Troy-Bilt 7000 Watt XP Series User Manual

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

MILWAUKEE, WISCONSIN, U.S.A.

Manual No. 313484GS Revision E

Portable Generator

Operator’s Manual

This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04

(motors and generators) and PGMA (Portable Generator Manufacturers’ Association) standard PGMA G200

(Standard for Testing and Validating Performance of Portable Generators).

2 troybilt.com

Thank you for purchasing this quality-built Troy-Bilt generator. We are pleased that you’ve placed your confidence in the Troy-Bilt brand. When operated and maintained according to the instructions in this manual, your Troy-Bilt generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with generators and how to avoid them. This generator is designed and intended only for supplying electrical power for operating compatible electrical lighting, appliances, tools and motor loads, and is not intended for any other purpose. It is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these original

instructions for future reference.

This generator requires final assembly before use. Refer to the Assembly section of this manual for instructions on final

assembly procedures. Follow the instructions completely.

Where to Find Us

You never have to look far to find Briggs & Stratton support and service for your generator. Consult your Yellow Pages. There are over 30,000 Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact Troy-Bilt Customer Service by phone at (888) 611-6708, or on the Internet at www.troybilt.com.

Generator

Model Number Revision Serial Number

Engine

Model Number Type Number Code Number

Date Purchased

Table of Contents

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unpack Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Install Wheel Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Moving Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Add Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Add Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Attach Negative Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Attach Extend-a-panel™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting to a Building’s Electrical System. . . . . . . . . . . . . . . . . . . . . . . 10

Generator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cord Sets and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Extend-a-panel™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connecting Electrical Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Stopping the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Low Oil Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Don’t Overload Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuel Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Warranties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Emissions Control System Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Generator Owner Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Common Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operator Safety

Equipment Description

Read this manual carefully and become familiar with your generator. Know its applications, its limitations and any hazards involved.

The generator is an engine–driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads. The generator’s revolving field is driven at about 3,600 rpm by a single-cylinder engine.

NOTICE

Exceeding generators wattage/amperage capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

Every effort has been made to ensure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve the generator and this documentation at any time without prior notice.

The Emission Control System for this generator is warranted for standards set by the Environmental Protection Agency and the California Air Resources Board.

Important Safety Information

The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator unsafe.

Safety Symbols and Meanings

The safety alert symbol indicates a potential personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.

DANGER indicates a hazard which, if not avoided, will

result in death or serious injury.

WARNING indicates a hazard which, if not avoided,

could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could

result in minor or moderate injury. NOTICE address practices not related to personal injury.

4 troybilt.com

Fire

Explosion

Toxic Fumes

Hot Surface

Moving Parts

Electrical Shock

Kickback

Flying Objects

Operator’s Manual

WARNING The engine exhaust from this product

contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product and

related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

WARNING

• 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 death or serious injury and/or property damage.

WARNING Fuel and its vapors are extremely

flammable and explosive which could cause burns, fire or explosion resulting in death or serious injury.

WHEN ADDING OR DRAINING FUEL

• Turn generator engine OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Fill or drain fuel tank outdoors.

• DO NOT overfill tank. Allow space for fuel expansion.

• If fuel spills, wait until it evaporates before starting engine.

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

• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

• DO NOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

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

• DO NOT crank engine with spark plug removed.

WHEN OPERATING EQUIPMENT

• DO NOT operate this product inside any building, carport, porch, mobile equipment, marine applications, or enclosure.

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• DO NOT stop engine by moving choke control to “Choke” position

().

WHEN TRANSPORTING, MOVING OR REPAIRING EQUIPMENT

• Transport/move/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

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

WARNING Starter cord kickback (rapid retraction) will

pull hand and arm toward engine faster than you can let go which could cause broken bones, fractures, bruises, or sprains resulting in

serious injury.

• 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 plugged in and turned on.

WARNING POISONOUS GAS HAZARD. Engine

exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You CANNOT

smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outside far away from windows, doors and vents to reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

• Install battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions. Smoke alarms cannot detect carbon monoxide gas.

• DO NOT run this product inside homes, garages, basements, crawlspaces, sheds, or other partially-enclosed spaces even if using fans or opening doors and windows for ventilation. Carbon monoxide can quickly build up in these spaces and can linger for hours, even after this product has shut off.

• ALWAYS place this product downwind and point the engine exhaust away from occupied spaces.

If you start to feel sick, dizzy, or weak while using this product, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

NOTICE

Exceeding generators wattage/amperage capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

• 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 generator.

NOTICE

Improper treatment of generator could damage it

and shorten its life.

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or contact local service center.

• 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.

6 troybilt.com

WARNING

Generator voltage could cause electrical shock or burn resulting in death or serious injury.

• Use approved transfer equipment to prevent backfeed by isolating generator from electric utility workers.

• When using generator for backup power, notify utility company.

• 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 or wet weather.

• 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 Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in death or

serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

• It is a violation of California Public Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.

Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

WARNING Unintentional sparking could cause fire or

electric shock resulting in death or serious injury.

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR

• Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

WARNING Starter and other rotating parts could

entangle hands, hair, clothing, or accessories resulting in serious injury.

• NEVER operate generator without protective housing or covers.

• DO NOT wear loose clothing, jewelry or anything that could be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

CAUTION Excessively high operating speeds could

result in minor injury. Excessively low speeds impose a heavy load.

• DO NOT tamper with governor spring, links or other parts to increase engine speed. Generator supplies correct rated frequency and voltage when running at governed speed.

• DO NOT modify generator in any way.

Assembly

Read entire operator’s manual before you attempt to assemble or operate your new generator.

Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended fuel and oil level is verified.

If you have any problems with the assembly of your generator, please call the generator helpline at (888) 611-6708. If calling for assistance, please have the model, revision, and serial number from the identification label available. See generator Features and Controls for identification label location.

Unpack Generator

1. Set the carton on a rigid, flat surface.

2. Remove everything from carton except generator.

3. Open carton completely by cutting each corner from top to bottom.

4. Leave generator on carton to install wheel kit.

The generator is supplied with:

• Operator’s manual

• Engine oil bottle

• Battery float charger

• Extend-a-panel™

• 25 ft. (7.6 m) Accessory cord

• Wheel kit

Install Wheel Kit

NOTICE Wheel kit is not intended for over-the-road use. You will need the following tools to install these components:

• 13 mm wrenches (2)

• Adjustable wrench

• Pliers

• Safety glasses

Install the wheel kit as follows:

1. Tip generator so that engine side is down. Tip generator back slightly and slide narrow end of one of the support legs under engine recoil.

NOTICE Be sure to slide support leg far enough under engine recoil to prevent generator from tipping over.

2. Slide axle (A) through holes in generator frame.

3. Slide a black nylon washer (B) over axle.

4. Slide a wheel (C) over axle.

NOTICE Be sure to install wheel with raised hub inboard.

5. Slide a flat washer (D) over axle.

6. Place an e-ring (E) in axle groove.

7. Install e-ring with pliers, squeezing from top of e-ring to bottom of axle.

8. Place hub cap (F) into center of wheel and push until it snaps into place.

9. Repeat step 3 thru 8 to secure second wheel.

10. Tip generator back slightly and remove support leg from under engine recoil.

11. Line up holes in support leg (G) with holes in generator frame.

12. Attach support leg using two capscrews (H) and two hex nuts (J). Tighten with 13 mm wrenches.

13. Repeat step 11 and 12 to secure second support leg.

14. Attach cord wrap posts (K) to generator frame. Tighten with an adjustable wrench.

15. Return generator to normal operating position (resting on wheels and support legs).

CAUTION E-rings could cause eye injury.

E-rings could spring back and become airborne when installing or removing, resulting in moderate injury.

• Always wear eye protection when installing/removing e-rings.

Moving Generator

1. Remove handle pin (A) from bracket on right side of

handle (viewing generator from engine end).

2. Pull folding handle to the upright position until latch (B)

locks into place.

3. Reinsert handle pin in bracket on right side of handle.

4. Place your foot onto the axle (C) located under the

recoil starter and pull back on the handle.

5. Always face generator and push or pull to desired location. When moving generator on an incline, always make sure you are uphill from generator.

6. Place foot on axle and gently let generator tip forward to rest on support leg.

7. Remove handle pin from right side of handle.

8. Pull up on latch and push handle forward to fold down handle.

Add Engine Oil

1. Place generator on a flat, level surface.

2. Clean area around oil fill and remove yellow oil fill cap/dipstick.

3. Using oil funnel (optional), slowly pour contents of provided oil bottle into oil fill opening to the “Full” mark on dipstick.

NOTICE

Improper treatment of generator could damage it

and shorten its life.

• DO NOT attempt to crank or start the engine before it has been properly serviced with the recommended oil. This may result in an engine failure.

4. Replace oil fill cap/dipstick and fully tighten.

Add Fuel

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

• A minimum of 87 octane/87 AKI (91 RON). For high altitude use, see High Altitude.

• Gasoline with up to 10% ethanol (gasohol) is acceptable.

NOTICE Use of unapproved fuels could damage generator and voids warranty.

• DO NOT use unapproved gasoline such as E15 and E85.

• DO NOT mix oil in gasoline or modify engine to run on alternate fuels.

To protect the fuel system from gum formation, mix in a fuel stabilizer when adding fuel. See Storage. All fuel is not the same. If you experience starting or performance problems after using fuel, switch to a different fuel provider or change brands. This engine is certified to operate on gasoline. The emission control system for this engine is EM (Engine Modifications).

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

2. Slowly add unleaded gasoline (D) to fuel tank (E). Be careful not to fill above the baffle (F). This allows adequate space for fuel expansion as shown.

3. Install fuel cap and let any spilled fuel evaporate before starting engine.

8 troybilt.com

WARNING Body Crush/Tip Over Hazard.

Generator could tip over while moving resulting in serious injury.

• Handle pin must be installed prior to moving generator.

FUEL

TANK

WARNING Fuel and its vapors are extremely flammable

and explosive which could cause burns, fire or explosion resulting in death or serious injury.

WHEN ADDING FUEL

• Turn generator engine OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank. Allow space for fuel expansion.

• If fuel spills, wait until it evaporates before starting engine.

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

• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

• DO NOT light a cigarette or smoke.

High Altitude

At altitudes over 5,000 feet (1524 meters), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased performance, increased fuel consumption, and increased emissions. See an authorized dealer for high altitude adjustment information. Operation of the engine at altitudes below 2,500 feet (762 meters) with the high altitude kit is not recommended.

Attach Negative Battery Cable

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.

The sealed battery on the generator pre–installed except for the negative (black) battery cable.

To install:

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

2. Using an 8 mm or 5/16” socket wrench, remove screw (A), lock washer (B) and flat washer (C) on negative battery terminal.

3. Slide lock washer, flat washer and negative battery cable (D) over screw as shown.

4. Reattach screw to negative battery terminal and tighten.

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

NOTICE If your battery is discharged, charge prior to use following the instructions in the section Battery Charger.

Attach Extend-a-panel™

The Extend-a-panel™ can be connected to the generator directly or with the provided 20 Amp, 25 ft. (7.6 m) accessory cord. To connect the Extend-a-panel™ directly to the generator, follow these instructions:

1. Twist knob (E) on main panel to horizontal position.

2. Place hole at top of Extend-a-panel™ over knob on main panel.

3. Twist knob to vertical position to lock Extend-a-panel™ onto main panel.

4. Connect Extend-a-panel™ twistlock to small twistlock cord under main panel on generator.

5. Connect Extend-a-panel™ two-pin connector to small two-pin connector cord under main panel on generator.

WARNING Battery posts, terminals and related

accessories contain lead and lead compounds - chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

10 troybilt.com

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 (the neutral is bonded to the generator frame).

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.

Generator Location

Carbon Monoxide Poisoning

Operate this product ONLY outside far away from windows, doors and vents to reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces. Install/maintain battery-operated carbon monoxide alarms or plug-in carbon monoxide alarms with battery back-up according to the manufacturer’s instructions. DO NOT run this product inside homes, garages, basements, crawlspaces, sheds, or other partially-enclosed spaces even if using fans or opening doors and windows for ventilation. ALWAYS place this product downwind and point the engine exhaust away from occupied spaces.

Risk of Fire Clearances

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in death or serious injury.

• Keep at least 5 ft. (1.5 m) clearance on all sides of generator including overhead.

WARNING

Generator voltage could cause electrical shock or burn resulting in death or serious injury.

• Use approved transfer equipment to prevent backfeed by isolating generator from electric utility workers.

• When using generator for backup power, notify utility company.

• 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 or wet weather.

• 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.

Exhaust Port

Pointed away from

occupied spaces

Features and Controls

Generator

Read this Operator’s Manual and safety rules before operating your generator.

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

A - Main Control Panel — Permanently affixed to generator.

See Control Panel on next page.

B - Extend-a-panel™ — May be removed and connected to

generator with accessory cord for remote operation. See Control Panel on next page.

C - Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen.

D - Twistlock Connector — Used to connect Extend-a-

panel™ directly to generator or with provided accessory cord.

E - 2 Pin Connector — Plug in to sense current for dual load

monitoring on Extend-a-panel™.

F - Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

G - Accessory Cord — Extend-a-panel™ can be connected to

generator with provided 20 Amp, 25 ft. (7.6 m) accessory cord.

H - Identification Label — Provides model, revision and

serial number of generator. Please have these readily available when calling for assistance.

J - Air Cleaner — Protects engine by filtering dust and

debris out of intake air.

K - Recoil Starter — Used to start the engine manually. L - Oil Fill Cap — Check and add engine oil here. M - Fuel Valve — Used to turn fuel supply on and off to

engine.

N - Fuel Tank — Capacity of 8.5 U.S. gallons (32.2 l).

Items Not Shown: Engine Identification — Provides model, type and code of

engine. Please have these readily available if calling for assistance.

Oil Drain Plug — Drain engine oil here.

12 troybilt.com

Control Panel

Read this Operator’s Manual and safety rules before operating your generator.

Compare the illustrations with your control panel, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

A - 120 Volt AC, 20 Amp, GFCI Duplex Receptacles — May

be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting, appliance, tool and motor loads.

B - On/Off Switch — Set this switch to on (I) before starting

engine. Set switch to off (O) to shut off engine.

C - Battery Float Charger Jack — Use battery float charger

jack to keep the starting battery charged and ready for use.

D - Display Button — Push to scroll through LCD screens

on Extend-a-panel™. Also push and hold for a minimum of 3 seconds to reset maintenance reminders and security features.

E - Choke Control — Used when starting a cold engine. F - Start Switch — Push and hold in “Start” position for a

maximum of 5 seconds during each start attempt, until engine starts.

G - Circuit Breakers (AC) — The 120 Volt AC, 20A GFCI

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

H - Rocker Switch Main Circuit Breaker — The

120/240 Volt AC, 30A locking receptacle is provided with a rocker switch circuit breaker to protect generator against electrical overload.

J - 120/240 Volt AC, 30 Amp Locking Receptacle — May 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.

K - Rocker Switch Cordset Circuit Breaker — The cordset

on main panel is provided with a double pole rocker switch circuit breaker to protect generator against electrical overload.

Battery Charger

Use battery float charger jack to keep the starting battery charged and ready for use. Battery charging should be done in a dry location, such as inside a garage.

1. Plug charger into unit’s “Battery Float Charger” jack, which is located above on/off switch. Plug battery charger into a 120 Volt AC wall receptacle.

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

NOTICE See Battery Maintenance for additional information.

Cord Sets and Receptacles

Use only high quality, well-insulated, grounded extension cords with the generator’s receptacles. Inspect extension cords before each use.

Check the ratings of all extension cords before you use them. Check the operator’s manuals of devices for the manufacturer’s recommendations.

A double pole rocker switch circuit breaker is provided to protect the locking receptacle. If this circuit breaker is tripped, all receptacles are disconnected.

120/240 Volt AC, 30 Amp, Locking Receptacle

Use a NEMA L14-30 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volt AC loads at 30 Amps (or greater). You can use the same 4-wire cord if you plan to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 7,000 watts of power (7.0 kW) at

29.1 Amps for 240 Volts or two independent 120 Volt loads at 29.1 Amps each. The outlet is protected by a two pole rocker switch circuit breaker.

NOTICE

Receptacles may be marked with rating value

greater than generator output capacity.

• NEVER attempt to power a device requiring more amperage than generator or receptacle can supply.

• DO NOT overload the generator. See Don’t Overload Generator.

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

WARNING Damaged or overloaded electrical cords

could overheat, arc, and burn resulting in death or serious injury.

• ONLY use cords rated for your loads.

• Follow all safeties on electrical cords.

• Inspect cord sets before each use.

14 troybilt.com

Extend-a-panel™

A double pole rocker switch circuit breaker on the main panel is provided to protect the cordset off main panel. If this circuit breaker is tripped, all power from cordset is disconnected.

120 Volt AC, 20 Amp, GFCI Duplex Receptacles

The Extend-a-panel™ has two 120 Volt, 20 Amp GFCI duplex receptacles. Each receptacle is protected against overload by push-to-reset circuit breakers.

Use each receptacle to operate 120 Volt AC, single-phase, 60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20 Amps of current. Use cord sets that are rated for 125 Volt AC loads at 20 Amps (or greater). Inspect cord sets before each use.

Ground Fault Protection

The duplex receptacles are equipped with Ground Fault Circuit Interrupter (GFCI) protection. This device meets applicable federal, state and local codes. The generator’s locking receptacle is not protected by a Ground Fault Circuit Interrupter (GFCI).

The GFCI protects against electrical shock that may be caused if your body becomes a path which electricity travels to reach ground. This could happen if you touch a “Live” appliance or wire, or are touching plumbing or other materials that connect to the ground.

When protected by a GFCI, one may still feel a shock, but the GFCI should cut current off quickly enough so that a person in normal health should not suffer any serious electrical injury.

Testing the GFCI

Test your GFCI outlet prior to each use, as follows:

• Push the “Test” button. The “Reset” button should pop

out, which should allow no power to reach the outlet. Use a test lamp in each outlet to test this.

• If the GFCI tests good, restore power by pressing the

“Reset” button firmly until it is fully in place and locks in that position. If the GFCI outlet does not reset

properly, do not use the outlet. Call or take your generator to a local service center.

• If the GFCI trips by itself at any time, reset and test the

outlet. If the reset button does not pop out when the

test button is pressed, do not use the outlet. Call or take your generator to a local service center.

Extend-a-panel™ Accessory Cord

The Extend-a-panel™ can be connected to the generator directly or with the provided 20 Amp, 25 ft. (7.6 m) accessory cord. When using the 25 ft. (7.6 m) accessory cord with the Extend-a-panel™, always make sure to follow all safeties and instructions on cord.

1. Disconnect Extend-a-panel™ twistlock from small

twistlock cord under main panel on generator.

2. Disconnect Extend-a-panel™ two-pin connector from

small two-pin connector cord under main panel on generator.

3. Connect Extend-a-panel™ twistlock and two-pin

connector to female end of accessory cord.

4. Connect male end of accessory cord twistlock and two-

pin connector to small cords under main panel on generator.

NOTICE DO NOT exceed a seperation length of 50 ft. (15.24 m) or a combination of two Extend-a-panel™ accessory cords. Use only with original replacement accessory cords.

WARNING

Generator voltage could cause electrical shock or burn resulting in death or serious injury.

• Contact with the hot and neutral conductor at the same time can cause electrical shock or burn, even if the circuit is GFCI protected.

• Before using the GFCI receptacle, ALWAYS push the test button to insure it works.

Extend-a-panel™ LCD

The Extend-a-panel™ also has a built in LCD display with alarm system to monitor the following features:

• Dual Load Monitor (Panel and Total)

• Maintenance Reminder

• Security Warning

• Generator Shutdown

Dual Load Monitor

The dual load monitor measures the wattage output of the Extend-a-panel™ 120V, 20A receptacles and will display “PANEL” along with bars and percentage of load. Each duplex receptacle will operate 120 Volt AC, single-phase, 60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20 Amps of current for a total of 4,800 watts (4.8 kW).

The “TOTAL” displays the wattage output of all receptacles on the main panel and Extend-a-panel™. The LCD will display “TOTAL” along with bars and percentage of load. If only the 120/240V, 30A receptacle is used, the LCD on the Extend-apanel™ will display “TOTAL” only.

If the wattage output of either the “PANEL” or “TOTAL” is between 90% and 100%, the text will flash. If either reaches 101%, the LCD display will change to “OVERLOAD REMOVE LOAD”. An audible beep will sound until enough load is removed and the wattage output is below 101%.

Maintenance Reminder

The Extend-a-panel™ also has a built in maintenance reminder to alert you to check oil, change air filter, change oil, and change spark plug. The LED will display the following screens for the different maintenance intervals:

• “CHECK OIL 8HRS HOLD TO RESET” after every

8 hours of operation.

• “AIR FILTER 25HRS HOLD TO RESET” after every

25 hours of operation.

• “CHANGE OIL 50HRS HOLD TO RESET” after every

50 hours of operation.

• “SPARK PLG 100HRS HOLD TO RESET” after every

100 hours of operation.

You must push and hold the display button on the Extend-apanel™ for a minimum of 3 seconds to reset the timer after each maintenance interval.

Security Warning

The Extend-a-panel™ has a built in security warning that sounds an audible beep when the generator shuts down or if the Extend-a-panel™ is disconnected from the generator. The LCD will display “GENERATOR SHUTDOWN” and sound an audible beep for 5 seconds. The LCD backlight will turn off when the audible beep stops.

The security warning can be turned off if desired. To turn the audible beep from the security warning off, push the display button to scroll through the maintenance screens until the LCD displays “SECURITY WRNG ON HOLD TO SET”. Push and hold the display button until the LCD displays “SECURITY WRNG OFF HOLD TO SET”.

NOTICE By turning the security warning off, the audible beep will also be turned off if the panel or generator is overloaded.

Generator Shutdown

In order for the generator shutdown feature to work as described in Security Warning, you must install 4 AAA batteries (not supplied) into the back of the Extend-a-panel™.

16 troybilt.com

Operation

Starting the Engine

NOTICE Always unplug the battery float charger before starting the generator.

Disconnect all electrical loads from the generator. Use the following start instructions:

1. Make sure unit is on a level surface.

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

2. Turn the fuel valve (A) to the “On” position.

3. Set on/off switch to on (I) position.

4. Pull choke handle out to choke ( ) position.

5A. For electric starting, push and hold the start switch in

“Start” position until generator starts. To prolong the life of starter components, DO NOT hold start switch in “Start” position for more than 5 seconds, and pause for at least 1 minute between starting attempts.

• If engine starts, proceed to step 7.

• If engine fails to start, proceed to step 6.

NOTICE If battery is discharged, use manual starting instructions.

5B. For manual starting, grasp recoil handle and pull

slowly until slight resistance is felt. Then pull rapidly one time only to start engine.

• If engine starts, proceed to step 7.

• If engine fails to start, proceed to step 6.

6. Push in the choke handle half way, and pull recoil handle twice or push and hold the start switch in the “Start” position as described in step 5A.

• If engine fails to start, repeat steps 4 thru 5.

7. As the engine warms up, gradually push choke handle in to run ( ) position.

NOTICE If engine floods, push choke handle all the way in to run ( ) position, and crank until engine starts.

NOTICE If engine starts after 3 pulls 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. If so, oil must be at proper level for engine to start.

WARNING Starter cord kickback (rapid retraction) will

pull hand and arm toward engine faster than you can let go which could cause broken bones, fractures, bruises, or sprains resulting in

serious injury.

• 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 plugged in and turned on.

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in death or

serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.

• Replacement parts must be the same and installed in the same position as the original parts.

Connecting Electrical Loads

1. Let engine stabilize and warm up for a few minutes after starting.

2. Ensure rocker switch circuit breakers on main panel are in “On” position.

3. Plug in and turn on the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads.

NOTICE When plugging into the 120 Volt receptacles on Extend-a-panel™, plug items to be powered in sequence as shown below.

NOTICE

• DO NOT connect 240 Volt loads to 120 Volt duplex receptacles.

• DO NOT connect 3-phase loads to generator.

• DO NOT connect 50 Hz loads to generator.

• DO NOT OVERLOAD THE GENERATOR. See Don’t Overload Generator.

NOTICE

Exceeding generators wattage/amperage capacity could damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

• 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 generator.

Stopping the Engine

1. Turn OFF and unplug all electrical 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. Push on/off switch to off (O) position.

4. Move fuel valve to “Off” position.

Low Oil Shutdown

If the engine oil drops below a preset level, an oil switch will stop the engine. Check oil level with dipstick.

If oil level is between ADD and FULL mark on dipstick:

1. DO NOT try to restart the engine.

2. Contact an Authorized Briggs & Stratton Service Dealer.

3. DO NOT operate engine until oil level is corrected.

If oil level is below ADD mark on dipstick:

1. Add oil to bring level to FULL mark.

2. Restart engine and if the engine stops again a low oil condition may still exist. DO NOT try to restart the engine.

3. Contact an Authorized Briggs & Stratton Service Dealer.

4. DO NOT operate engine until oil level is corrected.

Cold Weather Operation

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:

1. Make sure generator has clean, fresh fuel.

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

3. Use SAE 5W-30 oil.

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

5. Maintain generator following Maintenance Schedule in Maintenance section.

6. Shelter unit from elements.

WARNING Fuel and its vapors are extremely flammable

and explosive which could cause burns, fire or explosion resulting in death or serious injury.

• DO NOT stop engine by moving choke handle to “Choke”

position

().

18 troybilt.com

Creating a Temporary Cold Weather Shelter

1. For temporary shelter, the original shipping carton can be used.

2. Cut off top carton flaps and one long side of carton to expose muffler side of unit. If required, tape up other sides of carton to fit over generator as shown.

NOTICE If required, remove wheel kit to fit carton over generator as shown.

3. Cut appropriate slots to access receptacles of unit.

4. Face exposed end away from wind and elements.

5. Locate generator as described in the section Generator Location. Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.

6. Start generator as described in the section Starting the Engine, then place carton over generator. Keep at least 5 ft. (1.5 m) clearance on all sides of generator including overhead with shelter in place.

7. Remove shelter when temperatures are above 40°F [4°C].

8. Turn engine OFF and let cool two (2) minutes before refueling. Let any spilled fuel evaporate before starting engine.

Building a Cold Weather Shelter

1. Using non combustible material with a fire rating of at least one hour, build a shelter that will enclose three sides and the top of the generator. Make sure muffler side of generator is exposed.

NOTICE Contact your local building material supplier for non combustible materials with a fire rating of at least one hour.

NOTICE Be sure shelter can easily be repositioned for change in wind direction.

2. DO NOT enclose generator any more than shown. Shelter should hold enough heat created by the generator to prevent icing problem.

NOTICE If a wheel kit is installed on the generator, enlarge shelter accordingly.

3. Follow steps 3 through 8 as described previously in Creating a Temporary Cold Weather Shelter.

Wind

WARNING Exhaust heat/gases could ignite

combustibles, structures or damage fuel tank causing a fire, resulting in death or

serious injury. Contact with muffler area could cause burns resulting in serious injury.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

• Remove shelter when temperatures are above 40°F [4°C].

WARNING POISONOUS GAS HAZARD. Engine

exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You CANNOT

smell it, see it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas.

• Operate this product ONLY outside far away from windows, doors and vents to reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

• ALWAYS place this product downwind and point the engine exhaust away from occupied spaces.

If you start to feel sick, dizzy, or weak while using this product, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

+ 42 hidden pages