Craftsman 580.327141 User Manual [en, es]
Owner’s Manual
7.8 Horsepower 4200 Watt
AC GENERATOR
Model No. 580.327141
HOURS: Mon. - Fri. 8 a.m. to 5 p.m. (CT)
CAUTION:
Before using this product, read this
manual and follow all its Safety Rules
and Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
Visit our Craftsman website: www.sears.com/craftsman
Part No. B2552 Draft 5 (6/27/2000) Printed in the U.S.A.
Safety
Assembly
Operation
Maintenance
Parts
Español
TABLE OF CONTENTS
Warranty..................................................................2
Safety Rules............................................................3
Assembly ................................................................4
Operation ..........................................................5-10
Product Specifications..........................................11
Maintenance
Storage..................................................................15
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11-14
Troubleshooting
Schematic
Wiring Diagram
Replacement Parts
Emissions Warranty..............................................29
Español ...........................................................30-47
How to Order Parts
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20-27
Back Page
16
18
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WARRANTY
LIMITED WARRANTY FOR DELUXE PORTABLE GENERATORS
SEARS warrants to the original purchaser that the alternator and engine for its portable generator will be free
from defects in materials or workmanship for the items and period set forth below from the date of original pur
chase. This warranty is not transferable and applies only to portable generators driven by the GN-Series Sears
warranted engine.
CONSUMER*
Alternator 2 years (2nd year parts only)
Engine 2 years (2nd year parts only)
* NOTE: For the purpose of this warranty “Consumer Use” means personal residential household and emergency
use by original purchaser, not to be used as a primary source of power. “Commercial Use” means all other uses,
including rental, construction, commercial, and income producing purposes. Once a generator has experienced
commercial use, it shall thereafter be considered a commercial use generator for the purpose of this warranty.
During said warranty period, SEARS will, at its option, repair or replace any part which, upon examination by
SEARS, is found to be defective under normal use and service**. Starting batteries are not warranted by
SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by
the purchaser and prepaid by him. This warranty does not cover normal maintenance and service and does not
apply to a generator set, alternator or engine, or parts which have been subjected to improper or unauthorized
installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance,
repair or storage so as, in SEARS’s judgment, to adversely affect its performance and reliability.
COMMERCIAL*
1 year
1 year
** NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to
perform well. This warranty will not cover repair when normal use has exhausted the life of a part or engine.
THERE IS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL IMPLIED WAR
RANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PAR
TICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE DURATION OF ANY IMPLIED WAR
RANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE
EXPRESS WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER
ANY AND ALL WARRANTIES IS EXCLUDED. Some provinces do not allow limitations on how long an implied
warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or
exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other
rights, which vary from state to state.
For service, see your nearest SEARS authorized warranty service facility. Warranty service can be performed
only by a SEARS authorized service facility. This warranty will not apply to service at any other facility. At the
time of requesting warranty service, evidence of original purchase date must be presented.
SEARS, ROEBUCK and CO., D/817WA, Hoffman Estates, IL 60179 U.S.A.
SAFETY RULES
CAUTION! Before using this product, read this
manual and follow all Safety Rules and
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Operating Instructions.
WARNING:
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
DANGER! This generator is designed for
outdoor use only. Do Not use this generator
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inside any building or enclosure including the
generator compartment of a recreational vehicle
(RV). Fire or an explosion may result. No user
performed modifications, including venting of
exhaust and/or cooling ventilation, will eliminate
the danger. Also, allow at least two feet of
clearance on all sides of the generator even
while operating the unit outdoors.
CAUTION! Always disconnect spark plug wire
and place the wire where it cannot contact the
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spark plug. To prevent accidental starting when
setting up, transporting, adjusting or making
repairs to your generator.
The generator produces dangerously high voltage
that can cause extremely hazardous electrical
shock. Avoid contact with bare wires, terminals,
etc. Never permit any unqualified person to
operate or service the generator.
Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet. Dangerous electrical shock
will result.
The National Electric Code requires the frame and
external electrically conductive parts of generators
to be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the generator. Consult with a
local electrician for grounding requirements in your
area.
Use a ground fault circuit interrupter in any damp
or highly conductive area (such as metal decking or
steel work).
Do Not use worn, bare, frayed or otherwise
damaged electrical cord sets with the generator.
Using a defective cord set may result in electrical
shock or damage to equipment and/or property.
Operate generator only on level surfaces and
where it will not be exposed to excessive moisture,
dirt, dust or corrosive vapors.
• Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do Not permit smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine.
Comply with all laws regulating storage and
handling of gasoline.
• Never add fuel while unit is running.
• Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can
overflow onto a hot engine and cause FIRE or an
EXPLOSION.
• Never store the generator with fuel in the tank
where gasoline vapors might reach an open flame,
spark, or pilot light (as on a furnace, water heater
or clothes dryer). FIRE or an EXPLOSION might
result.
• Generator exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air where adequate
ventilation is available.
• Allow at least 2 feet of clearance on all sides of the
generator, even while operating unit outdoors, or
damage may occur. Never operate the unit inside
any room or enclosure where the free flow of
cooling air into and out of the unit might be
obstructed.
• Never start or stop the unit with electrical loads
connected to receptacles and with the connected
devices turned ON. Start the engine and let it
stabilize before connecting electrical loads.
Disconnect all electrical loads before shutting down
the generator. See page 9 for “Cold Weather
Operation”.
• Do Not insert any object through cooling slots of
the unit.
• Never operate the generator:
(a) in rain; (b) in any enclosed compartment; (c)
when connected electrical devices overheat; (d) if
electrical output is lost; (e) if engine or generator
sparks; (f) if flames or smoke are observed while
unit is running; (g) if unit vibrates excessively.
NOTE: The generator is equipped with a spark
arrester muffler that must be maintained in working
order by the owner/operator. In the State of California,
a spark arrester is required by law (Section 4442 of
the California Public Resources Code). Cther states
may have similar laws. Federal laws apply on federal
lands.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Cbey all safety
messages that follow this symbol to avoid possible injury or death.
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ASSEMBLY
Your Craftsman generator requires some assembly
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 1-800-222-3136.
IMPORTANT: Any attempt to run the engine before it
has been serviced with the recommended oil will result
in an engine failure.
TO REMOVE THE GENERATOR
FROM CARTON
• Set the carton on a rigid flat surface with “THIS
SIDE UP” arrows pointing upward. See “Cold
Weather Operation” on page 9 before cutting
carton.
• Carefully open the top flaps of the shipping carton.
• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.
• Remove all packing material, carton filters, etc.
• Remove the generator from the shipping carton.
CARTON CONTENTS
Check all contents. If any parts are missing or
damaged, call the generator helpline at
1-800-222-3136.
The carton contains:
• The main unit
• Battery charge cables
• Spark plug
• Air filter
• Spark plug wrench
• Owner’s manual
• Engine oil
• Wheel kit
ASSEMBLING THE WHEEL KIT
The wheel kit is designed to improve the portability of
your generator.
To install the wheel kit, you need the following tools:
• 15/16" box, open end or socket wrench.
• (2) 13mm box, open end or socket wrenches.
Install wheel kit as follows (refer to illustration below):
• Place the bottom of the generator cradle on a flat,
even surface.
• Place axle stud through metal tab on cradle frame.
• Use a 15/16 inch wrench to secure the axle stud to
frame with 5/8-18 Jam nut.
• Install the other axle stud in the same manner.
NOTE: Be sure to install the wheel with raised hub
inboard.
• Tip unit and install wheel.
• Retain wheel on axle stud with retaining pin and
flat washer. Install other wheel on remaining axle
shaft In the same manner.
• Remove the two front nuts and lock washers from
vibration mounting with 13mm wrench. Use these
nuts to retain the mounting leg.
Wheel Kit
OPERATION
KNOW YOUR GENERATOR
Read the owner’s manual and safety rules before operating your generator.
Compare the illustrations with your generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
Fuel Tank
120/240 Vo
Locking Re*
Air Cleaner
Circuit Breakers
120 Volt AC, 30 Amp
Locking Receptacle
12 Volt DC
Receptacle
12 Volt DC Receptacle —This receptacle allows you
to recharge a 12 Volt automotive or utility style storage
battery with the battery charge cables provided.
120 Volt AC, 15 Amp, Duplex Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC at 15 Amp, single phase, 60 Hz, electrical
lighting, appliance, tool and motor loads.
120 Volt AC, 30 Amp, Locking Receptacle — May
be used to supply electrical power for the operation of
120 Volt AC at 30 Amp, single phase, 60 Hz, electrical
lighting, appliance, tool and motor loads.
120/240 Volt AC, 20 Amp, Locking Receptacle —
May be used to supply electrical power to 120 and/or
240 Volt AC at 20 Amp, single phase, 60 Hz, electrical
lighting, appliance, tool and motor loads.
Air Cleaner — Filters intake air as it is drawn into the
engine.
Idle Control
Switch
Run/Stop Switch
Choke Lever
Spark Arrester Muffler
120 Volt AC, 15 Amp
Duplex Receptacle
Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided
with a push to reset circuit breaker to protect the
generator against electrical overload.
Fuel Tank — Tank holds 4 U.S. gallons of unleaded
gasoline.
Idle Control Switch — The idle control runs the
engine at normal (high) speeds when there is a load
present and runs the engine at idle (low) speeds when
a load is not present.
Run/Stop Switch — Must be in “Run” position to start
engine. Set to “Stop” to stop the unit.
Spark Arrester Muffler — Muffler lowers engine
noise and is equipped with a spark arrester screen.
CORD SETS AND CONNECTOR
PLUGS
120 Volt AC Duplex Receptacle
Use only high quality, well-insulated, extension cords
with the generator’s 120 Volt electrical receptacles.
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4-Wire Cord Set
A NEMA L14-20 mating connector plug is required for
use with this 240 Volt receptacle. Connect a suitable
4-wire cord set to the plug and to the desired load.
The cord set should be rated for 250 Volt AC loads at
20 Amps.
Each receptacle is protected against overload by a
single push-to-reset circuit breaker. Use each
receptacle to operate 120 Volt AC, single phase,
60 Hz, electrical loads requiring up to 1,800 watts
(1.8 kW) at 15 Amps of current.
CAUTION! Although each receptacle is rated
for 120 Volts at 15 Amps (1,800 watts or
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Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
electrical devices. Some devices, however, may not
require this type of extension cord. Check the owner’s
manuals of those devices for the manufacturer’s
recommendations.
Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
1.8 kW), the generator is rated for a total of
4,200 watts. Powering loads that exceed the
wattage capacity of the generator can damage it
or cause serious injuries. The total 120 Volt load
powered through these receptacles should not
exceed 15 Amps.
125 AC Volts at 15 Amps (or greater) for most
120/240 Volt AC, 20 Amp Receptacle
This is a full capacity receptacle which means you can
take the generator’s full rated wattage from this single
NEMA L14-20 receptacle. The outlet is protected by a
20 Amp push-to-reset circuit breaker.
CAUTION! Although this outlet is rated for
240 Volts AC at 20 Amps, the generator is
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capable of producing only 17.5 Amps at
240 Volts AC.
120 Volt AC, 30 Amp Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect
a 3-wire cord set rated for 125 Volts AC at 30 Amps to
the plug.
3-Wire Cord Set
Neutral
120V
Hot
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3,600 watts
(3.6 kW) of power at 30 Amps. The outlet is protected
by a 30 Amp push-to-reset circuit breaker.
12 Volt DC Receptacle
This receptacle allows you to recharge a 12 Volt
automotive or utility style storage battery with the
battery charge cables provided. This receptacle can
not recharge 6 Volt batteries and can not be used to
crank an engine having a
discharged battery. See the
sections “Battery Safety” and
“Charging a Battery” (page 9)
before attempting to recharge a
battery.
HOW TO USE YOUR GENERATOR
If you have any problems operating your generator,
please call the generator helpline at 1-800-222-3136.
Grounding The Generator
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 may also require proper
grounding of the unit. For that purpose, a grounding
wing nut is provided on the base of the cradle.
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding nut and
to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against
electrical shock. However, local codes may vary
widely. Consult with a local electrician for grounding
requirements in your area.
Proper grounding of the generator will help prevent
electrical shock in the event of a ground fault condition
in the generator or in connected electrical devices.
Proper grounding also helps dissipate static electricity,
which often builds up in ungrounded devices.
Although multi-viscosity oils (5W30, 10W30, etc.)
improve starting in cold weather, these multi-viscosity
oils will result in increased oil consumption when used
above 32°F. Check your engine oil level more
frequently to avoid possible damage from running low
on oil.
• Place generator on a level surface and remove the
yellow oil fill cap. Add engine oil until level is at
point of overflowing. Check engine oil level before
starting each time thereafter.
• Install oil fill plug, finger tighten securely.
Add Gasoline
WARNING! NEVER fill fuel tank indoors.
NEVER fill fuel tank when engine is running or
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hot. DO NOT light a cigarette or smoke when
filling the fuel tank.
CAUTION! Do Not overfill the fuel tank.
Always leave room for expansion.
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Use regular UNLEADED gasoline with the
generator engine. Do Not use premium gasoline.
Do Not mix oil with gasoline.
Clean area around fuel fill cap, remove cap.
Slowly add unleaded regular gasoline to fuel tank.
Be careful not to overfill. Allow about 1/2" of tank
space for fuel expansion, as shown here.
Before Starting The Generator
To operate the engine you will need to do the
following:
Add Engine Oil
NOTE: When adding oil to the engine crankcase in the
future, use only high quality detergent oil rated with API
service classification SF or SG rated SAE 30 weight. Use
no special additives. Select the oil's viscosity grade
according to your expected operating temperature:
colder
5W-30
32°F warmer
SAE 30 or 10W-30
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in fuel system parts such as the
carburetor, fuel hose or tank during storage. Alcohol-
blended fuels (called gasohol, ethanol or methanol)
can attract moisture, which leads to separation and
formation of acids during storage. Acidic gas can
damage the fuel system of an engine while in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See
“Storage” on page 15. Never use engine or carburetor
cleaner products in the fuel tank or permanent
damage may occur.
To Start The Engine
WARNING! Never start or stop engine with
electrical devices plugged into the panel
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receptacles AND turned on.
• Unplug all electrical loads from generator
receptacles before starting the engine.
• Make sure the unit is in a level position.
• Turn the fuel shut-off valve to ON position.
Locate the Idle Control On/Off switch on the control
panel and set it to the “Off position.
Place the Run/Stop switch in the “Run” position.
Move engine choke lever to the “Full” choke
position.
Connecting Electrical Loads
• Do Not connect 240 Volt loads to the 120 Volt
duplex receptacles.
• Do Not connect 3-phase loads to the generator.
• Do Not connect 50 Hz loads to the generator.
• Plug in and turn on the desired 120 and/or 240 Volt
AC, single phase, 60 Hertz, electrical loads. DC
NCT CVERLCAD THE GENERATCR. See “Don’t
Cverload the Generator” on page 10.
Stopping the Engine
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with
electrical devices plugged in and turned on.
• Turn “Off” the Idle Control switch.
• Let engine run at no-load for several minutes to
stabilize the internal temperatures of engine and
generator.
• Move Run/Stop switch to the “Stop” position.
• Close the fuel valve.
Operating Automatic Idle Control
This switch is designed to greatly improve fuel
economy. When this switch is turned “On,” the engine
will only run at its normal high governed engine speed
while an electrical load is connected. When the
electrical load is removed, the engine will run at a
reduced speed. With the switch “Off,” the engine
always runs at the normal high engine speed. Always
have the switch Off when starting and stopping
the engine.
CAUTION! Never run engine indoors or in
enclosed poorly ventilated areas. Engine
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exhaust contains carbon monoxide, an odorless
and deadly gas.
WARNING! Temperature of muffler and nearby
areas may exceed 150°F (65°C). Avoid these
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areas.
• Grasp starter handle and pull slowly until you feel
some resistance. Then pull with one rapid full arm
stroke. Let rope return slowly. Do Not let rope
“snap back” against starter.
• If engine starts, move choke lever to “Run”
position. Allow engine to warm up for two minutes
before applying load to generator.
• If engine falters, move choke lever to “Half” choke
position and pull starter handle twice.
NOTE: If engine fails to start after 3 pulls, move the
choke lever to “Full” position and repeat starting
instructions.
• Set the Idle Control Cn/Cff switch to the “On”
position.
Low Oil Pressure Shutdown System
The engine is equipped with a low oil pressure sensor
that shuts down the engine automatically when the oil
pressure drops below 6 psi. If the engine shuts down
by itself and the fuel tank has enough gasoline, check
engine oil level.
Initial Start-up
A delay built in the low oil shutdown system allows oil
pressure to build during starting. The delay allows the
engine to run for about 10 seconds before sensing oil
pressure.
Sensing Low Pressure
If the system senses low oil pressure during operation,
the engine shuts down. As the system shuts down, the
low oil light comes CN. However, once the engine has
stopped rotating, this light will go CFF.
Restarting
If you try to restart the engine within 10 seconds after
it shuts down, the engine may NCT start. The system
needs 5 to 10 seconds to reset.
If you do restart the engine after such a shutdown and
have not corrected the low oil pressure, the engine
runs for about 10 seconds as described above and
then stops.
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. In an emergency, use the
original shipping box as a temporary shelter:
• Cut off all flaps and one of the long sides of the
box to expose exhaust side of unit. Cut appropriate
slots to access receptacles of unit.
• Start unit, then place box over it. Ensure a
minimum of two feet clearance between open side
of box and nearest object.
IMPORTANT: Remove shelter when temperature is
above 40T [4°C].
For a more permanent shelter, build a structure that
will enclose three sides and the top of the generator.
Make sure entire muffler-side of generator is exposed,
with two feet clearance between open side of box and
nearest object. Face exposed end away from wind
and elements.
Wind
DANGER! Do Not permit smoking, open
flame, sparks or any other source of heat
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around a battery. 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. If spill occurs, flush area
with clear water immediately.
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:
• Check fluid level in all battery cells. If necessary,
add ONLY distilled water to cover separators in
battery cells. Do Not use tap water.
• If the battery is equipped with vent caps, make
sure they are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to
panel receptacle identified by the words
“12-VOLTS DC”
• Connect battery charge cable clamp with red
handle to the positive (+) battery terminal.
CHARGING A BATTERY
DANGER! Storage batteries give off explosive
hydrogen gas while recharging. An explosive
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mixture will remain around the battery for a long
time after it has been charged. The slightest
spark can ignite the hydrogen and cause an
explosion. Such an explosion can shatter the
battery and cause blindness or other serious
injury.
• Connect battery charge cable clamp with black
handle to the negative (-) battery terminal.
• Start engine. Let the engine run while battery
recharges.
• 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.
DON’T OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to the generator and to
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to
be connected at one time. This total should NOT
be greater than the generator’s wattage capacity.
• The rated wattage of lights can be taken from light
bulbs. The rated wattage of tools, appliances and
motors can usually be found on a data plate or
decal affixed to the device.
• If the appliance, tool or motor does not give
wattage, multiply volts times ampere rating to
determine watts (volts x amps = watts).
WATTAGE REFERENCE GUIDE
• Some electric motors, such as induction types,
require about three times more watts of power for
starting than for running. This surge of power lasts
only a few seconds when starting such motors.
Make sure you allow for this high starting wattage
when selecting electrical devices to connect to your
generator.
1. Figure the watts needed to start the largest
motor.
2. Add to that figure the running watts of all other
connected loads.
The Wattage Reference Guide below is provided to
assist you to determine how many items your
generator can operate at one time.
Device
*Air Conditioner (12,000 Btu)
*Air Conditioner (24,000 Btu)
*Air Conditioner (40,000 Btu)
Battery Charger (20 Amp)
Belt Sander (3")...................................................1000
Chain Saw...........................................................1200
Circular Saw (6-1/2")
‘Clothes Dryer (Electric)
‘Clothes Dryer (Gas)..............................................700
‘Clothes Washer
Coffee Maker.......................................................1750
‘Compressor (1 HP)............................................ 2000
‘Compressor (3/4 HP)..........................................1800
‘Compressor (1/2 HP)..........................................1400
Curling Iron............................................................700
‘Freezer
‘Dehumidifier..........................................................650
Disc Sander (9")..................................................1200
Edge Trimmer........................................................500
Electric Blanket......................................................400
Electric Nail Gun
Electric Range (per element)
Electric Skillet......................................................1250
‘Furnace Fan (3/5 HP)...........................................875
‘Garage Door Opener
Hair Dryer............................................................1200
Hand Drill
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Load (watts)
800 to 1000
500 to 750
250 to 1100
1700
3800
6000
500
5750
1150
700
1200
1500
Device
Hedge Trimmer
Impact Wrench
Iron......................................................................1200
‘Jet Pump...............................................................800
Lawn Mower........................................................1200
Light Bulb
Microwave Oven........................................ 700 to 1000
‘Milk Cooler..........................................................1100
Oil Burner on Furnace.........................................300
Oil Fired Space Heater (140,000 Btu)...................400
Oil Fired Space Heater (85,000 Btu).....................225
Oil Fired Space Heater (30,000 Btu).....................150
‘Paint Sprayer, Airless (1/3 HP)
Paint Sprayer, Airless (handheld)
Radio...........................................................50 to 200
‘Refrigerator...........................................................700
Slow Cooker..........................................................200
‘Submersible Pump (1-1/2 HP)
‘Submersible Pump (1 HP)................................. 2000
‘Submersible Pump (1/2 HP)...............................1500
‘Sump Pump
‘Table Saw (10")
Television.................................................... 200 to 500
Toaster.................................................... 1000 to 1650
Weed Trimmer.......................................................500
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* Allow 3 times the listed watts for starting these devices.
Load (watts)
450
500
100
600
150
2800
800 to 1050
1750 to 2000
10
MAINTENANCE
MAINTENANCE SCHEDULE
Follow the hourly or calendar Intervals, whichever occurs first.
More frequent service Is required when operating In adverse conditions noted below.
Maintenance
Operation
Check Oil Level
Service Air Cleaner Pre
Cleaner
Change Oil and Oil Filter^
Service Air Cleaner
Cartridge
Adjust valve Clearance
Retorque Head Bolts
Clean Spark Arrestor Screen
Replace Spark Plugs
Clean more often under dirty or dusty conditions. Replace air cleaner parts if very dirty.
■ Change oil after first 8 hours of operation then after every 50 hours or every season.
* Change oil and oil filter every 25 hours when operating under heavy load or in high temperatures.
‘ Perform this task only after first 50 hours of operation. Head bolts will not need further retorquing.
PRODUCT SPECIFICATIONS
Generator Specifications
Rated Maximum Power
Surge Power............................... 5,000 Watts (5.0 kW)
Rated AC Voltage
Rated Maximum Current
at 240 Volts
Rated Maximum Current
at 120 Volts
Rated Frequency
Phase
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Engine Specifications
Rated Horsepower
Displacement
Spark Plug Type:........................Champion RC12YC or
Set Gap To:
Gasoline Capacity
Oil
Summer
Winter
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Every 8 Hours 25 Hours or 50 Hours or 100 Hours or
or Daily
X
Every Season Every Season Every Season
X"
X^
X
X"
GENERAL RECOMMENDATIONS
The generator warranty does not cover items that
4,200 Watts (4.2 kW)
120/240 Volts
17.5 Amperes
35.0 Amperes
60 Hz at 3600 rpm
Single Phase
7.8 at 3600 rpm
220 cc
Equivalent
0.030inch (0.76mm)
4 U.S. gallons
Sae 30 or 10W-30
SAE 5W-30
have been subjected to operator abuse or negligence.
To receive full value from the warranty, the operator
must maintain the unit as instructed in this manual.
Some adjustments will need to be made periodically
to properly maintain the generator.
All adjustments in the Service and Adjustments
section of this manual should be made at least once
each season. Follow the requirements in the
“Maintenance Schedule” chart above.
NOTE: Once a year you should clean or replace the
spark plug and replace the air filter. A new spark plug
and clean air filter assure proper fuel-air mixture and
help your engine run better and last longer.
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.
X
X
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Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
CAUTION! Never insert any object or tool
through the air cooling slots, even if the engine
A
is not running.
NOTE: Do Not use a garden hose to clean generator.
Water can enter the engine fuel system and cause
problems. In addition, if water enters the 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.
To clean the generator:
• Use a damp cloth to wipe exterior surfaces clean.
• A soft, bristle brush may be used to loosen caked
on dirt, oil, etc.
• 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 away dirt. Inspect cooling air slots
and openings on the generator. These openings
must be kept clean and unobstructed.
ENGINE MAINTENANCE
DANGER! When working on the generator,
always disconnect spark plug wire from spark
A
plug and keep it away from spark plug.
Change oil while engine is still warm from running, as
follows:
• Clean area around oil drain plug.
• Remove oil drain plug and oil fill plug. Drain oil
completely into a suitable container.
• When oil has completely drained, install oil drain
plug and tighten securely.
• Place a suitable container beneath the oil filter and
turn filter counterclockwise to remove. Discard oil
and filter according to local regulations.
• Coat gasket of new filter with engine oil. Turn filter
clockwise until gasket contacts tightly with filter
adapter, then tighten an additional 3/4 turn.
• Fill oil sump with recommended oil. See “Before
Starting the Generator” on page 7 for oil
recommendations.
• Install the oil fill plug and tighten securely.
• Wipe up any spilled oil.
Clean/Replace Spark Plug
Change the spark plug every 100 hours of operation
or once each year, whichever comes first. This will
help your engine to start easier and run better.
Replace with recommended plug.
• Clean area around spark plug.
• Remove and inspect spark plug.
• Check electrode gap with wire feeler gauge and set
spark plug gap to 0.030 inch (0.76mm) if
necessary.
Checking Oil Level
Oil level should be checked prior to each use or at
least every 8 hours of operation. Keep oil level
maintained.
Changing Engine Oil and Oil Filter
Change oil after first 8 hours of operation. Change oil
and oil filter every 50 hours thereafter. If you are using
your generator under extremely dirty or dusty
conditions, or in extremely hot weather, change oil
more often.
Replace spark plug if electrodes are pitted, burned
or porcelain is cracked.
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Service Air Cleaner
Your engine will not run properly and may be
damaged if you run it using a dirty air cleaner. Clean
or replace the air cleaner paper filter once every
50 hours of operation or once a year, whichever
comes first. Clean or replace more often if operating
under dusty or dirty conditions. Clean foam precleaner
every 25 hours of operation or sooner under dusty
conditions.
To clean or replace foam precleaner:
• Remove air cleaner cover, then the foam pre-filter.
• Wash precleaner in soapy water. Squeeze pre-filter
dry in the clean cloth. Do Not twist.
• Clean air cleaner cover before installing it.
Clean Spark Arrester Screen
The engine exhaust muffler includes a spark arrester
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
NOTE: If you use your generator on any forest-
covered, brush-covered or grass-covered unimproved
land, it must have a spark arrester. The spark arrester
must be maintained in good condition by the
owner/operator.
Clean and inspect the spark arrester screen as follows:
• To remove the heat shield from the muffler, remove
the screws that connect the shield to the muffler.
• Remove the screws that attach the spark arrester
screen.
To clean or replace paper air filter:
• Remove air cleaner cover; then remove foam pre
filter (service if necessary) and remove paper filter.
• Clean paper filter by tapping it gently on a solid
surface. If the filter is too dirty, replace it with a new
one. Dispose of the old filter properly.
• Clean air cleaner cover then insert precleaner into
cover. Next insert new paper filter into cover to
hold precleaner in place and assemble all of them
to the base of the air cleaner.
NOTE: If you need to order a new air filter, please call
1-800-366-PART.
Inspect screen and replace if torn, perforated or
otherwise damaged. Do Not use a defective
screen. If screen is not damaged, clean it with
commercial solvent.
Reattach the screen and the heat shield.
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Retorque Head Bolts
After the first 50 hours of operation, you must retorque
the head bolts to 4.0 kg.-m. (22 ft.-lbs.)
IMPORTANT: If you feel uncomfortable about doing
this procedure or you don’t have the proper tools,
please take the unit to your nearest service center to
retorque the head bolts. This is a very important step
to insure the longest life for your engine.
NOTE: Only perform this adjustment after the first
50 hours of operation. The head bolts will need no
further adjustment.
• Torque sequence Is as follows: A, B, C, D, E (star
pattern).
C
Adjusting Valve Clearance
After the first 50 hours of operation, you should adjust
the valve clearance In the engine.
IMPORTANT: If you feel uncomfortable about doing
this procedure or you don’t have the proper tools,
please take the unit to your nearest service center to
have the valve clearance adjusted. This is a very
important step to insure the longest life for your
engine.
NOTE: You must hold the rocker arm jam nut In place
as you turn the pivot ball stud.
When valve clearance Is correct, hold the pivot ball
stud in place with the alien wrench and tighten the
rocker arm jam nut. Tighten the jam nut to
65-85 inch-pounds torque. After tightening the jam
nut, recheck valve clearance to make sure It did
not change.
To adjust valve clearance:
• Make sure the engine is at room temperature.
• Make sure that the spark plug wire is removed from
the spark plug and out of the way.
• Remove the breather tube from the valve cover.
• Remove the four screws attaching the valve cover
with a #2 or 3 phillips screwdriver.
• Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston at TDC, pull on the recoil handle
slowly watching the piston through the spark plug
hole. As you pull on the recoil handle the piston
should move up and down. The piston is at TDC
when it is up as high as it can go.
• Using a 10mm wrench, loosen the rocker arm jam
nut. Use an 8mm alien wrench to turn the pivot ball
stud while checking clearance between the rocker
arm and the valve stem with a feeler gauge.
Correct clearance Is 0.002-0.004 Inch
(0.05-0.1mm).
Reattach the valve cover, making sure the gasket
between the valve cover and cylinder head is in
place. Start all four screws before tightening or you
will not be able to get all the screws In place.
Reattach the breather tube.
Reattach the spark plug wire to the spark plug.
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STORAGE
GENERAL
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 information as a
guide to prepare it for storage.
WARNING! NEVER store engine with fuel in
tank indoors or in enclosed, poorly ventilated
A
areas where fumes may reach an open flame,
spark or pilot light as on a furnace, water heater,
clothes dryer or other gas appliance.
LONG TERM STORAGE
It is important to prevent gum deposits from forming in
essential fuel system parts such as the carburetor, fuel
filter, fuel hose or tank during storage. Also,
experience indicates that alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture,
which leads to separation and formation of acids
during storage. Acidic gas can damage the fuel
system of an engine while in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. Follow
these instructions:
Protect Fuel System
• Remove all gasoline from the fuel tank to prevent
gum deposits from forming on these parts and
causing possible malfunction of engine.
WARNING! Drain fuel into approved container
outdoors, away from open flame. Be sure
A
engine is cool. Do Not smoke.
Run engine until engine stops from lack of fuel.
Change Oil
While engine is still warm, drain oil from crankcase.
Refill with recommended grade.
Oil Cylinder Bore
• Remove spark plug and pour about 1/2 ounce
(15ml) of engine oil into the cylinder. Cover spark
plug hole with rag. Crank slowly to distribute oil.
CAUTION! Avoid spray from spark plug hole
when cranking engine slowly.
A
• Install spark plug. Do Not connect spark plug wire.
GENERATOR
• Clean the generator as outlined on page 12 (“To
Clean the Generator”).
• Check that cooling air slots and openings on
generator are open and unobstructed.
OTHER STORAGE TIPS
• Do Not store gasoline from one season to another.
• Replace the gasoline can if it starts to rust. Rust
and/or dirt in your gasoline will cause problems.
• If possible, store your unit indoors and cover it to
give protection from dust and dirt. BE SURE TO
EMPTY THE FUEL TANK.
• Cover your unit with a suitable protective cover that
does not retain moisture.
DANGER! NEVER cover your generator while
A
engine and exhaust area are warm.
Store generator in clean, dry area.
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