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Usr EV20i Owner's Manual

Usr ev20i generator
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  • Page 1 POWER EV20i...
  • Page 2 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 and without incurring any obligation whatever.
  • Page 3 INTRODUCTION Congratulations on your selection of a USR generator. We are certain you will be pleased with your purchase of one of the finest generators on the market. We want to help you get the best results from your new generator and to operate it safely.
  • Page 4 A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this generator safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS GENERATOR SAFETY ................Safety Label Locations ............... Important Safety Information ............COMPONENT IDENTIFICATION .............. CONTROLS ....................11 Engine Switch ..................11 Starter Grip ..................11 Fuel Tank Cap Vent Lever ..............12 Choke Lever ..................
  • Page 6 MAINTENANCE ..................36 The Importance of Maintenance ............36 Maintenance Safety ................37 Emission Control System Information ..........38 Air Index ....................40 Maintenance Schedule ..............41 Engine Oil Change ................42 Air Cleaner Service ................

  • Page 7: Generator Safety

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

  • Page 9: Important Safety Information

    IMPORTANT SAFETY INFORMATION USR generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner's manual before operating your generator. You can help prevent accidents by being familiar with your generator's controls, and by observing safe operating procedures.
  • Page 10 Do not connect to a building electrical system unless an isolation switch has been installed by a qualified electrician. Use only a USR approved parallel operation kit (optional equipment) when connecting two generators for parallel operation. Never connect different generator models and types.

  • Page 11: Component Identification

    COMPONENT IDENTIFICATION PARALLEL OPERATION OUTLETS ECO-THROTTLE SWITCH AC RECEPTACLES OIL ALERT INDICATOR LIGHT OVERLOAD INDICATOR LIGHT DC RECEPTACLE OUTPUT INDICATOR LIGHT DC CIRCUIT PROTECTOR AC CIRCUIT PROTECTOR GROUND TERMINAL FUEL TANK CAP VENT LEVER CHOKE LEVER FUEL TANK CAP MAINTENANCE COVER STARTER GRIP ENGINE SWITCH...
  • Page 12 SPARK PLUG MAINTENANCE COVER SPARK PLUG MUFFLER FRAME SERIAL NUMBER AIR CLEANER 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:...

  • Page 13: Controls

    CONTROLS ENGINE SWITCH To start and stop the engine. Switch position: OFF: To stop the engine. To start and run the engine. ENGINE SWITCH STARTER GRIP 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. Do not allow the starter grip to snap back against the engine.

  • Page 14: Fuel Tank Cap Vent Lever

    FUEL TANK CAP VENT LEVER The fuel tank cap is provided with a vent lever to seal the fuel tank. The vent lever must be in the ON position for the engine to run. When the engine is not in use, leave the vent lever in the OFF position to reduce the possibility of fuel leakage.

  • Page 15: Output Indicator Light

    OUTPUT INDICATOR LIGHT The output indicator light (green) is illuminated when the generator is operating normally. It indicates that the generator is producing electrical power at the receptacles. OUTPUT INDICATOR LIGHT (GREEN) OVERLOAD INDICATOR LIGHT 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.

  • Page 16: Oil Alert System

    OIL ALERT SYSTEM 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 can fall below a safe limit, the Oil Alert indicator light comes on and the Oil Alert system automatically will stop the engine (the engine switch will remain in the ON position).

  • Page 17: Eco-Throttle Switch

    These outlets are used for connecting two generators for parallel operation (see page A USR approved parallel operation kit (optional equipment) is required for parallel operation. This kit can be purchased from an authorized USR generator dealer. PARALLEL OPERATION OUTLETS...

  • Page 18: Ac Circuit Protector

    AC CIRCUIT PROTECTOR The AC circuit protector will automatically switch OFF if there is a short circuit or a significant overload of the generator at the AC receptacles. If the circuit protector 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.

  • Page 19: Generator Use

    GROUND SYSTEM USR portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the AC neutral wire.

  • Page 20: Special Requirements

    SPECIAL REQUIREMENTS Keep all cooling holes open and clear of debris, mud, water, etc. Cooling holes are located on the side panel, the control panel, and the bottom of the generator. If the cooling holes are blocked, the generator may overheat and damage the engine, inverter, or windings. Do not lay the generator on its side when moving, storing, or operating it.

  • Page 21: Ac Applications

    AC APPLICATIONS Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock. If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.

  • Page 22: Ac Operation

    When an electric motor is started, the overload indicator light (red) may come on. This is normal if the overload indicator light (red) goes off after about four (4) seconds. If the overload indicator light (red) stays on, consult your USR generator dealer.

  • Page 23: Ac Parallel Operation Applications

    30 minutes. Never connect different generator models and types. Use only a USR approved parallel operation kit (optional equipment) when connecting two generators for parallel operation. Never connect or remove the parallel operation kit when the generator is running.
  • Page 24 Limit operation requiring maximum power to 30 minutes. Maximum power in parallel operation is: 4.0 kVA For continuous operation, do not exceed the rated power. Rated power in parallel operation is: 3.2 kVA The total power requirements (VA) of all appliances connected must be considered.

  • Page 25: Ac Parallel Operation

    AC PARALLEL OPERATION Connect the parallel operation kit between the two generators following the instructions supplied with the kit. PARALLEL OPERATION KIT (optional equipment) Start the generators and make sure the output indicator lights (green) come on (see page Plug in the appliance following the instructions provided with the parallel operation kit.

  • Page 26: Dc Operation

    DC OPERATION The DC receptacle should ONLY be used for charging 12-volt automotive type batteries. The DC charging output is not regulated. When using the DC output, turn the Eco-Throttle switch to the OFF position. Connecting the battery charging cable (optional equipment): Before connecting the battery charging cable to a battery that is installed in a vehicle, disconnect the vehicle battery ground cable from the negative ( ) battery terminal.
  • Page 27 If this happens, wait a few minutes before pushing in the circuit protector to resume operation. If the DC circuit protector continues to go OFF, discontinue charging and see your authorized USR generator dealer. Disconnecting the battery charging cable: Stop the engine.

  • Page 28: Eco-Throttle System

    ECO-THROTTLE SYSTEM With the switch in the ON position, engine speed is automatically lowered when loads are reduced, turned OFF or disconnected. When appliances are turned ON or reconnected, the engine returns to the proper speed to power the electrical load. In the OFF position, the Eco- Throttle system does not operate.

  • Page 29: High Altitude Operation

    HIGH ALTITUDE OPERATION At high altitude, the standard carbur etor air/fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

  • Page 30: Pre-Operation Check

    PRE-OPERATION CHECK ENGINE OIL Check the oil level BEFORE EACH SAE VISCOSITY GRADES USE with the generator on a level surface and the engine stopped. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later (or equivalent).
  • Page 31 Remove the oil filler cap and wipe the 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.

  • Page 32: Refueling

    REFUELING 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. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 33 CALIFORNIA TYPE FUEL TANK CAP UPPER LIMIT MARK TETHER After refueling, tighten the fuel cap until it clicks.

  • Page 34: Fuel Recommendations

    FUEL RECOMMENDATIONS This engine is certified to operate on regular unleaded gasoline with a pump octane rating of 86 or higher. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume.

  • Page 35: Starting The Engine

    STARTING THE ENGINE STARTING THE ENGINE For your safety, avoid starting or operating the generator in an enclosed area such as a garage. Your generator's exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death. Carbon monoxide gas is toxic.
  • Page 36 If the choke lever was moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms 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.

  • Page 37: Stopping The Engine

    STOPPING THE ENGINE STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Unplug appliances from the generator receptacles. Turn the engine switch to the OFF position. The fuel valve will automatically close.

  • Page 38: Maintenance

    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...

  • Page 39: Maintenance Safety

    MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maint enance instructions and precautions can cause you to be seriously hurt or killed.

  • Page 40: Emission Control System Information

    The following instructions and procedures must be followed in order to keep the emissions from your USR engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit.
  • Page 41 EPA and California emission regulations (models certified for sale in California). We recommend the use of genuine USR parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.

  • Page 42: Air Index

    AIR INDEX (Models certified for sale in California) An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines.

  • Page 43: Maintenance Schedule

    Every 2 years (Replace if necessary) (2) 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.

  • Page 44: Engine Oil Change

    ENGINE OIL CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Turn the engine switch and vent lever to the OFF position to reduce the possibility of fuel leakage. Loosen the cover screw and remove the maintenance cover (see page 28 ).
  • Page 45 Wash your hands with soap and water after handling used oil. 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.

  • Page 46: Air Cleaner Service

    AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the gener ator in extremely dusty areas. Using gasoline or flammable solvent to clean the air filter can cause a fire or explosion.
  • Page 47 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. RUBBER SEAL Reinstall the maintenance cover, and tighten the cover screw securely.

  • Page 48: Spark Plug Service

    SPARK PLUG SERVICE In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plug: CR5HSB (NGK) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. An incorrect spark plug can cause engine damage.
  • Page 49 Visually inspect the spark plug. Replace it if the electrodes are worn or if the insulator is cracked, chipped, or fouled. Measure the spark plug electr ode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.024 0.028 in (0.60 0.70 mm) 0.024 0.028 in...

  • Page 50: Spark Arrester Maintenance

    SPARK ARRESTER MAINTENANCE 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. Clean the spark arrester as follows: Remove the four 6 mm screws, and remove the muffler protector.
  • Page 51 Use a brush to remove carbon deposits from the spark 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.

  • Page 52: Transporting/Storage

    TRANSPORTING/STORAGE TRANSPORTING Do not lay the generator on its side when moving, storing, or operating it. Oil may leak and damage the engine or your property. If the generator has been used, allow it cool for at least 15 minutes before loading the generator on the transport vehicle.

  • Page 53: Storage

    Change the engine oil (page 42 ). After removal from storage, fill with fresh gasoline before starting. ˎ Use gasoline stabilizers that are formulated to extend storage life. Follow the instructions included with the gasoline stabilizer. Contact your authorized USR generator dealer for gasoline stabilizer recommendations.
  • Page 54 Storage Procedure Drain the gasoline. Unscrew the fuel tank cap, remove the debris screen, and empty the fuel tank into an approved gasoline 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.
  • Page 55 Change the engine oil (see page 42). Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug. Reinstall the spark plug cap on the spark plug securely. Reinstall the spark plug maintenance cover.

  • Page 56: Troubleshooting

    Replace it if n e c e s s a r y ( s e e page 46). If the engine still does not start, take the generator to an authorized USR generator dealer.
  • Page 57 Is the output indicator light ON? (see page 13) I s t h e o v e r l o a d Take the generator to an indicator light ON? authorized USR generator (see page 13) dealer. NO DEFECTS Check the electrical ap-...

  • Page 58: Wiring Diagram

    WIRING DIAGRAM...

  • Page 59: Initial Use Instructions

    INITIAL USE INSTRUCTIONS ADDING ENGINE OIL The generator is shipped WITHOUT OIL in the engine. Place the generator on a level surface. Loosen the cover screw and remove the maintenance cover. COVER SCREW MAINTENANCE COVER With the generator in a level position, remove the oil filler cap/ dipstick.

  • Page 60: Adding Fuel

    ADDING FUEL This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. If the fuel level is low, refuel in a well-ventilated area with the engine stopped.
  • Page 61 Remove the fuel tank cap. NON-CALIFORNIA TYPE CALIFORNIA TYPE FUEL TANK CAP FUEL TANK CAP Fuel carefully to avoid spilling fuel. Do not fill the fuel tank above the upper limit mark on the fuel strainer. NON-CALIFORNIA TYPE CALIFORNIA TYPE UPPER LIMIT MARK UPPER LIMIT MARK TETHER...
  • Page 62 After refueling, tighten the fuel cap securely (Non-California type). After refueling, tighten the fuel cap until it clicks (California type). Keep the vent OFF for storage or transport, and ON to run the generator. NON-CALIFORNIA TYPE CALIFORNIA TYPE VENT LEVER VENT LEVER Move the generator at least 10 feet (3 meters) away from the fueling source and site before starting the engine.

  • Page 63: Specifications

    SPECIFICATIONS Dimensions Model EV20i Description code EAAJ Length 20.2 in (512 mm) Width 11.4 in (290 mm) Height 16.7 in (425 mm) Dry weight 45.9 lbs (20.8 kg) Engine Model GX100 Engine type 4-stroke, overhead camshaft, single cylinder Displacement 6.01 cu-in (98.5 cm ) 2.20...
  • Page 64 RECEPTACLE Shape Type G, GW...
  • Page 65 POWER...

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