Troy-Bilt MF85 CT 30331 User Manual

Model No. 030331 (3550 Watt Portable Generator) Manual No. 202371GS Revision - (12/13/2006)

BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

JEFFERSON, WISCONSIN, U.S.A.

Questions? Help is just a moment away!

Call: Generator Helpline

1-888-611-6708 M-F 8-5 CT

Operator’s Manual

WARNING

Failure to read and follow the

Operator’s Manual and all operating

instructions can result in death, bodily

injury, and/or property damage. Save

this manual for future reference.

0 3 0 3 3 1

Briggs & Stratton Power Products Group, LLC 900 North Parkway Jefferson, WI 53549

Copyright © 2006 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.

Troy-Bilt® is a registered trademark of MTD Products Inc and is used under license to Briggs & Stratton Power Products.

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. Because Troy-Bilt does not necessarily know all the applications this generator could be used for, it is important that you read and understand these instructions thoroughly before attempting to start or operate this equipment. Save these 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpack Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Shipment Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Install Wheel Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Add Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Add Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connecting to a Building’s Electrical System. . . . . . . . . . . . . . . . . . . . . . . . 7

Generator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Cord Sets and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Generator Adapter Cord Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting Electrical Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Stopping the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Don’t Overload Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warranties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Emissions Control System Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Generator Owner Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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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.

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.

Safety Rules

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The safety alert symbol ( ) is used with a signal word (DANGER, WARNING, CAUTION), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

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.

Hazard Symbols and Meanings

A - Explosion F - Hot Surface B - Fire G - Flying Objects C - Electric Shock H - Moving Parts D - Toxic Fumes J - Read Manual E - Kickback

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SAVE THESE INSTRUCTIONS

NOTICE

Exceeding generators wattage/amperage capacity can 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.

A B C

D E

G H

WARNING

Running engine gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near the bedrooms.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

• DO NOT start or run engine indoors or in an enclosed area, (even if windows and doors are open), including the generator compartment of a recreational vehicle (RV).

Using a generator indoors WILL KILL YOU IN MINUTES.

Exhaust contains carbon monoxide, a poison gas you cannot see or smell.

NEVER use in the home or in partly enclosed areas such as garages.

ONLY use outdoors and far from open windows, doors, and vents.

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

Generator produces hazardous voltage. Failure to isolate generator from power utility can

result in death or injury to electric utility workers due to backfeed of electrical energy.

• 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 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

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises, or sprains could result.

• 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

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

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 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.

• 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 tip engine or equipment at angle which causes fuel to spill.

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

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

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

• 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 can ignite fuel vapors.

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.

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WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• 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.

• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1C 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 laws.

WARNING

Starter and other rotating parts can entangle hands, hair, clothing, or accessories.

• NEVER operate generator without protective housing or covers.

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

• Tie up long hair and remove jewelry.

WARNING

Unintentional sparking can result in fire or electric shock.

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.

CAUTION

Excessively high operating speeds increase risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

• 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.

NOTICE

Improper treatment of generator can 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.

NOTICE

Exceeding generators wattage/amperage capacity can 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.

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 data tag available. See Features and Controls for data tag 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.

Shipment Contents

The generator is supplied with:

• Engine oil bottle

• Operator’s manual

• Adapter cord set

• Wheel kit

Install Wheel Kit

NOTE: Wheel kit is not intended for over-the-road use.

You will need the following tools to install these components:

• 13 mm wrench

• Socket wrench with a 13 mm socket

• Pliers

• Safety glasses

Install the wheel kit as follows:

1. Tip generator so that engine end is up.

2. Slide axle (A) through both mounting brackets.

3. Place a wheel (B) on each side as shown.

4. Place a washer (C) on axle and then place an e-ring (D)

in axle groove.

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

6. Repeat steps 4 and 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Line up holes in support leg (E) with holes in generator frame.

9. Attach support leg using two short capscrews (M8 x 16 mm) (F) and two locking hex nuts (G). Tighten with a 13 mm socket and wrench.

10. Return generator to normal operating position (resting on wheels and support leg).

CAUTION

E-rings can cause eye injury. E-rings can spring back and become airborne

when installing or removing.

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

Add Engine Oil

1. Place generator on a flat, level surface.

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

NOTE: See the section Oil to review oil recommendations. Verify provided oil bottle is correct viscosity for current ambient temperature.

3. Using oil funnel (optional), slowly pour contents of provided oil bottle into oil fill opening.

4. Replace oil fill cap and fully tighten.

Add Fuel

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

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

• Gasoline with up to 10% ethanol (gasohol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable.

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 (A) to fuel tank (B). Be

careful not to overfill. Allow about 1.5" (4 cm) of tank space (C) for fuel expansion.

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

High Altitude

At higher altitudes (over 5,000 feet), 85 octane/85 AKI (89 RON) gasoline is recommended. High-altitude use may require a carburetor jet kit to improve performance and decrease fuel consumption. See an authorized service center for more information.

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NOTICE

Improper treatment of generator can 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.

NOTICE

Avoid generator damage. Failure to follow Operator’s Manual for fuel

recommendations voids warranty.

• DO NOT use unapproved gasoline such as E85.

• DO NOT mix oil in gasoline.

• DO NOT modify engine to run on alternate fuels.

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN ADDING 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 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.

• DO NOT light a cigarette or smoke.

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 or other alternative power sources and must comply with all applicable laws and electrical codes.

Generator Location

Clearances and Air Movement

Place generator outdoors in an area that will not accumulate deadly exhaust gas. DO NOT place generator where exhaust gas (A) 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. Prevailing winds and air currents should be taken into consideration when positioning generator.

WARNING

Generator produces hazardous voltage. Failure to isolate generator from power utility can

result in death or injury to electric utility workers due to backfeed of electrical energy.

• 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 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 can ignite combustibles, structures or damage fuel tank causing a fire.

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

Using a generator indoors WILL KILL YOU IN MINUTES.

Exhaust contains carbon monoxide, a poison gas you cannot see or smell.

NEVER use in the home or in partly enclosed areas such as garages.

ONLY use outdoors and far from open windows, doors, and vents.

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Features and Controls

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 - 120 Volt AC, 20 Amp, 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 - Air Cleaner — Protects engine by filtering dust and

debris out of intake air.

C - Choke Lever — Used when starting a cold engine. D - Data Tag — Provides model, revision, and serial number

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

E - Circuit Breakers (AC) — Push-to-reset circuit breakers

are provided to protect the generator against electrical overload.

F - Engine Identification — Provides model, type and code

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

G - Fuel Tank — Capacity of four (4) U.S. gallons (15 L). H - Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

J - Oil Drain Plug — Drain engine oil here. K - Oil Fill Cap — Check and fill engine with oil here. L - Recoil Starter — Used to start the engine. M - Rocker Switch — Set this switch to “On” before using

recoil starter. Set switch to “Off” to stop engine.

N - Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen.

Cord Sets and Receptacles

Use only high quality, well-insulated, grounded extension cords with the generator’s 120 Volt duplex receptacle. Inspect extension cords before each use.

Check the ratings of all extension cords before you use them. Extension cord sets used should be rated for 125 Volt AC loads at 20 Amps or greater for most electrical devices. Some devices, however, may not require this type of extension cord. Check the operator’s manuals of those devices for the manufacturer’s recommendations.

Keep extension cords as short as possible to minimize voltage drop.

120 Volt AC, 20 Amp, Duplex Receptacles

Each duplex receptacle is protected against overload by a push-to-reset circuit breaker.

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).

Generator Adapter Cord Set

The generator comes with a 25' generator adapter cord set designed to provide two sets of 120 Volt, 20 Amp outlets from one 120 Volt, 20 Amp duplex receptacle.

The maximum load on each outlet is 20 Amps. The maximum total load on both black wire outlets or white stripe wire outlets is 20 Amps.

NOTE: Follow all safety precautions when connecting any extension cord or device to the generator.

WARNING

Overloaded electrical cords can overheat, arc, and burn resulting in death, bodily injury, and/or property damage.

• ONLY use cords rated for your loads.

• Follow all safeties on electrical cords.

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”.

Operation

Starting the Engine

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

1. Make sure unit is on a level surface.

IMPORTANT: 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 fuel valve to “On” position. Fuel valve handle

should be vertical (pointing toward ground) for fuel to flow.

3. Push choke lever to “Choke” position.

4. Push engine rocker switch to “On”.

5. Grasp recoil handle and pull slowly until slight resistance is felt. Then pull handle rapidly to overcome compression, prevent kickback, and start engine.

IMPORTANT: If excessive fuel is present in the air/fuel mixture causing a “flooded” condition, move the choke lever to “Run” ( ) position and pull the handle repeatedly until the engine starts.

6. Move choke lever to “Run” ( ) position a short

distance at a time over several seconds in warm weather or minutes in cold weather. Let engine run smoothly before each change. Operate with choke in “Run” position.

NOTE: If the engine starts after 3 pulls but fails to run, or if the unit shuts down during operation, make sure the unit is on a level surface and check for the proper oil level in the crankcase. This unit may be equipped with a low oil protection device.

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WARNING

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises, or sprains could result.

• 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

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• 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.

Connecting Electrical Loads

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

2. Plug in and turn on the desired 120 Volt AC, single phase, 60 Hz electrical loads.

NOTE:

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

• DO NOT connect 3-phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. See Don’t Overload 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 engine rocker switch to “Off” position.

4. Move fuel valve to “Off” position.

WARNING

Backfire, fire or engine damage could occur.

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

position.

NOTICE

Exceeding generators wattage/amperage capacity can 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.

Don’t Overload Generator

Capacity

You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps:

1. Select the items you will power at the same time.

2. Total the rated (running) watts of these items. This is the amount of power your generator must produce to keep your items running. See Wattage Reference Guide.

3. Estimate how many surge (starting) watts you will need. Surge wattage is the short burst of power needed to start electric motor-driven tools or appliances such as a circular saw or refrigerator. Because not all motors start at the same time, total surge watts can be estimated by adding only the item(s) with the highest additional surge watts to the total rated watts from step 2.

Example:

Total Rated (Running) Watts = 3075 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875

Power Management

To prolong the life of your generator and attached devices, it is important to take care when adding electrical loads to your generator. There should be nothing connected to the generator outlets before starting its engine. The correct and safe way to manage generator power is to sequentially add loads as follows:

1. With nothing connected to the generator, start the engine as described in this manual.

2. Plug in and turn on the first load, preferably the largest load you have.

3. Permit the generator output to stabilize (engine runs smoothly and attached device operates properly).

4. Plug in and turn on the next load.

5. Again, permit the generator to stabilize.

6. Repeat steps 4 and 5 for each additional load.

NEVER add more loads than the generator capacity. Take special care to consider surge loads in generator capacity, as described above.

* Wattages listed are approximate only. Check tool or appliance for actual wattage.

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Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts

Window Air Conditioner

1200 1800

Refrigerator 800 1600 Deep Freezer 500 500 Television 500 — Light (75 Watts) 75 —

3075 Total

Running Watts

1800 Highest

Surge Watts

Wattage Reference Guide

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt 75 — Deep Freezer 500 500 Sump Pump 800 1200 Refrigerator/Freezer - 18 cf 800 1600 Water Well Pump - 1/3 hp 1000 2000

Heating/Cooling

Window AC - 10,000 BTU 1200 1800 Window Fan 300 600 Furnace Fan Blower - 1/2 hp 800 1300

Kitchen

Microwave Oven - 1000 Watt 1000 — Coffee Maker 1500 — Electric Stove - Single Element 1500 — Hot Plate 2500 —

Family Room

DVD/CD Player 100 — VCR 100 — Stereo Receiver 450 — Color Television - 27 in 500 — Personal Computer w/17 in

monitor

800 —

Other

Security System 180 — AM/FM Clock Radio 300 — Garage Door Opener - 1/2 hp 480 520 Electric Water Heater - 40 gallon 4000 —

DIY/Job Site

Quartz Halogen Work Light 1000 — Airless Sprayer - 1/3 hp 600 1200 Reciprocating Saw 960 960 Electric Drill - 1/2 hp 1000 1000 Circular Saw - 7-1/4 in 1500 1500 Miter Saw - 10 in 1800 1800 Table Planer - 6 in 1800 1800 Table Saw/Radial Arm Saw - 10 in 2000 2000 Air Compressor - 1-1/2 hp 2500 2500

Maintenance

Maintenance Schedule

Follow the hourly or calendar intervals, whichever occurs first. More frequent service is required when operating in adverse conditions noted below.

Change oil after the first (5) operating hours and every 50 hours or every year, whichever occurs first, thereafter. Change oil sooner when operating under dirty or dusty conditions.

Replace more often under dirty or dusty conditions.

General Recommendations

Regular maintenance will improve the performance and extend the life of the generator. See any authorized dealer for service.

The generator’s warranty does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain your generator.

All service and adjustments should be made at least once each season. Follow the requirements in the Maintenance Schedule chart above.

NOTE: Once a year you should clean or replace the spark plug and replace the air filter. A new spark plug and clean air filter assure proper fuel-air mixture and help your engine run better and last longer.

Emissions Control

Maintenance, replacement, or repair of the emissions control devices and systems may be performed by any non-road engine repair establishment or individual. See Emissions Control System Warranty in Warranty section.

Generator Maintenance

Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture, or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material.

NOTE: DO NOT use water or other liquids to clean generator. Liquids can enter engine fuel system, causing poor performance and/or failure to occur. In addition, if liquid enters generator through cooling air slots, some of the liquid will be retained in voids and cracks of the rotor and stator winding insulation. Liquid and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

Cleaning

Daily or before use, look around and underneath the generator for signs of oil or fuel leaks. Clean accumulated debris from inside and outside the generator. Keep the linkage, spring and other engine controls clean. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed.

Engine parts should be kept clean to reduce the risk of overheating and ignition of accumulated debris:

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt and debris.

Maintenance Schedule - Fill in Dates as You Complete Regular Service

Maintenance Task Service Intervals Service Dates

Before Each

Use

Every 25 Hours

or Yearly

Every 50 Hours

or Yearly

Every 100 Hours

or Yearly

Clean debris

Check oil level

Change engine oil

Service air cleaner

Service spark plug

Clean cooling system

Prepare for storage

If unit is to remain idle for longer than 30 days.

NOTICE

Improper treatment of generator can damage it and shorten its life.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

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