Replace Control Unit (3100-3500-watt Inverters)

Updated 1 month ago by Juan Velez

190603-60-50-1

This bulletin cover the following models: 75531i, 75537i, 75555i, 100204, 100233, 100261, 100262, 100263, 100264, 100396, 100476, 100477, 100523.

Please read the instructions carefully and completely before performing service.

*Specification, descriptions, and illustrations in this Technical Bulletin are as accurate as known at the time of publication, but are subject to change without notice.

SAFETY PRECAUTIONS:
  • To reduce the risk of injury, user must read and understand the operator’s manual before using this product.
  • DO NOT make any adjustments to the generator without first stopping the engine and disconnecting the spark plug wire.
  • Burns from hot parts — let the engine cool completely before touching hot parts.
  • Injury from moving parts
  • To reduce the possibility of fire or explosion, be careful when working around gasoline. Keep cigarettes, sparks and flames away from all fuel‐related parts.

Tools Required

Ratchet

1/4 or 3/8 drive

Extension

6 or 12"

Sockets

7 mm, 8 mm, and 10 mm

Phillips Screwdriver

#2

Nitrile Gloves

  1. Ensure that the battery switch, start switch, and the fuel valve are in the "OFF" position.
  2. Remove the two Phillips screws from the battery maintenance cover and pull on the rubber tab to access the battery. Release the clip of the pinch rubber and slide the battery out to access the cables. Pull back on the protective boots to expose the battery bolts and, using a 10 mm wrench or socket, remove the black (-) negative cable first, and then remove the red (+) positive cable. Set the battery off to the side in a safe location while performing the procedure.
  3. Remove the two Phillips screws to remove the access panel.
  4. Gently pull the spark plug cap by firmly grasping the spark plug insulator at the base. Leave it disconnected while working on the unit.
  5. Remove the three Phillips screws from the left handle.
  6. Separate the handle along the center seam and pull it downwards toward the top of the unit.
  7. With a Phillips screwdriver, remove the two screws on each side and, using a ratchet with a 10 mm socket, remove the two shoulder bolts at the bottom.
  8. To remove the left-hand side cover, gently pull away from the right side toward the left like opening a door. Disconnect both rubber pipes from the carbon canister and them remove the left-hand cover completely. For Electric-Start Models, go to step #14.
  9. Lift up the wire clamp and pull it back to release the wires.
  10. Remove the two pressure plate bolts with a 7 mm socket.
  11. Once the screws are removed, gently pull upwards on the control unit evenly. DO NOT USE FORCE.
  12. We suggest take a picture of the control unit while the Molex connectors are in place. Disconnect all the wires and replace it with the new control unit. Unbolt the rectifier with an 8 mm socket and disconnect the wires; transfer it to the new control unit.
  13. Reverse steps for reassembly.
    1. Control Unit Listing (Wiring Colors)

      B

      Black

      Y

      Yellow

      L

      Blue

      R

      Red

      W

      White

      C

      Carnation/Pink

      BW

      Black-White

      O

      Orange

  14. FOR ELECTRIC-START MODELS: Remove the bottom two control holder bolts with a 7 mm socket. Remove the top two control holder bolts on each side with a 10 mm socket.
  15. Lift up the wire clamp and pull it back to release the wires.
  16. Disconnect the Molex connector with the black wire insulator by squeezing the locking tab and pull it towards the inside of the unit.
  17. Move the stepper wire connector off to the left-hand side and pull the control unit down.
  18. Place the control unit face down and rotate it 90 degrees as shown. Make sure the stepper motor wire connector is off to the left-hand side as in the previous step.
  19. We suggest taking a picture of the control unit while the Molex connectors are in place. Disconnect all the wires and replace the old unit with the new control unit. Unbolt the rectifier with a 7 mm socket and replace it on the new control unit. (In the picture, the bolt is on the left outer frame.)
  20. Reverse these steps for reassembly.
    1. Control Unit Listing (Wiring Colors)

      B

      Black

      Y

      Yellow

      L

      Blue

      R

      Red

      W

      White

      C

      Carnation/Pink

      BW

      Black-White

      O

      Orange

      G

      Green


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