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MAINTENANCE

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement, or repair of the emission control devices
and systems may be performed by any engine repair establishment or
individual, using parts that are ‘‘certified’’ to EPA standards.

Improper maintenance, or failure t

o correct a problem before

operation, can cause a malfunction

in

which you can be seriously hurt

or killed.

Always follow the inspection and maintenance recommendations and
schedules in this owner’s manual.

Good maintenance is essential for safe, economical, and trouble free
operation. It will also help reduce air pollution.

To help you properly care for your generator, the following pages
include a maintenance schedule, routine inspection procedures, and
simple maintenance procedures using basic hand tools. Other service
tasks that are more difficult, or require special tools, are best handled
by professionals and are normally performed by a

USR

technician or

other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If
you operate your generator under severe conditions, such as
sustained high-load or high-temperature operation, or use it in
unusually wet or dusty conditions, consult your servicing dealer for
recommendations applicable to your individual needs and use.

Remember that your servicing dealer knows your generator best and
is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, genuine

USR

parts or their equivalents for repair or replacement.

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Содержание EV20i

Страница 1: ...POWER EV20i ...

Страница 2: ... manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the generator and should remain with the generator if resold The information and specifications included in this publication were in effect at the time of approval for printing USR power Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice...

Страница 3: ...on is intended to help you avoid damage to your generator other property or the environment When your generator needs scheduled maintenance keep in mind that your USR servicing dealer is specially trained in servicing the generators Your authorized the servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes USR Power Co Ltd We sugges...

Страница 4: ...d important safety information in a variety of forms including These signal words mean be or if you don t follow instructions be or if you don t follow instructions be if you don t follow instruc tions Your safety and the safety of others are very important And using this generator safely is an important responsibility This entire book is filled with important safety information please read it car...

Страница 5: ...ttle Switch 15 Parallel Operation Outlets 15 AC Circuit Protector 16 DC Receptacle 16 DC Circuit Protector 16 GENERATOR USE 17 Connections to a Building Electrical System 17 Ground System 17 Special Requirements 18 AC Applications 19 AC Operation 20 AC Parallel Operation Applications 21 AC Parallel Operation 23 DC Operation 24 Eco Throttle System 26 High Altitude Operation 27 PRE OPERATION CHECK 2...

Страница 6: ...n 38 Air Index 40 Maintenance Schedule 41 Engine Oil Change 42 Air Cleaner Service 44 Spark Plug Service 46 Spark Arrester Maintenance 48 TRANSPORTING STORAGE 50 Transporting 50 Storage 51 TROUBLESHOOTING 54 WIRING DIAGRAM 56 INITIAL USE INSTRUCTIONS 57 Adding Engine Oil 57 Adding Fuel 58 SPECIFICATIONS 61 ...

Страница 7: ...ETY SAFETY LABEL LOCATIONS If a label comes off or becomes hard to read contact your USR generator dealer for a replacement These labels warn you of potential hazards that can cause serious injury Read them carefully ...

Страница 8: ...6 ...

Страница 9: ...ccidents by being familiar with your generator s controls and by observing safe operating procedures Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output receptacles and connections Exhaust contains poisonous carbon monoxide a colorless and odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you ...

Страница 10: ...rator in any structure Keep flammable materials away from the generator Never connect different generator models and types The generator produces enough electric power to cause a serious shock or electrocution if misused Using a generator or electrical appliance in wet conditions such as rain or snow or near a pool or sprinkler system or when your hands are wet could result in electr ocution Keep ...

Страница 11: ...ICATOR LIGHT OUTPUT INDICATOR LIGHT FUEL TANK CAP VENT LEVER FUEL TANK CAP AC RECEPTACLES GROUND TERMINAL DC CIRCUIT PROTECTOR DC RECEPTACLE MAINTENANCE COVER AC CIRCUIT PROTECTOR CHOKE LEVER ENGINE SWITCH OIL ALERT INDICATOR LIGHT STARTER GRIP ECO THROTTLE SWITCH TM ...

Страница 12: ...UG MUFFLER AIR CLEANER FRAME SERIAL NUMBER Record the frame serial number for your future reference Refer to this serial number when ordering parts and when making technical or warranty inquiries see page Frame serial number Date purchased 62 ...

Страница 13: ...o p pu ul ll l To start and stop the engine To stop the engine To start and run the engine Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter To start the engine pull the starter grip lightly until you feel resistance then pull briskly in the direction of the arrow as shown below ...

Страница 14: ...ever must be in the ON position for the engine to run The choke is used to provide proper starting mixture when the engine is cold It can be opened and closed by operating the choke lever manually Move the choke lever to the CLOSED position to enrich the mixture for cold starting When the engine is not in use leave the vent lever in the OFF position to reduce the possibility of fuel leakage Allow ...

Страница 15: ...ndicates that the generator is producing electrical power at the receptacles If the generator is overloaded in excess of 2 000 VA or if there is a short circuit in a connected appliance the overload indicator light red will go ON The overload indicator light red will stay ON and after about four seconds current to the connected appliance s will shut off and the output indicator light green will go...

Страница 16: ...for local codes or ordinances that apply to the intended use of the generator If the engine stops or the Oil Alert indicator light comes on when you pull the starter grip check the engine oil level see page before troubleshooting in other areas The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase ca...

Страница 17: ...nnected simultaneously turn the Eco Throttle switch to the OFF position to reduce voltage changes When using the DC output turn the Eco Throttle switch to the OFF position Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator The Eco Throttle system does not operate These outlets are used for connecting two generators for parallel operati...

Страница 18: ...ector switches OFF automatically check that the appliance is working properly and does not exceed the rated load capacity of the circuit before resetting the circuit protector ON The DC circuit protector automatically shuts off the DC battery charging circuit when the DC charging circuit is overloaded when there is a problem with the battery or when the connections between the battery and the gene...

Страница 19: ...ty company or a qualified electrician GROUND SYSTEM Connections for standby power to a building electrical system must be made by a qualified electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes USR portable generators have a system ground that connects generator frame components to the ground terminals in the ...

Страница 20: ...a qualified electrician electrical inspector or the local agency having jurisdiction In some areas generators are required to be registered with local utility companies If the generator is used at a construction site there may be additional regulations that must be observed Keep all cooling holes open and clear of debris mud water etc Cooling holes are located on the side panel the control panel a...

Страница 21: ...otector OFF but will shorten the service life of the generator Make sure that the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately...

Страница 22: ...ator If the generator is overloaded in excess of 2 000 VA or if there is a short circuit in a connected appliance the overload indicator light red will go ON The overload indicator light red will stay ON and after about four seconds current to the connected appliance s will shut off and the output indicator light green will go OFF Stop the engine and investigate the problem When an electric motor ...

Страница 23: ...ifferent generator models and types Make sure that the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately Disconnect the appliance a...

Страница 24: ...For continuous operation do not exceed the rated power Rated power in parallel operation is The total power requirements VA of all appliances connected must be considered Appliance and power tool manufacturers usually list rating information near the m odel number or serial number 4 0 kVA 3 2 kVA ...

Страница 25: ...hts red will go ON The overload indicator lights red will stay ON and after about four seconds current to the connected appliance s will shut off and the output indicator lights green will go OFF Stop the engines and investigate the problem Most motorized appliances require more than their rated wattage for startup Plug in the appliance following the instructions provided with the parallel operati...

Страница 26: ...e battery charging cable to a battery that is installed in a vehicle disconnect the vehicle battery ground cable from the negative battery terminal The DC receptacle should ONLY be used for charging 12 volt automotive type batteries The DC charging output is not regulated Start the generator Connect the red lead of the battery charging cable to the positive battery terminal and the black lead to t...

Страница 27: ...es to go OFF discontinue charging and see your authorized USR generator dealer Stop the engine Disconnect the black lead of the battery charging cable from the negative battery terminal Disconnect the red lead of the battery charging cable from the positive battery terminal Disconnect the battery charging cable from the DC receptacle of the generator Connect the vehicle battery ground cable to the...

Страница 28: ... for use with appliances that require only momentary power If the tool or appliance will be turned ON and OFF quickly the Eco Throttle switch should be in the OFF position When using the DC output turn the Eco Throttle switch to the OFF position If high electrical loads are connected simultaneously turn the Eco Throttle switch to the OFF position to reduce voltage changes With the switch in the ON...

Страница 29: ...tor modification This e ngine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The ef fect of altitude on horsepower will be greater than this if no carburetor modification is...

Страница 30: ...ements for API service classification SJ or later or equivalent Always check the API SERVICE label on the oil container to be sure it includes the letter SJ or later or equivalent SAE 10W 30 is recommended for general all temperature use Other viscosities shown in the chart may be used when the average temperature in your ar ea is within the indicated range Loosen the cover screw and remove the ma...

Страница 31: ...he dipstick clean Check the oil level by inserting the dipstick into the filler neck without screwing it in If the level is low fill to the upper limit of the oil filler neck with the recommended oil Reinstall the maintenance cover and tighten the cover screw securely 3 4 5 6 ...

Страница 32: ...PER LIMIT MARK NON CALIFORNIA TYPE With the engine stopped remove the fuel tank cap and check the fuel level Refill the fuel tank if the fuel level is low Refuel carefully to avoid spilling fuel Do not fill above the upper limit mark Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty After refueling...

Страница 33: ...31 UPPER LIMIT MARK FUEL TANK CAP CALIFORNIA TYPE TETHER After refueling tighten the fuel cap until it clicks ...

Страница 34: ...ontaining no more than 10 Ethanol E10 or 5 Methanol by volume In addition Methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with perce...

Страница 35: ...lect rapidly in an enclosed area and cause illness or death Perform PRE OPERATION CHECK see page Make sure that all appliances are disconnected from the AC receptacles Turn the fuel cap vent lever to the ON position To start a cold engine move the choke lever to the CLOSED position To restart a warm engine leave the choke lever in the OPEN position Turn the engine switch to the ON position Pull th...

Страница 36: ...to the OPEN position as the engine warms up If you wish to use the Eco Throttle system turn the Eco Throttle switch to the ON position after the engine has warmed up for 2 or 3 minutes Refer to the AC OPERATION see page or DC OPERATION see page for connecting loads to the generator 7 8 9 20 24 ...

Страница 37: ...the engine switch to the OFF position Under normal conditions use the following procedure Turn the engine switch to the OFF position Allow the engine to cool well turn the vent lever to the OFF position If two generators were connected fo r parallel operation disconnect the parallel operation kit after stopping the engines if you do not wish to resume parallel operation 4 3 2 1 ...

Страница 38: ... pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a USR technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your generator und...

Страница 39: ...ly you can decide whether or not you should perform a given task Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Be sure there is adequate ventilation whenever you operate the engine Let the engine and exhaust system cool before touching Do not run the engine unless instructed to do so Read the instructions before you begin and ...

Страница 40: ...e legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of e...

Страница 41: ...acement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer...

Страница 42: ...mediate Extended The durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine s emission control system See your Emission Control System Warranty for additional information The bar graph is intended to provide you our customer the ability to compare the emissions perfo...

Страница 43: ...use Service more frequently when used in dusty areas These items should be serviced by an authorized USR generator dealer unless the owner has the proper tools and is mechanically proficient See the USR Shop Manual For commercial use log hours of operation to determine proper maintenance intervals Failure to follow this maintenance schedule could result in non warrantable failures After every 300 ...

Страница 44: ...the possibility of fuel leakage Remove the oil filler cap dipstick and drain the oil into the container by tipping the engine toward the oil filler neck Reinstall the oil filler cap dipstick securely Reinstall the maintenance cover and tighten the cover screw securely Loosen the cover screw and remove the maintenance cover see page 28 With the engine in a level position fill to the upper limit of ...

Страница 45: ...Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of it properly Put it in a sealed container and take it to a recycling center Do not discard it in a trash bin dump it on the ground or pour it down a drain ...

Страница 46: ...t an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty Soak the main and outer filter in clean engine oil and squeeze out the excess oil The engine will smoke during initial startup if too much oil is left in the air filters Wash the main and outer filter in a solution of ho...

Страница 47: ...BER SEAL Reinstall the air filters Make sure that the rubber seal is set in the groove of the air cleaner cover Reinstall the air cleaner cover and tighten the air cleaner cover screw Reinstall the maintenance cover and tighten the cover screw securely 5 6 7 8 ...

Страница 48: ...ilable To ensure proper engine operation the spark plug must be properly gapped and free of deposits An incorrect spark plug can cause engine damage Remove the spark plug maintenance cover Use a spark plug wrench to remove the spark plug Remove the spark plug cap Clean any dirt from around the spark plug base CR5HSB NGK If the engine has been running allow it to cool before servicing the spark plu...

Страница 49: ...rrect the gap if necessary by carefully bending the side electrode Check that the spark plug sealing washer is in good condition and thread the spark plug in by hand to prevent cross threading A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head Reinstall the spark plug cap on the spark plug securely Reinstall the spark plu...

Страница 50: ...llows If the generator has been running the muffler will be very hot Allow it to cool before proceeding The spark arrester must be serviced every 100 hours to maintain its efficiency Remove the four 6 mm screws and remove the muffler protector Remove the three 6 mm bolts and remove the muffler the spark arrester and the muffler gasket 1 2 ...

Страница 51: ...ark arrester screen Inspect the screen for breaks or tears and replace it if necessary Check the muffler gasket replace if damaged Reinstall the muffler gasket the spark arrester the muffler and the muffler protector in the reverse order of removal 3 4 5 ...

Страница 52: ...rating position with the engine switch OFF and the fuel tank cap vent lever turned fully counterclockwise to the OFF position If the generator has been used allow it cool for at least 15 minutes before loading the generator on the transport vehicle A hot engine and exhaust system can burn you and can ignite some material Do not lay the generator on its side when moving storing or operating it Oil ...

Страница 53: ...l with fresh gasoline and add gasoline stabilizer Run the engine for 10 minutes to use up the non treated gasoline Or drain the gasoline page 52 Drain the gasoline page 52 Remove the spark plug Put a tablespoon of engine oil into the cylinder Turn the engine slowly with the starter grip to distribute the oil Reinstall the spark plug Change the engine oil page 42 After removal from storage fill wit...

Страница 54: ...container using a commercially available hand siphon Reinstall the debris screen and the fuel tank cap Loosen the cover screw and remove the maintenance cover Loosen the carburetor drain screw Drain the gasoline from the carburetor into a suitable container Remove the spark plug maintenance cover Remove the spark plug cap Turn the engine switch to the ON position Pull the starter grip 3 to 4 times...

Страница 55: ...distribute the oil then reinstall the spark plug Reinstall the spark plug cap on the spark plug securely Reinstall the spark plug maintenance cover Reinstall the maintenance cover and tighten the cover screw securely Pull the starter grip slowly until you feel resistance then return the starter grip gently This closes the valves so moisture cannot enter 2 3 4 5 6 7 ...

Страница 56: ... engine Is the spark plug in good condition If the engine still does not start take the generator to an authorized USR generator dealer Refill the fuel tank see page 30 Add the recom mended oil see page 28 Clean readjust gap and dry the spark plug Replace it if necessary see page 46 YES YES NO NO YES NO ...

Страница 57: ... to an authorized USR generator dealer Replace the electrical ap pliance or equipment Take the electrical ap pliance or equipment to an electrical shop for repair Stop and restart the engine Is the output indicator light ON see page 13 I s t h e o v e r l o a d indicator light ON see page 13 Turn the DC circuit protector on see page 16 Take the generator to an authorized USR generator dealer YES N...

Страница 58: ...56 WIRING DIAGRAM ...

Страница 59: ...lled the excess oil may be transferred to the air cleaner housing and air filter Screw in the oil filler cap dipstick securely Reinstall the maintenance cover Add enough SAE 10W 30 API service classification SJ or later or equivalent oil to bring the oil level to the upper limit of the oil filler neck SAE 10W 30 oil is recommended for general use for additional recommendations see page Loosen the ...

Страница 60: ...has been running allow it to cool first Never refuel the engine inside a building where gasoline fumes can reach flames or sparks You may use regular unleaded gasoline containing no more than 10 Ethanol E10 or 5 Methanol by volume In addition Methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and or...

Страница 61: ...YPE CALIFORNIA TYPE TETHER Remove the fuel tank cap Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty Fuel carefully to avoid spilling fuel Do not fill the fuel tank above the upper limit mark on the fuel strainer 1 2 ...

Страница 62: ... or transport and ON to run the generator Before using the generator all g enerator operators must read the following chapters and sections pages pages pages pages pages page page Move the generator at least 10 feet 3 meters away from the fueling source and site before starting the engine After initial fueling or anytime the generator is run completely out of fuel starting the engine may require a...

Страница 63: ...tion code Length Width Height Dry weight Model Engine type Displacement Bore Stroke Compression ratio Engine speed Cooling system Ignition system Oil capacity Fuel tank capacity Spark plug Model Type Rated voltage Rated frequency Ac output Rated current Rated output Maximum output DC output Refer to page 46 See your authorized USR dealer EV20i 2 20 1 57 in 56 0 40 0 mm California type AC type Non ...

Страница 64: ...RECEPTACLE Shape Type B W F U G GW 62 ...

Страница 65: ...POWER ...

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