CUMMINS Onan P2500i Operator's Manual

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Page 1

Operator Manual

Onan P2500i Inverter

English Original Instructions

1-2019 A062R850 (Issue 1)

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WARNING

Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing your equipment. For more information go to www.P65Warnings.ca.gov.

DISCLAIMERS:

All information, illustrations and specications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Some images may vary depending upon which model is shown.

No part of this publication may be reproduced or used in any form by any means – graphic, electronic or mechanical, including photocopying, recording, taping or information storage and retrieval systems – without the written permission of Cummins Inc.

1-2019

DANGER

This manual contains important instructions for operating this inverter. For your safety and the safety of others, be sure to read this manual thoroughly before operating the inverter. Failure to properly follow all instructions and precautions can cause you and others to be seriously hurt or killed.

TECHNICAL SPECIFICATIONS

Fuel

Model Number

P2500i 2200 2500 3.8/1.0 5500 CDI E6RTC 98 52X46 0.35 10W30 <5%

Running Watts

Peak Watts

Tank Size (L/G)

Rated Speed (RPM)

Ignition Type

Spark plug

Engine Disp (cc)

Stroke X Bore

Oil Capacity (L) Oil Type THD

1-800-CUMMINS

(1-800-286-6467)

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FOR YOUR RECORDS:

Date of Purchase:

Inverter Model Number:

Purchased from Store/Dealer:

Inverter Serial Number:

IMPORTANT: KEEP YOUR PURCHASE RECEIPT TO ENSURE TROUBLE-FREE WARRANTY COVERAGE.

PRODUCT REGISTRATION

To ensure trouble-free warranty coverage, it is important you register your Cummins inverter. You can register your inverter by either:

1. Filling in the product registration form below and mailing to:

Product Registration

Model Info Decal located on side panel.

Cummins Inc 301 E. Market St.

Indianapolis, IN 46204

2. Registering your product Online at www.cummins.com/support/product-registration

To register your inverter you will need to locate the following information:

000000000000000

Serial Number which is located on

bottom of muer cover.

CUMMINS PRODUCT REGISTRATION FORM

PERSONAL INFORMATION INVERTER INFORMATION

First Name: _______________________________________ Model Number: _____________________________________

Last Name: _______________________________________ Serial Number: ______________________________________

Street Address: ___________________________________ Date Purchased: ____________________________________

Street Address: ___________________________________ Purchased From: ____________________________________

City, State, ZIP: ____________________________________

Country: __________________________________________

Phone Number: ___________________________________

E-Mail: ___________________________________________

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TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS ..................2

PRODUCT REGISTRATION .....................3

For Your Records: ..........................3

Product Registration .......................3

Product Registration Form ...................3

SAFETY .....................................5

Safety Denitions ...........................5

Safety Symbol Denitions ....................5

General Safety Rules ........................6

Safety Labels and Decals ....................7

UNPACKING .................................7

FEATURES ..................................8

Basic Inverter Features ......................8

Control Panel Features ......................9

LED Digital Data Display .....................10

OPERATION .................................11

Before Starting the Inverter ...................11

Location Selection .......................11

Weather ................................11

Dry Surface .............................11

No Connected Loads .....................11

Grounding the Inverter ....................11

Powercord ................................12

Initial Oil Fill ...............................13

Adding/Checking Engine Fluids and Fuel ........14

Checking and/or Adding Engine Oil. . . . . . . . . . . . . 14

Adding Gasoline to the Fuel Tank ..............14

Starting P2500i ............................15

Stopping the Inverter ........................16

Using Eciency Mode .......................16

Resetting the Reset Breaker ..................16

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MAINTENANCE ..............................17

Maintenance Schedule ......................17

Engine Oil Maintenance ......................18

Checking Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . 18

Adding Engine Oil ..........................18

Changing Engine Oil ........................19

Air Filter Maintenance .......................19

Cleaning the Air Filter ........................19

Draining the Float Bowl ......................20

Spark Plug Maintenance .....................21

Cleaning the Spark Arrestor ...................22

Checking and Adjusting Valve Lash. . . . . . . . . . . . . 22

Cleaning the Inverter ........................23

Storage ..................................23

TROUBLESHOOTING .........................24

EXPLODED AND ENGINE VIEWS ................25

P2500i Exploded View .......................25

P2500i Exploded View Part No ................26

P2500i Engine View .........................27

P2500i Engine View Part No ..................28

P2500i Schematic ..........................29

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SAFETY DEFINITIONS

The words DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to highlight important information. Be certain that the meanings of these alerts are known to all who work on or near the equipment.

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alerts symbol.

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

SAFETY SYMBOL DEFINITIONS

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which can cause damage to the inverter, personal property and/or the environment, or cause the equipment to operate improperly.

NOTE: Indicates a procedure, practice or condition

that should be followed in order for the inverter to function in the manner intended.

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SAFETY

GENERAL SAFETY RULES

Never use the inverter in a location that is wet or damp. Never expose the inverter to rain, snow, water spray or standing water while in use. Protect the inverter from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.

Never operate the inverter in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the inverter outside and away from windows, doors and vents.

Voltage produced by the inverter could result in death or serious injury.

• Never operate the inverter in rain or a ood plain unless proper precautions are taken to avoid being subject to rain or a ood.

• Never use worn or damaged extension cords.

• Always have a licensed electrician connect the inverter to the utility circuit.

• Never touch an operating inverter if the inverter is wet or if you have wet hands.

• Never operate the inverter in highly conductive areas such as around metal decking or steel works.

• Always use grounded extension cords. Always use three-wire or double-insulated power tools.

• Never touch live terminals or bare wires while the inverter is operating.

• Be sure the inverter is properly grounded before operating.

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DANGER

WARNING

Gasoline and gasoline vapors are extremely ammable and explosive under certain conditions.

• Always refuel the inverter outdoors, in a well-ventilated area.

• Never remove the fuel cap with the engine running.

• Never refuel the inverter while the engine is running. Always turn engine o and allow the inverter to

cool before refueling.

• Only ll fuel tank with gasoline.

• Keep sparks, open ames or other form of ignition (such as match, cigarette, static electric source)

away when refueling.

• Never overll the fuel tank. Leave room for fuel to expand. Overlling the fuel tank can result in a sudden overow of gasoline and result in spilled gasoline coming in contact with HOT surfaces. Spilled fuel can ignite. If fuel is spilled on the inverter, wipe up any spills immediately. Dispose of rag properly. Allow area of spilled fuel to dry before operating the inverter.

• Wear eye protection while refueling.

• Never use gasoline as a cleaning agent.

• Store any containers containing gasoline in a well-ventilated area, away from any combustibles or

source of ignition.

• Check for fuel leaks after refueling. Never operate the engine if a fuel leak is discovered.

WARNING

Never operate the inverter if powered items overheat, electrical output drops, there is sparking, ames or smoke coming from the inverter, or if the receptacles are damaged.

Never use the inverter to power medical support equipment.

Always remove any tools or other service equipment used during maintenance from the inverter before operating.

Never modify the inverter.

Never operate the inverter if it vibrates at high levels, if engine speed changes greatly

or if the engine misres often.

Always disconnect tools or appliances from the inverter before starting.

NOTICE

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Model

Part No

SAFETY LABELS AND DECALS

Have Questions?

1-800-CUMMINS

Model Modelo Onan P2500i Part No Numero de parte A058U944 AC Voltage Voltaje 120V Power (Running) Potencia (nominal) 2200W Power (Peak) Potencia (pico) 2500W Current Corriente 18A DC Voltage Voltaje 12V Current Corriente 8A Frequency Frecuencia 60Hz Phase Fase Single Soltero RPM TR 5200 Power Factor Factor de potencia 1.0 Insul Class Clase de aislamiento F Max Amb Temp Temperatura máxima 40 Fuel Combustible Gasoline Fuel Tank Size Tamaño del tanque de combustible 3.7L/1G

Oil: SAE10W-30

Oil Capacity Capacidad de aceite .37 QT/11.8 OZ/350 ML

Read and understand operating instructions before starting.

Lea y comprenda las instrucciones de operación antes de comenzar.

Provide proper ventilation! Do not operate in a confined area.

Proporcione una ventilación adecuada! No opere en un área confinada.

Do not operate in wet conditions. Electrical shock may result and could be fatal! No opere en condiciones húmedas. ¡Puede producirse una

descarga eléctrica y podría ser fatal!

FOR USE IN DRY WEATHER PROTECTED LOCATIONS ONLY.

PARA USO EN LUGARES PROTEGIDOS CON TIEMPO SECO SOLAMENTE.

FOR USE IN DRY WEATHER PROTECTED LOCATIONS ONLY.

PARA USO EN LUGARES PROTEGIDOS CON TIEMPO SECO SOLAMENTE.

C (104

Cummins Inc.

Columbus Indiana 47201 USA

Designed in Columbus, Ohio USA Made in China

Diseñado en Columbus, Ohio, EE. UU. Hecho en China

Spark Plug Bujía

Use OEM spark plug only.

Please refer to Owner’s Manual.

Utilice únicamente bujías OEM. Por favor, consulte el manual del propietario

Spark plug: Torch E6RTC Spark plug gap: .8 mm/.03 in

WARNING:

• Use gasoline with a minimum octane rating of 87.

• Do not direct exhaust fumes toward people, buildings or equipment.

• Check and refill oil as required to ensure proper inverter performance.

• When refueling, always stop the engine.

• Immediately wipe up any spilled fuel.

• Keep any flammable items away from this equipment.

• Do not touch or contact outlets with wet hands.

• Do not expose inverter directly to rain or snow.

• Do not connect the AC output to any indoor wiring.

• Clean spark arrestor every 50 hours to prevent engine damage.

• When operating your inverter, do not erect any barriers or obstacles around the equipment or inhibit air or exhaust flow.

SAFETY

Using a generator indoors

CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Usar un generador en el interior PUEDE MATARLE EN

MINUTOS. El escape del generador contiene monóxido de

carbono. Este es un veneno que no puedes ver ni oler.

Use solo FUERA y lejos

NUNCA lo use dentro de una

casa o un garaje, INCLUSO SI

las puertas y ventanas están

abiertas

de ventanas, puertas y ventilaciones.

UNPACKING

CAUTION

Always have assistance when lifting the inverter. The inverter is heavy; lifting it could cause bodily harm.

Avoid cutting on or near staples to prevent personal injury.

Tools required – box cutter or similar device.

1. Remove socket wrench, oil and funnel and save for later.

2. Carefully cut two sides of the carton to remove the inverter.

WHAT COMES IN THE BOX

Spark Plug Socket Wrench (1) Owner Manual (1) Quick Start Guide (1) Warranty Information (1) Funnel (1) .37 QT/.35 L Bottle of 10W-30 Oil (1)

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FEATURES

BASIC INVERTER FEATURES

1-2019

Fuel Cap: Vent-less cap must be secure before

operating.

Control Panel: Contains the reset breaker,

outlets and warning lights.

Recoil Handle: Pull to start the engine.

Engine Control Switch: Sets the choke, turns

the fuel on and o.

Engine Service Panel: Remove the panel

to access the spark plug and engine for

maintenance.

Muer and Spark Arrestor: Avoid contact until the engine is cooled down. The spark arrestor prevents sparks from exiting the muer. It must be removed for servicing.

Engine Cooling Vents: Helps move airow in unit to regulate engine temperatures. DO NOT BLOCK

Recoil Maintenance Panel: Remove to perform

maintenance on pull cord or engine control switch.

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CONTROL PANEL FEATURE

120-Volt, 20-Amp Duplex Outlet (NEMA 5-20R): The

outlet is capable of carrying a maximum of 20 amps.

USB Duplex: 5V DC that come in 1 amps and 2.1 amps.

Reset Breaker: If the inverter is overloaded, the reset breaker will trip.

The engine will continue to run, but there will be no output from the inverter. Unplug the devices and reduce the load. Push in the reset breaker to reset it.

Eciency Mode Switch: When turned to the ON position, the engine

will sense the load needed and run at a slower RPM to save fuel.

Ground Terminal: The ground terminal is used to externally ground

the inverter.

Parallel Ports: For use with Cummins 30A Parallel Kit (sold separate)

and another P2500i inverter (sold separate) to double power output. Ideal for use in RV applications.

LED Data Center: Indicates low oil, overload and output ready.

Displays fuel level, power output, remaining run time, voltage. See more information on the next page.

12V DC Outlet: 12V DC that has 8A output.

ECO MODE

12V 8A DC

LOW OIL

OVERLOAD

OUTPUT READY

FEATURES

PARALLEL OUTLETS

DC 5V

RESET

BREAKER

DC 8A

DATA CENTER

F: Remaining Run Time P: Power Output in kW

L: Fuel Level in Liters

V: Voltage

Lifetime Run Hours

120 VOLTS AC

NEUTRAL FLOATING

DC SYSTEM FLOATING

GROUND

12V DC Breaker: 8A breaker for 12V outlet.

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FEATURES

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LED Data Display

4 56

LOW OIL INDICATOR

Description:

Lights up red when unit is low or out of oil. Engine will not run when indicator is lit.

Recommended Action:

When this light appears conrm engine is o, let the unit cool down, then add oil. Make sure to periodically check oil levels while lling to prevent overlling.

OVERLOAD INDICATOR

Description:

Red light ashes when the unit is close to overloading. If any more load is added when the light is ashing the electrical power will be cut to the receptacles and light will become a constant red.

Recommended Action:

While the engine is running, disconnect all appliances and hit the RESET breaker on the panel. Reduce the amount of appliances before plugging back in.

OUTPUT READY INDICATOR

Description:

The output ready indicator shows a green light when the inverter is operating normally and producing electrical power to the receptacles.

FUEL LEVEL INDICATOR

Description:

Displays estimated fuel level percentage. Four green lights indicate a full tank. One green light indicates the unit is almost out of fuel. For accurate fuel levels refer to “L” number in display.

ELECTRICAL POWER OUTPUT TO

RECEPTACLES

Description:

Displays percentage of power output to the receptacles. A red light will display next to the “100%” if the unit is close to being overloaded. For accurate power output refer to the “P” number in display.

AUTOMATIC ROTATING DATA NUMBER DISPLAY

Remaining Run Time (F):

Displays time remaining with current fuel level and power output. Does not display lifetime hours.

Power Output (P):

Displays electrical power output to receptacles in kilowatts.

Fuel level (L):

Displays current fuel level in liters.

Voltage (V):

Displays current voltage output of inverter.

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OPERATION

BEFORE STARTING THE INVERTER

BEFORE STARTING THE INVERTER, REVIEW SAFETY SECTION STARTING ON PAGE 5.

Location Selection – Before starting the inverter, avoid

exhaust and location hazards by verifying:

• You have selected a location to operate the inverter that is outdoors and well ventilated.

• You have selected a location with a level and solid surface on which to place the inverter.

• You have selected a location that is at least 15 feet (4.5 m) away from any building, other equipment or combustible material.

• If the inverter is located close to a building, make sure it is not located near any windows, doors and/ or vents.

Weather – Never operate your inverter outdoors during rain, snow or any combination of weather conditions that could lead to moisture collecting on, in or around the inverter.

Dry Surface – Always operate the inverter on a dry surface free of any moisture.

No Connected Loads – Make sure the inverter has no connected loads before starting it. To ensure there are no connected loads, unplug any electrical extension cords that are plugged into the control panel receptacles.

NOTICE

Starting the inverter with loads already applied to it could result in damage to any appliance being powered o the inverter during the brief start-up period.

Grounding the Inverter

Consult with your local municipalities for your grounding codes.

WARNING

Always operate the inverter on a level surface. Placing the inverter on non level surfaces can cause the inverter to tip over, causing fuel and oil to spill. Spilled fuel can ignite if it comes in contact with an ignition source such as a very hot surface.

NOTICE

Only operate the inverter on a solid, level surface. Operating the inverter on a surface with loose

material such as sand or grass clippings can cause

debris to be ingested by the inverter that could:

• Block cooling vents

• Block air intake system

Be sure the inverter is properly connected to earth ground before operating.

High Altitude Operation

Engine power is reduced the higher you operate above sea level. Output will be reduced approximately 3.5% for every 1000ft of increased altitude from sea level. This is a natural occurrence and cannot be adjusted by engine. Increased exhaust emissions can also result due to increased fuel mixture. Other issues include hard starting, increased fuel consumption and spark plug fouling.

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OPERATION

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POWERCORD

Using Extension Cords

Cummins Inc. assumes no responsibility for the content within this table. The use of this table is the responsibility of the user only. This table is intended for reference only. The results produced by using this table are not guaranteed to be correct or applicable in all situations as the type and construction of cords are highly variable. Always check with local

regulations and a licensed electrician prior to installing or connecting an electrical appliance

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OPERATION

INITIAL OIL FILL

BEFORE ADDING ENGINE OIL, REVIEW SAFETY SECTION STARTING ON PAGE 5.

NOTICE

Engine oil must be added when the inverter is on a at, level surface, or an inaccurate reading may result. Do not overll. If the engine is overlled with oil, it can cause serious engine damage.

1. Turn the locking knob on the engine access panel

and set aside (see Figure 1).

3. Using the supplied funnel and oil, pour the entire bottle of oil into the engine (see Figure 3).

Figure 3: Oil Funnel

4. Do not overll, if oil level is too high, oil will drain out through the ll plug. See correct oil level in Figure 4.

Figure 1: Engine Service Panel

2. Clean the area around the oil ll/drain plug and remove plug (See Figure 2).

Figure 4: Engine Oil Correct Level

Figure 2: Oil Fill/Drain Plug

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OPERATION

1-2019

ADDING/CHECKING ENGINE FLUIDS AND FUEL

BEFORE ADDING/CHECKING ENGINE FLUIDS AND FUEL, REVIEW SAFETY SECTION STARTING ON PAGE 5.

DANGER

Filling the fuel tank with gasoline while the inverter is running can cause

gasoline to leak and come in contact

with hot surfaces that can ignite the gasoline.

Before starting the inverter, always check the level of:

• Engine oil

• Gasoline in the fuel tank

Once the inverter is started and the engine gets warm,

it is not safe to add gasoline to the fuel tank or engine

oil to the engine while the engine is running or the engine and muer are hot.

CHECKING AND / OR ADDING ENGINE OIL

ADDING GASOLINE TO THE FUEL TANK

WARNING

Never refuel the inverter while the engine is running.

Always turn the engine o and allow the inverter to cool before refueling.

CAUTION

Avoid prolonged skin contact with gasoline. Avoid prolonged breathing of gasoline vapors.

Required Gasoline – Only use gasoline that meets the following requirements:

• Unleaded gasoline only

• Gasoline with maximum 10% ethanol added

• Gasoline with an 87 octane rating or higher

WARNING

Internal pressure can build in the engine crankcase while the engine is running. Removing the oil ll plug/ dipstick while the engine is hot can cause extremely hot oil to spray out of the crankcase and can severely burn skin. Allow engine oil to cool for several minutes before removing the oil ll plug/dipstick.

The unit as shipped does not contain oil in the engine. You must add engine oil before starting the inverter for the rst time. See Initial Oil Fill for instructions on checking engine oil level and the procedure for adding engine oil.

NOTICE

The engine does not contain engine oil as shipped. Attempting to start the engine without adding engine oil will permanently damage internal engine components.

The engine is equipped with a low oil shutdown switch. If the oil level becomes low, the engine may shut down and not start until the oil is lled to the proper level.

The owner of the inverter is responsible to ensure the proper oil level is maintained during the operation of the inverter. Failure to maintain the proper oil level can result in engine damage.

Filling the Fuel Tank – Follow the steps below to ll the fuel tank:

1. Shut o the inverter.

2. Allow the inverter to cool down so all surface areas of the muer and engine are cool to the touch.

3. Move the inverter to a at surface.

4. Clean area around the fuel cap.

5. Remove the fuel cap by rotating counterclockwise.

NOTICE

Do not overll the fuel tank. Spilled fuel will damage some plastic parts.

6. Slowly add gasoline into the fuel tank. Be very careful not to overll the tank. The gasoline level should NOT be higher than the red ring (see Figure 5).

7. Install the fuel cap by rotating clockwise.

Figure 5: Maximum Gasoline Fill Level

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OPERATION

STARTING THE INVERTER

BEFORE STARTING THE INVERTER, REVIEW SAFETY SECTION STARTING ON PAGE 5.

For proper starting and operation of the inverter, make sure you review the inverter features and their descriptions starting on page 8.

Before attempting to start the inverter, verify the following:

• The engine is lled with engine oil (see Figure 4: Engine Oil Correct Level on page 13).

• The inverter is situated in a proper location (see Location Selection on page 11).

• The inverter is on a dry surface (see Weather and Dry Surface on page 11).

• All loads are disconnected from the inverter (see No Connected Loads on page 11).

• The inverter is properly grounded (see Grounding the Inverter on page 11)

DANGER

3. For cold starting, turn the engine/fuel control switch to the CHOKE position (see Figure 7). NOTE: If you are re-starting turn knob to RUN.

Figure 7: Turn Engine/Fuel Switch to CHOKE Position

4. Firmly grasp and pull the recoil handle slowly until you feel increased resistance. At this point, apply a rapid pull while pulling out from the inverter (see Figure 8).

or ice can cause a short circuit or other

malfunction in the electrical circuit.

Never operate the inverter in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the inverter outside and away from windows, doors and vents.

Starting Inverter

1. Check oil and fuel levels. If it is the rst time starting make sure to add oil (see Initial Oil Fill on page 13).

2. Make sure the circuit breakers are properly set (see Figure 6).

Figure 8: Pull the Recoil Handle away from Inverter

5. As the engine starts and stabilizes, turn the choke switch back in to the RUN position (see Figure 9).

Figure 9: Turn Engine/Fuel Switch to RUN

6. Plug in electronic devices.

1 2

Figure 6: breakers 1-operating 2-tripped

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OPERATION

1-2019

STOPPING THE INVERTER

Normal Operation

During normal operation, use the following steps to stop your inverter:

1. Remove any connected loads from the control panel receptacles.

2. Allow the inverter to run at “no load” to reduce and stabilize engine and alternator temperatures.

3. Move the engine control switch to the OFF position (see Figure 10) .

Figure 10: Turn Engine/Fuel Switch to OFF Position

During an Emergency

If there is an emergency and the inverter must be stopped quickly, move the engine control switch to the

OFF position immediately (see Figure 10).

USING EFFICIENCY MODE

The inverter is equipped with an eciency mode switch to minimize fuel consumption. In eciency mode, the inverter will sense the load and adjust the engine RPM to the current load requirements. Eciency mode should be used only after the inverter has been warmed up to operating temperature.

RESETTING THE RESET BREAKER

The inverter will trip the breaker and automatically disconnect from the load when the controls sense a predetermined overload condition. The inverter engine will continue to run, but there will not be any electrical output.

1. Turn o all devices and unplug them from the inverter.

2. Determine the wattage required from the devices being powered by the inverter. Make sure the wattage required does not exceed the maximum output of the inverter.

3. Press in the reset breaker to reset it (see Figure 11).

OUTPUT READY

PARALLEL OUTLETS

RESET

DATA CENTER

F: Remaining Run Time P: Power Output in kW

L: Fuel Level in Liters

V: Voltage

Lifetime Run Hours

ECO MODE

12V 8A DC

LOW OIL

OVERLOAD

Figure 11: Press the reset breaker

4. Plug the devices in to the inverter.

5. Turn on the devices as needed.

DC 5V

BREAKER

DC 8A

120 VOLTS AC

NEUTRAL FLOATING

DC SYSTEM FLOATING

GROUND

1. To turn on the eciency mode, press the switch to the ON position).

2. If no load is present, the inverter RPM will drop down to an idle speed.

3. As a load is applied, the inverter will sense the load and engine RPM will increase according to the load applied.

4. To run the inverter at maximum power and RPM, press the eciency mode switch to the OFF position.

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MAINTENANCE

BEFORE PERFORMING MAINTENANCE ON THE INVERTER, REVIEW THE SAFETY SECTION STARTING ON PAGE 5, AS WELL AS THE FOLLOWING SAFETY MESSAGES.

WARNING

Avoid accidentally starting the inverter during maintenance by removing the spark plug boot from the spark plug. For electric start inverters, also disconnect the battery cables from the battery (disconnect the black negative (-) cable rst) and place the cables away from the battery posts to avoid arcing.

Allow hot components to cool to the touch prior to performing any maintenance procedure.

Always perform maintenance in a wellventilated area. Gasoline fuel and fuel vapors are extremely ammable and can ignite under certain conditions.

CAUTION

Avoid skin contact with engine oil or gasoline. Prolonged skin contact with engine oil or gasoline can be harmful. Frequent and prolonged contact with engine oil may cause skin cancer. Take protective measures and wear protective clothing and equipment. Wash all exposed skin with soap and water.

WARNING

Failure to perform periodic maintenance or not following maintenance procedures can cause the inverter to

malfunction and could result in death or

serious injury.

NOTICE

Periodic maintenance intervals vary depending on inverter operating conditions. Operating the inverter under severe conditions, such as sustained high- load, hightemperature, or unusually wet or dusty environments, will require more frequent periodic maintenance. The intervals listed in the maintenance schedule should be treated only as a general guideline.

Following the maintenance schedule is important to keep the inverter in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals.

TABLE 1: MAINTENANCE SCHEDULE - OWNER PERFORMED

After First 20

Before Every

Maintenance Item

Engine Oil

Cooling Features

Air Filter

Spark Plug

Spark Arrestor

*Service more frequently if operating in dry and dusty conditions

Use

Check Level Change Change - -

Check/Clean - - - -

Check - Clean* - Replace

- - - Check/Clean Replace

- - - Check/Clean -

Hours or First

Month of Use

After 50 Hours

of Use or Every

6 Months

After 100 Hour

of Use or Every

6 Months

A062R850 (Issue 1)

After 300 Hours of

Use or Every Year

Page 19

MAINTENANCE

1-2019

ENGINE OIL MAINTENANCE

Engine Oil Specication

1. Only use the engine oil specied in Figure 12.

2. Only use 4-stroke/cycle engine oil. NEVER USE 2-STROKE/CYCLE OIL. Synthetic oil is an acceptable substitute for conventional oil.

Figure 12: Recommended Oil

CHECKING ENGINE OIL

NOTICE

Always maintain proper engine oil level. Failure to maintain proper engine oil level could result in severe damage to the engine and/or shorten the life of the engine. Always use the specied engine oil. Failure to use the specied engine oil can cause accelerated wear and/ or shorten the life of the engine.

If oil level is below

this line it is too

low to operate.

NOTICE

Engine oil must always be checked and added when the inverter is on a at, level surface, or an inaccurate reading may result, causing serious engine damage.

ADDING ENGINE OIL

1. Always operate or maintain the inverter on a at surface.

2. Stop engine if running.

3. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).

4. Remove the engine service panel to gain access to the oil ll/drain plug.

5. Thoroughly clean around the oil ll/drain plug.

6. Remove the oil ll/drain plug.

Engine oil level should be checked before every use.

1. Always operate or maintain the inverter on a at surface.

2. Stop engine if running.

3. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).

4. Remove the engine service panel to access the oil ll/drain plug.

5. With a damp rag, clean around the oil ll/drain plug.

6. Remove the oil ll/drain plug.

7. Check oil level: When checking the engine oil, remove the oil ll/ drain plug.

• The oil level is acceptable if oil is visible at the

bottom of the threads of the oil ll plug.

• If oil level is low, add to the correct level using

the supplied oil ll bottle. Do not overll the oil crankcase.

7. Select the proper engine oil as specied in Figure 12.

8. Using the supplied oil funnel, slowly add engine oil to the engine. Stop frequently to check the oil level and avoid overlling.

9. Continue to add oil until the oil is at the correct level.

A062R850 (Issue 1)

Page 20

1-2019

MAINTENANCE

CHANGING ENGINE OIL

1. Stop the engine.

2. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).

3. Remove the engine service panel to gain access to the oil ll/drain plug.

4. Place oil pan (or suitable container) under the oil drain hole (see Figure 13).

AIR FILTER MAINTENANCE

WARNING

Never use gasoline or other ammable solvents to clean the air lter. Use only

household detergent soap to clean the air

lter.

Cleaning the Air Filter

The air lter must be cleaned after every 50 hours of use or 3 months (frequency should be increased if inverter is operated in a dusty environment).

1. Turn o the inverter and let it cool for several minutes if running.

2. Remove the engine service panel to gain access to the air lter.

3. Unscrew the air cleaner cover and tip the cover down (see Figure 14).

Oil Pan

Figure 13: Place oil pan under oil drain hole

5. With a damp rag, thoroughly clean around the oil ll/ drain plug.

6. Tilt the inverter so the oil drains down through the hole in the bottom of the inverter into the container.

7. Allow oil to completely drain.

8. Fill crankcase with oil following the steps outlined in Adding Engine Oil on page 18.

9. Dispose of used engine oil properly.

NOTICE

Never dispose of used engine oil by dumping the oil into a sewer, on the ground, or into groundwater or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

Figure 14: Remove air lter screw

4. Remove the foam element from the air cleaner housing.

5. Wash the foam air lter element by submerging

the element in a solution of household detergent

soap and warm water. Slowly squeeze the foam to thoroughly clean.

NOTICE

NEVER twist or tear the foam air lter element during cleaning or drying. Only apply slow but rm squeezing action.

6. Rinse in clean water by submerging the air lter element in fresh water and applying a slow squeezing action (see Figure 15).

A062R850 (Issue 1)

Page 21

MAINTENANCE

Figure 15

NOTICE

Never dispose of soap cleaning solution used to clean the air lter by dumping the solution into a sewer, on the ground, or into ground water or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

1-2019

DRAINING THE FLOAT BOWL

1. Remove the engine service panel to access the carburetor.

2. Locate the clear plastic hose from the oat that is exiting out the bottom of the inverter, and place a suitable container under it to catch the drained fuel (see Figure 16).

7. Dispose of used soap cleaning solution properly.

8. Dry the air lter element by again applying a slow rm squeezing action.

9. Return the air lter element to its position in the air cleaner housing.

10. Install the air cleaner cover, making sure the tabs lock into place.

11. Install the engine service panel.

Fuel Drain Hose

Fuel Pan

Figure 16: Locate fuel drain screw and fuel drain hose

3. Loosen the oat bowl drain screw (see Figure 16) until fuel is seen draining from the oat bowl.

4. Allow fuel to drain into the container, and then tighten the oat bowl drain screw.

NOTICE

Never dispose of fuel by dumping fuel into a sewer, on the ground, or into groundwater or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility.

5. Install the engine service panel.

A062R850 (Issue 1)

Page 22

1-2019

MAINTENANCE

SPARK PLUG MAINTENANCE

The spark plug must be checked and cleaned after every 100 hours of use or 6 months and must be replaced after 300 hours of use or every year.

1. Stop the inverter and let it cool for several minutes if running.

2. Move the inverter to a at, level surface.

3. Remove the engine service panel by unlocking knob and locate spark plug boot at top of engine (see Figure 17).

7. Place a clean rag over the opening created by the removal of the spark plug to make sure no dirt can get into the combustion chamber.

8. Inspect the spark plug for:

• Cracked or chipped insulator

• Excessive wear

• Spark plug gap of 0.032 in. (0.80 mm).

If the spark plug fails any one of the conditions listed above, replace the plug.

SPARK PLUG GAP

NOTICE

Only use the recommended spark plug. See chart below.

Using a non- recommended spark plug could result in

damage to the engine.

9. Install the spark plug by carefully following the steps outlined below:

a. Carefully insert the spark plug back into the

cylinder head. Hand-thread the spark plug until it bottoms out.

b. Using the spark plug socket wrench provided, turn

the spark plug to ensure it is fully seated.

Figure 17: Locate spark plug

4. Remove the spark plug boot by rmly pulling the plastic spark plug boot handle directly away from the engine.

NOTICE

Never apply any side load or move the spark plug laterally when removing the spark plug. Applying a side load or moving the spark plug laterally may crack and damage the spark plug boot.

5. Clean area around the spark plug.

6. Using the spark plug socket wrench provided, remove the spark plug from the cylinder head (see Figure 18).

c. Replace the spark plug boot, making sure the boot

fully engages the spark plug’s tip.

d. Install the spark plug access cover.

Recommended Spark Plug Replacement:

Cummins Torch Spark

plug

A058U948 E6RTC BPR6HS WR7BC R43FS

NGK Bosch AC Delco

Figure 18: Using spark plug wrench remove the spark plug

A062R850 (Issue 1)

Page 23

MAINTENANCE

1-2019

CLEANING THE SPARK ARRESTOR

Check and clean the spark arrestor after every 100 hours of use or 6 months.

1. Stop the inverter and let it cool for several minutes if running.

2. Move the inverter to a at, level surface.

3. Remove the screws holding the muer cover in place (see Figure 19).

Figure 19: Remove screws holding muer cover

4. Loosen the clamp holding the spark arrestor onto the muer.

CHECKING AND ADJUSTING VALVE LASH

CAUTION

Checking and adjusting valve lash must be done when the engine is cold.

1. Remove the rocker arm cover and carefully remove the gasket. If the gasket is torn or damaged, it must be replaced.

2. Remove the spark plug so the engine can be rotated more easily.

3. Rotate the engine to top dead center (TDC) of the compression stroke. Looking through the spark plug hole, the piston should be at the top.

4. Both the rocker arms should be loose at TDC on the compression stroke. If they are not, rotate the engine 360°.

5. Insert a feeler gauge between the rocker arm and the push rod and check for clearance (see Figure 20). See Table 1 for

valve lash specications.

5. Slide the spark arrestor band clamp o the spark arrestor screen.

6. Pull the spark arrestor screen o the muer exhaust pipe.

7. Using a wire brush, remove any dirt and debris that may have collected on the spark arrestor screen.

8. If the spark arrestor screen shows signs of wear

(rips, tears or large openings in the screen), replace

the spark arrestor screen.

9. Install the spark arrestor components in the following order:

a. Place spark arrestor screen over the muer

exhaust pipe. Push on the screen until it fully bottoms out.

b. Place the spark arrestor band clamp over the

screen and tighten with a athead screwdriver

10. Replace the discharge gate.

Figure 20

(1) Push Rod, (2) Feeler Gauge Area

(3) Rocker Arm, (4) Jam Nut, (5) Adjusting Nut

Table 1: Standard Valve Lash

Intake Valve Exhaust Valve

Valve Lash

Bolt Torque

6. If an adjustment is required, hold the adjusting nut and loosen the jam nut.

7. Turn the adjusting nut to obtain the correct valve lash. When the valve lash is correct, hold the adjusting nut and tighten the jam nut to 106 in-lb (12 N•m).

8. Recheck the valve lash after tightening the jam nut.

9. Perform this procedure for both the intake and exhaust valves.

10. Install the rocker arm cover, gasket and spark plug.

.0023-.0039in

(.06-.10mm)

8-12N.m 8-12N.m

.0031-.0048in

(.08-.12mm)

A062R850 (Issue 1)

Page 24

1-2019

MAINTENANCE

CLEANING THE INVERTER

It is important to inspect and clean the inverter before every use.

Clean All Engine Air Inlet and Outlet Ports – Make sure all engine air inlet and outlet ports are clean of any dirt and debris to ensure the engine does not run hot.

STORAGE

WARNING

Never store an inverter with fuel in the tank indoors or in a poorly ventilated area where the fumes can come in contact with an ignition source such as a: 1) pilot light of a stove, water heater, clothes dryer or any other gas appliance; or 2) spark from an electric appliance.

NOTICE

Gasoline stored for as little as 60 days can go bad, causing gum, varnish and corrosive buildup in fuel lines, fuel passages and the engine. This corrosive buildup restricts the ow of fuel, preventing an engine from starting after a prolonged storage period.

Proper care should be taken to prepare the inverter for any

storage

1. Clean the inverter as outlined in Cleaning the Inverter.

2. Siphon all gasoline from the fuel tank as best as possible.

3. Start the engine and allow the inverter to run until all the remaining gasoline in the fuel lines and carburetor is consumed and the engine shuts o.

4. Drain any remaining fuel from the oat bowl. See Draining the Float Bowl on page 20.

5. Change the oil (see Changing Engine Oil on page 19).

6. Remove the spark plug (see Spark Plug Maintenance on page 21) and place about 1 tablespoon of oil in the spark plug opening. While placing a clean rag over the spark plug opening, slowly pull the recoil handle to allow the engine to turn over several times. This will distribute the oil and protect the cylinder wall from corroding during storage.

7. Replace the spark plug (see Spark Plug Maintenance on page 21).

8. Move the inverter to a clean, dry place for storage.

A062R850 (Issue 1)

Page 25

TROUBLESHOOTING

WARNING

Before attempting to service or troubleshoot the inverter, the owner or service technician must rst read the owner’s manual and understand and follow all safety instructions. Failure to follow all instructions may result in conditions that can lead to voiding of the EPA certication or product warranty, serious personal injury, property damage or even death.

PROBLEM POTENTIAL CAUSE SOLUTION

1. Reset breaker is tripped. 1. Reset the reset breaker (see page 16).

Engine is running, but no electrical output.

Engine will not start or remain running while trying to start.

2. The power cord’s plug connector is not fully engaged in the inverter’s outlet.

3. Faulty or defective power cord 3. Replace power cord.

4. Faulty or defective electrical appliance 4. Try connecting a known good appliance

1. Inverter is out of gasoline. 1. Add gasoline to the inverter (see page 14).

2. Fuel ow is obstructed. 2. Inspect and clean fuel delivery passages.

3. Dirty air lter 3. Check and clean the air lter (see page 19).

4. Low oil level shutdown switch is preventing the unit from starting.

5. Spark plug boot is not fully engaged with the spark plug tip.

6. Spark plug is faulty. 6. Remove and check the spark plug. Replace

2. Verify plug connector is rmly engaged in the inverter’s outlet.

to verify the inverter is producing electrical power.

4. Check oil level and add oil if necessary (see page 18).

5. Firmly push down on the spark plug boot to ensure the boot is fully engaged.

if faulty (see pages 21).

1-2019

Inverter suddenly stops running.

Engine runs

erratic; does not hold a steady RPM.

7. Dirty/plugged spark arrestor 7. Check and clean the spark arrestor (see page 22).

8. Stale fuel 8. Drain fuel and replace with fresh fuel.

1. Inverter is out of fuel. 1. Check fuel level (see page 14). Add fuel if necessary.

2. The low oil shut down switch has stopped

the engine.

3. Too much load 3. Restart the inverter and reduce the load.

1. Choke was left in the CHOKE position. 1. Move choke to the RUN position

2. Dirty air lter 2. Clean the air lter (see page 19).

3. Applied loads maybe cycling on and o 3. As applied loads cycle, changes in engine

2. Check oil level and add oil if necessary (see page 18).

speed may occur; this is a normal condition.

A062R850 (Issue 1)

Page 26

1-2019

EXPLODED VIEW

A062R850 (Issue 1)

Page 27

EXPLODED VIEW PART NO.

# PART NO. DESCRIPTION

12 A058U965 CROSS RECESSED PAN HEAD

SCREW M5×12

17 A058U984 HEX FLANGE SCREWS

40 A058U989 FUEL TANK

50 A058U953 INVERTER

NA A058U946 Maintenance Kit

NA A058U947 Generator Cover

NA A058U945 Parallel Kit

1-2019

A062R850 (Issue 1)

Page 28

1-2019

ENGINE VIEW

A062R850 (Issue 1)

Page 29

ENGINE VIEW PART NO.

# PART NO. DESCRIPTION

2 A058U949 SWITCH ASSEMBLY,OIL LEVEL

13 A058U998 LIFTER,VALVE

19 A058U983 GASKET,CYLINDER HEAD

21 A058U948 SPARK PLUG

23 A058V000 EXHAUST VALVE ROCKER ASSY

24 A058U999 ROCKSHAFT

25 A058V001 INLET VALVE SPRING SEAT

27 A058U988 VALVE EXHAUST

28 A058V002 SPRING,VALVE

29 A058U991 SEAT, VALVE SPRING,IN

30 A058U987 VALVE LOCK CLAMP

33 A058U985 ROD,PUSH

35 A058U995 PACKING, HEADCOVER

36 A058U990 COVER COMP,CYLINDER HEAD

40 A058U994 BOLT M6X20

45 A058U986 BOLT M6X16

49 A058U950 CARBURETOR ASSEMBLY

53 A058U997 AIR CLEANER GASKET

54.1 A058U954 AIR CLEANER ELEMENT

56 A058U952 STEPPER MOTOR

60 A058U996 MUFFLER ASSY

61 A058U951 IGNITION COIL

62 A058U992 EXHAUST GASKET (INTAKE)

0 A058V023 HIGH ALTITUDE CARBURETOR 98CC

1-2019

A062R850 (Issue 1)

Page 30

1-2019

SCHEMATIC

A062R850 (Issue 1)

Page 31

Page 32

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