts Listing This list is provided for reference purposes only All repairs and part replacement should be performed by a qualified technician Some parts may not be available as individual replacements 42 60 64 ...

Page 18: ...ead Cover 1 17 Bolt M6 4 5 Lock Nut 2 18 Air Cleaner Cover 1 6 Adjusting Screw 2 19 Air Cleaner Element 1 7 Rocker Arm 3 20 Air Cleaner Separator 1 8 Rocker Arm Bolt 2 21 Choke Lever 1 9 Valve Push Rod Guiding Board 1 22 Carburetor Packing 1 10 Valve Push Rod 2 23 Stud Bolt M6 109 2 11 Cylinder Head 1 24 Intake Valve 1 12 Carburetor Shield 1 25 Exhaust Valve 1 13 Carburetor Packing 1 26 Cylinder H...

Page 19: ...het 2 32 Valve Stem Protector 2 47 Friction Plate Screw 1 33 Cylinder Head Cover Packing 1 48 Cover 1 34 Governor Spring 1 49 Starter Pulley 1 35 Bolt 1 50 Cooling Fan 1 36 High Tension Line 1 51 Flywheel Magneto 1 37 Ignition Coil 1 52 Cylinder Block 1 38 Nut Special 14mm 1 53 Speed Control Lever 1 39 Starter Ratchet Spring 2 54 Governor Arm 1 40 Start Rope 1 55 Governor Spring 1 41 Start Handle ...

Page 20: ...al 2 62 Bolt M6 2 74 Connecting Rod Bolt 2 63 Crankshaft 1 75 Connecting Rod Cap 1 64 Crankshaft Gear 1 76 Connecting Rod 1 65 Oil Dipstick 2 77 Piston 1 66 Oil Dipstick Seal Ring 2 78 Compression Ring I 1 67 Gear Casing 1 79 Compression Ring II 1 68 Bolt M8x35 6 80 Oil Scraper Ring 1 69 Gear Case Packing 2 81 Piston Pin 1 70 Bearing 2 82 Piston Pin Circlip 2 ...

Page 21: ...age or flood waters can not reach it z Generator placement should allow four feet of access to all sides for maintenance z Place the generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords z If the generator in located indoors the engine exhaust must be ventilated to the outdoors using leak proof heat resistant flexible metal flex ...

Page 22: ...Attach the frame to the concrete slab using 3 8 diameter expansion anchor bolts not supplied Grounding Connect a 6 AWG grounding wire not included from the ground connector 8 on the generator to a grounding rod not included that has been driven at least 24 inches deep into the earth The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the generator No...

Page 23: ... necessary refill the fuel tank with unleaded gasoline the generator must be turned off and cooled down before refilling the fuel tank Note The parts listings above are helpful for locating the controls mentioned below CAUTION PRIOR TO FIRST USING THE GENERATOR THE ENGINE MUST BE FILLED WITH APPROXIMATELY 0 63 QUART OF A HIGH QUALITY SAE 10W 30 GRADE ENGINE OIL TO DO SO UNSCREW AND REMOVE THE ENGI...

Page 24: ...er 21A to about 1 8 clearance 5 Turn the engine power switch 2 to its ON position 6 Hold the start handle 41A loosely and pull it slowly several times to allow the gasoline to flow into the engine s carburetor Then hold the start handle firmly and pull the rope hard and fast Pull the rope all the way out using two hands if necessary If necessary pull the rope several times until the engine starts ...

Page 25: ...cal powered tools and equipment from the generator s 110 120 volt AC duel outlets See Figures E F and G 5 After the engine and generator have completely cooled store generator in a safe clean dry location if not already installed CAUTION ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO THE EQUIPMENT ALL POWER AMERICA IS NOT RESP...

Page 26: ...ngine power switch 2 to its OFF position Turn the fuel valve to its OFF position 6 Disconnect the electrical powered tools power cord from the generator s DC terminals See Figure H 7 After the engine and generator have completely cooled store the generator in a safe clean dry location if not already installed in one CAUTION MAKE SURE TO CONNECT THE POSITIVE LEAD OF THE POWER CORD TO THE POSITIVE T...

Page 27: ...remove all debris with a soft brush rag or vacuum z Lubricate all moving parts using a premium quality lightweight machine oil z Every 20 hours of use drain the old engine oil and replace with approximately 0 63 quart of a high quality SAE 10W 30 grade engine oil z Every 300 hours of use have a qualified certified technician perform thorough maintenance on the generator and engine z For long term ...

Page 28: ...ng the model year stated on this certificate This certificate of conformity does not cover small non road engines imported prior to the effective date of the certificate This certificate of conformity is conditional upon compliance of said manufacturer with the averaging banking and trading provisions of 40 CFR Part 90 Subpart C both during and after model year production Failure to comply with th...