Sears Companion D20508, Companion 919.329110 User Manual

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OWNER'S

MANUAL

Model No.

919.329110

120/240 VOLT • 5500 WATT GENERATOR

SAFETY GUIDELINES

ASSEMBLY

OPERATION

MAINTENANCE

TROUBLESHOOTING

REPAIR PARTS

IMPORTANT:

Read the Safety Guidelines and All Instructions Carefully Before Operating

Sold by Sears Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

D20508 Rev. 1 5/1/02

TABLE OF CONTENTS

Warranty ....................................................

2

Storage ...................................................

17

Safety Guidelines...................................

3-8

Troubleshooting Guide ...........................

17

Assembly................................................

9-10

Generator Parts ................................

18-22

Operation ...........................................

11-14

Engine Parts .....................................

23-26

Maintenance ......................................

14-16

EPA Codes ........................................

27-28

Service Adjustments ..............................

16

How To Order Parts .................

Back Cover

DATE PURCHASED:

MODEL NO:

SERIAL NO:

STORE WHERE PURCHASED:

ADDRESS:

CITY:

TELEPHONE:

Record the above information about your unit so that you will be able to provide it in case of loss or theft.

HORSE POWER

10 HP

GASOLINE CAPACITY

7 GALLON

OIL CAPACITY

26 OZ.

 

 

MAINTENANCE AGREEMENT

The Sears Warranty, plus a Maintenance Agreement, provide maximum value for your Sears products. Contact your nearest Sears store for details.

CUSTOMER RESPONSIBILITIES

Read and observe the safety rules.

Follow a regular schedule in maintaining, caring for and using your generator.

Follow the instructions under “Customer Responsibilities” and “Storage” sections of this owner’s manual.

FULL ONE YEAR WARRANTY ON SEARS GENERATORS

For one year from the date of purchase, when this Sears generator is maintained and operated according to the instructions in this owner’s manual, Sears will repair, free of charge, any defect in material and workmanship.

If your Sears Generator is used for commercial or rental purposes, this warranty applies for only 90 days from the original date of purchase.

FULL ONE YEAR WARRANTY ON SEARS ENGINE

For one year from the date of purchase, when this Tecumseh engine is maintained and operated according to the instructions in this owner’s manual, Sears will repair, free of charge, any defect in material and workmanship.

If your Tecumseh engine is used for commercial or rental purposes, this warranty applies only for 90 days from the date of purchase. This warranty does not cover: Expendable items such as spark plugs and air filters, which become worn during normal use.

Repairs necessary because of operator abuse or negligence, including damage resulting from no oil being supplied to the engine or failure to maintain the equipment according to the instructions contained in this owner’s manual, are not covered under warranty.

WARRANTY SERVICE IS AVAILABLE BY RETURNING THE GENERATOR TO THE NEAREST SEARS SERVICE CENTER. This warranty gives you specific legal rights and you may also have other rights, which vary from STATE TO STATE.

Sears, Roebuck and Co., D/817 WA, Hoffman Estates, IL 60179

D20508

2 — ENG

SAFETY GUIDELINES - DEFINITIONS

This manual contains information that is important for you to know and understand. This information relates to protecting YOUR SAFETY andPREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the symbols to the right. Please read the manual and pay attention to these sections.

DANGER indicates an imminently hazardous situation

CAUTION indicates a potentially hazardous situation

 

which, if not avoided, may result inminor or moderate

 

which, if not avoided, will result in death or serious

 

injury.

 

injury.

 

 

 

WARNING indicates a potentially hazardous situation

CAUTION used without the safety alert symbol indicates a

 

which, if not avoided, could result indeath of serious

potentially hazardous situation which, if not avoided, may

 

injury.

result in property damage.

 

 

 

 

This product is not equipped with a spark arresting muffler. If the product will be used around flammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or other similar items, then an approved spark arrester must be installed and is legally required in the state of California. It is a violation of California statutes section 130050 and/or sections 4442 and 4443 of the California Public Resources Code, unless the engine is equipped with a spark arrestor, as defined in section 4442, and maintained in effective working order. Spark arresters are also required on some U. S. Forest service land and may also be legally required under other statutes and ordinances.

This product may contain chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm. This warning is given in compliance with California Proposition 65, as detectable amounts of chemicals subject to proposition 65 may be contained in this product.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

When using this product basic precautions should always be followed including the following:

RISK OF ELECTROCUTION AND FIRE

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

Attempting to connect generator

Back feeding electricity through a

Never backfeed electricity through

directly to the electrical system of

building’s electrical system to the

a structure's electrical system.

any building structure.

outside utility feed lines could en-

To connect to a structure's electri-

 

danger repair persons attempting to

 

restore service.

cal system in a safe manner,

 

 

always have a Double-Throw

 

Attempting to connect to the incom-

Transfer Switch installed by a

 

ing utility service could result in

qualified electrician and in compli-

 

electrocution.

ance with local ordinances. (When

 

 

installing a Double-Throw

 

Restoration of electrical service while

Transfer Switch, a minimum of

 

the generator is connected to the

10 gauge wiring must be used.)

 

incoming utility could result in a fire or

 

 

serious damage if a isolator switch is

 

 

not installed.

 

 

Failure to use a double throw transfer

 

 

switch when connecting to a

 

 

structure's electrical system can

 

 

damage appliances and WILL VOID

 

 

the manufacturer's warranty.

 

 

 

 

3 — ENG

D20508

READ AND UNDERSTAND ALL WARNINGS BEFORE

ATTEMPTING TO OPERATE GENERATOR.

RISK OF ELECTROCUTION AND FIRE (cont’d)

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

 

 

Operation of generator in rain, wet,

Water is an excellent conductor of

Operate generator in a clean, dry,

 

icy, or flooded conditions.

electricity! Water which comes in

well ventilated area. Make sure

 

contact with electrically charged

hands are dry before touching unit.

 

components can transmit electricity to

 

 

 

the frame and other surfaces, resulting

 

 

 

in electrical shock to anyone contact-

 

 

 

ing them.

 

 

 

 

 

 

Use of worn damaged, undersized

Contact with worn or damaged

Inspect extension cords before

or ungrounded extension cords.

extension cords could result in

use and replace with new cord if

 

electrocution.

required.

 

Use of undersize extension cords

Use proper size (wire gauge)

 

could result in overheating of the

cordset for application see chart in

 

wires or attached items, resulting in

the Assembly section of this

 

fire.

manual.

 

Use of ungrounded cordsets could

Always use a cordset having a

 

prevent operation of circuit breakers

grounding wire with an appropriate

 

and result in electrical shock.

grounding plug. DO NOT use an

 

 

ungrounded plug.

 

 

 

 

Placing generator on or against

Accidental leakage of electrical

Place generator on low conductiv-

highly conductive surface, such as

current could charge conductive

ity surface such as a concrete

a steel walkway or metal roof.

surfaces in contact with the generator.

slab.

 

 

ALWAYS operate generator a

 

 

minimum of six feet from any

 

 

conductive surface.

Improper connection of items to

Exceeding the load capacity of the

Read the load rating chart and

generator.

generator by attaching too many

instructions in the Wattage Calcu-

 

items, or items with very high load

lation section. Make sure that the

 

ratings to it could result in overheating

summation of electrical loads for

 

of some items or their attachment

all attachments does not exceed

 

wiring resulting in fire or electrical

the load rating of the generator.

 

shock.

 

 

Operation of unit when damaged,

Attempting to use the unit when it has

Do not operate generator with

or with guards or panels removed.

been damaged, or when it is not

mechanical or electrical problem.

 

functioning normally could result in

Have unit repaired by an Autho-

 

fire or electrocution.

rized Service Center.

 

Removal of guarding could expose

Do not operate generator with

 

electrically charged components and

protective guarding removed.

 

result in electrocution.

 

 

 

 

 

 

D20508

4 — ENG

READ AND UNDERSTAND ALL WARNINGS BEFORE

ATTEMPTING TO OPERATE GENERATOR.

RISK OF FIRE

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

 

 

Attempting to fill the fuel tank while

Gasoline and gasoline vapors can

Turn engine off and allow it to cool

the engine is running.

become ignited by coming in contact

before adding fuel to the tank. Equip

 

with hot components such as the

area of operation with a fire extin-

 

muffler, engine exhaust gases, or from

guisher certified to handle gasoline

 

an electrical spark.

or fuel fires.

Sparks, fire, hot objects

Cigarettes, sparks, fires, or other hot

Add fuel to tank in well ventilated

 

objects can cause gasoline or gaso-

area. Make sure there are no

 

line vapors to ignite.

sources of ignition near the genera-

 

 

tor.

 

 

 

Improper storage of fuel

Improperly stored fuel could lead to ac-

Store fuel in a OSHA approved con-

 

 

cidental ignition. Fuel improperly se-

tainer designed to hold gasoline.

 

cured could get into the hands of chil-

Store container in secure location to

 

dren or other unqualified persons.

prevent use by others.

 

 

 

Inadequate ventilation for generator

Materials placed against or near the

Operate generator in a clean, dry,

 

generator or operating the generator in

well ventilated area a minimum of

 

areas where the temperature exceeds

four feet from any building, object

 

104° F. ambient (such as storage rooms

or wall. DO NOT OPERATE UNIT

 

or garages) can interfere with its proper

INDOORS OR IN ANY CONFINED

 

ventilation features causing overheat-

AREA.

 

ing and possible ignition of the materi-

 

 

 

als or buildings.

 

 

 

 

 

Tampering with factory set engine

Engine speed has been factory set to

Never attempt to “speed-up” the

speed settings.

provide safe operation. Tampering with

engine to obtain more performance.

 

the engine speed adjustment could re-

Both the output voltage and fre-

 

sult in overheating of attachments and

quency will be thrown out of stan-

 

could cause a fire.

dard by this practice, endangering

 

 

attachments and the user.

 

 

 

Overfilling the fuel tank – fuel spill-

Spilled fuel and its vapors can become

Use care in filling the tank to avoid

age.

ignited from hot surfaces or sparks.

spilling fuel. Make sure fuel cap is

 

 

secured tightly and check engine

 

 

for fuel leaks before starting

 

 

engine. Move generator away

 

 

from refueling area or any spillage

 

 

before starting engine. Allow for

 

 

fuel expansion. Keep maximum

 

 

fuel level ¼ inch below the tip of

 

 

the fuel tank. Never refuel with the

 

 

engine running.

 

 

 

 

5 — ENG

D20508

READ AND UNDERSTAND ALL WARNINGS BEFORE

ATTEMPTING TO OPERATE GENERATOR.

Risk of Injury and Property Damage When

Transporting Generator

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

Fire, Inhalation, Damage to

Fuel or oil can leak or spill and could

If generator is equipped with a fuel

Vehicle Surfaces

result in fire or breathing hazard, seri-

shut-offvalve, turn the valve to the

 

ous injury or death can result. Fuel or

off position before transporting to

 

oil leaks will damage carpet, paint or

avoid fuel leaks. If generator is not

 

other surfaces in vehicles or trailers.

equipped with a fuel shut-offvalve,

 

 

drain the fuel from tank before trans-

 

 

porting. Transport fuel only in an

 

 

OSHA approved container. Always

 

 

place generator on a protective mat

 

 

when transporting to protect against

 

 

damage to vehicle from leaks. Re-

 

 

move generator from vehicle imme-

 

 

diately upon arrival at your destina-

 

 

tion

 

 

 

RISK OF BREATHING - INHALATION HAZARD

H A Z A R D

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

Gasoline engines produce toxic car-

Breathing exhaust fumes will cause se-

Operate generator in clean, dry, well

bon monoxide exhaust fumes.

rious injury or death.

ventilated area. Never operate unit

 

 

in enclosed areas such as garages,

 

 

basements, storage, sheds, or in

 

 

any location occupied by humans or

 

 

animals. Keep children, pets and

 

 

others away from area of operating

 

 

unit.

 

 

 

D20508

6 — ENG

READ AND UNDERSTAND ALL WARNINGS BEFORE

ATTEMPTING TO OPERATE GENERATOR.

RISK OF UNSAFE OPERATION

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

 

Operation of generator in careless

All sources of energy include the po-

• Review and understand all of

manner.

tential for injury. Unsafe operation or

the operating instructions and

 

maintenance of your generator could

warnings in this manual.

 

lead to serious injury or death to you or

• Become familiar with the

 

others.

operation and controls of the

 

 

generator. Know how to shut it

 

 

off quickly.

 

 

• Equip area of operation with a

 

 

fire extinguisher certified to

 

 

handle gasoline or fuel fires.

 

 

• Keep children or others away

 

 

from the generator at all times.

 

 

 

 

Operation of voltage sensitive appli-

Any gasoline operated household gen-

Always use a U.L. listed voltage sen-

ances without a voltage surge pro-

erator will incur voltage variations caus-

sitive surge protector to connect

tector.

ing damage to voltage sensitive appli-

voltage sensitive appliances (TV,

 

ances or could result in fire.

computer, stereo, etc.). Failure to

 

 

use a U.L. listed voltage surge

 

 

protector will void the warranty on

 

 

your generator.

 

 

Notice: A multiple outlet strip is not

 

 

a surge protector make sure you use

 

 

a U.L. listed voltage surge protec-

 

 

tor.

 

 

 

 

Raising or suspending generators

Generator could fall causing serious in-

Always use proper connecting pro-

equipped with lift rings improperly

jury or death to you or others.

cedures as described in this manual

 

Improper raising or suspending can

when connecting cables, chains, or

 

straps for raising or suspending gen-

 

cause damage to the generator.

 

erators equipped with lift rings.

 

 

 

 

Always use cables, chains, or straps

 

 

rated at 2000 lbs working load or

 

 

more to raise or suspend generator.

 

 

 

Operating generator while sus-

Generator will not operate properly and

Never operate generator while sus-

pended

will cause damage to the generator and

pended or in an unlevel position.

 

could cause serious injury or death to

Always operate generate on a flat,

 

you or others.

level surface.

 

 

 

 

7 — ENG

D20508

READ AND UNDERSTAND ALL WARNINGS BEFORE

ATTEMPTING TO OPERATE GENERATOR.

RISK OF HOT SURFACES

 

 

 

 

 

 

 

 

HAZARD

 

WHAT COULD HAPPEN

HOW TO PREVENT IT

Contact with hot engine and generator components.

Contact with hot surfaces, such as engines exhaust components, could result in serious burns.

During operation, touch only the control surfaces of the generator. Keep children away from the generator at all times. They may not be able to recognize the hazards of this product.

RISK OF MOVING PARTS

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

Contact with moving parts can re-

The generator contains parts which ro-

Never operate generator with guard-

sult in serious injury.

tate at high speed during operation.

ing or cover plates removed. Avoid

 

These parts are covered by guarding

wearing loose fitting clothing or jew-

 

to prevent injury.

elry which could be caught by mov-

 

 

ing parts.

 

 

 

 

 

 

RISK FROM LIFTING

 

 

 

 

 

HAZARD

WHAT COULD HAPPEN

HOW TO PREVENT IT

 

 

 

 

 

Lifting a very heavy object.

Serious injury can result from attempt-

The generator is too heavy to be

 

 

 

ing to lift too heavy an object.

lifted by one person. Obtain assis-

 

 

 

 

tance from others before you try to

 

 

 

 

move it.

 

 

 

 

 

D20508

8 — ENG

ASSEMBLY

CARTON CONTENTS

1 - Parts Bag

 

 

1 - Owner's Manual

*1 - Twistlock

1 - Bottle of oil

 

 

 

Plug L14-30P

 

 

 

*

To be installed and/or used in

1 - Generator

1 - Handle

accordance with appropriate local electrical codes

 

 

and regulations. Refer to enclosed instructions for

1 - Parts Box

 

proper installation.

 

 

 

 

 

 

2 - Wheels

1 - Foot Bracket

1 - Isolator Foot

4 - 5/16-18x 3/4 "

7 - 5/16-18

 

Cap Screws

Lock Nuts

2 - Bracket

2 - 5/16-18x 1 3/4 "

2 - Washers

2 - 3/8-16

Cap Screws

 

Lock Nuts

2 - Shoulder

2 - Handle Caps

Bolts

 

Read owner’s manual. Do not attempt to operate equipment until you have read Owner’s Manual for Safety, Assembly, Operation, Maintenance, Storage Instructions.

TOOLS NEEDED FOR ASSEMBLY

1- Box Cutter or Knife

2 - 9/16 " Wrenches

2 - 1/2" Wrenches

1 - 1" thick x 1' square piece of wood

REMOVE GENERATOR FROM CARTON

Open carton from top.

Cut carton along dotted lines.

Remove all carton inserts.

Remove generator through opening in carton.

Using a 9/16 inch socket remove shipping block from under the generator head. Unscrew the bolt and remove the wood block. NOTE: It is very important that this is removed before starting your generator.

IMPORTANT: Before any attempt to start your generator be sure to check engine oil (See Adding Engine Oil paragraph in the Operation section on page 13 of this manual.)

9 — ENG

D20508

GROUNDING THE GENERATOR

A grounding lug is supplied with the generator for use when required by local electrical ordinances. Refer to article 250 of the National Electrical Code to clarify any needed grounding information. Your local electric company or a certified electrician should be able to help you with this information.

Grounding Lug

NOTE: Your engine is already grounded to the frame by a grounding strap.

INSTALLING WHEEL KIT

The Sears Wheel Kit was designed to greatly improve the portability of your generator.

Drain gas and oil before assembling the portability

kit. Failure to do so will cause damage to the engine.

NOTE: Always follow state regulations for proper oil disposal.

Place generator on level ground; drain all gas and oil from the engine (see engine manual for correct procedure).

Place a 1” thick x 1’ square piece of wood on the ground in front of the engine. With the help of another person, tilt the generator and rest the recoil starter on the wood. NOTE: This will support the gasoline engine during assembly and make assembly easier.

Place a handle cap (7) onto each end of handle prior to installation.

The handle should be installed on the electrical outlet end of the generator. Place one washer (12) on long cap screws (11). Align the handle brackets with the upper holes pre-drilledin the generator frame. Place mentioned screws through frame and handle brackets. Secure with lock nuts (8) and tighten.

Locate the engine support. Place one wheel bracket (4) on top of support as shown in illustration. Align with the pre-drilledholes in support. Place cap screw (9) through hole in bracket and support. Secure with lock nut (8) and tighten.

Insert one shoulder bolt (2) into wheel (1). Insert threaded end of bolt through wheel bracket, secure with lock nut (3) and tighten. NOTE: The wheel will not rub frame if installed properly.

Repeat the above steps for the opposite side.

Insert the threaded stud of rubber foot (10) through the middle hole of the foot bracket (5). Secure with lock nut (8) and tighten.

Locate the support under the electrical outlet end of the generator. Position foot bracket (5), with rubber foot installed, under the support and align the holes in the foot bracket (5) with the slots in the support. Place one cap screw (9) through each slot in the support and the holes in the foot bracket. Secure with the lock nuts (8) and tighten.

Once completed, the wheel kit is ready for use.

D20508

10 — ENG