Troy-Bilt 1925 User manual

Owner’s Manual / Manual del Propietario
Questions? Preguntas?
Helpline - 1-888-611-6708 M-F 8-5 CT
Manual No. 192472GS Revision 6 (03/23/2004)
Portable Generator / Generador Portátil
Model / Modelo 01925
Printed in USA
BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC
JEFFERSON,WISCONSIN, U.S.A.
IMPORTANT: READ SAFETY RULES AND INSTRUCTIONS CAREFULLY
IMPORTANTE: LEYO LA SEGURIDAD LAS ORDENESY LAS INSTRUCCIONES DETENIDAMENTE
Troy-Bilt® is a registered trademark of Troy-Bilt, LLC and is used under license to Briggs & Stratton Power Products.
Troy-Bilt® es una marca registrada de Troy-Bilt, LLC y se usa abajo licencia a Briggs & Stratton Power Products.

2
Safety Rules
TABLE OF CONTENTS
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Know Your Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 18-19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
This manual describes an engine–driven, revolving field,
alternating current (AC) generator 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.
CAUTION! DO NOT exceed the generator’s
wattage/amperage capacity. See “Don’t Overload
Generator” on page 13.
Every effort has been made to ensure that information in this
manual is accurate and current. However, we reserve the
right to change, alter or otherwise improve the product and
this document at any time without prior notice.
The Emission Control System for this generator is warranted
for standards set by the Environmental Protection Agency. For
warranty information refer to the engine owner’s manual.
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, CAUTION,WARNING), 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. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
Hazard Symbols and Meanings
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
In the State of California a spark arrester is required by law
(Section 4442 of the California Public Resources Code).
Other states may have similar laws. Federal laws apply on
federal lands. If you equip the muffler with a spark arrester,
it must be maintained in effective working order.
1
Section
Fire
Explosion
Toxic Fumes
Hot Surface
Electrical Shock
Electrocution Electrical Shock
Explosive Pressure Chemical Burn

3
• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays around battery for a long
time after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
DANGER
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground circuit fault interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• DO NOT operate generator in the rain.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
Generator produces powerful voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
DANGER
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.
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.
• 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.
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or
death.
WARNING
Section 1: Safety Rules
• This generator does not meet U. S. Coast Guard Regulation
33CFR-183 and should not be used on marine applications.
• Failure to use the appropriate U. S. Coast Guard approved
generator could result in bodily injury and/or property
damage.
WARNING

4
Section 1: Safety Rules
• 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.
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
• See “Don’t Overload Generator” on page 13.
• 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.
Exceeding generator’s wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
• Use generator only for intended uses.
• If 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 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.
Improper treatment of generator can damage it and
shorten its life.
CAUTION
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
Unintentional sparking can result in fire or
electric shock.
WARNING
• DO NOT touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
Severe burns can occur on contact.
WARNING

5
Features and Controls
KNOWYOUR GENERATOR
Read this owner’s manual and safety rules before operating your generator.
Compare this illustration with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
2
Section
12 Volt DC Receptacle — Use this receptacle with
battery charge cables to charge a 12 Volt battery.
120Volt AC, 20 Amp Duplex Receptacles — May be
used to supply electrical power for the operation of 120Volt
AC, 20 Amp, single phase, 60 Hz electrical lighting, appliance,
tool and motor loads.
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.
Air Cleaner — Uses a dry type filter element and foam
pre–cleaner to limit the amount of dirt and dust sucked
into the engine.
Battery — Located behind plastic cover. 12 Volt DC sealed
battery provides power to start the engine.
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — The 120 Volt AC, 20A duplex
receptacles are provided with "push to reset" circuit
breakers to protect the generator against electrical overload.
Data Tag – Provides model, revision and serial number of
generator. Please have these readily available if calling for
assistance.
Fuel Tank — Capacity of seven (7) U.S. gallons.
Start Switch — Turn to start the engine.
Grounding Fastener — If required, please consult a
qualified electrician, electrical inspector, or local agency
having jurisdiction.
Oil Fill Cap — Add oil to engine here.
Spark Arrester Muffler — Exhaust muffler lowers engine
noise and is equipped with a spark arrester screen.
Rocker Switch Circuit Breaker — The 120/240 Volt AC,
30A locking receptacle is provided with a rocker switch circuit
breaker to protect the generator against electrical overload.
This switch also controls all receptacles.
Choke Lever
Rocker Switch Circuit
Breaker
Circuit Breakers (AC)
120 Volt AC, 20 Amp
Duplex Receptacles
120/240 Volt AC, 30 Amp
Locking Receptacle
12 Volt DC
Receptacle
Spark Arrester Muffler
Start Switch
Grounding
Fastener
Air Cleaner
Fuel Tank
Oil Fill Cap
Data Tag
Battery

6
3
Section
ASSEMBLY
Your generator requires attachment of the negative battery
cable and is ready for use after it has been properly
serviced with the recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-888-611-6708.
Remove Generator From Carton
1. Set carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
2. Carefully open top flaps of shipping carton.
3. Cut down corners of carton from top to bottom and
lay that side of carton down flat.
4. Remove all packing material, carton fillers, etc.
5. Roll generator out of shipping carton.
Attach Negative Battery Cable
The sealed battery on the generator is fully charged and
pre–installed except for the negative (black) battery cable.
You will need a 1/2” or 13 mm wrench to install the
negative battery cable.
To install:
1. Cut off tie wrap securing loose end of negative (black)
cable.
2. Attach negative battery cable with 5/16” x 3/4” screw
and lock washer to the engine block, next to the
starter (Figure 1).Tighten securely.
Assembly
Figure 1 — Negative Battery Connection
Positive
battery
cable
Screw
Negative
battery
cable
Washer

7
Attach Handle
You will need two 1/2” or 13 mm wrenches to attach the
handle.
1. Attach handle to right side of generator frame (viewing
unit from front), as shown in Figure 2, with a 60 mm
capscrew, flat washers, nylon washers, and lock nut.
NOTE: DO NOT overtighten. Handle must be able to
move up and down freely.
2. Raise handle and insert handle pin to move generator.
BEFORE STARTING THE
ENGINE
Add Engine Oil and Fuel
• Place generator on a level surface.
• Refer to engine owner’s manual and follow oil and fuel
recommendations and instructions.
NOTE: Check oil often during engine break–in. Refer to
engine owner’s manual for recommendations.
NOTE: The generator assembly rotates on a prelubricated
and sealed ball bearing that requires no additional
lubrication for the life of the bearing.
Section 3: Assembly
60mm Capscrew
Nylon Washers
Flat Washers
Lock Nut
Handle Pin
Figure 2 — Attach Handle
• Replace “1-1/2” with “2-1/4” fuel fill level given in engine manual.
• Failure to follow this instruction may cause fuel to overexpand
and spill from tank.
Fill tank to approximately 2-1/4” below top of neck to
allow for fuel expansion.
WARNING
CAUTION
• Refer to engine manual for oil and fuel fill information.
• Damage to equipment resulting from failure to follow this
instruction will void warranty.
Any attempt to crank or start the engine before it has
been properly filled with the recommended oil will result
in equipment failure.
Nut
Washer
Nylon Washer
Handle Bracket
Nylon Washer
Handle Bracket
Washer
60mm Capscrew
Handle Pin

8
USING THE GENERATOR
System Ground
The generator has a system ground that connects the
generator frame components to the ground terminals on
the AC output receptacles.The system ground is connected
to the AC neutral wire (see “Equipment Description”,
earlier in this manual).
Special Requirements
There may be Federal or State Occupational Safety and
Health Administration (OSHA) regulations, local codes, or
ordinances that apply to the intended use of the generator.
Please consult a qualified electrician, electrical inspector, or
the local agency having jurisdiction.
• In some areas, generators are required to be registered
with local utility companies.
• If the generator is used at a construction site, there may
be additional regulations which must be observed.
Connecting to a Building’s Electrical
System
Connections for standby power to a building’s electrical
system must be made by a qualified electrician.The
connection must isolate the generator power from utility
power, and must comply with all applicable laws and
electrical codes.
OPERATING THE
GENERATOR
IMPORTANT: Always unplug the battery float charger
before starting the generator.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
start instruction steps in numerical order:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a level
surface will cause the unit not to start or shut down during
operation.
2. Follow start instructions given in engine owner’s manual
and turn start switch on generator to “Start” position
(Figure 3).To prolong life of starter components, DO
NOT hold starter switch in “Start” position for more
than 15 seconds, and pause for 1 minute.
NOTE: If engine starts but fails to run, or if unit shuts
down during operation, make sure unit is on a level surface
and check for proper oil level in crankcase.This unit may be
equipped with a low oil protection device. See engine
manual.
• See “Don’t Overload Generator” on page 13.
• 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.
Exceeding generator’s wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
CAUTION
Figure 3 — Starter Switch
4
Section Operation
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground fault circuit interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• DO NOT operate generator in the rain.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
Generator produces powerful voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
DANGER

9
Section 4: Operation
Jump Start Procedure
If the generator’s starting battery fails, use the following
instructions to jump start your generator.You can jump
start the generator using any 12 Volt automotive or utility
style storage battery.
1. Unscrew the fuse holder and remove the generator’s
10 Amp in-line fuse (Figure 4).Verify the fuse is good
or replace with a known good fuse. Reinstall fuse in
the fuse holder.
2. Slide the red rubber boot off the generator’s battery
terminal and push it onto the red wire, thus
uncovering the POSITIVE battery terminal.
3. Using standard automotive jumper cables, connect the
RED jumper cable clamp to the generator’s POSITIVE
battery terminal (Figure 5).
4. Connect the other RED jumper cable clamp to the
starting battery’s POSITIVE battery terminal.
5. Connect the BLACK jumper cable clamp to the
starting battery’s NEGATIVE battery terminal.
6. Connect the other BLACK jumper cable clamp to the
GROUNDING FASTENER on the generator, as shown
in Figure 5.
7. Start the generator as described in “Starting the
Engine” and remove jumper cables in reverse order of
connections.
8. Slide the red rubber boot back onto the generator’s
POSITIVE battery terminal.
If you have any questions, please call the Generator
Helpline at 1-888-611-6708, M-F 8-5 CT.
IMPORTANT: When jump starting, always wear proper eye
protection and never lean over battery. Inspect both
batteries before connecting booster cables. DO NOT jump
start a damaged battery. Be sure vent caps are tight and level.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes after
starting.
• Plug in and turn on the desired 120 and/or 240 Volt AC,
single phase, 60 Hz electrical loads.
• DO NOT connect 240 Volt loads to the 120Volt duplex
receptacles.
• DO NOT connect 3–phase loads to the generator.
• DO NOT connect 50 Hz loads to the generator.
•DO NOT OVERLOAD GENERATOR. See “Don’t
Overload Generator” on page 13.
Stopping the Engine
1. 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. Turn start switch to “Stop” position.
Figure 5 — Jumper Cable Connections
Figure 4 — In-Line Fuse
Grounding
Fastener

10
Section 4: Operation
Charging a Battery
Your generator has the capability of recharging a discharged
12 Volt automotive or utility style storage battery. DO
NOT use the unit to charge any 6 Volt batteries. DO NOT
use the unit to crank an engine having a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
1. Check fluid level in all battery cells. If necessary, add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap water.
2. If battery is equipped with vent caps, make sure they
are installed and are tight.
3. If necessary, clean battery terminals.
4. Connect battery charge cable connector plug to panel
receptacle identified by the words “12-VOLTS D.C.”.
5. Connect battery charge cable clamp with red handle
to the positive (+) battery terminal (Figure 6).
6. Connect battery charge cable clamp with black handle
to the negative (–) battery terminal (Figure 6).
7. Start engine. Let engine run while battery recharges.
8. When battery has charged, shut down engine
NOTE: Use an automotive hydrometer to test battery state
of charge and condition. Follow the hydrometer
manufacturer’s instructions carefully. Generally, a battery is
considered to be at 100% state of charge when specific gravity
of its fluid (as measured by hydrometer) is 1.260 or higher.
How to Use the 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 next to starter switch (Figure 7). 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 in operation.
3. Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in
float equalizer and will not overcharge the battery,
even when plugged in for an extended period of time.
IMPORTANT: See “Battery Maintenance” on page 15 for
additional information.
Figure 6 — Battery Connections
• DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
Storage batteries give off explosive hydrogen gas
during recharging.
Hydrogen gas stays near battery for a long time
after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
DANGER
Figure 7 — Battery Charger Jack

11
COLD WEATHER
OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the crankcase
breather system.
Build a structure that will enclose three sides and top of
generator:
1. Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from
that shown in Figure 8.
2. Ensure a minimum of two feet clearance between open
side of box and nearest object.
3. Face exposed end away from wind and elements.
4. Enclosure should hold enough heat created by
generator to prevent problems.
GENERATOR ADAPTER
CORD SET
The generator is equipped with a 25’ generator adapter cord
set designed for a 240Volt, 30 Amp grounded neutral circuit
(Figure 9).The generator adapter cord set provides a
convenient supply of emergency power into your dwelling so
that your generator can be operated safely outside.
The maximum load on each outlet is 20 Amps.The
maximum total load on both yellow wire outlets or both
black wire outlets is 30 Amps.
NOTE: Follow all safety precautions when connecting any
extension cord or device to the generator.
• Operate generator ONLY outdoors.
• Keep at least 2 feet of clearance on all sides of generator for
adequate ventilation.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
• Remove generator from shelter when temperature is above
40°F [4°C].
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
DANGER
Figure 9 — Generator Adapter Cord Set
Figure 8 — Permanent Cold Weather Shelter
Wind
Section 4: Operation

12
Section 4: Operation
RECEPTACLES
12 Volt DC, 10 Amp Receptacle
This receptacle allows you to recharge a 12 Volt
automotive or utility style storage battery with the battery
charge cables provided (Figure 10).
This receptacle can not recharge 6 Volt batteries and can
not be used to crank an engine having a discharged battery.
See the section “Charging a Battery” (page 10) before
attempting to recharge a battery.
120 Volt AC, 20 Amp, Duplex
Receptacles
Each duplex receptacle (Figure 11) is protected against
overload by a push–to–reset circuit breaker.
Use each receptacle to operate 120Volt 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).
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) (Figure 12).You can use the same 4–wire cord if
you plan to run a 120Volt load.
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 7,200 watts of power (7.2 kW)
at 30 Amps for 120 Volts or 240 Volts.The outlet is
protected by a rocker switch circuit breaker.
Figure 10 — 12Volt DC, 10 Amp Receptacle
• 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”.
Receptacles may be marked with rating value greater
than generator output capacity.
CAUTION
Figure 11 — 120Volt, 20 Amp Duplex Receptacle
Figure 12 — 120/240 Volt AC, 30 Amp Receptacle
4-Wire Cord Set
240V
120V 120V W (Neutral)
X (Hot)
Y (Hot)
NEMA L14-30 Ground (Green)

13
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 Figure 13.
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 it's 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.
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
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 Cu. Ft.
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”
500
-
Personal Computer w/17” 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”
1500
1500
Miter Saw -10”
1800
1800
Table Planer -6”
1800
1800
Table Saw/Radial Arm Saw -10”
2000
2000
Air Compressor -1-1/2 HP
2500
2500
Figure 13 - Wattage Reference Chart
Section 4: Operation

14
GENERAL MAINTENANCE
RECOMMENDATIONS
The Owner/Operator is responsible for making sure that
all periodic maintenance tasks are completed on a timely
basis; that all discrepancies are corrected; and that the unit
is kept clean and properly stored. NEVER operate a
damaged or defective generator.
NOTE: If equipped with inflatable tires, keep the air
pressure at the value marked on the tire or within 15 and
40 psi.
Engine Maintenance
See engine owner’s manual for instructions.
An oil drain tray is provided for your convenience to
change the oil and oil filter. Store tray in a convenient
location for periodic maintenance.
Changing Oil
1. Place the half moon notch in the oil drain tray under
the oil drain plug (Figure 14).
2. Place the oil drain tray foot tab in the slot on the base
of the generator, as shown.
3. Follow the instructions given in the engine owner’s
manual for draining oil.
4. After oil has drained, reinstall the oil drain plug.
5. Remove the oil drain tray from under the oil drain plug
and clean up any spilled oil.
Changing Oil Filter
1. Place the half moon notch in the oil drain tray under
the oil filter (Figure 15).
2. Place the oil drain tray foot tab in the slot on the base
of the generator, as shown.
3. Follow the instructions given in the engine owner’s
manual for changing oil filter and adding oil.
4. Remove the oil drain tray from under the oil filter and
clean up any spilled oil.
KEEP OUT OF REACH OF CHILDREN. DON'T
POLLUTE. CONSERVE RESOURCES. RETURN
USED OIL TO COLLECTION CENTERS.
Maintenance
• Used motor oil has been shown to cause skin cancer in
certain laboratory animals.
• Thoroughly wash exposed areas with soap and water.
Avoid prolonged or repeated skin contact with used
motor oil.
CAUTION
Figure 14 — Changing Oil With Oil Drain Tray
Figure 15 — Changing Oil Filter With Oil Drain Tray
drain tray foot
drain tray notch
drain tray
notch
drain tray foot
5
Section

15
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 a garden hose to clean generator.
Water can enter engine fuel system and cause problems. In
addition, if water enters generator through cooling air slots,
some of the water will be retained in voids and cracks of
the rotor and stator winding insulation.Water and dirt
buildup on the generator internal windings will eventually
decrease the insulation resistance of these windings.
Battery Maintenance
Other than float charging, as described in “How to Use the
Battery Charger”, no maintenance is required for the
battery. Keep the battery and terminals clean and dry.
IMPORTANT: Battery charging should be performed in a
dry location, such as inside a garage.
Generator Cleaning
• 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.
• Use low pressure air (not to exceed 25 psi) to blow away
dirt. Inspect cooling air slots and opening on generator.
These openings must be kept clean and unobstructed.
Data Tag
Data tag information is very important if you need help
from our Customer Service Department or an authorized
service dealer.
• The data tag (Figure 16) is located either on the base
plate of the generator. For future reference, please copy
the model, revision, and serial number of the generator in
the space below.
Figure 16 — Data Tag
Copy Model
Number Here
Copy Revision
Here
Copy Serial
Number Here
• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
• DO NOT insert any objects through cooling slots.
Improper treatment of generator can damage it and
shorten its life.
CAUTION
Section 5: Maintenance

16
STORAGE
The generator should be started at least once every seven
days and allowed to run at least 30 minutes. If this cannot
be done and you must store the unit for more than
30 days, use the following guidelines to prepare it for
storage.
Generator Storage
• Clean the generator as outlined in “Generator Cleaning”.
• Check that cooling air slots and openings on generator
are open and unobstructed.
Engine Storage
See engine owner’s manual for instructions.
Other Storage Tips
• To prevent gum from forming in fuel system or on
essential carburetor parts, add fuel stabilizer into fuel
tank and fill with fresh fuel. Run the unit for several
minutes to circulate the additive through the carburetor.
The unit and fuel can then be stored for up to
24 months. Fuel stabilizer can be purchased locally.
• DO NOT store fuel from one season to another unless
it has been treated as described above.
• Replace fuel container if it starts to rust. Rust and/or dirt
in fuel can cause problems if it's used with this unit.
• Store unit in a clean and dry area.
• DO NOT place a storage cover over a hot generator.
• Let equipment cool for a sufficient time before placing the
cover on the equipment.
Storage covers can be flammable.
WARNING
Storage
6
Section

17
7
Section
Troubleshooting
TROUBLESHOOTING
Problem
No AC output is available, but
generator is running.
Generator runs good at no-load
but "bogs" down" when loads are
connected.
Generator will not start; or starts
and runs rough.
Generator shuts down during
operation.
Generator lacks power.
Cause
1. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Shorted generator circuit.
1. 10 Amp in-line fuse is blown.
2. Discharged battery.
3. Failed battery.
4. Low oil level.
1. Out of gasoline.
2. Low oil level.
Load is too high.
Correction
1. Reset circuit breaker.
2. Contact Authorized service
facility.
3. Check and repair.
4. Connect another device that is in
good condition.
1. Disconnect shorted electrical
load.
2. See "Don't Overload Generator".
3. Contact Authorized service
facility.
1. Replace fuse.
2. Jump start generator and/or
charge battery.
3. Replace battery.
4. Fill crankcase to proper level or
place generator on level surface.
1. Fill fuel tank.
2. Fill crankcase to proper level or
place generator on level surface.
See "Don't Overload Generator".

18
8
Section Wiring Diagram and Schematic
SCHEMATIC

19
Section 8: Wiring Diagram and Schematic
WIRING DIAGRAM

20
9
Section Exploded Views and Parts Lists
EXPLODED VIEW - MAIN UNIT