operation manual I2500_3500 Inverter Generator Manual_2011.
table of contents Introduction 4 Using the Operators Manual Product Identification 5 Inverter Generator Safety 6 6 Safety Rules Hazard Symbols and Meanings Inverter generator Components 11 Component Chart Pre-Operation Checklist 12 Engine Oil 12 SAE Viscosity Grades 13 Fuel 14 Air Cleaner Starting the Inverter generator 15 Starting Your Inverter Generator Operation 17 High Altitude Operation 17 General Operation 18 AC Application 19 Output and Overload Indicators 21 DC Applicat
table of contents Transporting and Storage 30 Transporting and Storage 30 When Transporting the Generator 30 Before Storing the Unit for an Extended Period Spark Arrest Service 31 Spark Arrest Service Troubleshooting 32 Engine will not start 33 The Equipment that connects to the Generator doesn’t start 33 There is no power in the DC Electric Outlet 34 Deficient AC Output Specifications 35 Size and Weight 35 Engine 35 Generator Wiring Diagram 36 Wiring Diagram Exploded Part
introduction Attention: Read through the complete manual prior to the initial use of your generator. Using the Operator’s manual The operating manual is an important part of your generator and should be read thoroughly before initial use, and referred to often to make sure adequate safety and service concerns are being addressed. Reading the owner’s manual thoroughly will help avoid any personal injury or damage to your machine.
product identification Record Identification Numbers Generator If you need to contact an Authorized Dealer or Customer Service line (1-866-850-6662) for information on servicing, always provide the product model and identification numbers. You will need to locate the model and serial number for the machine and record the information in the places provided below.
safety Save these Instructions Safety Rules This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury.
safety warning Generator exhaust contains carbon monoxide, a poisonous gas that can kill you. You CANNOT smell or see this gas. • Use the generator outdoors, away from open windows, vents, or doors that could allow the carbon monoxide gas to come indoors. Keep the generator at least 1 meter (3 feet) away from any structure or building during use.
safety warning Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death. When Adding or Draining Fuel • Observe all safety regulations for the safe handling of fuel. Handle fuel in safety containers. If the container does not have a spout, use a funnel. • Do not overfill the fuel tank, leave room for the fuel to expand. • Do not refill fuel tank while the engine is running. Before refueling the generator, turn it off and let it cool down.
safety Ground Fault Circuit Interrupter Protection These generators are equipped with a GFCI (Ground Fault Circuit Interrupters) 120V duplex receptacles for protection against the hazards of electrical shock from defective attachments such as, tools, cords, and cables. warning The GFCI may not function unless the generator is properly grounded. Follow the correct procedure specified in the section labeled GROUNDING INSTRUCTIONS.
safety This product has been designed with internal grounding or floating bonded neutral. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. Danger Improper grounding can result in a risk of electrocution. Check with a qualified electrician for your local requirements if you are in doubt as to whether the unit is properly grounded. This generator is equipped with a grounding terminal for added protection.
components Read this operator’s manual and safety rules before operating your inverter generator. 15. 14. 1. 11. 12. 13. 5. 6. 7. 2. 9. 3. 1. Control Panel 2. Recoil Starter 3. ON/OFF Switch 4. Auto throttle 5. DC Connection 6. DC Breaker 7. 120V Receptacles 8. 120V Receptacles (I2000 only) 8. 120V 3 Prong Twistlock (I3000 only) 9. Ground 10. AC Breaker 11. Output Indicator Light 4. 8. 12. Overload Indicator Warning 13. Oil Alarm Indicator 14. Fuel Cap 15.
pre-operation checklist CAution • Be sure to check the generator on a level surface with the engine stopped. • Using non-detergent oil or 2-stroke engine oil could shorten the engine’s service life. warning Always check the level of the engine oil prior to starting the inverter generator. • Failure to do so could cause the engine to seize if the oil is low or empty. Engine Oil Use high-detergent, premium quality 4 –stroke engine oil, certified to meet or exceed U.S.
L WARNING SYSTEM the oil level falls below the lower level, the engine stops automatically. you refill with oil, the engine will not start again. NGINE SWITCH pre-operation checklist ngine switch controls the ignition system. “ON”(run) circuit is switched on. The engine can be started. “OFF”(stop) Fuel circuit is switched off. The engine will not run.
pre-operation checklist Air Cleaner Check the air cleaner element to be sure it is clean and in good condition. 1. Loosen the cover screw and remove the left side maintenance cover. 2. Press the latch tab on the top of the air cleaner body, remove the air cleaner cartridge, and check the element. 3. Clean or replace the element if necessary. Air Filter Cover 4. Never run the engine without the air cleaner. Rapid engine wear will result from contaminants.
control switch is turned “ON”, the economy control unit peed according to the connected load. The results are 1 and less noise. starting your inverter generator 2 OTECTOR ctor turns off automatically when the load exceeds the Starting Your Inverter Generator . warning 1 �������������������� d to within specified generator rated output if the DC circuit Before starting the engine, disconnect any load. . 2 �������������������� 1 turn counterclockwise from the tigened position.
starting your inverter generator notice A hot motor will not start if there is too much fuel in the cylinder. If this happens, wait five to ten minutes before trying again. Position the choke completely to the right and the motor should start. 4. Set the motor switch in the “ON’-position. 5. Pull slightly on the start cord until you feel resistance and then yank hard and swiftly. Engine Switch ON OFF CAution • DO NOT let the start cord retract by itself; guide it back by hand.
operation r High Altitude Operation • At high altitude, the standard carburetor air–fuel mixture will be excessively rich. • Performance will decrease, and fuel consumption will increase. • High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the slow tempo screws. • If you always operate the generator at altitudes higher than 1,500 m (4,000 feet) above sea level, have your dealer perform these carburetor modifications.
operation • When an extension cable is required, be sure to use a rubber sheathed flexible cable. • Limit length of extension cables; 60m for cables of 1.5mm2 and 100m for cables of 2.5mm2. • Keep the generator away from other electric cables or wires such as distribution network. • The DC receptacle can be used while the AC power is in use. If you use both at the same time, be sure not to exceed the total power for AC and DC.
operation Output and Overload Indicators. • The output indicator light (green) will remain lighted during normal operating conditions. • If the generator is overloaded or of here is a short in the connected appliance, the output indicator light (green) will go OFF, the overload indicator light (red) will go ON and current to the connected appliance will be shut off. • Stop the engine if the overload indicator light (red) switches ON and investigate the overload source.
operation CAution When the output indicator light (green) does not light and the overload indicator light (red) lights instead, set the engine switch to STOP, stop the engine at once and then start the engine again. 2. Start engine according to “STARTING THE ENGINE” 3. Confirm that the equipment to be used is switched off, and insert the plug of the equipment to be used into the AC receptacle unit A. warning Check that the equipment to be connected is switch off.
operation DC Applications Idling Voltage (V) Loading Voltage (V) Loading Current (A) Opening the Econo Switch 22 12 6 Closing the Econo Switch 27 13 8.5 DC Max Output Power 37 13.5 8.5 Example Model I2500 I3500 Generator Rated Output 2200VA 3000VA Frequency AC DC Power Factor 1.0 2200W 3000W 0.4-0.75 0-720W-1350W 0-920W-1725W 100W (12V/8.
operation warning When charging batteries, person must be present to monitor the voltage. Stop charging when the voltage of the batteries is above 16V. Failure to do so may result in battery explosion, causing serious injury or death. • Before connecting charging cables to a battery that is installed in a vehicle, disconnect the vehicles grounded battery cable. Reconnect the vehicle’s grounded battery cable after the charging cables are removed.
starting the engine Starting the Engine • The DC receptacle may be used while the AC power is in use. • An overloaded DC circuit will trip the DC circuit protector. If this happens, disengage the DC load before pushing in the circuit protector to resume operation. **I2500 Image ON OFF DC Circuit Breaker Oil Alert System • The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil.
stopping the engine Stopping The Engine To stop the engine in an emergency, turn the engine switch to the OFF position. In normal use: 1. Switch off the connected equipment and pull the inserted plug out. 2. Turn the engine switch to the OFF position. Engine Switch ON OFF 3. Turn the cap lever fully counter clockwise to the “OFF” position.
maintenance Maintenance • The purpose of the maintenance and adjustment schedule is to keep the generator in the best operating condition. • Inspect or service as scheduled in the table below. warning Shut off the engine before performing any maintenance, If the engine must be run, make sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas. notice Use authorized parts or their equivalent.
maintenance Temperature oC Time for Changing Oil (hr) Recommended Power Factor 25 Normal 100% 30 18 95% 35 15 85% 40 12 70% Engine Oil Replacement 1. Place the machine on a level surface and warm up the engine for several minutes. Then stop the engine and turn the fuel cock knob to “OFF””. Turn the fuel tank cap air vent knob clockwise. 2. Loosen the screw and remove the cover. 3. Remove the oil filler cap. 4. Place an oil pan under the engine.
maintenance notice Wash your hands with soap and water after handling used oil. notice Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station for reclamation. Do not throw it in the trash or pour it on the ground. Air Cleaner Service A dirty air cleaner will restrict airflow to carburetor. To prevent carburetor malfunction, service the air cleaner regularly.
maintenance Spark Plug Servicing CAUTION: ���������������������� Please use high quality authentic spark plug. To ensure proper engine operation, the spark plug must be properly cylinder wear may result. gapped and free of deposits The engine should never run without the element; excessive piston and/or ��������������������������� 1. Remove the bolts on the top maintenance cover and the cover. 4）CLEANING AND ADJUSTING SPARK PLUG 1. Remove the cover. 2. Check for discoloration and remove the carbon.
maintenance 4. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. Clean spark plug with a wire brush if it is to be reused. 0.6 - 0.7mm (0.024 - 0.028in) 5. Install the spark plug carefully by hand, to avoid cross threading. 6. After a new spark plug has been seated by hand, it should be tightened 1/2 turn with a wrench to compress its washer. If a used plug is being reinstalled, it should only require 1/8 to 1/4 turns after being seated. 7.
transporting and storage Transporting and Storage To prevent fuel spillage when transporting or during temporary storage: • The generator should be secured upright in its normal operating position, with the engine switch OFF. • The fuel cap vent lever is turned to the OFF position. • Allow the engine to cool well before turning the fuel cap vent lever to the OFF position. When Transporting Generator: • Do not overfill the tank.(There should be no fuel in the filler neck).
spark arrest service Spark Arrest Service A dirty muffler can increase the noise level and affect the proper running of the engine. Clean and maintain the spark arrest, making sure the generator operates normally. The spark arrest may need cleaning frequently if the generator is used in dirty conditions. Replace the spark arrest if necessary. warning The muffler becomes very hot during operating and remains hot for a while after stopping the engine. • Be careful not to touch the muffler while it is hot.
troubleshooting Troubleshooting Engine will not start. NO Enough Fuel? Add Fuel. YES Are the Engine Switch and Fuel Valve “ON”? NO Turn them to “ON”. YES Enough Lubricating Oil? NO Add more Oil. YES NO Is there fuel in the Carburetor? YES Does the Spark Plug work? NO Replace NO Spark Plug. Start a few times to ensure that Fuel enters the Carburetor. Take the Generator to an Authourized Service provider • Make sure there is no spilled fuel around the spark plug. Spilled fuel may ignite.
troubleshooting The Equipment that connects to the Generator doesn’t start. Is the Output Indicator on? NO Is the Overload Indicator on? NO Take the Generator to an Authourized Service provider NO Restart after turning off the Overload Indicator. YES Does the Electrical Equipment work when pluggged in directly? YES Take the Generator to an Authourized Service provider 1. Replace the Electrical Equipment 2.
troubleshooting Deficient AC Output Check Air Filter. DIRTY Clean or Replace Air Filter. Check Spark Arrest of Muffler. DIRTY Clean or Replace Spark Arrest. Check if the Gasoline is bad. YES Replace Gasoline. Take the Generator to an Authourized Service provider. 34 I2500_3500 Inverter Generator Manual_2011.
specifications Size and Weight I2500 L x W x H (mm) I3500 565 x 320 x 470 Net Weight (kg) 29 31 Engine Model I2500 I3500 152F 157F Type 4-Stroke, OHV, 1-Cylinder Displacement 125cc 150cc Bore x Stroke 52.4 x 57.8 57.4 x 57.8 Engine Speed 5 RPM (ECO Switch is off) Cooling System Forced Air Cooling Ignition System T.D.I.
wiring diagram Charging Winding bu bu bu bu Protector 8A r bl r r bl o o bl y y p bl bu bu bl w Stepping Motor y/g bl bl bl bl r r bl bl r r y r bu Economic Switch o bl bl Main Winding Working Indicator bu gr Control Winding w bl w bl a y/g p o bu Spring Winding Overload Indicator Low Oil Indicator pu Engine Switch w bl AC27V Winding OIL SENSOR Spark Plug w Ignition Equipment bu r y/g High Pressure Wrap b1 bLACk bR bu bLuE R bROWN REd g gREEN
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I2500 parts list # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part I2500001 I2500002 I2500003 I2500004 I2500005 I2500006 I2500007 I2500008 I2500009 I2500010 I2500011 I2500012 I2500013 I2500014 I2500015 I2500016 I2500017 I2500018 I2500019 I2500020 I2500021 I2500022 I2500023 I2500024 I2500025 I2500026 I2500027 I2500028 I2500029 I2500030 I2500031 I2500032 I2500033 I2500034 I2500035 I2500036 Description Side Cover Left Cover Above Cover Right Cover Muff
I2500 parts list # 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Part I2500037 I2500038 I2500039 I2500040 I2500041 I2500042 I2500043 I2500044 I2500045 I2500046 I2500047 I2500048 I2500049 I2500050 I2500051 I2500052 I2500053 I2500054 I2500055 I2500056 I2500057 I2500058 I2500059 I2500060 Description Gasoline Pump Fuel Cock Cover Plate Bottom Rubber A Bottom Rubber B Base Plate U-Shaped Mounting-1 Grounding Bar U-Shaped Mounting-2 Fuel Tank Cap Fuel Filter Rubber for Tank Port Fuel T
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I3500 parts list # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part I3500001 I3500002 I3500003 I3500004 I3500005 I3500006 I3500007 I3500008 I3500009 I3500010 I3500011 I3500012 I3500013 I3500014 I3500015 I3500016 I3500017 I3500018 I3500019 I3500020 I3500021 I3500022 I3500023 I3500024 I3500025 I3500026 I3500027 I3500028 I3500029 I3500030 I3500031 I3500032 I3500033 I3500034 I3500035 I3500036 Description Side Cover Left Cover Above Cover Right Cover Muffl
I3500 parts list # 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Part I3500037 I3500038 I3500039 I3500040 I3500041 I3500042 I3500043 I3500044 I3500045 I3500046 I3500047 I3500048 I3500049 I3500050 I3500051 I3500052 I3500053 I3500054 I3500055 I3500056 I3500057 I3500058 I3500059 I3500060 Description Gasoline Pump Fuel Cock Cover Plate Bottom Rubber A Bottom Rubber B Base Plate U-Shaped Mounting-1 Grounding Bar U-Shaped Mounting-2 Fuel Tank Cap Fuel Filter Rubber for Tank Port Fuel T
I2500_3500 Inverter Generator Manual_2011.
If you need assistance with the assembly or operation of your Generator please call 1-866-850-6662 I2500_3500 Inverter Generator Manual_2011.
