Craftsman 580327203 Owner’s Manual

Operators Manual

CRRFTSHRN°

120/240 Volt Electric Start

10000 Watt

AC GENERATOR

Model No 580.327203

CusGemneraHt°lpline_

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

Visit our Craftsman website: www.sears.com/craftsman

Part No. B4659 Draft 1 (10/1/1999) Printed in the U.S.A.

60179

• Safety

• Assembly

• Operation

• Maintenance

• Parts

• Espahol

Warranty ................................. 2

Safety Rules .............................. 3

Assembly ................................. 4

Operation .............................. 5-12

Product Specifications ...................... 13

Maintenance ........................... 13-16

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

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

Wiring Diagram/Schematic ................ 20-21

Replacement Parts ...................... 22-33

Emissions Warranty ..................... 34-34

EspaSol .............................. 36-55

How to Order Parts .................. Back Page

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

purchase. This warranty is not transferable and applies only to portable generators driven by the Sears

warranted engine.

CONSUMER* COMMERCIAL*

Alternator 2 years (2nd year parts only) 1 year Engine 2 years (2nd year parts only) 1 year

* 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.

** 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 WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE DURATION

OF ANY IMPLIED WARRANTIES 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 states 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

LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. IT MEANS "ATTENTION!!! BECOME ALERT!!!

YOUR SAFETY IS INVOLVED."

CAUTION! Before using this product, read

this manual and follow all Safety Rules and

Operating Instructions.

DANGER! This generator is designed for outdoor use only. Do not use this generator 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 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 an 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 generator

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 any defective cord set may result in

electrical shock or damage to 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 generator with fuel in tank where gasoline vapors might reach an open flame or spark or pilot light (as on a furnace, water heater or clothes dryer). FIRE or EXPLOSION may 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 generator, even while operating unit outdoors, or

you could damage the unit. Never operate the unit

inside a 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.

• Do not insert any object through cooling slots of the unit.

• Never operate generator (a) in rain; (b) in any enclosed compartment; (c) if 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: Your generator is equipped with a spark arrestor muffler, the spark arrestor must be maintained in effective working order by the owner/ operator. In the State of California a spark arrestor is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

Yourgeneratorrequiressomeassemblyandisready foruseafterithasbeenproperlyservicedwiththe

recommendedoilandfuel. Ifyouhaveanyproblemswiththeassemblyof

yourgenerator,pleasecallthegeneratorhelpline at1-800-222-3136.

Important:Anyattempttoruntheenginebeforeithas beenservicedwiththerecommendedoilwillresultin

anenginefailure. TO REMOVE THE GENERATOR

FROM CARTON

• Set the palleted carton on a rigid flat surface.

• Carefully cut bands around the shipping carton.

• Lift carton off the generator.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping pallet.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged, call the generator helpline at

1-800-222-3136. Contents include:

• 10,000 Watt generator

• Battery charge cables

• 3 Locking plugs

• Owner's manual

• Engine oil

• Battery hold down components

INSTALLING TRAY AND BATTERY

NOTE: The generator can be started manually. If you choose not to use the electric start feature of this

generator, you do not need to install the battery. Purchase and install a 12 Volt DC battery (Sears

DieHard 28-27135). The battery should be serviced with electrolyte fluid and fully charged prior to

installation.

Install the battery as follows:

• Locate the battery fasteners and wires shipped loose in the carton. Included are 7" bolts, lock

washers, flat washers, battery hold down bracket, and hex nuts. In addition you should have one M8 x 1.25 inch bolt to attach the black battery cable to the engine.

• Set battery onto tray as shown.

• Secure battery with the 7" bolts, lock washers, flat washers, hold down bracket, and hex nuts as

shown.

Connect the red battery cable to the engine starter switch.

Connect :h_ red battery

cable to this connection on

the electric

starter switch.

• Connect the red battery cable from the electric starter switch to positive (+) post on the battery.

• Connect the black battery cable to the engine using the M8 x 1.25 inch bolt.

Connect black battery

cable here using M8 x

1.25 bolt.

_ CAUTION! Be sure the black cable isconnected to the engine mount and not the

frame. You could damage the ground wire.

• Connect the other end of the black battery cable to the negative (-) battery post.

• Double check all connections to insure they are in the correct locations.

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 Shut-off Fuel Tank

Valve

Circuit Breakers (AC)

Hour Meter

Run/Stop Switch

Idle Control Switch

12 Volt DC, 10 Amp Receptacle

120 Volt AC, 20 Amp

GFCI Duplex Receptacle

120 Volt AC, 20 Amp

Locking Receptacle 120 Volt AC, 30 Amp

J Button

120/240 Volt AC,

50 Amp Receptacle

120/240 Volt AC, 30 Amp Locking Receptacle

Grounding Lug

Locking Receptacle

Electric Start

Air Cleaner (on top of engine)

Choke Lever

Spark Arrestor Muffler

12 Volt DC, 10 Amp Receptacle --This receptacle allows you to recharge a 12 Volt DC storage battery with provided battery charge cable.

120 Volt AC, 20 Amp Locking Receptacle -- Supplies electrical power for the operation of 120 Volt

AC, 20 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120 Volt AC, 20 Amp, GFCI, Duplex Receptacles --

Each socket supplies electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical

lighting, appliance, tool and motor loads. Circuits are

protected with a ground fault interrupt device.

120 Volt AC, 30 Amp Locking Receptacle -- Supplies electrical power for the operation of 120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle -- Supplies 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.

120/240 Volt AC, 50 Amp -- Supplies electrical

power for the operation of 120/240 Volt AC, 50 Amp, single phase, 60 Hz, welder or motor loads.

Air Cleaner -- Filters intake air as it is drawn into the engine.

Choke Lever-- Used when starting a cold engine. Circuit Breakers (AC) -- Each receptacle is provided

with a circuit breaker to protect the generator against electrical overload. Breakers are "push to reset" type.

Electric Start Button -- Pressed to start the engine. Fuel Shut Off Valve -- Used to stop the supply of

gasoline to the carburetor. Fuel Tank -- Tank holds 10 U.S. gallons of unleaded

gasoline. Grounding Lug -- Used to connect unit to earth

ground. Hour Meter -- Measures engine running time.

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 a running engine.

Spark Arrestor Muffler -- Muffler lowers engine noise and is equipped with a spark arrestor screen.

CORD SETS AND CONNECTOR

PLUGS

120 Volt, 20 Amp, GFCI, Duplex

Receptacle

This is a 120 Volt ground fault circuit interrupter

(GFCI) outlet, consisting of a pair of receptacles

protected against overload by a 20 Amp push-to-reset circuit breaker. Use each receptacle to power 120 Volt

AC, single phase, 60 Hz electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 Amps of

current.

I RESET I

I TESTI

4 u

Testing the GFCI Outlet

Test your GFCI outlet every month. Follow these instructions:

1. Push the black "TEST" button. The red "RESET" button should pop out, which should disconnect

power from the outlet. Use a test lamp and test each outlet.

,_ DANGER: Ifthe "RESET" button does not pop

2. If the GFCI tests good, restore power by pressing

3. If the GFCI trips by itself at any time, reset and test

out or the test lamp remains lit when the "RESET" button is popped out, do not use any outlets on the circuit. Call a qualified electrician.

the "RESET" button firmly until it is fully in place and locks in that position. If the GFCI outlet does

not reset properly, do not use the outlet -- call a qualified electrician.

the outlet. If the reset button does pop out when the test button is pressed, do not use the outlet. Call a qualified electrician.

120 Volt AC, 20 Amp Receptacle

Use a NEMA L5-20 plug with this receptacle. Connect a 3-wire cord set rated for 125 Volt loads at 20 Amps (or greater) to the plug.

3-Wire Cord Set

Use only high quality, well-insulated, 3-wire grounded

cord sets rated 125 Volts at 20 Amps (or greater).

Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires.

Ground Fault Protection

The generator isequipped with a Ground Fault Circuit

Interrupter (GFCI). This device meets all requirements

of applicable federal, state and local codes.

The GFCI protects against electrical shock that may

be caused if your body becomes a path which electricity travels to reach ground. This could happen if you touch a "Live" appliance, or cord or are touching

plumbing or other materials that go to ground. When protected by a GFCI, a person will still feel a

shock, but the GFCI should cut it off quickly enough so that a person in normal health should not suffer any serious electrical injury.

,_ DANGER: The GFCI will not protect you

against the following situations: (1) Line-to-line shocks; (2) Current overloads or line-to-line

short circuits. The fuse or circuit breaker at the distribution panel must provide such protection.

Neutral

120V

Hot

/_ Ground

NEMA L5-20

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 2400 watts (2.4 kW) of power at 20 Amps. The outlet is protected by a 20 Amp push-to-reset circuit breaker.

(Green)

120 Volt, 30 Amp Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set rated for 125 Volt AC loads at

30 Amps (or greater) to the plug.

3-Wire Cord Set

Neutral

12 Volt DC, 10 Amp Receptacle

The 12 Volt DC receptacle allows you to recharge a

12 Volt automotive or utility style storage battery with

the battery charge cables provided.

120V

Hot

/__ Ground

NEMA L5-30

(Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

120/240 Volt, 30 Amp Receptacle

Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounded cord set to the

plug and to the desired load. The cord set should be rated for 250 Volt AC loads at 30 Amps (or greater).

4-Wire Cord Set

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 11) before attempting to recharge a battery.

120/240 Volt AC, 50 Amp Receptacle

Use a NEMA 14-50 plug with this receptacle. Connect

a 4-wire cord set rated for 250 Volt AC loads at

50 Amps to the plug.

240 Volts AC

Frame Ground

Y (Hot)

X (Hot)

W (Neutral)

Y (Hot)

X (Hot)

Ground

NEMA L14-30

(Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW)

of power at 30 Amps or 240 Volt AC, 60 Hz, single

phase loads requiring up to 7200 watts (7.2 kW) of

power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

120 Volts

AC -----_

W (Neutral)

NEMA 14-50

Use this receptacle to operate 240 Volt AC, 60 Hz, single phase loads requiring up to 10,000 watts

(10.0 kW) of power.

,_ CAUTION! Although this outlet states it has a

240 Volt 50 Amp rating (up to 12,500 watts), the generator is only rated for 10,000 watts. Powering loads that exceed the wattage/ amperage capacity of the generator can damage it and cause serious injuries.

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 lug is provided on the base of the cradle.

Grounding Lug

Generally, connecting a No. 12 AWG (American Wire Gauge) stranded copper wire to the grounding lug 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 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.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes

after starting.

• Plug in and turn on the desired 120 Volt AC or

240 Volt AC, single phase, 60 Hz electrical loads.

• DO NOT connect 240 Volt loads to 120 Volt

receptacles.

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

• DO NOT connect 50 Hz loads to the generator.

• Add up the rated watts (or amps) of all loads to be

connected at one time. This total should not be greater than (a) the rated wattage/amperage

capacity of the generator or (b) circuit breaker rating of the receptacle supplying the power. See "Don't Overload the Generator" on page 12.

BEFORE STARTING THE GENERATOR

To operate the generator you will need to first add engine oil and gasoline:

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. Use no

special additives. Select the oil's viscosity grade according to your

expected operating temperature:

°F -20 0 20 32 40 60 80 100

°c. 0 -i0 6 1'0

TemperatureRangeof ExpectedUse

• Above 40°F, use SAE 10W-30 or SAE 30.

• Below 40°F, use synthetic 5W-20 or 5W-30

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.

• Clean area around oil fill and remove oil fill cap and dipstick.

• Wipe dipstick clean.

• Slowly fill engine with oil through the oil fill opening until it reaches the full mark on the dipstick. Stop

filling occasionally to check oil level. DO NOT OVERFILL.

• Install dipstick. Install oil fill cap and hand tighten securely.

• Check engine oil level before starting unit each time thereafter.

Add Gasoline

,_ DANGER! NEVER fill fuel tank indoors.

NEVER fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank.

,_ DANGER! Do not overfill the fuel tank. Always

• Use regular UNLEADED gasoline in the

• Clean area around fuel fill cap; remove cap.

leave room for expansion.

generator. DO NOT use premium gasoline. DO NOT mix oil with gasoline. DO NOT overfill the gas

tank.

Fillfueltankwithclean,fresh,unleadedgasoline. Becarefulnottooverfill.Allowabout1/2"tank

spaceforfuelexpansion.

Place the Run/Stop Switch in the "Run" position.

IGNITION

1/2"AirSpace Tank

Fuel

• Install fuel cap and wipe up any spilled gasoline. IMPORTANT: 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. See "Storage" on

page 17. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may

Occur.

TO START THE ENGINE

RUN position

Pull engine choke out to close choke. DO NOT FORCE. If the engine is warm, you may not need as much choking.

DANGER! Never run engine indoors or in enclosed poorly ventilated areas. Engine

exhaust contains carbon monoxide, an odorless and deadly gas.

_ ARNING! Never start or stop engine with

• Unplug all electrical loads from generator

• Make sure the unit is in a level position.

• Open the fuel shut-off valve.

electrical devices plugged into the panel receptacles and turned on.

receptacles before starting the engine.

Turn Clockwise to

"OFF" Position

• Locate the idle control on/off switch on the control

panel and set it to the "Off" position.

IDLE

OFF position

_ ANGER! Temperature of muffler and nearbyareas may exceed 150°F (65°C). Avoid these

areas on the generator.

Electric Starting

• Press the Run/Stop switch to the "RUN" position, Press the electric start button, located on the

generator cradle opposite the control panel, until engine cranks.

• Use short starting cycles (15 sec. per min.) to prolong starter life. Extended cranking can damage

starter motor.

,_ WARNING! Ifstarting the engine with the

electric starter, always operate the engine with the battery connected. This ensures that the battery will be recharged.

• When the engine starts, OPEN the choke gradually as engine warms up up by pushing in on the choke

handle.

• Set the idle control on/off switch to the "On" position.

Manual Starting

• Grasp starter grip handle and pull slowly until you feel some resistance. Then pull cord out with rapid

full arm stroke. Let rope return slowly. Do not let rope "snap back" against starter. Repeat, if

necessary, with choke opened slightly.

• When engine starts, OPEN the choke gradually as the engine warms up by pushing in on the choke

handle.

• Set the idle control on/off switch to the "On"

position.

AUTOMATIC IDLE CONTROL

OPERATION

This switch is designed to greatly improve fuel

economy. When this switch isturned "On", the engine will only run at its normal high governed engine speed

when an electrical load is connected. When an electrical load is removed, the engine will run at a

reduced speed. With the switch "Off," the engine runs at the normal high engine speed all the time. Always

have the switch off when starting and stopping the

engine.

IMPORTANT: Do not overload the generator. Also, do

not overload individual panel receptacles. These outlets are protected against overload with push-to- reset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read "Don't Overload the Generator" on page 12 carefully.

STOPPING THE ENGINE

• Unplug (or turn OFF) all electrical loads connected

to generator panel receptacles. Never start or stop engine with devices plugged in and turned on.

• Turn "Off" the idle control switch.

• Let engine run at no-load for 30 seconds to

stabilize the internal temperatures of engine and generator.

• Move run/stop switch to "Stop" position.

• Close the fuel valve.

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 inthe 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

Ifthe system senses low oil pressure during operation,

the engine shuts down.

Restarting

If you try to restart the engine within 10 seconds after it

shuts down, the engine may NOT 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.

CHARGING A BATTERY

DANGER! Storage batteries give off explosive

hydrogen gas while recharging. An explosive 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.

• If necessary, clean battery terminals.

• Connect battery charge cable connector plug to panel receptacle identified by the words

"12-VOLT D.C."

• Connect battery charge cable clamp with red handle to the positive (+) battery terminal.

12 VOLT D.C.

RECEPTACLE

RED wire

,_ DANGER! Do not permit smoking, open flame,

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,

• If the battery is equipped with vent caps, make sure

sparks or any other source of heat 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.

add ONLY distilled water to cover separators in

battery cells. Do not use tap water.

they are installed and are tight.

f Black wire

POS NEG

• 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 REFENCE 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 in determining how many items your

generator can operate at one time. (NOTE: All figures are approximate. See data plate on appliance for

wattage requirements.)

Device .............................. Watts

*Air Conditioner (12,000 Btu) .............. 1700

*Air Conditioner (24,000 Btu) .............. 3800

*Air Conditioner (40,000 Btu) .............. 6000

Battery Charger (20 Amp) .................. 500

Belt Sander (3") ........................ 1000

Chain Saw ............................ 1200

Circular Saw (6-1/2") ............... 800 to 1000

*Clothes Dryer (Electric) .................. 5750

*Clothes Dryer (Gas) ..................... 700

*Clothes Washer ........................ 1150

Coffee Maker .......................... 1750

*Compressor (1 HP) ..................... 2000

*Compressor (3/4 HP).................... 1800

*Compressor (1/2 HP).................... 1400

Curling Iron............................. 700

*Freezer ............................... 700

*Dehumidifier ........................... 650

Disc Sander (9") ........................ 1200

Edge Trimmer ........................... 500

Electric Blanket .......................... 400

Electric Nail Gun ........................ 1200

Electric Range (per element) .............. 1500

Electric Skillet .......................... 1250

*Furnace Fan (3/5 HP) .................... 875

*Garage Door Opener ............... 500 to 750

Hair Dryer ............................. 1200

Hand Drill ........................ 250 to 1100

Device .............................. Watts

Hedge Trimmer ......................... 450

Impact Wrench .......................... 500

Iron.................................. 1200

*Jet Pump ............................. 800

Lawn Mower ........................... 1200

Light Bulb .............................. 100

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) ............. 600

Paint Sprayer, Airless (handheld) ............ 150

Radio ............................. 50 to 200

*Refrigerator ............................ 700

Slow Cooker ............................ 200

*Submersible Pump (1-1/2 HP) ............. 2800

*Submersible Pump (1 HP) ................ 2000

*Submersible Pump (1/2 HP) .............. 1500

*Sump Pump ..................... 800 to 1050

*Table Saw (10") ................. 1750 to 2000

Television ........................ 200 to 500

Toaster ........................ 1000 to 1650

Weed Trimmer .......................... 500

* Allow 3 times the listed watts for starting these devices.

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 Pre-Cleaner

Changer Oil And Oil Filters Clean Spark Arrestor Screen

Adjust Valve Clearance

Retorque Head Bolts

Service Air Cleaner

Replace Spark Plugs

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. ** Clean more often under dirty or dusty conditions. Replace cleaner parts if very dirty.

*** Retorque head bolts only after the first 50 hours.

Every 8 Hours

or Daily

PRODUCT SPECIFICATIONS

Generator Specifications

Rated Maximum Power ................ 10,000 Watts (10.0

kW)

Surge Power ................................. 12,500 Watts (12.5

kW)

Rated AC Voltage ......................... 120/240 Volts AC

Rated Maximum AC Load Current

at 240 Volts ................................ 41.7 Amperes

at 120 Volts ................................ 83.3 Amperes

Rated Frequency .......................... 60 Hz at 3600 rpm

Phase Single Phase

Rated DC Voltage ......................... 12 Volts

Rated Maximum DC Load Current

at 12 Volts .................................. 10.0 Amperes

Engine Specifications

Rated Horsepower ........................ 19 at 3600 rpm

Displacement ................................ 570 cc

Spark Plug

Type: ................................. Champion RC12YC or

Equivalent

Set Gap To: ....................... 0.030inch (0.76mm)

Set Torque To: .................. 200 in-lbs (22.5 N-m)

Gasoline Capacity ......................... 10 U.S. gallons

Oil Type:

Summer ............................. SAE 30 or 10W-30

Winter ................................ Synthetic 5W-20 or

5W-30

25 Hours or 50 Hours or 100 Hours or

Every Season Every Season Every Season

x** .....

X X

GENERAL RECOMMENDATIONS

The generator warranty does not cover items that have been subjected to operator abuse or negligence.

To receive full value from the warranty, the operator

must maintain the generator as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain 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. 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 is not running.

X**

NOTE:DONOTuseagardenhosetoclean generator.Watercanentertheenginefuelsystemand causeproblems.Inaddition,ifwaterentersthe generatorthroughcoolingairslots,somewaterwillbe

retainedinvoidsandcracksoftherotorandstator

windinginsulation.Wateranddirtbuilduponthe

generatorinternalwindingswilleventuallydecrease

theinsulationresistanceofthesewindings.

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

5. Remove the oil fill cap and insert a clean funnel into the cap opening. Slowly fill the crankcase with

the recommended oil until the oil level is at the

FULL mark.

6. When the crankcase is filled to the proper level, install and tighten the oil fill cap.

Replacing the Spark Plugs

Use the recommended spark plugs set to the correct air gap [0.76 mm (0.030 in.)]. Replace the plugs every 100 hours of operation or once each year, whichever comes first. This will help your engine to

start easier and run better.

1. Stop the engine and pull the spark plug wires off of the spark plugs.

2. Clean around the spark plugs and remove them from the cylinder head.

3. Set the spark plugs' gap to 0.76 mm (0.030 in.).

Install the correctly gapped spark plugs into the

cylinder heads.

,_ DANGER! When working on the generator,

always disconnect negative cable from battery. Also disconnect spark plug wires from spark plugs and keep wires away from spark plugs.

Checking Oil Level

See the "BEFORE STARTING THE GENERATOR" section on page 8 for information on checking the oil

level. The oil level should be checked before each use, orat least every eight hours of operation. Keep

the oil level properly maintained.

Changing the Oil and Oil Filter

Change the oil and filter after the first eight hours of

operation. Change the oil every 50 hours thereafter. If you are using this engine under dirty or

dusty conditions, or in extremely hot weather, change

the oil more often.

Use the following instructions to change the oilwhile

the engine is still warm:

1. Clean the area around the oil drain plug, remove the plug and drain the oil completely into a suitable

container.

2. When the oil is drained, install and tighten the oil drain plug.

3. Place a suitable container beneath the oil filter and

turn the filter counterclockwise to remove the filter.

4. Lightly coat the gasket of a new filter with fresh engine oil. Turn the new filter clockwise until the

gasket contacts the filter adapter, then tighten an additional 3/4 turn.

Service Air Cleaner

Your equipment's air cleaner is one of the most important areas to maintain. This engine will not run properly and may get damaged if it is run with a dirty air cleaner system.

Clean the foam pre-cleaner every 25 hours of operation, or sooner under dusty or dirty conditions. Clean or replace the paper air filter every 50 hours of operation or once a year, whichever comes first. Clean or replace the filter more often if the engine is operated under dusty or dirty conditions.

_ CAUTION: Never run this equipment without

the complete air cleaner system installed on the engine. This could result in premature wear to the engine.

Use the following instructions to clean or replace the

air cleaner components:

1. Remove the cover by loosening both hold-down

straps.

2. Slide the foam pre-cleaner off the cartridge.

LATCHES

_C KNOB

CARTRIDGE

RETAINER'

ARTRIDGE

I I I I I I I I

FOAM PRE-CLEANER

HG ISING

3. Wash the pre-cleaner in liquid detergent and water.

4. Squeeze the pre-cleaner dry with a clean cloth. DO NOT TWIST.

5. Prelube the pre-cleaner with clean motor oil.

6. Squeeze the pre-cleaner in a clean cloth to remove excess oil. DO NOT TWIST.

7. Remove the knob and plate. Tap the cartridge gently on a solid surface to loosen and remove trapped particles.

NOTE: If the filter is too dirty, it must be replaced.

8. Reinstall the pre-cleaner over the cartridge.

9. Reinstall the air cleaner assembly.

10.Reinstall the plate, knob and cover.

NOTE: If you need to order a new air filter, please call

1-800-366-7278.

Clean Spark Arrestor Screen

The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 50 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 arrestor. The spark arrestor

must be maintained in good condition by the owner/ operator. The proceeding is required by the law in the

state of California. Other states may have similar laws. Federal laws apply on federal lands.

To clean and inspect the spark arrestor:

• Remove four screws that attach the spark arrestor screen.

• 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 with four screws.

Engine Governed Speed

,_ CAUTION! The engine speed was properly

Your engine runs at a constant speed. This constant operating speed is maintained by a mechanical fixed speed governor. DO NOT try to adjust the governed speed setting for the following reasons:

• Operating the engine at high engine speeds is

• Operating the engine at low engine speeds with

Incorrect speed settings also affects electrical operation of your generator as follows:

• Operating at high speeds results in an over-

• Operating at low speeds causes an under-

adjusted at the factory and should require no additional adjustment. Do not attempt to change engine speed. If you believe the engine is running too fast or too slow, take your engine to an authorized service center for repair and adjustment. CHANGING THE ENGINE

GOVERNED SPEED WILL VOID THE ENGINE WARRANTY.

dangerous and increases the risk of personal injury or damage to the equipment.

heavy loads may shorten the engine's life.

frequency and over-voltage condition.

frequency and under-voltage condition.

_ ARNING: Let the muffler cool before working

on it. Contact with a hot muffler or engine can cause severe burns.

IMPORTANT: Incorrect frequency and/or voltage may damage some connected electrical loads.

If you suspect engine speed is incorrect, take the generator to an authorized service facility for repair and adjustment.

Carburetor Adjustments

Your engine carburetor is preset at the factory. The carburetor should not be tampered with because this

will void the emission control system warranty. If you experience problems or your engine is used at an

altitude in excess of 5,000 feet, contact the nearest authorized dealer regarding high altitude setting changes.

6. Adjust the valve so clearance is 0.1-0.15 mm (0.004-0.006 in.) for both intake and exhaust

valves.

7. Tighten each lock nut while holding the adjusting screw. Torque the lock nut to 7 N-m (60 in.-Ibs).

8. Reinstall the valve cover gaskets, valve covers, seals and nuts. Torque the nuts to 3 N-m

(25 in.-Ibs).

Check/Adjust Valve to Rocker Arm Clearance

Every 50 hours of operation, remove the rocker cover and check the valve to rocker arm clearance.

Important: If you feel uncomfortable about doing this

procedure or you don't have the proper tools, please take your generator in to the nearest service center to have the valve clearance adjusted. This is a very important step to insure the longest life for your engine.

When adjusting the clearance, the engine should be at room temperature, and each piston should be at top dead center (TDC) of its compression stroke (both valves are closed). The correct clearance is

0.10-0.15 mm (0.004-0.006 in.). Check and adjust the valve to rocker arm clearance as follows:

1. Remove the two nuts and seals from the valve covers.

2. Remove the valve covers and gaskets.

3. With the spark plugs removed, rotate the crankshaft until the piston in the cylinder you are checking is at

TDC of its compression stroke (both valves are closed).

4. Place a caliper end through the spark plug hole and continue turning the crankshaft until the piston has

moved 1/4 inch past TDC.

5. Check the valve clearance with a feeler gage between the valve stem and rocker arm.

Retorque the Head Bolts

After the first 50 hours of operation, retorque the head

bolts. NOTE: Only perform this adjustment after the first

50 hours of operation. The head bolts will need no

further adjustment.

Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please

take your generator into the nearest service center to

have the valve clearance adjusted. This is a very important step to insure the longest lifefor your

engine.

1. Remove the valve covers as described previously.

2. Torque the head bolts in the sequence shown below to 19 N-m (165 in.-Ibs).

SEALING WASHERS

CYLINDER

HEAD

=BOLTS

® ®

WRENCH

LOCK

NUT

ADJUSTING

SCREW

13MM

5MM

HEX WRENCH

FEELER GAUGE

3. Reinstall the valve cover gaskets and valve covers as described previously.

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.

_ DANGER! NEVER store engine with fuel in

tank indoors or in enclosed, poorly ventilated 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 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, as

follows:

• Remove all gasoline from the fuel tank.

_ ANGER! Drain fuel into approved container

outdoors, away from open flame. Be sure engine is cool. Do not smoke.

• Start and run engine until engine stops from lack of

fuel.

• Disconnect negative battery cable from battery.

• While engine is still warm, drain oil from crankcase. Refill with recommended grade.

• Remove spark plug and pour about 1/2 ounce

(15 ml) of engine oil into the cylinder. Cover spark

plug hole with rag. Pull recoil starter slowly to

distribute oil.

_ AUTION! Avoid spray from spark plug hole

when cranking engine.

• Install and tighten spark plug. Do not connect spark plug wire.

• Clean the generator outer surfaces. Check that

cooling air slots and openings on generator are open and unobstructed.

• Store the unit in a clean, dry place.

OTHER STORAGE TIPS:

• Do not store gasoline from one season to another.

• Replace your gasoline can if your can 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.

_ ANGER! NEVER cover your generator while

engine and exhaust area are warm.

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