Troybilt 030237 Owner’s Manual

O

r®

d

Portabme Generator/Generador Port_tii

Model / Modeio 030237

CAO'rmON

Beforeusingthisproduct_read thismanuaH and followaH

Safet7 RuHesand Operating Instructions.

Quesdons? Preguntas?

- 1-888-611-6708 H=F8=5CT

Troy-Bilt® is a registered trademark of blTD and is used under license to Brigs & Str_tton Power Products.

Troy-Bilt® es una marca registrada de blTD y se usa abaio licencia a Brigs &Strat_on Power Products.

BPJGG$ & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON,WiSCONSiN, U.S.A.

Printed in USA

PReCAUCmON

Antes de utiHizareHproducto_HeaestemanuaH 7 sigatodasHas

Reghs de Seguridade Instruccionesde Uso.

Manual No. 197325GS Revision 2 (08/15/2005)

Safety Rules

SAVE THESE mNSTRUCTmONS

TABLE OF CONTENTS

Section HoSafety Rules .......................... 2-4

Section 2 - Features and Controis ................... S

Section 3 oAssembiy ............................ 6-7

Section 4 o Operation .......................... 8- i4

Section 5 o Maintenance ........................ i S°i 6

Section 6 o Storage .............................. i7

Section 7 oTroubieshooting ........................ i8

VVarranty ...................................... i9

EQUmPNENT

,j----] Read this manuam carefummy and become

iI--:!---I famimiar with your generator. Know its

appmications, its mimitations and any hazards

involved.

This manuai describes an engine-driven, revoiving fieid,
aHternating current (AC) generator designed to supply
electrical power for operating compatible electrical lighting,
appiiances, toois and motor ioads.The generator's revoiving
field is driven at about 3,600 rpm by a singleocylinder
engine.

SAFETY RULES

This is the safety amert symbol it is used to
amert you to potentiam personam iniury hazards.

Obey atomsafety messages that fommow this
symbom to avoid possibmeiniuryor death.

The safety alert symbol (_k) 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, wilt resuit in death or serious

injury. WARNING indicates a hazard which, if not avoided,

couid result in death or serious injury. CAUTmON

indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used

without the alert symbol, indicates a situation that could

result in equipment damage. Follow safety messages to

avoid or reduce the risk of injury or death.

{

CAUTION! DO NOT exceed the generator's
wattage/amperage capacity. See "Don't Overload

Generator".

Every effort has been made to ensure that information in

this manual is accurate and current. However, we reserve
the right to change, alter or otherwise improve the product

and this document at any time without prior notice.

The Emission Control System for this generator is
warranted for standards set by the Environmental

Protection Agency. For warranty information refer to the

engine owner's manual

Copyright @ 2005 Briggs & Stratton Power Products
Group, LLC. AHHrights reserved. No part of this materiai
may be reproduced or transmitted in any form by any
means without the express written permission of Briggs &
Stratton Power Products Group, LLC.

Hazard Symbols and Meanings

Electrocution Electrical Shock

Toxic Fumes Fire

Explosive Pressure Chemical Burn Hot Surface

Explosion

Section 1: Safety Rules

DANGER

DO NOT aiIow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.

Wear protective go_Jes, rubber apron, and rubber gloves.

WANNING

Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator inside any building or enclosure
(even if doors or windows are open), including the generator
compartment of a recreational vehicle (RV).

WARNING

WHEN ADDING OR DRAINING FUEL

Turn generator OFF and let it cool at least 2 minutes before

removing fuel cap. Loosen cap slowly to relieve pressure in

tank.

Fill or drain fuet tank outdoors.
DO NOT overfill tank.AIIow space for fuel expansion.

Keep fuel away from sparks, open flames, pilot lights, heat, and
other ignition sources.

DO NOT light a cigarette or smoke.

_fHEN STARTING EQUiPHENT

Ensure spark plug, muffier_ fuel cap and air cleaner are in place.

• DO NOT crank engine with spark plug removed.
If fuel spills, wait until it evaporates before starting engine.

WHEN OPERATING EQUIPNENT

Do not tip engine or equipment at angle which causes fuel to
spill.

This generator is not for use in mobile equipment or marine
applications.

VHEN TRANSPORTING OR REPAiRiNG

EQUIPNENT

WARNING

When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utility.

Use a ground circuit fault interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.

DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

DO NOT operate generator in the rain.
DO NOT handle generator or electrical cords while standing

in waten while barefoot, or while hands or feet are wet.
DO NOT allow unqualified persons or children to operate or

service generator.

iN TANK

Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite fuel vapors.

This generator does not meet U. S. Coast Guard Regulation

33CFR-183 and should not be used on marine applications.
Failure to use the appropriate U. S.Coast Guard approved

generator could result in bodily injury and/or property

damage,

0

Section 1: Safety Rules

WARNING

WHEN ADJUSTING OR MAKING REPAiRSTOYOUR
GENERATOR

Disconnect the spark piug wh_e from the spark plug and place
the w@e where it cannot contact spark plug.

WNENTESTmNG FOR ENGINE SPARK

Use approved spark plug tester:
DO NOT check for spark with spark plug removed,

WARMING

DO NOT touch hot surfaces,
Allow equipment to coot before touching.

The generator must be at least S feet from structures having
combustible wails and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator for
adequate coding, maintenance and servicing.

Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Tide 36 Parks, Forests, and

Public Property require equipment powered by an internal
combustion engine to have a spark arrested; maintained in
effective working order, complying to USDA Forest service

standard SI00-IC or later revision. In the State of California a
spark arrester is required under section 4442 of the California

Public resources code. Other states may have similar Jaws,

CAUTION

DO NC)T tamper with governed speed, Generator supplies
correct rated frequency and voltage when running at governed

speed.

DO NOT modify generator in any way.

See "Don't Overload Generator _.
Start generator and let engine stabilize before connecting

electrical loads,
Connect electrical loads in OFF posidon, then turn ON for

operation,

Turn electrical loads OFF and disconnect from generator

before stopping generator,

Use generator only for intended uses,
If you have questions about intended use, ask dealer or call

1-888-61 1-6708.

Operate generator only on level surfaces.
DO NOT expose generator to excessive moisture, dust, dirt,

or corrosive vapors.

DO NOT insert any objects through cooling slots,

If connected devices overheat_ turn them off and disconnect

them from generator:

Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

Features and Controls

KNOWYOUR GENERATOR

Read this owner's manual and safety rules before operating your generator,

Compare this H[ustration with your generator to familiarize yourseff with the locations of various controls and
ad]ustments. Save this manual for future reference.

Oil Fill Cap Fuel Tan[<

Air Cleaner Circuit Breakers (AC)

Spar[<Arrester Muffler Duplex Receptacles

-_ Rocker Switch Circuit

Breaker

[20Vok AC, 20 Amp

[20/240 Vok AC, 30 Amp

Locking Receptacle

Choke Lever

Battery

[2Volt DC Receptacle -- Use this receptacle with

battery charge cables to charge a [ 2Volt battery.

[20 Volt AC, 20 Amp Duplex Receptacles -- Hay be

used to supply electrical power for the operation of [20Volt
AC, 20 Amp, single phase, 60 Hz electrical lighting appliance,

tool and motor loads.

[ 20/240 Volt AC, 30 Amp Locking Receptacle- Hay

be used to supply electrical power for the operation of

120 and/or 240VoltAC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.
Air Cleaner -- Uses a dry type filter element and foam

pre-deaner to limit the amount of dirt and dust sucked

into the engine.
Battery- Located behind plastic cover. 12Vok DC sealed

battery provides power to start the engine.
Choke Lever -- Used when starting a cold engine.

Data Tag

[2Volt DC

Receptacle

/

Start Switch

Grounding

Fastener

Circuit Breakers (AC) --The [20Vo[tAC, 20A duplex

receptacles are provided with "push to reset" circuit
breakers to protect the generator against electrical overload.

DataTag - Provides model, revision and serial number of

generator. Please have these readily available if calling for

assistance.

Pue[ Tank -- Capacity of seven (7) U.S.gallons.
Start Switch --Turn to start the engine.
Grounding Pastener -- Consult your local agency having

]ur[sdiction for grounding requirements in your area.

Oil Pill Cap --Add oil to engine here.

Spark Attester Muffler -- Exhaust muffler lowers engine
noise and is equipped with a spark attester screen.

Rocker Switch Circuit Breaker --The 120/240VokAC_
30A locking receptacle is provided with a rocker switch circuit

breaker to protect the generator against electrical oveHoad.

This switch also controls all receptacles.

ASSEMBLY

Your generator requires some assembHyand is ready for
use after it has been properHy serviced with the

recommended oiHand fuel

mfyou have any probmerns with the assernbmy of your

generator, please car the generator helpiine at

l=888=61 l =6708. if caHHingfor assistance_pHeasehave the
model revision_ and seriaHnumber from the data tag available.
See "KnowYour Generator" for data tag Hocation.

Remove Generator From Carton

H. Set carton on a rigid fiat surface with "This Side Up"

arrows pointing upward.

2. CarefuHHyopen top flaps of shipping carton.

3. Cut down corners of carton from top to bottom and
Haythat side of carton down fiat.

4. Remove aHHpacking material carton fiHHers_etc.

5. RoHHgenerator out of shipping carton.

A ach Handle

You wiHHneed two H/2"or H3 mm wrenches to attachthe

handHe.

H. Attach handHeto right side of generator frame (viewing

unit from front), as shown in Figure H,with a 60 mm
capscrew, fiat washers, nyHon washers, and Hock nut.

60ram Capscrew

li

Nut

' /Vqasher

: i Handle Bracke_

Handle Pin

I

NOTE: DO NOT overtighten. Handle must be able to
move up and down freely.

2. Raise handHe and insert handHe pin to move generator.

O

Section 3: Assembly

BEFORE STARTmNG THE

ENGmNE

Add Engine Oil

° Place genera[or on a level surface.

[

• Refer to engine manuaIfor oil fill information.

• Damage to equipment resuking from failure to follow this
instruction will void warranty.

° Refer to engine owner's manuaHand follow oiH

recommendations and instructions.

[NOTE: Check oil often during engine break-in. Refer to

engine owner's manual for recommendations.

[NOTE: The generator assembly rotates on a prehbricated
and sealed ball bearing that requires no additional
lubrication for the life of the bearing.

Add Fuel

I. Use clean, fresh, regular UNLEADED fuel with a

minimum of 85 octane. DO NOT use fuel which
contains Hethanol. DO NOT mix oil with fuel.

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded gasoline to fuel tank. Be
careful not to overfill.Allow about 2.25" of tank space

for fuel expansion (Figure 2).

Fuel

Replace"1.5" with "2.25" fuel fill levelgiven in enginemanual
Failureto follow this instruction may cause fuel to overexpand

and spill from tank.

Install fuel cap and wipe up any spilled fuel.

NOTE:This gasoline engine is certified to operate on

gasoline.Exhaust Emission Control System:EH (Engine

Hodifications).

_WARNING

WHEN ADDING FUEL

Turn generator OFF and let it cool at Ieast 2 minutes before
removing fuel cap_Loosen cap s!owly to relieve p_ssure in _nk.

Fill fuel tank outdoors,
DO NOT overfill tank.Allow space for fuel expansion_

Keep fuel away from sparks, open flames, pilot lights, heat, and
other ignition sources

DO NOT light a cigarette or smoke,

Remove Cover on Start Switch

A protective plastic cover is placed over the start switch to

prevent the generator from being started.
* Open cap on battery float charger.

° Remove and discard plastic cover over the start switch

(Figure 3).

° Replace cap on battery float charger.

O

Operation

USmNG THE GENERATOR

System Ground

The generator has a system ground that connects the

generator frame components to the ground terminals on
the AC output receptacles.The system ground is connected
to the AC neutral wire (see "Equipment Description",
earlier in this manual).

Special Requirements
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 which must be observed.

Connecting to a Building's Electrical

System

Connections for standby power to a building's 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.

Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings_

DO NOT operate generator inside any building or enclosure
(even if doors or windows are open), including the generator
compartment of a recreational vehicle (RV).

The generator must be at least 5 ft. (I 52 cm) from

structures having combustible walls and/or other
combustible materials. Leave at least 3 ft. (92 cm) all around

generator including overhea& for adequate cooling,

maintenance and servicing.

Place generator in a well ventilated area, which will allow
for removal of deadly exhaust gas. DO NOT place
generator where exhaust gas could accumulate and enter

inside or be drawn into a potentially occupied building.

Ensure exhaust gas is kept away from any windows, doors,
ventilation intakes or other openings that can allow exhaust
gas to collect in a confined area (Figure 4). Prevailing winds

and air currents should be taken into consideration when

positioning generaton

WARNING

When using generator for backup power, notify utility

company. Use approved transfer equipment to isolate

generator from electric utility.

Use a ground fault circuit interrupter (GFCI) in any damp or
highly conductive area_ such as metal decking or steel work_

DO NOT touch bare wires or receptacles_
DO NOT use generator with electrical cords which are worn,

frayed, bare or otherwise damaged.

DO NOT operate generator in the rain.
DO NOT handle generator or electrical cords while standing

in water, while barefoot, or while hands or feet are wet_
DO NOT allow unqualified persons or children to operate or

service generato_i

Exhaust Port

0

Section 4: Operation

OPERATmNG THE

G EN E RATO R

Startin the En

Disconnectallelectricalloadsfrom thegenerator.Follow

start instruction steps in numerical order:

IMPORTANT:Always unplug the battery float charger

before starting the generator.

I. Hake sure unit is on a level surface.

iMPORTANT: Failure to start and operate unit on a level
surface will cause the unit not to start or shut down during
operation.

2. Follow start instructions given in engine owner's manual

and turn start switch on generator to "Start" position
(Figure S).To prolong life of starter components, DO
NOT hold starter switch in "Start" position for more
than 15 seconds_and pause for I minute.

Jump Start Procedure

If generator's starting battery fails, use following instructions
to jump start generatonYou can jump start generator using
any 12Vok automotive or utility style storage battery.

I. Unscrew fuse holder and remove generator's 10Amp

in4ine fuse (Figure 6).Verify fuse is good or replace

with a known good fuse. Reinstall fuse in fuse holder.

/

/

/

2. Slide red rubber boot off generator's battery terminal
and push it onto red wire, thus uncovering POSITIVE

battery terminal.

3. Using standard automotive jumper cables, connect

RED jumper cable clamp to generator's POSITIVE
battery terminal (Figure 7).

WARNING

DO NOT touch hot surfaces.
Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator for"
adequate cooling, maintenance and servicing.

Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Tide 36 Parks, Forests, and

Public Property require equipment powered by an internal
combustion engine to have a spark arresten maintained in
effective working order, complying to USDA Forest service

standard 5100-IC or later revision. In the State of California a
spark attester is required under section 4442 of the California

Public resources code. Other states may have similar laws,

Fastener

ii

i!

4. Connect the other RED jumper cable damp to the
starting battery's POSITIVE battery terminal.

S. Connect the BLACK jumper cable clamp to the

starting battery's NEGATIVE battery terminal.

6. Connect the other BLACK jumper cable clamp to the
GROUNDING FASTENER on the generator, as shown
in Figure 7.

7. Start the generator as described in "Starting the
Engine" and remove jumper cables in reverse order of

connections.

8. Slide the red rubber boot back onto the generator's
POSITIVE battery terminal.

If you have any questions, please call the Generator
Helpline at l =888=61 l =6708, M=F 8=5 CT.

iMPORTANT: When jump starting, always wear proper eye
protection and never lean over battery. Inspect both
batteries before connecting booster cables. DO NOT jump
start a damaged battery. Be sure vent caps are tight and level.

O

Section 4: Operation

Connectin_ Fiectrica[ Loads

" Let engine stabiHize and warm up for a few minutes after

starting.

° PHug in and turn on the desired [20 and/or 240 VokAC,

singHe phase, 60 Hz eHectricaH Hoads.

° DO NOT connect 240VoHt Hoads to the H20Vok dupHex

receptacles.

° DO NOT connect 3-phase Hoads to the generator.
° DO NOT connect 50 Hz [oads to the generator.

. DO NOT OVERLOAD GENEP_ATOR. See "Don't

OveHoad Generator".

See"Don't Overload Generator".
Start generator and let engine stabilize before connecting

electrical loads.
Connect electrical loads in OFF position, then turn ON for

operatiom
Turn electrical loads OFF and disconnect from generator

before stopping generatol_

Sto_ the Engine

I. Turn OFF and unplug aSSelectrical loads from

generator panel receptacles. NEVER start or stop engine
with electrical devices plugged in and turned ON.

2. Let engine run at no-load for several minutes to
stabilize internal temperatures of engine and generator.

3. Turn start switch to "Stop" position.

DANGER

DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a batteD;

Wear protective goggles, rubber apron, and rubber gJoves_

To recharge [ 2 Volt batteries, proceed as follows:

I. Check fluid level in all battery cells. If necessary, add

ONLY distilled water to cover separators in battery

cells. DO NOT use tap water.

2. ff battery is equipped with vent caps, make sure they
are installed and are tight.

3. [f necessary, clean battery terminals.

4. Connect battery charge cable connector plug to panel
receptacle identified by the words "12:VOLTS D.C.".

5. Connect battery charge cable clamp with red handle
to the positive (+) battery terminal (Figure 8).

12 VOLT D,C.

RECEPTACLE

Charging a Battery

Your generator has the capability of recharging a discharged

i2Voit automotive or utility style storage battery. DO

NOT use the unit to charge any 6Volt batteries. DO NOT

use the unit to crank an engine having a discharged battery.

+

POS NEG

i2 VOLT BATTERY

6. Connect battery charge cable clamp with bmack handle

to the negative (-) battery terminal (Figure 8).

7. Start engine. Let engine run while battery recharges.

8. When battery has charged_ shut down engine

NOTE: Use an automotive hydrometer to test battery state

of charge and condition. Follow the hydrometer

manufacturer's instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific gravity

of its fluid (as measured by hydrometer) is 1.260 or higher.

Section 4: Operation

blow to Use the Battery Char er

Use batteryfloatchargerjackto keep the startingbattery

charged and ready for use. Battery charging should be done
in a dry location, such as inside agarage.

I. Plug charger into unit's "Battery Float Charger" jack,

whch is located next to starter switch (Figure 9). Plug
battery charger into a 120Vok AC wall receptacle.

2. Unplug charger from unit and wall outlet when
generator is being started and while in operation.

3. Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge the battery,
even when plugged in for an extended period of time.

iMPORTANT: See "Battery Haintenance" on page 15 for

additional information.

COLD WEATHER

[n an emergency, use the original shipping carton as a

temporary shelter:

7. Cut off ail carton flaps.

8. Cut out one long side of carton to expose muffler side
of unit as shown in Figure I O.

Wind

[MPORTANT: The generator must be at least 5 ft.
(152 cm) from structures having combustible wails and/or

other combustible materials. Leave at least 3 ft. (92 cm) all
around generator including overhead, for adequate cooling,

maintenance and servicing.

WARNING

Under certain weather conditions (temperatures below
40°F [4°C] combined with high humidity), your generator
may experience icing of the carburetor and/or the
crankcase breather system.To reduce this problem_ you
need to perform the following:

I. Hake sure generator has dean, fresh fuel.

2. Open fuel valve (turn valve to open position).

3. Use SAE 5_Azo30oil (synthetic preferred_ see engine
manual).

4. Check oil level daily or after every eight (8) hours of
operation.

5. Maintain generator following "Maintenance Schedule"
in engine manual.

6. Shelter unit from elements.

DO NOT touch hot surfaces_
Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having

combustible walls and/or other combustible materials.
Keep at least 3 feet of clearance on all sides of generator for

adequate cooling, maintenance and servicing_

Reflective exhaust heat may damage fuel tank causing fire.
Remove shelter when temperatures are above 40°F [4°C].

9. Cut appropriate slots to access receptacles of unit.

10. Start unit, then place carton over it.

NOTE: Remove shelter when temperatures are above

40°F {4°C].