Components/accessories of a small portable gasoline generator

Small portable gasoline generators consist of four main hardware groups: ignition, fuel, power regulation, and frame/hardware. The ignition system includes the flywheel magneto, ignition module, and spark plug, which together generate and time the high-voltage spark. Fuel is metered and atomized by a carburetor, controlled by a petcock and protected by a sediment screen. Output voltage is stabilized either by an automatic voltage regulator in conventional sets or by a permanent-magnet generator plus inverter in variable-speed units, the latter delivering cleaner sine waves for sensitive electronics. Mobility and durability are provided by powder-coated steel carry frames, vibration-isolating rubber feet, and optional lockable canopies. Routine-maintenance items—air filters, low-oil sensors, and mufflers—ensure reliable, quiet operation and long engine life.

Section 1 – Narrative (arranged by functional system)

1. Ignition system
   The ignition module (TCI or CDI) is the “heart” of a gasoline engine. It steps up the low-voltage current from the flywheel magneto and delivers a high-voltage pulse to the spark plug at the correct time. The flywheel itself contains embedded permanent magnets; as it spins it both powers the ignition module and, on battery-equipped sets, charges the battery. The spark plug conducts the high-voltage arc into the combustion chamber; electrode gap and heat range must match the engine specification, otherwise idle instability or pre-ignition can occur.
2. Fuel-supply system
   The carburetor uses intake vacuum to atomize gasoline and create a combustible mixture. Inside it, the main jet, pilot jet and float needle are normal wear items. The fuel petcock (fuel outlet valve) is often designed for 90° quick shut-off to prevent leakage during transport. Many models include a detachable sediment bowl that traps water and dirt, reducing carburetor malfunctions.
3. Power-output & voltage-regulation system
   Conventional sets use an Automatic Voltage Regulator (AVR) that senses output voltage and adjusts excitation current to keep 230 V (or 120 V) within ±3 %. Inverter sets omit the AVR; instead they employ a “permanent-magnet generator + inverter (converter)” topology: the AC is first rectified to DC, then inverted back to 50 Hz (or 60 Hz) AC with <3 % THD—safe for laptops and sensitive instruments. For outdoor work, receptacles should be the locking, weather-proof type to avoid accidental disconnection.
4. Frame & mobility parts
   Carry frames or folding handles are usually welded from 22 mm steel tube and 3 mm plate, then powder-coated to ≥80 µm thickness so they pass a 48 h salt-spray test without rust. Anti-vibration foot pads are a rubber–steel sandwich (65±5 Shore A SBR) that cut vibration noise by 5–8 dB. RV or truck-air-conditioner units can be fitted with full-coverage anti-theft canopies made from 1.2 mm perforated steel for ventilation and security.
5. Protection & maintenance items
   Air-filter elements are either dry paper or oiled foam: the foam type is washable but must be cleaned every 8 h in dusty sites; the paper type is disposable. The low-oil sensor uses a magnetic reed switch that grounds the ignition when oil falls below the safe level, preventing seizure. The muffler contains dual baffles and glass-fiber wool to lower exhaust noise by 10–15 dB; when the wool disintegrates the exhaust note becomes “crackly” and the whole muffler should be replaced.

Section 2 – Detailed spare-parts table

Major group	Sub-part / component name	Primary function	Typical mounting location	Normal service life or change interval
Ignition	Ignition module (TCI / CDI)	Voltage step-up & timing	Beside flywheel or inside panel	1 000 h, or when misfire occurs
Ignition	Flywheel	Energy storage, cooling, triggering	Front end of crankshaft	Designed ≥2 000 h; replace if impact-deformed
Ignition	Charging coil	Power generation	Fixed around flywheel rim	1 000–1 500 h
Ignition	Spark plug	Ignite mixture	Cylinder-head top	Clean carbon every 100 h, replace at 300 h
Fuel	Carburetor assembly	Atomize fuel	Between air filter & head	Clean every 500 h, replace jets when worn
Fuel	Fuel petcock / outlet valve	On/off control	Bottom of fuel tank	Replace when seal hardens / leaks
Fuel	Sediment cup + screen	Water / dirt trap	Below petcock	Drain every 30 h, replace screen if torn
Power	AVR regulator	Voltage stabilization	Rear end-cover or panel	800–1 200 h
Power	Inverter (converter)	AC-DC-AC conversion	Fan-cooled box on inverter sets	Designed 2 000 h; heat is main killer
Power	PM stator / rotor	Power generation	Inside brushless inverter genset	1 500 h; check if bearing noise appears
Power	Output receptacle	Power take-off	Control panel	2 000 insertions or when loose
Frame	Carry frame / handle set	Load bearing, portability	Around entire set	Re-paint or replace if rust >5 % area
Frame	Anti-vibration foot pads	Damping & noise reduction	Four corners of base	Replace when cracked (2–3 years typical)
Maintenance	Air filter (paper or foam)	Dust filtration	Carburetor inlet	Paper: 50 h; foam: wash every 30 h
Maintenance	Low-oil sensor	Low-oil shutdown	Crankcase side wall	500 h, or if false alarms appear
Maintenance	Muffler / silencer	Noise reduction	Cylinder-head exhaust port	Replace when fiber wool disintegrates

Note: Intervals may be shortened in dusty, high-temperature or continuous-load conditions. If output drops, unusual noise, blue/white smoke or voltage instability appear, inspect the related parts first.