Troy-Bilt 30240 Owner's Manual

O

,®

Portabme Generator/Generador Port,tim

Modem / Modemo 030240

Before using this product, read this manuaHand follow aH

Safety RuHes and Operating Instructions.

Troy-BiltO is a registered trademark ofTroy-Bilt, LLC and is used under license to Briggs & Stratton Power Products.

Troy-Bilt® es una marca registrada registrada de Tro>,-Bilt,LLC y se usa abaio licencia a Briggs & Stratton Power Products.

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

Printed in USA

4

Antes de utiHizar eH producto, Heaeste manuaH y siga todas Has

Reghs de Seguridad e Instrucdones de Uso.

Questions? Preguntas?

- 1=888=611=6708 P1-F84 CT

JEFFERSON,WISCONSIN, U.$.A.

Manual No. 197484GS Revision O(05/06/2005)

Safety Rules

SAVE THESE mNSTRUCTmONS

TABLE OF CONTENTS

Section H o Safety RuNes .......................... 2-4

Section 2 ° Features and ControHs ................... 5

Section 3 oAssembHy ............................ 6-8

Section 4 o Operation .......................... 9- H2

Section 5 o Maintenance .......................... H3

Section 6 o Storage .............................. H4

Section 7 oTroubleshooting ........................ H5

Notes ......................................... H6

Warranty ...................................... H7

EQUmPNENT

DESCRmPTmON

- ead this manuam carefummy and become

fam,iarwith,oorge°erator.,°owits

appmications, its mimitadons and any hazards

invomved.

The generator described herein is an engine:driven,
revoHving fiend, aHternating current (AC) device. Each is
designed to supply electrical power for operating

compatibHe eHectricaH Highting, appHiance, tool and motor
Hoads. Each unit's revoHving fiend rotates at about 3,600 rpm.

SAFETY RULES

This is the safety amert symbol [t is used to
amert you to potendam personam iniury hazards.
Obey all safety messages that follow this
symbol to avoid possible iniury or death.

The safety aHert symboH (_) is used with a signaHword

(DANGER, CAUTION)A!ARNING), a pictorial and/or a
safety message to aHert you to hazards. DANGER indicates

a hazard which, if not avoided, will resuHt in death or serious

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

could resuHt in death or serious iniury. CAUTION

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

without the aHert symbol indicates a situation that couHd

resuHt in equipment damage. FoHHowsafety messages to

avoid or reduce the risk of iniury or death.

[

CAUT|ON! DO NOT exceed the generator's
wattage/amperage capacity. See "Don't OverHoad

Generator".

Every effort has been made to ensure that information in

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

and this document at any time without prior notice.
The Emission ControH System for these unit's are

warranted for standards set by the Environmenta[

Protection Agency. For warranty information refer to the

engine owner's manua[.

Copyright © 2005 Brigs & Stratton Power Products
Group, LLC. AHHrights reserved. No part of this materiaH

may be reproduced or transmitted in any form by any
means without the express written permission of Brigs &

Stratton Power Products Group, LLC.

Hazard Symbols and Meanings

EHectrocution EHectricaHShock

ExpHosion

Toxic Fumes Kickback

EHectricaHShock

Fire

Hot Surface

WARNING

Section 1: Safety Rules

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,

including the generator compartment of a recreadona[ vehicle (RV).

WARNING

When using generator for backup power; notify utility
company,, Use approved transfer equipment to isolate
generator from electric utility

Use a ground fauk 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 generator

WARNING

WHEN ADDmNG OR DRAmNHNG FUEL

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

removing fue! cap. Loosen cap slowly to relieve pressure in

tank.

Fill or drain fuel tank outdoors.
DO NOT overfill tank.Allow space for fiJel expansion.

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

DO NOT light a cigarette or smoke.

VHEN STARTING EQUIPMENT

• Ensure spark plug, muffler, fiJel 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 EQUIPMENT

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

EQUIPMENT

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.

• When starting engine, pull cord slowly until resistance is felt
and then pull rapidly to avoid kickback.

. NEVER start or stop engine with electrical devices phJgged in

and turned on.

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

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

generator could resuk in bodily injury and/or property

damage.

Section 1: Safety RuJes

WARNING

WHEN ADJUSTmNG OR MAKmNG REPAmRS TOYOUR
GENERATOR

Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spurt< plug

WHENTESTmNG FOR ENGmNE SPARK

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

WARNING

DO NOT touch hot surfaces.
Allow equipment to cod 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.

In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code). Other

states may have similar laws. Federal laws apply on federal
lands. [f you equip the muffler with a spark arrester, it must be
maintained in effective working order:

CAUTION

DO NOT 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 position, then turn ON for

operation.

Turn electrical loads OFF and disconnect from generator

before stopping generaton

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 excessiveJy.

KNOW YOU R G I=NI=RATOR

FueHTank

[ 20 Vok AC, 20 Amp

DupHex Receptacles

Features and Controls

Choke Lever

Air

CHeaner

Circuit Breakers

H20/240VokAC_

30 Amp Receptacle

Grounding Fastener

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

used to supply electrical power for the operation of

[ 20Vo[tAC, 20 Amp, single phase, 60 Hz electrical lighting,

appliance, too[ and motor loads.

[ 201240 Volt AC, 30 Amp Locldng Receptacle -- Hay

be used to supply electrical power for the operation of

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

electrical lighting, appliance, tool and motor loads.
Air Cleaner -- Protects engine by fikering dust and debris

out of intake air_

Battery Float Charger -- Use battery float charger jack

to keep the starting battery charged and ready for use.

Choke Lever -- Used when starting a cold engine.

Spark Attester Muffler

Circuit Breakers (AC) -- Push:to-reset circuit breakers
are provided to protect generator against electrical overload.

Fuel Tank -- Capacity of seven (7) U.S. gallons.

Grounding Fastener -- If required, please consult a
qualified electrician, electrical inspector, or local agency

Oil Fill Cap/Dipstick--Add engine oil here.

Recoil starter i Used to start the engine manually.
Rocker Switch -- Set this switch to "On" before using

recoil starter. Set switch to "O_' to switch off engine.
SparkArrester Mumer -- Exhaust muffler lowers

engine noise and is equipped with a spark arrester screen.
Start Button -- Push to start the engine.

Assembly

ASSEMBLY

Your generator requires some assembiy and is ready for
use after it has been properiy serviced with the

recommended oH and fuel

If you have any probiems with the assembiy of your

generator, piease cali the generator heipiine at

i-888-6 i 1-6708. If calling for assistance, piease have the

model revision_ and seMai number from the data tag avaHabie.

Remove Generator From Carton

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

arrows pointing upward.

2. Carefuliy open top flaps of shipping carton.

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

4. Remove ali packing material carton flirters, etc.

5. Remove generator from shipping carton.

Carton Contents

Check ali contents. If any parts are missing or damaged_ cali
the generator heipiine at 1-800-743-4 i i 5.

Main unit
EngineoiH

Owner's manuai
Engine manual

Battery float charger

VVheeikit

ELECTRmC START

Your unit is equipped with electric start capability but can

be started manually. If you choose not to use the electric
start feature, you do not need to connect the negative
battery cable.

Check Battery / Attach Negative

The sealed battery on the generator is fully charged and

pre-installed except for the negative (black) battery cable.

To install:

I. Cut off tie wrap securing loose end of negative (black)

cable.

2. Remove screw, lock washer and fiat washer on

negative battery termina[.

3. Siide Hock washer, fiat washer and negative battery
cabie over screw (Figure 1).

cable

/

Lock Washer

Positive battery cable

4_

Reattach screw to negative battery termina[ and

tighten.

5.

Verify that connections to battery and generator are
tight and secure.

Section 3: Assembly

mNSTALLWHEEL KIT" 3. Slideawheelovertheaxle.

The wheeH Haltis designed to greatly improve the portability 4. SHidea fiat washer over the axle and pHacethe e-ring
of your generator, onto the groove in the axHe.

NOTE:_6/heeH Haltis not intended for overothe-road use. 5. Place one end of the needle nose pHierson the bottom

You will need the following tools to instaHHthis wheel kit:

" H/2" or H3mm socket wrench
" H/2" or H3mm open end wrench

, 7/H6" socket wrench 8. Attach the vibration mounts to the support Hegwith

, 7/H6" open end wrench H/4-20 x H" capscrews and H/4-20 Hock nuts.

" Needle-nose pliers 9. To aid support leg assembly, rest generator on cradle,

NOTE: AdjustabHe wrenches may be substituted for open engine end down. Remove the existing Hod<nut from

end wrenches, the left unit vibration mount with 13mm wrench. Use

Refer to Figure 2, and install the wheel kit as follows: the same Hod<nut to attach the support Heg.

H. Race the bottom of the generator frame on a fiat, even H0. Attach the other side of the support Hegwith a P18 x

surface.TemporariHy place unit on blocks to ease assembly. 20 mm capscrew and H8 lock nut. Rest generator on

2. SHide axle through both axle mounting brackets on
cradHe frame, as shown in Figure 2.

of the axHeand the other end of the pHiers on top of
the e-ring. Seat the e-ring by pressing the pHiers closed,

6. Repeat step 3 through 5 to secure second wheel

7. Remove the temporary bHocks.

wheeHs and support Heg.

HH. Check each fastener to ensure it is secure.

Use existing hardware
to attach Heft side of

support Hegto unit

Hex Nut _

Support

Vibration Hount

Capscrew -- - Hex Nut

\

Capscrew

Axle

Wheel

Rat Washer

/

_. /

E-Ring

Section 3: Assembly

BEFORE STARTmNG THE

ENGmNE

Add Engine Oil

* Place generator on a [eve[surface.

° Refer to engine owner's manual and follow oil

recommendations and instructions.

Refer to engine manual for oil fill information.
Damage to equipment resuking from failure to follow this

instruction will void warrant><

NOTE: Ched< 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

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EH (Engine

Hodifications).

WHEN ADDING FUEL

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

removing rue! cap. Loosen cap slow, ly to relieve pressure in

tank.

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.

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 fuel to fuel tank. Be careful

not to overfill.Allow about 1.5" of tank space for fuel

expansion (Figure 3).

_NNNNNNNNNNNNNNN

_NNNNNNNNNNNNNNf"

INNNNNNNNNNNNNNN

4. Install fuel cap and wipe up any spilled fuel.

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 "Eqopment Description',
earlier in this manual).

Special Requirements
There may be Federal or State Occupational Safety and

HeaHthAdministration (OSHA) reguHations, HocaHcodes, or

ordinances that apply to the intended use of the generator,

Please consuk a qualified electridan, electrical inspector, or

the local agency having jurisdiction,
o In some areas, generators are required to be registered

with local utility companies,

o If the generator is used at a construction site, there may

be additional regulations which must be observed,

Connecting to a Build[rig's Electrical

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.

Operation

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,
including the generator compartment of a r_creational 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 overhead, 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 generator.

WANNING

When using generator for backup power1 notify utility
company. Use approved transfer equipment to isolate
generator from electric utility:

Use a ground fauk 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 generatoi:

Typical Generator Shown

Exhaust Port

Section 4: Operation

OPERATmNG THE

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

operation.
Turn electrical loads OFF and disconnect from generator

before stopping generaton

[HPORTANT: Always unplug the battery float charger

before starring the generator.

Starting the Engine

Disconnect ai[ electrical loads from the generator. Use the

following start instructions:

i, Hake sure unit is on a level surface.

IMPORTANT: Failure to start and operate unit on a level

surface wiil cause the unit not to start or to shut down
during operation.

2. Turn the fuel valve to the "On" position (Figure 5).The
fuel valve handle should be vertical (pointing toward
the ground) for fuel to flow,

in the On position

3. Start engine according to instructions given in the
engine owner's manual

1 WAR.I.G 1

When starting engine, pull cord slowly until resistance is felt
and then pull rapidIy to avoid kickback.

NEVER start or stop engine with electrical devices plugged in
and turned on.

NOTE: If engine starts after 3 pulis but fails to run, or if
unit shuts down during operation, make sure unit is on a

level surface and check for proper oil level in crankcase.

This unit may be equipped with a low oil protection device.
See engine manual.

WANNING

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.

in the S_ate of California a spark attester is required by law
(Section 4442 of the California Public Resources Code). Other
states may have similar laws. Federal laws apply on federal
lands, if you equip the muffler with a spark arresten it must be

maintained in effective working order:

Cormecting Electrical Loads

° Let engine stabilize and warm up for a few minutes after

starting.

° Plug in and turn on the desired 120 and/or 240VoitAC_

single phase_60 Hz electrical loads.

* DO NOT connect 240Volt loads to the i20Voit duplex

receptacles.

° DO NOT connect 3-phase loads to the generator.
° DO NOT connect 50 Hz loads to the generator.

* DO NOT OVERLOADTHE GENEPJ:kTOR. See

"Don't Overload the Generator".

the Ens:ine

I. Turn OFF and unplug ali electrical loads from

generator panel receptacles, NEVER s_rt 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 engine off according to instructions given in the

engine owner's manual,

4. Hove fuel valve to "Off" position.