Troybilt 01923 Owner's manual
- Category
- Power generators
- Type
- Owner's manual
This manual is also suitable for
O
m m IWm
Owner's Manual / Manual del Propietario
Portable Generator / Generador Port_til
Model / Modelo 01923
®
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
IMPORTANTE: LEYO LA SEGURIDAD LAS ORDENES Y LAS INSTRUCCIONES DETENIDAMENTE
Questions? Preguntas?
Helpline - 1-888-611-6708 M-F 8-5 CT
Troy-Bilt@ isa registered trademark of MTD and isusedunder licenseto Briggs& Stratton Power Products.
Troy-Bilt_ esuna marca registrada registradade MTD y se usaabajo licencia a Briggs& Stratton Power Products.
BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC
JEFFERSON, WISCONSIN, U.S.A.
Printed in USA ManualNo. 192411GS Revision I (02/05/2003)
!
Safety Rules
TABLE OF CONTENTS
SafetyRules.................................. 2-4
Know Your Generator ........................... 5
Assembly.................................... 6-7
Operation .................................. 8-I0
Maintenance ............................... 11-13
Storage ................................... 13-14
Troubleshooting ............................... 15
Wiring Diagram ............................... 16
Replacement Parts........................... 17-24
Emmision Control System Warranty ............... 25
Warranty ............................... Last Page
EQUIPMENT
DESCRIPTION
_Read this manual carefully and become
familiar with your generator. Know its
applications, its limitations and any hazards
involved.
The generators are an engine-driven, revolvingfield,
alternating current (AC) generator. It was designedto
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.
CAUTION! DO NOT exceedthe generator's
wattage/amperagecapacity.See"Don't Overload
Generator" on page 10.
Every effort hasbeen madeto ensure that information inthis
manualisaccurateand current. However, we reservethe
right to change,alter or otherwise improve the product and
this document at anytime without prior notice.
The EmissionControl Systemfor this generator iswarranted
for standardsset by the EnvironmentalProtection Agency.
For warranty informationrefer to the engineowner's manual.
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 (_.) isusedwith a signalword
(DANGER, CAUTION, WARNING), apictorial and/or a
safety messageto alert you to hazards.DANGER
indicatesa hazardwhich, if not avoided, will result in death
or serious injury.WARNING indicates a hazardwhich, if
not avoided, couldresult in death or serious injury.
CAUTION indicates a hazard which, if not avoided,might
result in minor or moderate injury. CAUTION, when
usedwithout the alert symbol, indicates a situation that
could result in equipment damage.Follow safety messages
to avoid or reduce the risk of injury or death.
In the State of California a spark arrester is required by law
(Section 4442 of the California PublicResourcesCode).
Other states mayhavesimilar laws.Federallawsapplyon
federal lands.If you equip the muffler with a spark attester,
it must be maintained in effectiveworking order.
WARNING
The engine exhaust from this product contains I
chemicals known to the State of California to cause
cancer, b rth defects, or other reproduct ve harm.
Section 1: Safety Rules
DANGER
Operate generator ONLY outdoors.
Keepat least 2 feet of clearance on all sidesof generator for
adequate ventilation.
DO NOT operategeneratorinsideanybuildingor enclosure,
includingthe generator compartmentof a recreationalvehicle(RV).
DANGER
National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
localgrounding requirements.
DANGER
When usinggenerator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use aground circuit fault interrupter (GFCt) in anydamp or
highly conductive area, such asmetal 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
inwater, while barefoot, or while handsor feet are wet.
DO NOT allow unqualified persons or children to operate or
service generator.
IKWARNING
Thisgenerator does not meet U. S.Coast Guard Regulation
33CFR-183and should not be usedon marine applications.
Failureto use the appropriate U. S.Coast Guard approved
generator could result in bodily injuryand/or property
damage.
WARNING
WHEN ADDING FUEL
Turn generator OFF and let it cool at least 2 minutes before
removing gas cap. Loosen cap slowly 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.
_HEN 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.
'HEN TRANSPORTING OR REPAIRING EQUIPMENT
Transportlrepair with fuel tank EMPTY or with fuel shutoff
valve OFE
Disconnect spark plug wire.
_HEN 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.
DANGER
DO NOT allow anyopen flame, spark, heat, or lit cigarette
during and for several minutes after charginga battery.
Wear protective goggles, rubber apron, and rubber gloves.
Section 1: Safety Rules
WARNING
;ENERATOR
Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
, WARNING
DO NOT touch hot surfaces.
Allow equipment to cool before touching.
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.
CAUTION
See "Don't Overload Generator" on page 10.
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.
CAUTION
Use generator only for intended uses.
tf you have questions about intended use, ask dealer or call
1-888-611-6708.
Operate generator only on level surfaces.
DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
DO NOT insert anyobiects through cooling slots.
If connected devices overheat, turn them off and disconnect
them from generato_
Shut off generator if.'
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
2
Features and Controls
KNOW YOUR GENERATOR
Read this owner's manual and safety rules before operating your generator.
Compare the illustrationswith your generator to familiarize yourself with the locationsof various controls and
adjustments. Savethis manualfor future reference.
SparkPlug (inside FuelTank
cover)
Choke Lever
Air Cleaner
Fuel Shut-Off Valve
EngineON/OFF Switch
12Volt DC, 8.3 Amp
Accessory Jack
Circuit Breaker (AC)
120Volt AC, 7.5 Amp
Receptacle
Recoil Starter
Oil Fill/Drain
(inside cover
Data Tag
12 Volt DC, 8.3 Amp Accessory Jack -- May be used
to power 12Volt DC electrical devicesor recharge 12Volt
DC batteries.
120 Volt AC, 7,5 Amp Receptacles -- May be used to
supply electrical power for the operation of 120Volt AC,
single phase,60 Hz electrical lighting,appliance,tool and
motor loads.
Air Cleaner-- Usesa foam element to limitthe amount
of dirt and dust that enters the engine.
Choke Lever -- Used to manuallyprovide proper starting
mixture when engine iscold.
Circuit Breaker (AC) -- Receptaclesare provided with a
push-to-reset circuit breaker to protect the generator
againstelectrical overload.
Data Tag -- Provides model, revision and serial number
of generator. Pleasehavethese readily availablewhen calling
forassistance.
Grounding Lug
Engine ON/OFF Switch -- Used to stop a running
engine.
Fuel Shut-Off"Valve -- Use this valve to turn the fuel
supplyon and off.
Fuel Tank -- Capacity of 1.2U.S.gallons (4.5 liters)of
fuel.
Grounding Lug -- Usethis connection to properly
ground the generator. See"Grounding the Generator" on
page7.
Oil Fill/Drain -- Access to oil fill dipstick and engine oil
drain plug.
Recoil Starter -- Used for starting the engine.
Spark Plug -- Access to engine spark plug.
ASSEMBLY
Carton Contents
Check allcontents. Ifany parts are missingor damaged,call
the generator helpline at 1-888-611-6708. Shippedwith
your generator is:
• Main unit
• Oil bottle
• Owner's manual
• Battery charge cables
BEFORE STARTING ENGINE
Add Oil
NOTE: When adding oil to the engine crankcase in the
future, use only high quality detergent oil rated with API
service classification SG,SF/CC, CD. Select the oil's
viscosity grade according to your expected operating
temperature:
colder _ 32°F ._warmer
SAE lOW30 SAE30
SAE 10W-30 is recommended for general all temperature
use. Multi-viscosity oils (lOW30, etc.) improvestarting in
cold weather, but these oils will result in increasedoil
consumption. Check your engine oil level more frequently
to avoid possible damagefrom running low on oil.
To Add Engine Oil:
• Placethe generator on a level surface.
• Remove the oil fill cover.
• Remove oil filler capand wipe dipstick clean (Figure I).
Oil Filler Neck
• Ifthe oil level isnot at the point of overflowing from the
oil filler neck, slowly fill enginewith recommended oil.
• Reinstalloil filler capand tighten securely.
• Replacethe oil fill cover.
• Check the engineoil level before starting each time
thereafter.
Add Fuel
A ARNING! NEVERfill fuel tank indoors.NEVER
fillfuel tank when engineisrunning or hot. Allow unit
to cool for two minutesbefore refueling.DO NOT
light a cigaretteor smokewhen fillingthe fuel tank.
_IL WARNING! DO NOT overfill the fuel tank.
Always allow room for fuel expansion.
• Use cleanfresh UNLEADED fuel with a pump rating of
86 or higher. DO NOT usepremium or leaded fuel. DO
NOT mix oil with fuel.
• Clean area around fuel fill cap, remove cap.
• Check the fuel level.
• If fuel levelislow, slowly add recommended fuel to fuel
tank, up to the shoulder of the fuel strainer (Figure 2).
Be careful not to overfill (there should be no fuel inthe
filler neck).
NOTE: Occasionally clear the fuel strainer of anydirt,
rust, or other particulate matter.
• Install fuel cap and wipe up any spilled fuel.
Occasionally you may hear a light "spark knock" or
"pinging" (metallic rapping noise) while operating under
heavy loads. This isno causefor concern. If spark knock or
pinging occurs at a steady engine speed under normal load,
changebrands of fuel or obtain a higher octane rated fuel.
If pingingor spark knock persists, see your local Briggs&
Stratton repair center.
Operation
GROUNDING THE
G EN ERATO R
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes mayalso require proper grounding of the
unit. For that purpose, a GROUNDING WING NUT is
provided on the generator housing (Figure 3).
Grounding Wing Nut
Generally, connecting a No. 12AWG (American Wire
Gauge) stranded copper wire to the grounding wingnut
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against electrical
shock. Becareful to keepthe grounding wire attached after
connecting the stranded copper wire. However, localcodes
may vary widely. Consult with a localelectrician for
grounding requirements in your area.
Properly grounding the generator helps prevent electrical
shock if aground fault condition exists in the generator or
in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in
ungrounded devices.
OPERATING THE
G EN ERATO R
A AUTION! NEVER start or stop the engine with
electrical loadsconnected to the unit and with the
connected devicesturned ON.
Starting the Engine
Disconnect all electrical loadsfrom the generator. Use the
following start instructions:
• Be sure the spark plug wire is attached to the spark plug.
• Turn the fuel valve to the "Open" position (fully
clockwise) (Figure 4).
• Slidethe choke leverto the "Choke" position (all the
way to the right) (Figure 5).
• Place the engine switch in the "On" position (Figure 6).
• Grasp starter grip and slowly pull the rope untilyou feel
some resistance,then pull the cord out with a rapid full
arm stroke. Let rope return slowly. DO NOT let rope
"snap back" againstthe unit.
Section 4: Operation
NOTE: If engine starts after 3 pulls, but fails to run for
more than l0 seconds, checkfor proper oil level in
crankcase.This unit is equipped with a Oil Alert System
(see page8).
• Slide the choke lever leftto the "Run" position asthe
engine warms up.
NOTE: Under no loadconditions, the engine speed may
vary slightly faster or slower until engine temperatures
stabilize.
_ CAUTION! Breathing Hazard! NEVER run
engine in enclosed poorly ventilated areas.Engine
exhaust contains carbon monoxide, an odorless and
deadlygas.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• DO NOT connect 240 Volt loadsto 120Volt receptacles.
• DO NOT connect 3-phase loads to the generator.
• DO NOT connect 50 Hz loadsto the generator.
• Plug in and turn on the desired 120Volt AC, single
phase, 60 Hertz electrical loads.
• DO NOT OVERLOAD GENERATOR. Add up the
rated watts (or amps) of all loadsto be connected at
one time. This total should not be greater than the rated
wattage/amperagecapacity of the generator. See "Don't
Overload Generator" on page 10.
Stopping the Engine
• Unplug all electrical loadsfrom the unit. NEVERstart or
stop engine with electrical devices pluggedin and turned
on.
• Let engine run at no-load for two minutes to stabilize
the internal temperatures.
• Move engineswitch to the "Off" position.
• Turn the fuel valveto the "Close" position (fully
counterclockwise).
NOTE: In an emergency,stop the engine by moving the
engine switch to the "Off' position.
Oil Alert System
The Oil Alert Systemisdesignedto prevent engine damage
caused by an insufficient amount of oil in the crankcase.
Before the oil levelin the crankcase can fall below a safe
limit, the Oil Alert Systemwill automatically shut clown the
engine (the engine switch will remain in the "On" position).
Ifthe Oil Alert System shuts clown the engine, add engine
oil.
Charging a Battery
_ ARNING! Storage batteries emit explosive gas
while charging that remains around a battery for a
long time after it hasbeen charged. The slightest
spark can ignite the gas,causingan explosion that
can shatter the battery and cause blindnessor
other injury.
_ WARNING! DO NOT permit smoking, open
flame, sparks or any other source of heat around a
battery. DO NOT use a lighter or other flame for
checking battery fluid levels. Wear protective
goggles, rubber apron and rubber gloves when
working around a battery. Battery electrolyte fluid is
an extremely caustic sulfuric acid solution that can
cause severe burns. DO NOT permit fluid contact
with eyes, skin, clothing, etc. If spill occurs, flush
area with clear water immediately.
Your generator hasthe capability of recharging a discharged
12Volt automotive or utility style storage battery. DO
NOT usethe unit to charge any6 Volt batteries. DO NOT
usethe unit to crank an engine havinga discharged battery.
To recharge 12 Volt batteries, proceed as follows:
• If necessary,cleanbattery posts or terminals.
• Check fluid levelin allbattery cells. If necessary,add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap water.
• If the battery isequipped with vent caps,make sure they
are installed and are tight.
• Connect battery charge cableconnector plug to the
12Volt DC panel receptacle.
• Connect battery charge cableclamp with red handle to
battery post or terminal indicated by Positive, POS or
(+) (Figure7).
I:|
Section 4: Operation
Red Lead
To 12 Volt DC Panel
Receptacle
= m
Positive Negative
• Connect battery charge cable clamp with black handle
to battery post or terminal indicatedby Negative,
NEG, or (-) (Figure7).
• Start generator. Let the engine run while battery
recharges.
• When battery hascharged,shut down engine (see
"Stopping The Engine")
NOTE: Use an automotive hydrometer to test battery
state of chargeand condition. Follow the hydrometer
manufacturer's instructionscarefully. Generally, a battery is
considered to be at 100%state of charge when specific
gravity of its fluid (asmeasured by hydrometer) is 1.260or
higher.
CONNECTOR PLUGS
120 Volt AC, 15 Amp Receptacle
Eachoutlet socket isprotected againstoverload by a
7.5Amp push-to-reset circuit breaker. Use each receptacle
to operate 120Volt AC, single phase,60 Hz electrical loads
requiring up to 1,000watts (I.0 kW) of power (Figure8).
_ AUTION! Although each receptacle is rated
for 120Volts at 15Amps (I,440 watts or 1.44kW),
the generator israted for a total of 1,000watts.
Powering loads that exceed the wattage capacity of
the generator can damageit or cause serious
injuries.The total of loadspowered through these
receptacles should not exceed 7.5 Amps.
12 Volt DC Accessory Jack
This receptacle allows you to recharge a 12Vott
automotive or utilitystyle storage battery with the battery
charge cable provided. Camping-style air pumps, lanterns,
fans,or other 12Volt devices havinga cigarette lighter-type
plug may also be powered by this outlet (Figure9).
This receptacle can not recharge 6 Volt batteries and can
not be usedto crank an engine havinga discharged battery.
See "Charging a Battery" (page 8) before attempting to
rechargea battery.
EXTENSION CORDS
Use only high quality,well-insulated, extension cords with
the generator's 120Volt electrical receptacles.
Check the ratings of all extension cords before you use
them. Suchcords should be rated for 125Volt AC loadsat
15Amps (or greater) for most electrical devices.Some
devices, however, may not require this type of extension
cord. Check the owner's manualsof those devicesfor their
recommendations.
Keep extension cords asshort as possible,preferably less
than 15feet long, to prevent voltage drop and possible
overheating of wires.
Section 4: Operation
DON'T OVERLOAD
G EN ERATO R
Capacity
You must make sure your generator cansupply enough
rated (running) and surge (starting) watts for the itemsyou
will power at the sametime. Follow these simple steps:
I. Selectthe itemsyou wilt 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 itemsrunning. SeeFigure 10.
3. Estimate how many surge (starting) watts you wilt
need. Surge wattage isthe short burst of power
needed to start electric motor-driven tools or
appliancessuch asa circular saw or refrigerator.
Becausenot all motors start at the sametime, total
surge watts can be estimated by addingonly the
item(s)with the highest additional surge watts to the
total rated watts from step 2.
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated (Running)
Watts
1200
800
50O
500
75
3075 Total
Running Watts
Total Rated (Running)Watts = 3075
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
Additional Surge
(Starting)Watts
1800
1600
5O0
1800 Highest
SurgeWatts
Power Management
To prolong the lifeof your generator and attached devices,
it is important to take care when addingelectrical loads to
your generator. There should be nothing connected to the
generator outlets before starting it's engine. The correct
and safeway to managegenerator power isto sequentially
add loadsasfollows:
I. With nothingconnected to the generator, start the
engine asdescribed in this manual.
2. Plugin and turn on the first load,preferably the largest
loadyou have.
3. Permit the generator output to stabilize (engine runs
smoothly and attached device operates properly.
4. Plugin 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 loadsthan the generator capacity.Take
specialcare to consider surge loadsingenerator capacity,
asdescribed above.
Tool or Appliance
Essentials
LightBulb - 75 watt
Deep Freezer
SumpPump
Refrigerator/Freezer - 18Cu. Ft.
Water Well Pump - I/3 HP
Heating/Cooling
Window AC - 10,000BTU
Window Fan
FurnaceFanBlower - I/2 HP
Kitchen
Microwave Oven - 1000Watt
Coffee Maker
Electric Stove - SingleElement
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television - 27"
Personal Computer w/I 7" monitor
Other
SecuritySystem
AM/FM Clock Radio
GarageDoor Opener - I/2 HP
Electric Water Heater - 40 Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - I/3 HP
Reciprocating Saw
Electric Drill - I/2 HP
Circular Saw- 7 I/4"
Miter Saw- 10"
Table Planer - 6"
Table Saw/RadialArm Saw- 10"
Air Compressor - I-I/2 HP
Rated*
(Running)
Watts
75
500
8O0
8O0
1000
12O0
3OO
8O0
1000
1500
1500
25O0
I00
I00
450
5O0
8O0
Additional
Surge
(Starting)
Watts
500
1200
1600
20O0
1800
6O0
1300
180
300
480 520
40O0
1000
600 1200
960 960
1000 1000
1500 1500
1800 1800
1800 1800
2000 2000
2500 2500
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
Maintenance
5
PRODUCT
SPECIFICATIONS
Generator Specifications
RatedSurgeWatts ............... 1,000Watts
Rated RunningWatts ............. 900 Watts
Rated MaximumCurrent
At 120Volts AC .............. 7.5Amps
At 12VoltsDC ............... 8.3Amps
Phase ........................ SinglePhase
Rated Frequency ................ 60 Hertz
PackagedWeight ................ 61 Ibs.
Engine Specifications
Model ........................ MitsubishiGM82
Rated Horsepower .............. 2.4at 4000 rpm
Displacement ................... 80cc
SparkPlugType:................. NGK BP6HSor
equivalent
SetGapTo: ..................... O.030inch(0.75ram)
FuelCapacity ................... 1.2U.S.gallons(4.5 I)
GENERAL MAINTENANCE
RECOMMENDATIONS
The generator warranty does not cover items that have
been subjected to operator abuse or negligence. To receive
full value from the warranty, operator must maintain
generator as instructed in this manual.
Some adjustments will need to be made periodically to
properly maintain your generator.
All adjustments in this section should be made at least
once each season.Follow the requirements in the
"Maintenance Schedule"chart shown below in Figure I I.
NOTE: Once a year you should cleanor replace the spark
plug and replacethe air filter. A new spark plug and clean
air filter assureproper fuel-air mixture and help your
engine run better and last longer.
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.
Check the cleanliness of the generator frequently and clean
when dust, dirt, oil, moisture or other foreign substances
are visible on its exterior surface.
NOTE: DO NOT usea garden hose to cleangenerator.
Water can enter engine fuel system and causeproblems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voidsand cracks of
the rotor andstator winding insulation. Water and dirt
buildup on the generator internal windings will eventually
decreasethe insulation resistanceof these windings.
II1_ I IIBl_llfi'_l'_i,_l_illm
Item
Engineoil
Air cleaner
Spark arrester
Spark plug
Valve clearance
Fuel tank strainer
Fuel line
I
2
3
Operation
Check level
Change
Check
Clean
Check - Clean
Check - Clean
Check - Adjust
Clean
Check (Replaceif
necessary)
Each use First Month or Every 3 months
25 hours or 50 hours
X
X X
)4
X(I)
x (2,3)
x
Every 3 years (3)
Clean more often under dirty or dusty conditions. Replace cleaner parts if very dirty.
Check every I0 hours or 3 months.
Every 6 months
or 100 hours
!?: iit:_; (_ii _ i t i¸ii _ i t i¸ii _i_
x (3)
x (3)
These items should be serviced by an authorized dealer,unless the owner hasthe proper tools and is mechanically
proficient.
II I
Section 5: Maintenance
To Clean the Generator
• Use a damp cloth to wipe exterior surfacesclean.
• Soft, bristle brush may be usedto loosen caked on dirt
or oil.
A CAUTION! NEVERinsert anyobject or tool
through the air cooling slots, even if the engine is
not running.
• A vacuum cleaner may be used to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow awaydirt. Inspect cooling air slots and opening on
generator. These openings must be kept cleanand
unobstructed.
A DANGER! When working on the generator
alwaysdisconnect spark plug wire from spark plug
and keepit awayfrom spark plug.
ENGINE MAINTENANCE
Checking Oil Level
Oil level should be checked prior to each use or at least
every 5 hours of operation. Keep oil level maintained.
Changing Engine Oil
Changethe oil after the first month of operation, then
every 25 hours. If you are usingyour generator under
extremely dirty or dusty conditions, or in extremely hot
weather, changethe oil more often.
Changethe oil while the engine isstill warm from running,
asfollows:
• Remove the oil fill cover and clean area around oil drain
plug (Figure 12).
• Remove oil drain plug, sealing washer, and oil filler cap.
Drain oil completely into a suitable container.
• Install oil drain plug and sealing washer. Tighten securely.
• Refill with recommended oil and check the level. See
page 6 for oil recommendations.
• Wipe up any spilled oil.
A AUTION! Avoid prolonged or repeated skin
contact with used motor oil. Used motor oil has
been shown to causeskin cancer in certain
laboratory animals.Thoroughly wash exposed areas
with soapand water. KEEPOUT OF REACH OF
CHILDREN.
DON'T POLLUTE. CONSERVERESOURCES.
RETURN USED OIL TO COLLECTION CENTERS.
• Replace oil fill cover.
Clean/Replace Spark Plug
Check and clean the spark plug every 50 hours of
operation or every three months, whichever comes first.
This will help your engine to start easier and run better.
• Remove spark plug accesscover. Remove spark plug cap.
• Clean the area around the spark plug.
• Remove and inspect the spark plug.
• Replace the spark plug if electrodes are pitted or burned
or the porcelain is cracked. Use recommended plug for
replacement.
• Check electrode gap with wire feeler gauge and set spark
plug gap between 0.028 and 0.031 inch (0.7 to 0.8 mm) if
necessary (Figure 13).
Oil Drain Plug
• Reinstall spark plug.
Service Air Cleaner
Your engine will not run properly and may be damagedif
you run it using a dirty air filter element.
Check the air filterevery useand clean or replacethe paper
air filterelement every 50 hours of operation or every three
months, whichever comesfirst. Clean or replacemore often
if operating under dusty or dirty conditions.
Section 5 & 6: Maintenance & Storage
To clean or replace air filter element:
• Loosen the air cleaner cover screws,remove the air
cleaner cover, and remove the element (see item
number 4, exploded view on page21.
• Wipe cleanthe insideof the filter housing and cover
thoroughly.
• Wash the element in a solution of household detergent
and warm water, then rinse thoroughly. Or wash in
nonflammable or high flash point solvent. Allow the
element to dry thoroughly.
• Soakthe element in cleanengine oil and squeezeout the
excess oil. DO NOT twist The engine will smoke during
initial start-up iftoo much oil is left in the element.
NOTE: If you need to order a new air filter element,
contact your Authorized service center.
• Reinstallthe air cleaner element and the cover. Hand
tighten the air cleaner cover screws.
Clean Spark Arrester Screen
The enginemuffler isequipped with a removable spark
arrester screen.Inspectand cleanthe screen every 10hours
of operation or every three months, asshown in Figure 14:
• Loosen the screw on the muffler tail pipe and remove
the spark arrester screen.
• Use a brassor stiff-bristle brush to remove carbon
deposits from the spark arrester surface.
• Inspect the spark arrester for breaks or tears and
replace it if necessary.
NOTE: If you need to order a new spark arrester, contact
your Authorized service center.
• Install the clean screen in the reverse order of removal.
NOTE: Ifyou useyour generator on anyforest-covered,
brush-covered or grass-covered unimprovedland,it must
havea spark arrester installed.The spark attester must be
maintained ingood condition by the owner/operator.
Data Tag
Data tag informationisvery important ifyou need help
from our Customer Service Depatment or an authorized
service deaier.
• The data tag(Figure9) islocatedon the heat shield on the
muffler sideof the generator. For future reference, please
copy the model, revision, and serial number of the
enerator inthe spacebelow.
I
MODEL
REV NO
SERIAL
AC VOLTS
AC AMPS
AC WATTS
DC VOLTS
DCAMPS
Single Phase / 60 Hz / 3600 RPM
Rated at40 "C / ClassF insulation
.k,
]
!
]
]
!
O BILT"
Tmy-Bilt_isa registeredtrademarkof
MTDandisusedunderlicenseto
Briggs &Stratton
Power Products Group, LLC
Jefferson, WI
] MADE IN U.S.A.
,..Copy Model
Number Here
_Copy Revision
Here
Copy Serial
Number Here
STORAGE INSTRUCTIONS
Transporting and Storage
When transporting the generator, turn the engine switch
to "Off' and the fuel valveto "Close". Keep the generator
levelto prevent fuel spillage.
_hL WARNING! Contact with a hot engine or
exhaust system can cause serious burns or fires. Let
the engine coot before transporting or storing the
generator.
Takecare to not drop or strike the generator when
transporting. DO NOT place heavyobjects on the
generator.
The generator should be started at leastonce every seven
daysand allowed to run at least30 minutes. If this cannot
be done and you must store the unit for more than 30 days,
use the following guidelinesto prepare it for storage.
Long Term Storage Instructions
_hL WARNING! NEVER store engine with fuel in
tank indoorsor in enclosed, poorly ventilated areas
where fumes may reach an open flame, spark or
pilot lightason a furnace, water heater, clothes
dryer or other gasappliance.
Be sure the storage area isfree from excessive
humidity and dust.
One Month to One Year
Drain the carburetor float bowl (see following section) and
fuel tank intoa suitable container. After removal from
storage, fill with fresh fuel before starting.
More than One Year
It isimportant to prevent gum deposits from forming in
essentialfuel system parts such asthe carburetor, fuel filter,
fuel hose or tank during storage. Also, experience indicates
that alcohol-blended fuels (called gasohot,ethanol or
methanol) can attract moisture, which leadsto separation
and formation of acids during storage. Acidic gascan
damagethe fuel system of an engine while in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 daysor longer. Follow these
instructions:
Protect Fuel System
_hL WARNING! Drain fuel into approved container
outdoors, awayfrom openflame. Be sure engine is
cool. DO NOT smoke.
• Drain carburetor float bowl and fuel tank into a suitable
container by looseningthe drain screw (Figure 15).
• Retighten drain screw before refueling.
Change Oil
While engine isstill warm, changeoil asdescribed on
page 12.Refill with recommended grade.
Oil Cylinder Bore
• Remove spark plug and pour about one tablespoon of
clean engineoil into the cylinder.
_llL CAUTION! Avoid sprayfrom spark plug hole
when cranking engine slowly.
• Cover spark plug hole with rag. Crank slowly several
times to distribute oil.
• Install spark plug. DO NOT connect spark plug wire.
• Slowly pull the starter grip until resistance isfelt. At this
point, the piston iscoming up on itscompression stroke
and both the intakeand exhaust valvesare closed.
Storing the engine in this position will help to protect it
from internalcorrosion.
Generator
• Clean the generator asoutlined on page 12 ("To Clean
the Generator").
• Check that cooling air slots and openingson generator
are open and unobstructed.
Other Storage Tips
• DO NOT store fuel from one seasonto another.
• Replacethe fuel can if it starts to rust. Rust and/or dirt
in fuel will causeproblems.
• If possible, store your unit indoors.BE SURE TO
EMPTY THE FUEL TANK.
• Cover your unit with a suitable protective cover that
does not retain moisture.
IMPORTANT: NEVERcover your generator while engine
and exhaust area are warm.
• Store generator in clean, dry area.
Troubleshooting
7
TROUBLESHOOTING
Problem
No AC or DC output
is available but
engine is running.
Generator runs good
at no-load but
"bogs down" when
loads are
connected.
Engine will not start;
or starts and runs
rough.
Engine shuts down
when running.
Engine lacks power.
Engine "hunts" or
falters.
Cause
I. One of the circuitbreakers isopen.
2. Fault ingenerator.
3. Poor connection or defective cord set.
4. Connected device isbad.
t. Short circuitin a connectedload.
2. Enginespeedistoo slow.
3. Generator isoverloaded.
4. Shorted generator circuit.
I. Engineswitch set to "Off".
2. Dirty air cleaner.
3. Out of gasoline.
4. Stalegasoline.
5. Sparkplug wire not connected to spark
plug.
6. Badspark plug.
7. Water in gasoline.
8. Overchoked or flooded.
9. Excessivelyrich fuel mixture.
10. Intake valve stuck open or closed.
I I. Enginehaslost compression.
Out of gasoline.
I. Load is too high.
2. Dirty air filter.
Carburetor is running too rich or too lean.
Correction
I. Resetcircuit breaker.
2. Contact Authorized service facility.
3. Check and repair.
4. Connect another device that isin
good condition.
I. Disconnect shorted electrical toad.
2. Contact Authorized service facility.
3. See"Don't Overload Generator".
4. Contact Authorized service facility.
I. Setswitchto "On".
2. Clean or replaceair cleaner.
3. Fill fuel tank.
4. Drain gastank and carburetor; fill
with fresh fuel.
5. Connect wire to spark plug.
6. Replacespark plug.
7. Drain gastank and carburetor;fill
with fresh fuel.
8. Wait 5 minutes and re-crank engine.
9. Contact Authorized service facility.
10. Contact Authorized service facility.
I I. Contact Authorized service facility.
Fillfuet tank.
I. See "Don't Overload Generator".
2. Replace air filter.
Contact Authorized service facliity.
8
Wiring Diagram
WIRING DIAGRAM
EN@ZNE
t
I
6LTERN6TDR
J
BLUE
BL_CK
YELLOW
YELLOW
[
EB
RED
YELLOW
[_ _LUE
_ GREE_
[_ BL_CK
BL_K
_HZrE _
CZRCUK BRE_KEe
GRI]UI_
i
Exploded Views and Parts Lists
9
EXPLODED VIEW AND PARTS LIST - HAIN UNIT
1
2
_ 3 4 5 _./13
29 27., t 8
28
9
10
26
23
24
25\_e'23 17
22_
15
21
,14
/
20
Item Part #
I NSP
2 187378GS
3 187411GS
4 187379GS
5 187430GS
6 187409GS
7 187381GS
8 187399GS
9 187382GS
10 187388GS
II 187389GS
12 187405GS
13 187384GS
14 187407GS
15 187403GS
Qty Description
ENG, MITSUB,2.4HP
ROTOR
BRG
STATOR
LEAD, GREEN
BUSHING, LEAD WIRE
RBC, IK
SCREW,SELFTAP
FAN, COOLING
BOLT,RTR
BOLT,STATOR
INSLTN, HEAT SEALED
MFFLR,SEALED
INSLTN, HEAT SEALED
DUCT, AIR
Item Part # Qty Description
16 187392GS 2 SCREW
17 187383GS I BASE,GEN
18 187390GS 4 BOLT, FLNG
19 187385GS 4 MNT, VIBR
20 187427GS 4 SCREW
21 187424GS I NUT, WING
22 187423GS I NUT
23 187419GS 2 WSHR, LOCK
24 187420GS 2 WSHR
25 187401GS 2 NUT, FLANGE
26 187415GS I SCREW
27 187413GS 2 CNNCTR
28 187434GS 4 HHCS, FLNG
29 187431GS I STND, ENG
Section 9: Exploded Views and Parts Lists
EXPLODED VIEW AND PARTS LIST - HAIN UNIT
4t j6
11_e |
32 53
30_ 11 26
B
29
Item Part # Qty Description Item Part #
1 187436GS I CAP, FUEL 25 187371AGS
2 187439GS I PACKING, TANK 26 192413GS
3 187438GS I FLTR,FUEL 27 187773GS
4 187769GS 3 U-PACKING 28 187460GS
5 187437GS I TANK, FUEL,4.5L 29 187454GS
6 187766GS I DECAL, CHOKE 30 187873GS
7 187756GS 4 BOLT, COVER 31 187450GS
8 187433GS I HSG, GEN, MFFLR 32 187812GS
l0 187772GS I COVER, SPARKPLUG 33 187456GS
11 187757GS 5 BOLT, COVER 34 187763GS
12 187760GS I I SCREW 35 187876GS
13 187435GS I CVR, MFFLR,GEN 36 192412GS
14 187775GS 3 BOLT, MFFLRCVR 37 191545GS
15 191436GS I DECAL CAUTION HOT 38 187447GS
16 187774GS 4 BOLT, COVER 39 187448GS
17 187761GS 8 NUT 40 187442GS
18 187463GS I INSLTN, MFFLR 41 187758GS
19 187432GS I HSG, GEN 42 187443GS
20 NSP I DECAL, EMISSIONS 43 187770GS
21 187457GS I CONDENSER 44 187579GS
22 191528GS I DECAL, WARNING 45 187440GS
23 187759GS 2 BOLT, COVER 46 187578GS
24 187462GS I DIODE, BRIDGE
Qty
2
Description
BOTTLE, OIL
DECAL, LWR PANEL
COVER, OIL FILL
CB, DC
CB
OUTLET, ACCESSORYDC
SWITCH, ENG, ON/OFF
CPNL
RECPTCL, 15A, 125V
DECAL, CAUTION OIL
CABLE, BATTERYCHARGE
DECAL, UNIT
DECAL, FUELSHUTOFF
INSLTN, HTSHLD, TANK
INSLTN, HTSHLD, TANK
BRKT,TANK, FUEL
BRKT, FUELCOCK
COCK, FUEL
SCREW
CLIP,FUELHOSE
FLTR,FUEL
HOSE, FUEL
I|:!
Section 9: Exploded Views and Parts Lists
EXPLODED VIEW AND PARTS LIST - ENGINE
Cylinder Block, Cylinder Head
/
3
_J
?
Item Part # Qty Description
I 187380GS I BLOCK, CYL
2 187386GS I ASSY,GOV, GEAR
3 187387GS I SLIDER,GOV
4 187391GS I SHFT,GOV
5 187393GS 2 PLUG, DRAIN
6 187394GS 2 SEAL,OIL
7 187395GS I BRG, BALL
8 187400GS I WSHR, CYLBLOCK
9 187402GS 2 GSKT, CYLBLOCK
17
/
I
16 18
8 9 12 12_':_
19
5 4
Item Part # Qty Description
I 187404GS I ASSY,CYL HEAD
2 187406GS 2 TPPT,CYL HEAD
3 187408GS 2 VLV,EXH
4 187410GS 2 SPRNG,VLV
5 187412GS 2 RTNR,VLV SPG
6 187414GS 2 ROD, PUSH
7 187416GS I ASSY,RCKR, ARM
8 187417GS 2 NUT, CYL HEAD
9 187418GS 2 SCRW,ADJST
10 187421GS I PLT,CYL HEAD
11
4
5 \
\ \
®®-
lo
3
15
t
3 14
Item Part # Qty
II 187422GS I
12 187423GS 4
13 187426GS 4
14 187428GS 2
15 187429GS I
16 187468GS I
17 187470GS 4
18 187472GS I
19 187569GS 2
Description
SEAL,VLV STEM
NUT, M5 X 0.8
BOLT, FLNG
PIN, DWL
GSKT, HEAD
CVR, VALVE
BOLT,VALVE CVR
GSKT,VALVECVR
BOLT, STUD
Section 9: Exploded Views and Parts Lists
EXPLODED VIEW AND PARTS LIST - ENGINE
Crankcase Cover, Crankshaft/Camshaft
5
Item Part # Qty Description
I 187394GS 2 SEAL,OIL
2 187473GS I CVR, CRANKCASE
3 187474GS I DIPSTICK, OIL
4 187475GS I O-RING, DIPSTICK
5 187477GS I BRG, PTO
6 187478GS 6 BOLT,CRANKCASE CVR
7 187428GS 2 PIN, DWL
8 187479GS I GSKT,CRANKCASE CVR
4
3
Item Part #
I 187481GS
2 187484GS
3 187486GS
6 4 187487GS
6 187488GS
7 187489GS
8 187490GS
Qty Description
ASSY,CRNKSHFT
GEAR, CRNKSHFT
KEY,WOODRFF
GEAR, CRNKSHFT
ASSY,CAMSHAFT
PIN, CMPR REL
RNG, SNP,CMPRSSN
REL
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Troybilt 01923 Owner's manual
- Category
- Power generators
- Type
- Owner's manual
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