Usr EV20i Owner's Manual

POWER

EV20i

The generator is a potential source of electrical shock if misused. Do
not expose the generator to moisture, rain or snow. Do not let the
generator get wet, and do not operate it with wet hands.

Exhaust contains poisonous carbon monoxide gas that can build up
to dangerous levels in closed areas.
Breathing carbon monoxide can cause unconsciousness or death.

Never run the generator in a closed or even partially closed area
where people may be present.

Keep this owner's 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 and without incurring any obligation
whatever. No part of this publication may be reproduced without
written permission.

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

1

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. This manual contains the information on how to
do that; please read it carefully.

As you read this manual, you will find information preceded by a

symbol. That information 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 suggest you read the

Distributor's Limited Warranty

to fully

understand its coverage and your responsibilities of ownership. The

Distributor's Limited Warranty

is a separate document that should

have been given to you by your dealer.

ʵ

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

To help you make informed decisions about safety, we have provided
operating procedures and other information on labels and in this
manual. This information alerts you to potential hazards that could
hurt you or others.

Of course, it is not practical or possible to warn you about all the
hazards associated with operating or maintaining a generator. You
must use your own good judgement.

You will find 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 carefully.

on the generator.

preceded by a safety alert symbol and

one of three signal words, DANGER, WARNING, or CAUTION.

such as

IMPORTANT SAFETY INFORMATION

.

such as

how to use this generator correctly and safely.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERAT OR SAF ET Y.

-

-

-

-

-

2

3

CONTENTS

..............................................................................GENERATOR SAFETY . 5

.......................................................................Safety Label Locations . 5

............................................................Important Safety Information . 7

..............................................................COMPONENT IDENTIFICATION . 9

..............................................................................................CONTROLS . 11

....................................................................................Engine Switch . 11

........................................................................................Starter Grip . 11

.................................................................Fuel Tank Cap Vent Lever . 12

.......................................................................................Choke Lever . 12

.......................................................................Output Indicator Light . 13

...................................................................Overload Indicator Light . 13

..............................................................................Oil Alert

System . 14

...............................................................................Ground Terminal . 14

........................................................................Eco-Throttle 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 . 28

..........................................................................................Engine Oil . 28

............................................................................................Refueling . 30

....................................................................Fuel Recommendations . 32

........................................................................STARTING THE ENGINE . 33

........................................................................STOPPING THE ENGINE . 35

TM

TM

4

......................................................................................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 . 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

5

GENERATOR SAFETY

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.

6

7

Carbon Monoxide Hazards

Operator Responsibility

IMPORTANT SAFETY INFORMATION

Be sure that anyone who operates the generator receives proper
instruction. Do not let children operate the generator without
parental supervision.

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.

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 run the generator in an area that is confined, or even partially
enclosed area, the air you breathe could contain a dangerous
amount of exhaust gas.

Never run your generator inside a garage, house or near open
windows or doors.

ʵ

ʵ
ʵ

8

Electric Shock Hazards

Fire and Burn Hazards

Fuel vapors are extremely flammable and may ignite after the
engine has started. Make sure that any spilled fuel has been wiped
up before starting the generator.

Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks where the
generator is refueled or where gasoline is stored. Refuel in a well­ventilated area with the engine stopped.

The muffler becomes very hot during operation and remains hot for
a while after stopping the engine. Be careful not to touch the muffler
while it is hot. Let the engine cool before storing the generator
indoors.

Keep the generator at least 3 feet (1 meter) away from buildings
and other equipment during operation.
Do not enclose the generator 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 the generator dry.

If the generator is stored outdoors, unprotected from the weather,
check all of the electrical components on the control panel before
each use. Moisture or ice can cause a malfunction or short circuit in
electrical components which could result in electrocution.

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.

The exhaust system gets hot enough to ignite some materials.

9

COMPONENT IDENTIFICATION

PARALLEL OPERATION OUTLETS

OVERLOAD INDICATOR 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

10

SPARK PLUG MAINTENANCE COVER

SPARK PLUG

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

11

CONTROLS

ENGINE SWITCH

STARTER GRIP

Switch position:
OFF:
ON:

OOFFFF

OONN

ENGINE SWITCH

STARTER GRIP

DDiirreeccttiioonn ttoo ppuullll

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.

12

FUEL TANK CAP VENT LEVER

CHOKE LEVER

CHOKE LEVER

OOPPEENN

OONN

OOFFFF

FUEL TANK CAP VENT LEVER

CLOSED

FUEL TANK CAP VENT LEVER

OONN

OOFFFF

NON-CALIFORNIA TYPE CALIFORNIA TYPE

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.

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 the engine to cool well
before turning the vent lever to the OFF position.

13

OUTPUT INDICATOR LIGHT

OVERLOAD INDICATOR LIGHT

OVERLOAD INDICATOR
LIGHT (RED)

OUTPUT INDICATOR
LIGHT (GREEN)

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.

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.

14

OIL ALERT SYSTEM

GROUND TERMINAL

GROUND TERMINAL

OIL ALERT INDICATOR
LIGHT (RED)

The generator ground terminal is connected to the frame of the
generator, the metal non-current-carrying parts of the generator, and
the ground terminals of each receptacle.

Before using the ground terminal, consult a qualified electrician,
electrical inspector or local agency having jurisdiction 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 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).

28

15

PARALLEL OPERATION OUTLETS

ECO-THROTTLE SWITCH

ON:

OFF:

OOFFFF

PARALLEL OPERATION OUTLETS

OONN

ECO-THROTTLE SWITCH

The Eco-Throttle system automatically reduces engine speed when
all loads are turned off or disconnected. When appliances are turned
on or reconnected, the engine returns to the proper speed to power
the electrical load.
If high electrical loads are connected simultaneously, turn the Eco­Throttle 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 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.

23

16

AC CIRCUIT PROTECTOR

DC RECEPTACLE

DC CIRCUIT PROTECTOR

PUSH

AC CIRCUIT PROTECTOR

AC RECEPTACLES

AC CIRCUIT PROTECTOR

ON

OFF

ON

OFF

DC CIRCUIT PROTECTOR

DC RECEPTACLE

PUSH

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.

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 generator are improper.

The DC receptacle should ONLY be used for charging 12-volt
automotive type batteries. The DC charging output is not regulated.

17

GENERATOR USE

CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM

Improper connections to a building electrical system can allow
electrical current from the generator to backfeed into the utility lines.
Such backfeed may electroc ute utility company workers or others
who contact the lines during a power outage, and the generator may
explode, burn, or cause fires when utility power is restored. Consult
the utility 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 AC output
receptacles. The system ground is not connected to the AC neutral
wire. If the generator is tested by a receptacle tester, it will not show
the same ground circuit condition as for a home receptacle.

18

SPECIAL REQUIREMENTS

Do not lay the generator on its side when moving, storing, or
operating it. Oil may leak and damage the engine or your property.

There may be Federal or State Occupational Safety and Health
Administration (OSHA) regulations, local codes, or ordinances that
apply to the intended use of the generator. Please consult 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, and the
bottom of the generator. If the cooling holes are blocked, the
generator may overheat and damage the engine, inverter, or windings.

19

AC APPLICATIONS

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.

For continuous operation, do not exceed the rated power.
Rated power is:

Limit operation requiring maximum power to 30 minutes.
Maximum power is:

Substantial overloading will switch o ff the AC circuit protector.
Exceeding the time limit for maximum power operation or slightly
overloading the generator may not switch the AC circuit protector 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. Disconnect the appliance,
and determine whether the problem is the appliance, or if the rated
load capacity of the generator has been exceeded.

Make sure that it is in good working order. Faulty appliances or
power cords can create a potential for electrical shock.

Before connecting an appliance or power cord to the generator:

1,600 VA

2,000 VA

20

AC OPERATION

OVERLOAD INDICATOR
LIGHT (RED)

OUTPUT INDICATOR
LIGHT (GREEN)

Most motorized appliances require more than their rated wattage for
startup.

Plug in the appliance.

Before connecting an appliance to the generator, make sure that it is in
good order and that its electrical rating does not exceed that of the
generator. Then start the generator and connect the appliance power
cord.

Determine if the cause is a short circuit in a connected appliance or an
overload. Correct the problem and restart the generator.

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 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.

Start the engine and make sure the output indicator light (green)
comes on (see page ).

1.

2.

33

21

AC PARALLEL OPERATION APPLICATIONS

Substantial overloading that continuously lights the overload indicator
light (red) may damage the generat or. Marginal overloading that
temporarily lights the overload indicator light (red) may shorten the
service life of the generator.

For single generator operation, the parallel operation kit must be
removed.

Never connect or remove the parallel operation kit when the
generator is running.

Use only a USR approved parallel operation kit (optional
equipment) when connecting two generators for parallel operation.

Never connect different 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,
and determine whether the problem is the appliance, or if the rated
load capacity of the generator has been exceeded.

Make sure that it is in good working order. Faulty appliances or
power cords can create a potential for electrical shock.

Before connecting an appliance or power cord to the generator:

Follow the instructions included with the parallel operation kit.

22

Limit operation requiring maximum power to 30 minutes.
Maximum power in parallel operation is:

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

23

AC PARALLEL OPERATION

PARALLEL OPERATION KIT
(optional equipment)

Connect the parallel operation kit between the two
generators following the instructions supplied with the kit.

If the generators are overloaded (see page ), or if there is a short
circuit in a connected appliance, the overload indicator lights (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 operation kit.

Start the generators and make sure the output indicator lights
(green) come on (see page ).

1.

2.

3.

33

22

24

DC OPERATION

Connecting the battery charging cable (optional equipment):

The battery gives off explosive gases; keep sparks, flames and
cigarettes away. Provide adequate ventilation when charging or using
batteries.

WARNING:

Wash hands after handling.

PUSHOFF

ON

DC CIRCUIT PROTECTOR

DC RECEPTACLE

When using the DC output, turn the Eco-Throttle switch to the OFF
position.

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.

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 the negative ( ) battery
terminal.

Plug the battery charging cable into the DC receptacle of the
generator.

Battery posts, terminals and related accessories contain

lead and lead components.

1.

4.

2.

3.

+

-

-

25

Disconnecting the battery charging cable:

BLACK LEAD

RED LEAD

BATTERY CHARGING CABLE
(optional equipment)

An overloaded DC circuit, excessive current draw by the battery, or a
wiring problem will trip the DC circuit protector (PUSH button extends
out). 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.

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 negative ( ) battery
terminal.

Do not start the vehicle while the battery charging cable is connected
and the generator is running. The vehicle or the generator may be
damaged.

1.

2.

3.

4.

5.

-

+

-

26

ECO-THROTTLE SYSTEM

OOFFFF

OONN

ECO-THROTTLE SWITCH

TM

Appliances with large start-up power demands may not allow the
engine to reach normal operating rpm when they are connected to the
generator. Turn the Eco-Throttle to the OFF position and connect the
appliance to the generator. If the engine still will not reach normal
operating speed, check that the appliance does not exceed the rated
load capacity of the generator.

The Eco-Throttle system is not effective 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 Eco­Throttle switch to the OFF position to reduce voltage changes.

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 Eco­Throttle system does not operate.

27

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.

High altitude performance can be improved by specific modifications
to the carburetor. If you always operate your generator at altitudes
above 5,000 feet (1,500 meters), have your servicing dealer perform
this carburetor 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 ef­fect of altitude on horsepower will be greater than this if no carburetor
modification is made.

When the carburetor has been modified for high altitude operation,
the air/fuel mixture will be too lean for low altitude use. Operation at
altitudes below 5,000 feet (1,500 meters) with a modified carburetor
may cause the engine to overheat and result in serious engine damage.
For use at low altitudes, have your servicing dealer return the
carburetor to original factory specifications.

28

PRE-OPERATION CHECK

ENGINE OIL

AMBIENT TEMPERATURE

SAE VISCOSITY GRADES

COVER SCREW

MAINTENANCE
COVER

Check the oil level BEFORE EACH
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). Always check
the API SERVICE label on the oil
container to be sure it includes
th e l e t t e r SJ or lat e r ( o r
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 maintenance cover.

Place the generator on a level surface.1.

2.

29

DIPSTICK

OIL FILLER CAP

UPPER LIMIT

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.
Reinstall the maintenance cover and tighten the cover screw
securely.

3.

4.

5.

6.

30

REFUELING

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Stop the engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.

FUEL TANK CAP

UPPER 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, reinstall the fuel tank cap securely.

31

UPPER LIMIT MARKFUEL TANK CAP

CALIFORNIA TYPE

TETHER

After refueling, tighten the fuel cap until it clicks.

32

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. 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 percentages of Ethanol or Methanol greater than shown above
are not covered under warranty.

33

STARTING THE ENGINE

STARTING THE ENGINE

Carbon monoxid e gas is toxic . B re at hi ng it can cause
unconsciousness and even kill you.

Avoid any enclosed areas, partially enclosed areas or activities that
may expose you to carbon monoxide.

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.

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 the starter grip lightly until you feel resistance, then pull
briskly.

Do not allow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter or housing.

6.

1.

2.

3.

4.

5.

28

34

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
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

35

STOPPING THE ENGINE

STOPPING THE ENGINE

Unplug appliances from the generator receptacles.

The fuel valve will automatically close.

To stop the engine in an emergency, simply turn 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.

36

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 to 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.

37

MAINTENANCE SAFETY

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

Failure to properly follow maint enance instructions and precautions
can cause you to be seriously hurt or killed.

Always follow the procedures and pre cautions in the owner’s manual.

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.

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 make sure you have the
tools and skills required.

To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a nonflammable solvent, not
gasoline, to clean parts. Keep cigarettes, sparks, and flames away
from all fuel-related parts.

_

_

_

38

EMISSION CONTROL SYSTEM INFORMATION

Source of Emissions

Tampering and Altering

The U.S. and California Clean Air Acts

The combustion process produces carbon monoxide, oxides of
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of
nitrogen are very important because, under certain conditions, they
react to form photochemical smog when subjected to sunlight. Carbon
monoxide does not react in the same way, but it is toxic.

Tampering with or altering the emission control system may increase
emissions beyond the 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
emission control systems.

The following instructions and procedures must be followed in order
to keep the emissions from your USR engine within the emission
standards.

USR utilizes appropriate air/fuel ratios and other emissions control
systems to reduce the emissions of carbon monoxide, oxides of
nitrogen and hydrocarbons.

39

Problems That May Affect Emissions

Replacement Parts

Maintenance

If you are aware of any of the following symptoms, have your engine
inspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

The emission control systems on your USR engine were designed,
built, and certified to conform with 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. 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 or rebuilder of the part m ust certify that use of the part
will not result in a failure of the engine to comply with emission
regulations.

Follow the

maintenance schedule

on page . Remember that this
schedule is based on the assumption that your machine will be used
for its designed purpose. Sustained high-load or high-temperature
operation, or use in unusually wet or dusty conditions, will require
more frequent service.

41

40

AIR INDEX
(Models certified for sale in California)

The Air Index Information hang tag must remain on the generator until
it is sold. Remove the hang tag before operating the generator.

300 hours (0 80 cc, inclusive)
500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

125 hours (0 80 cc, inclusive)
250 hours (greater than 80 cc)

50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)

Applicable to Emission Durability PeriodDescriptive Term

Moderate

Intermediate

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 performance of available engines. The lower
the Air Index, the less pollution.

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.

_

_

_

41

MAINTENANCE SCHEDULE

Engine oil

Air cleaner

Spark plug

Spark arrester
Valve clearance
Combustion chamber
Fuel tank and filter
Fuel line

Check level
Change
Check
Clean
Check-adjust
Replace
Clean
Check-readjust
Clean
Clean
Check

Perform at every indicated month
or o p er a ti n g h our int erv al,
whichever comes first.

ITEM

REGULAR SERVICE PERIOD (3)

Each

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 hrs (2)

Every 2 years (Replace if necessary) (2)

First

month

or

20 hrs.

Every

3 months

or

50 hrs.

(1)

Every

6 months

or

100 hrs.

(2)

Every

year

or

200 hrs.

(2)

(1)
(2)

(3)

42

ENGINE OIL CHANGE

OIL FILLER NECK

UPPER LIMIT

Drain the used oil while the engine is warm. Warm oil drains quickly
and completely.

Place a suitable container next to the engine to catch the used oil.

Turn the engine switch and vent lever to the OFF position to reduce
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 the oil
filler neck with the recommended oil (see page ).

1.

2.

3.

4.

5.

6.

7.

28

43

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.

44

AIR CLEANER SERVICE

Using gasoline or flammable solvent to clean the air filter can cause a
fire or explosion. Use only soapy water or nonflammable solvent.

AIR CLEANER
COVER

AIR CLEANER
COVER SCREW

OUTER FILTER

COVER SCREW

MAINTENANCE COVER

MAIN FILTER

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.

Operating the engine without 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 household detergent
an d warm wa te r, t hen ri nse
t h o r o u g h l y , o r w a s h i n
nonflammable or high flash point
solvent. Allow the air filters to dry
thoroughly.

Loosen the cover screw and remove
the maintenance cover.

Loosen the air cleaner cover screw,
and remove the air cleaner cover.

4.

3.

2.

1.

45

AIR CLEANER
CASE

AIR FILTERS

AIR CLEANER
CASE SCREW

RUBBER 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 t ighten the cover screw
securely.

5.

6.

7.

8.

46

SPARK PLUG SERVICE

Recommended spark plug:

SPARK PLUG
MAINTENANCE
COVER

SPARK PLUG CAP

SPARK PLUG WRENCH

SPARK PLUG CAP

In order to service the spark plug, you will need a spark plug wrench
(commercially available).

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 plug.

1.

2.

3.

4.

47

0.024 0.028 in
(0.60 0.70 mm)

SEALING WASHER

After the spark plug is seated, tighten with a spark plug wrench to
compress the washer.

If installing a new spark plug, tighten 1/2 turn after the spark plug
seats to compress the washer. If reinstalling a used spark plug,
tighten 1/8 1/4 turn after the spark plug seats to compress the
washer.

Measure the spark plug electr ode gap with a wire-type feeler gauge.
Correct 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 plug maintenance cover.

0.024 0.028 in (0.60 0.70 mm)

Visually inspect the spark plug. Replace it if the electrodes are worn
or if the insulator is cracked, chipped, or fouled.

7.

8.

9.

5.

6.

10.

The gap should be:

_

_

_ _

_

48

SPARK ARRESTER MAINTENANCE

MUFFLER GASKET

SPARK ARRESTER

MUFFLER

6 mm BOLTS

6 mm SCREWS

MUFFLER PROTECTOR

Clean the spark arrester as follows:

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.

49

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.

3.

4.

5.

50

TRANSPORTING/STORAGE

TRANSPORTING

Take care not to drop or strike the generator when transporting. Do not
place heavy objects on the generator.

To prevent fuel spillage when transporting, the generator should be
secured upright in its normal operating 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 may leak and damage the engine or your property.

ˎ

ˎ

ˎ

51

STORAGE

STORAGE TIME RECOMMENDED SERVICE PROCEDURE TO

PREVENT HARD STARTING

Before storing the unit for an extended period:

1. Be sure the storage area is free of excessive humidity and dust.

2. Service according to the table below:

Less than 1 month

1 to 2 months

2 to 6 months

6 months or more

No preparation required
Fill with fresh gasoline and add gasoline
stabilizer . Run the engine for 10 minutes to
use up the non-treated gasoline.
Fill 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 with fresh

gasoline before starting.
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.

52

Storage Procedure

You can be burned or seriously injured when handling fuel.

Gasoline is highly flammable and explosive.

Keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.

DRAIN SCREW

NON-CALIFORNIA TYPE SHOWN

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.
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 to drain the gasoline from the fuel
pump into a suitable container.
Turn the engine switch to the OFF position.
Tighten the carburetor drain screw.

1.
a.

b.
c.
d.
e.
f.
g.
h.

i.
j.

53

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.

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.

54

TROUBLESHOOTING

When the engine will not start:

Is there fuel in the
tank?

Is there enough oil
in the 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 recom­mended oil (see
page 28).

Clean, readjust gap,
and dry the spark
plug. Replace it if
n e c e s s a r y ( s e e
page 46).

YES

YES

NO

NO

YES

NO

55

Appliance does not operate:

Check the electrical ap­pliance or equipment for
any defects.

Is the DC circuit protector
on?

No electricity at the DC receptacle:

Take the generator to an
authorized USR generator
dealer.

Take the generator to an
authorized USR generator
dealer.

Replace the electrical ap­pliance or equipment.
Take the electrical ap­pliance 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

NO DEFECTS

DEFECTS

NO

YES

NO

NO

YES

56

WIRING DIAGRAM

57

INITIAL USE INSTRUCTIONS

ADDING ENGINE OIL

WITHOUT OIL

Do not overfill the engine with oil.

COVER SCREW

MAINTENANCE COVER

OIL FILLER CAP/DIPSTICK

UPPER LIMIT

The generator is shipped in the engine.

With the generator in a level position, remove the oil filler cap/
dipstick.

If the engine is overfilled, 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 cover screw and remove the maintenance cover.

Place the generator on a level surface.1.

28

2.

3.

4.

5.

6.

58

ADDING FUEL

Gasoline is highly flammable and explosive.

Stop the engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.

You can be burned or seriously injured when handling 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. If the engine 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 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 percentages of Ethanol or Methanol greater than shown above
are not covered under warranty.

With the engine stopped, add fuel to the generator in a well-ventilated
area.

59

FUEL TANK CAP

UPPER LIMIT MARK

FUEL TANK CAP

UPPER LIMIT MARK

NON-CALIFORNIA TYPE CALIFORNIA TYPE

NON-CALIFORNIA TYPE 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.

60

BEFORE OPERATION

GENERATOR SAFETY

CONTROLS

GENERATOR USE

PRE-OPERATION CHECK

STARTING THE ENGINE

STOPPING THE ENGINE

MAINTENANCE SCHEDULE

VENT LEVER

OOFFFF

OONN

VENT LEVER

OONN

OOFFFF

NON-CALIFORNIA TYPE CALIFORNIA TYPE

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.

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 additional pulls of the starter
grip. This generator utilizes a vacuum operated fuel pump and may
require additional pulls to draw fuel into the carburetor.

5 8

11 16

17 27

28 32

33 34

35

41

3.

_

_

_

_

_

ʵ

ʶ

61

SPECIFICATIONS

Tuneup

ITEM SPECIFICATION

Dimensions

Engine

Generator

MAINTENANCE

EAAJ

8.5: 1

Forced air
Full transistor

CR5HSB (NGK)

GX100

20.2 in (512 mm)

11.4 in (290 mm)

16.7 in (425 mm)

45.9 lbs (20.8 kg)

6.01 cu-in (98.5 cm

)

0.42 US qt (0.40

)

0.95 US gal (3.6

)

Spark plug gap

Valve clearance (cold)

Other specifications No other adjustments needed.

IN: 0.15 0.04 mm
EX: 0.20 0.04 mm

0.024 0.028 i n
(0.60 0.70 mm)

2,000 VA

1,600 VA

13.3 A

60 Hz

120 V

Model
Description 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-California type (AN type)

4-stroke, overhead camshaft, single cylinder

4,300 5,000 rpm (with Eco-Throttle switch OFF)

Only for charging 12V automotive batteries.
Maximum charging output= 8A

Specifications are subject to change without notice.

+

-

+

-

_

_

x x

x

_

3

EV20i

RECEPTACLE

Shape

Type

B

W

F

U

G, GW

62

POWER