Operator's Manual
CRAFTSMAN°
7500 Watt
AC Generator
Model No.
580.327181
GENERATOR
CUSTOMER
HELPLINE
HOURS: Mon.-
7
Fri. 8 a.m. to 5 p.m. (CT)
•
•
•
•
•
CAUTION:
Before using this product,
read this manual and follow all Safety
Rules and Operating Instructions.
SEARS,
ROEBUCK
and CO.,
Hoffman
Estates,
Safety
Assembly
Operation
Maintenance
Parts
IL 60179
Visit our Craftsman website: www.sears.com/craftsman
Part No, B1901
Draft
4 (6/29/1999)
U.S.A.
Safety Rules ...........................
Assembly ..............................
Operation .............................
Maintenance .........................
Specifications
...........................
2-3
Storage ................................
4-5
Troubleshooting
6-10
11-13
14
.........................
Replacement Parts ....................
HOW TO ORDER PARTS ..........
15
17-27
BACK PAGE
11
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 GN-Series 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
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.
CAUTION:Always disconnectspark plug wire and place the wire where it cannotcontact the spark plug. To
preventaccidental startingwhen setting up, transporting,adjustingor makingrepairs to your generator.
DANGER:This generatoris designedfor outdooruse only. Do not usethis generatorinside any building or
enclosureincludingthe generatorcompartmentof a recreationalvehicle(RV). Fire or an explosion may result. No
user performedmodifications, includingventing of exhaustand/or cooling ventilation,will eliminatethe danger.
Also, allow at least two feet of clearanceon all sides of the generatoreven while operatingthe unit outdoors.
1,_
manual and follow all Safety Rulesand
CAUTION: Beforeusing this product,read this
OperatingInstructions.
•
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 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 an EXPLOSION might
result.
•
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.
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.
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 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.
Allow at least 2 feet of clearance on all sides of
generator, even while operating unit outdoors, or
you could damage the unit.
I,_
•
The engine-generator requires an adequate flow of
cooling air for its continued proper operation.
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. Without
sufficient cooling air flow, the unit quickly
overheats, damaging the generator or nearby
property.
•
Never start, or stop, the engine-generator with
electrical loads connected to receptacles 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 engine-generator. You could damage the unit
or injure yourself.
•
Never operate generator (a) in rain; (b) in any
enclosed compartment; (c) if engine speed
changes; (d) if connected electrical devices
overheat; (e) if electrical output is lost; (f) if engine
or generator sparks; (g) if flames or smoke are
observed while unit is running; (h) 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.
MEANS
"ATTENTION!!!
BECOME
ALERT!!!
YOUR SAFETY
IS INVOLVED."
LOOK FOR
THIS SYMBOL
TO POINT
OUT IMPORTANT
SAFETY
PRECAUTIONS.
IT I
TO REMOVE
CARTON
GENERATOR
FROM
•
Slice two corners at end of carton from top to
bottom so the panel can be folded down fiat.
•
Remove all packing material, carton fillers, etc.
•
Remove the generator from the shipping carton.
CARTON
•
Set battery onto tray
•
Retain battery to tray with two J bolts, two lock
washers, two flat washers and two hex nuts.
•
Connect the red battery cable from the engine
starter switch to positive (+) terminal on the
battery.
CONTENTS
•
Generator
•
Wheel Kit
•
Locking Plugs
•
•
Battery Tray components
Manual
Check all contents. If any parts are missing or
damaged, call the Generator Helpline at
1-800-222-3136.
INSTALLING
TRAY
AND BATTERY
You must purchase and install a 12 Volt DC battery
(Sears DieHard Lawn & Garden Battery #28-27145).
The battery should be serviced with electrolyte fluid
and fully charged prior to installation. Install the battery
as follows:
•
Find the battery tray and fasteners shipped loose in
the carton. You should have two 7" J bolts, two
lock washers,two flat washers and two hex nuts
•
Remove the 4 battery tray screws from cradle
•
Position the battery tray and install with supplied
hardware.
RED bNi_ery'_
•
Connect the black battery cable to the negative
terminal on the battery.
•
Connect the other end of the black cable to the
engine, not the frame.
I,_
(-)
connectedto the engine mountand not the frame.
AUTION:
Be sure the
BLACKcable
is
You
could damagethe
ground
wire.
ASSEMBLING
THE WHEEL
KIT
The wheel kit is designed to greatly improve the
portability of your generator. You will need a socket
wrench with 1/2" or 13mm sockets to install the wheel
kit.
•
Slide on the wheels (item 2) and flat washer
(item10) on each end of the axle and insert
retaining pin (item 4). Remove the blocks.
•
Attach the vibration mounts (item 7) to the support
leg (item 6) with two M8 x 30mm capscrews
(item 8), M8 washers (item 12) and M8 Lock Nuts
(item 9).
•
With the Wheels on, you can now tilt the generator
end forward and attach the support leg with two
M8 x 20mm cap screws (item 11) and two lock nuts
(item 9).
•
Set the generator down so it is level and attach the
handle with four M8x45mm capscrews(item 13) and
four lock nuts (item 9).
Refer to illustration shown below and install the wheel
kit as follows:
•
Place the generator on a hard flat surface.
•
Slide the axle (item 3) through the holes in the
brackets provided on the generator cradle and then
add the two spacers (item 5) on each protruding
end of the axle.
•
Stand at the engine end of the generator and gently
tilt the generator forward, high enough to place
blocks beneath the cradle. This will allow you to
add the wheels.
Wheel Kit Exploded View
/
13
/
/
/
9
9
6
!
4
Item
Pan #
Qty
1
93393A
1
Description
HANDLE
2
89742
2
WHEEL
3
93693A
1
AXLE
4
87005
2
PIN, Retaining
5
89635
2
SPACER, Wheel
6
93696
1
LEG, Support
7
27007
2
MOUNT, Vibration
Item
Pan #
Qty
8
42909
2
CAPSCREW, Hex Hd. M8 1.25 x 30 Lg.
Description
9
52858
8
NUT, Lock M8
10
22247
2
WASHER, Wheel
11
39253
2
CAPSCREW, Hex Hd. - M8 1.25 x 20 Lg.
12
22145
2
WASHER, Vibration Mtg.
13
39287
4
HHCS, M8 - 1.25 x 45 Lg
GR 10.9
CORD SETS AND CONNECTOR
PLUGS
120 Volt Cord Sets
Use only high quality, well-insulated, extension cords
with the generator's 120 Volt type electrical
receptacles.
Each receptacle socket is protected against overload
by a single 20-Amp push-to-reset type of circuit
breaker. Use each receptacle to operate 120 Volts,
single phase 60 Hz, AC electrical loads requiring up to
2400 watts (2.4 kW) at 20 Amps of current.
120 Volt, 30 AMP Receptacle
Use a NEMA L5-30P type plug with this receptacle.
Connect a 3-wire cord set rated for 125 Volts at 30 AC
Amps to the plug. 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 AC Amps. The
outlet is protected by a 30 Amp circuit breaker.
3-Wira Cord Set
--
Neutral
120V
Hot
NEMA L5-30
240 VOLT,
Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
125 Volts at 20 AC Amps or greater for most 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.
50 AMP RECEPTACLE
Use a compatible 3 prong plug with this receptacle.
Connect a 3-wire cord set rated for 250 Volts at 50 AC
Amps to the plug. Use this receptacle to operate 240
Volt AC, 60 Hz single phase loads requiring up to
7,500 watts (7.5 kW) of power.
Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
120/240 Volt, 30 AMP Receptacle
This is a full capacity receptacle which means you can
take the full rated generator capacity from this
receptacle. The outlet is protected by a 30 Amp pushto-reset circuit breaker.
4-Wire Cord Set
240V
_- 120V_-
120V--_
CAUTION! Althoughthis outlet states it has a
240 Volt 50-Amp rating (up to 12,000watts),the
generator is rated for 7,500watts. Powering loads
that exceed the generatorcapacitycan damage it
or cause serious injuries.240 Volt loadspowered
through this outletshould not exceed31.25Amps.
DO NOT connect120 Volt AC loads to this
receptacle.
2 Volt DC Receptacle
Neutrai)
Y I P_ot)_
NEMA
L14-30
X (Hot)
,/-717 _rrOUenn_
A NEMA L14-30P mating connector plug is required
for use with this receptacle. Connect a suitable 4-wire
cord set to the plug and to the desired load. The cord
set should be rated for 250 Volts at 30 Amps.
Use this receptacle to operate 120/240 Volt AC, 60 Hz
single phase loads requiring up to 7200 watts (7.2 kW)
of power.
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.
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.
FuelTank
Circuit Breakers
"_
Choke Lever
12 Volt DC 10 Amp
Receptacle
Run/Stop
Switch
Cleaner
Idle Control
Switch
120 Volt AC, 30 Amp
Receptacle
Engine
120/240 Volt AC, 30 Amp
Receptacle
120 Volt AC, 20 Amp"
Receptacles
120/240 Volt AC, 30 Amp Receptacle -- May be
used to supply electrical power for the operation of
120 and/or 240 Volt at 30 Amp AC, single phase,
60 Hz electrical lighting, appliance, tool and motor
loads.
120 Volt AC, 30 Amp Receptacle -- May be used to
supply electrical power for the operation of 120 Volt at
30 Amp AC, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 20 Amp Receptacles -- May be used
to supply electrical power for the operation of 120 Volt
at 20 Amp AC, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
240 Volt AC, 50 Amp Receptacle -- May be used to
supply electrical power for the operation of 240 Volt at
31.25 Amp AC, single phase, 60 Hz electrical loads.
12 Volt DC, 10 Amp Receptacle --This receptacle
allows you to recharge a 12 Volt automotive or utility
style storage battery with the charge cables provided.
240 Volt AC, 50 Amp
Receptacle
15 H.P. Engine -- Provides the power needed to
generate 7,500 watts of AC output.
Air Cleaner -- Filters intake air as it is drawn into the
engine.
Circuit Breakers (AC) -- Circuit breakers are
provided for most receptacles to protect the generator
against electrical overload. Breakers are "push to
reset" type.
Choke Lever-
Used when starting a cold engine.
Fuel Tank -- Tank holds 5 U.S. gallons of automotive
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. This feature greatly improves
fuel economy, extends the life of the engine, and
reduces engine noise.
Run/Stop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop a running engine.
HOW TO USE YOUR
GENERATOR
IF YOU HAVE ANY PROBLEMS operating your
generator, please call the generator helpline at
1-800-222-3136.
GROUNDING
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.
ELECTRICAL
LOADS
Let engine stabilize and warm up for a few minutes
after starting.
Do not connect 240 Volts to 120 Volt duplex
receptacles
Do not connect 3-phase
loads to receptacles.
Plug in and turn on the desired 120 and/or 240
Volt, single phase, 60 Hertz, AC electrical loads.
DO NOT OVERLOAD 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 the rated wattage/amperage capacity
of the generator. See Don't Overload the Generator
on Page 10.
BEFORE
STARTING
THE GENERATOR
_
32°F
_
warmer
!
5W30
SAE 30
Place generator on a level surface and remove the
yellow oil fill cap and add engine oil until level is at
point of overflowing. Check engine oil level before
starting each time thereafter.
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.
CONNECTING
I
colder
Add Gasoline
WARNING NEVERfill fuel tank indoors.NEVER fill
fuel tank when engine is runningor hot. DO NOT
light a cigaretteor smokewhen filling the fuel tank.
_
AUTION: Donotoverfill
leaveroomfor
expansion. thefueltank.Always
•
Use regular UNLEADED gasoline with the
generator engine.
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 14. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may
Occur.
TO START
•
THE ENGINE
Unplug all electrical loads from generator
receptacles before starting the engine. NEVER
start or stop engine with electrical devices plugged
into the panel receptacles and turned on.
Make sure the idle control switch is "Off".
•
_
AUTION! Never run engine indoors or in enclosed
poorly ventilatedareas. Engine Exhaustcontains
carbon monoxide,an odorlessand deadly gas.
,_
WARNING!Temperatureof mufflerand nearby
areas may exceed 150°F(65°C). Avoid these areas.
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.
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.
•
Open the fuel valve.
*
Place the Run/Stop Switch in the "RUN"
•
Move engine CHOKE LEVER to "FULL CHOKE
POSITION."
•
For manual starting: Grasp starter grip 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.
•
For electric starting: Press start switch on
generator cradle until engine cranks. Keep
pressing until it starts.
position.
Whenenginestarts,movechokeleverto "1/2
ChokePosition"untilthe enginerunssmoothly
andthento "Run Position."If enginefalters,
movechokeleverto "1/2ChokePosition"until
theenginerunssmoothlyandthento "Run
Position."
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 ON. However, once the engine has
stopped rotating, this light will go OFF.
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.
FULL
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.
RUN
HALF
BATTERY
//
DANGER: Storagebatteriesgive off explosive
hydrogengas while recharging.An explosive
mixturewill remainaroundthe battery for a long
time after it has been charged.The slightest spark
can ignite the hydrogenand causean explosion.
Such an explosioncan shatter the battery and
cause blindnessor other serious injury.
Note: If engine fails to start after 3 pulls, move the
choke lever to "Run Position" and pull starter rope
again.
Note: If engine fires, but does not continue to run,
move choke lever to "Full Choke" and repeat starting
instructions.
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 if on.
DANGER: Donotpermitsmoking,openflame,
sparksoranyothersourceofheatarounda
battery.Wearprotectivegoggles,rubberapronand
rubbergloveswhenworkingarounda battery.
Batteryelectrolyte
fluid isan extremelycaustic
sulfuricacidsolutionthatcancausesevereburns.
If spilloccursflush areawithclearwater
immediately.
Let engine run at no-load for several minutes to
stabilize the internal temperatures of engine and
generator.
Move Run/Stop switch to "Stop" position.
Close 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
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 will
run at the normal high engine speed. Always have the
switch off when starting and stopping the engine.
LOW OIL PRESSURE
SYSTEM
CHARGING
To recharge 12 Volt batteries, proceed as follows:
•
•
sensor
the oil
down
check
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.
A BATTERY
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do not use the unit to charge any 6 Volt
batteries. Do not use the unit to crank an engine
having a discharged battery.
SHUTDOWN
The engine is equipped with a low oil pressure
that shuts down the engine automatically when
pressure drops below 6 psi. If the engine shuts
by itself and the fuel tank has enough gasoline,
engine oil level.
SAFETY
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 VOLT
D.C."
•
Connect battery charge cable clamp with red
handle to the positive (+) battery terminal
•
Connect battery charge cable clamp with black
handle to the negative (-) battery terminal.
• Startengine.Lettheenginerunwhilebattery
recharges.
• Whenbatteryhascharged,shutdownengine
NOTE:Useanautomotivehydrometer
totestbattery
stateofchargeandcondition.Followthe hydrometer
manufacturer's
instructions
carefully.Generally,a
batteryis considered
to beat 100%stateof charge
whenspecificgravityof itsfluid(asmeasured
by
hydrometer)
is 1.260or higher.
DON'T OVERLOAD
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).
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. First, figure the watts needed to start the
largest motor. Add to that figure the running watts
of all other connected loads.
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.
WATTAGE
The Wattage Reference Guide below is provided to
assist you in determining how many items your
generator can operate at one time.
REFERENCE
RUNNING
WATTS
*Air Conditioner (12,000 Btu) ........................................
Battery Charger (20 Amp) ...............................................
Belt Sander (3") .............................................................
Chain Saw .....................................................................
Circular Saw (6-1/2") .......................................... 800 to
Coffee Maker .................................................................
1700
500
1000
1200
1000
1000
*Compressor (1 HP) ......................................................
*Compressor (3/4 HP) ...................................................
*Compressor (1/2 HP) ...................................................
Curling Iron ......................................................................
*Freezer ..........................................................................
Disc Sander (9") ............................................................
Edge Trimmer .................................................................
Electric Nail Gun ...........................................................
2000
1800
1400
700
500
1200
500
1200
Electric Range (one element) .......................................
Electric Skillet ................................................................
*Furnace Fan (1/3 HP) ..................................................
Hair Dryer ......................................................................
Hand Drill (1") ................................................................
Hand Drill (1/2") .................................................
750 to
Hand Drill (3/8") ...............................................................
Hand Drill (1/4") ...............................................................
Hedge Trimmer ...............................................................
1500
1250
1200
1200
1100
1000
500
250
450
GUIDE
RUNNING
WATTS
Impact Wrench ................................................................
*Jet Pump ........................................................................
Lawn Mower ..................................................................
500
800
1200
Light Bulb ........................................................................
100
Microwave Oven .............................................................
700
*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 ....................................................................
600
Slow Cooker ....................................................................
200
*Submersible Pump (1-1/2 HP) ..................................... 2800
*Submersible Pump (1 HP) ........................................... 2000
*Submersible Pump (1/2 HP) ........................................ 1500
Sump Pump ...................................................................
600
*Table Saw (10") ..............................................
1750 to 2000
Television .............................................................
200 to 500
Weed Trimmer ................................................................
500
* Allow 3 times the listed watts for starting these devices.
/0
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
Every 8 Hours
or Daily
Check oil level
25 Hours or
Every Season
50 Hours or
Every Season
100 Hours or
Every Season
Yearly
X
Change oil and oil filter-J:
Clean Spark Arrestor Screen
Service air cleaner
Service air cleaner cartridge
Adjust Valve Clearance
Replace spark plugs
Retorque head bolts
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.
*** Perform this task only after first 50 hours of operation. Head bolts will not need further
re-torquing.
PRODUCT
SPECIFICATIONS
Generator Specifications
Rated Maximum Power ........
Rated Voltage ...............
Rated Maximum Current
at 240 Volts ................
Rated Maximum Current
at 120 Volts ................
Rated Frequency ............
Phase .....................
Engine Specifications
Rated Horsepower ...........
Displacement ...............
Spark Plug
Type: ................
Set Gap To: ...........
Gasoline Capacity ............
Oil
Summer .............
Winter ..............
GENERAL
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.
7500 Watts (7.5kW)
120/240 Volts AC
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.
31.2 AC Amperes
62.5 AC Amperes
60 Hz at 3600 rpm
Single Phase
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.
15 at 3600 rpm
410 cc
Champion RC12YC or
Equivalent
0.030inch (0.76mm)
5 U.S. gallons
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
Note: We DO NOT recommend using 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.
SAE 30 (10W-30)
SAE 5W-20 or 5W-30
RECOMMENDATIONS
The warranty of the generator does not cover items
that have been subjected to operator abuse or
negligence. To receive full value from the warranty,
operator must maintain generator as instructed in this
manual.
Some adjustments will need to be made periodically to
properly maintain your generator.
/1
TO CLEAN
IA
THE GENERATOR:
through the air cooling slots,even if the engine is
CAUTION: Never Insertany objector tool
not running,
•
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
used to blow
and openings
must be kept
ENGINE
A
•
Clean area around spark plug.
•
•
Remove and inspect spark plug.
Replace spark plug if electrodes are pitted, burned
or porcelain is cracked. For Replacement use
Champion RC12YC or equivalent.
•
Check electrode gap with wire feeler gauge and set
spark plug gap to 0.030 inch (0.76mm) if
necessary.
air (not to exceed 25 psi) may be
away dirt. Inspect cooling air slots
on the generator. These openings
clean and unobstructed.
MAINTENANCE
RETORQUE HEAD BOLTS
After the first 50 hours of operation, you must retorque
the head bolts 6.9 kg.-m. (44 ft.-Ibs.)
ANGER:
Whenworking
onthegenerator
always
disconnect
sparkplugwirefrom
sparkplug
andkeepitawayfrom sparkplug.
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 head bolts re-torqued. This is a very
important step to insure the longest life for your
engine.
CHECKING OIL LEVEL
Oil level should be checked prior to each use or at
least every 8 hours of operation. Keep oil level
maintained.
NOTE: Only perform this adjustment after the first 50
hours of operation. The head bolts will need no further
adjustment.
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.
•
Torque sequence is as follows: A, B, C, D,
(alternating pattern).
A
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 and 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
according to local regulations.
•
•
Coat gasket of new filter (p/n 70185) 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 Engine" on page 8 for oil
recommendations)
•
Install the oil fill plug and tighten securely.
•
Wipe up any spilled oil.
g
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 conditions. Clean foam pre-cleaner every 25
hours of operation or sooner under dusty conditions.
PAPER
FILTER
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 Champion RC12YC or equivalent.
FOAM
/2
PRE-FILTER
To clean or replace foam
pre-cleaner:
To adjusting
valve clearance:
•
Remove air cleaner cover, then foam pre-filter.
•
Make sure the engine is at room temperature
•
Wash pre-cleaner in soapy water. Squeeze prefilter dry in clean cloth (DO NOT TWIST).
•
•
Clean air cleaner cover before installing it.
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.
To clean or replace paper air filter:
•
Remove the four screws attaching the valve cover
with a #2 or 3 phillips screwdriver.
Remove air cleaner cover; then remove foam prefilter (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 pre-cleaner into
cover. Next insert new paper filter into cover to hold
pre-cleaner in place and assemble all of them to
the base of the air cleaner.
Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston at top dead center, pull on the recoil
handle slowly watching the piston trough the spark
plug hole. As you pull on the recoil handle the
piston should move up and down. The piston is put
Top Dead Center when it is up as high as it can go.
Note: If you need to order a new air filter, please call
1-800-366-PART.
Allen Wrench
CLEAN SPARK ARRESTOR SCREEN
The engine exhaust muffler has a spark arrestor
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
Loosen
Jam Nut
NOTE: If you use your generator on any forestcovered, 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.
•
Loosen the rocker arm jam nut. Use an 8mm allen
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). 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 allen wrench and tighten the
rocker arm jam nut. Tighten the jam nut to 165-183
inch-pounds torque. After tightening the jam nut,
recheck valve clearance to make sure it did not
change.
Clean and inspect the spark arrestor as follows:
•
Feeler
Gauge
To remove the muffler guard from the muffler,
remove the four screws that connect the guard to
the muffler bracket.
SPARKARRESTER
SCREEN
MUFFLER
HEAT SHIELD
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.
Tighten Jam Nut to 165
inch-pounds - 183
inch-pounds (19-21 N-m)
Reattach the screen and the muffler guard.
ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust
the valve clearance in the engine.
Reattach the valve cover. Note: Start all four
screws before tightening or you will not be able to
get all the screws in place. Note: Make sure the
gasket between the valve cover and cylinder head
is in place.
Reattach the breather tube.
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 longest life for your engine.
Reattach the spark plug wire to the spark plug.
/3
GENERAL
Change
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.
While engine is still warm, drain oil from crankcase.
Refill with recommended grade.
Oil Cylinder Bore
I_,
I_,
indoorsorin enclosed,poorlyventilatedareaswhere
fumesmayreachan openflame,sparkorpilotlight
asona
furnace,waterheater,
clothes
dryerorother
WARNING:
NEVERstoreengine
withfuel
in tank
gasappliance.
LONG TERM STORAGE
outdoors,away from open flame. Be sure engine is
WARNING:Drain
fuel into approvedcontainer
cool. Do not smoke.
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.
•
Run engine until engine stops from lack of fuel.
•
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.
•
Install spark plug. Do not connect spark plug wire.
•
Clean the generator as outlined on Page 11 ("To
Clean the Generator").
•
Check that cooling air slots and openings on
generator are open and unobstructed.
OTHER
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. Follow
these instructions:
•
CAUTION!
cranking
engine
Avoid
slowly.
sprayfromsparkplug hole when
GENERATOR:
INSTRUCTIONS
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.
I_
Oil
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.
•
Store generator in clean, dry area.
IMPORTANT: NEVER cover your generator while
engine and exhaust area are warm.
14
Problem
Engineisrunning,butno
AC outputis available.
Enginerunsgood at no-loadbut"bogs
down"whenloadsare connected
Cause
Correction
1. One of the circuitbreakersis open.
2. Fault in generator.
3. Poor connectionor defective
cordset.
4. Connecteddeviceis bad.
1. Shortcircuitin a connectedload.
2. Enginespeedis too slow.
3. Generatoris overloaded.
4. Shortedgeneratorcircuit.
Enginewillnot start;or starts
and runs rough.
1. Run/StopSwitchset to STOP.
2. Dirtyair cleaner
3. Out of gasoline.
4. Stalegasoline.
5. Sparkplug wire notconnected
to spark plug.
6. Bad spark plug.
7. Waterin gasoline.
8. Overchoking.
9. Lowoil level
10.Excessivelyrich fuel mixture.
11.Intakevalve stuck open or closed.
12.Enginehas lost compression.
1.Resetcircuit breaker.
2.ContactSearsServiceFacility.
3.Checkand repair.
4.Connectanotherdevicethat
is in good condition.
1.Disconnectshortedelectrical
load.
2.ContactSearsService Facility.
3.See"Don't Overloadthe
Generator"
4.ContactSearsServiceFacility.
1.Setswitchto RUN.
2.Cleanor replaceair cleaner.
3.Fillfuel tank.
4. Draingas tank;fill with freshfuel.
5.Connectwire to spark plug.
6. Replacespark plug.
7. Draingas tank;fill with freshfuel.
8.Open chokefully and crank engine.
9. Fillcrankcaseto properlevel.
10. ContactSearsServiceFacility.
11. ContactSearsServiceFacility.
12. ContactSearsServiceFacility.
Engineshutsdownduringoperation
1. Out of gasoline.
2. Lowoil level.
1.Fillfuel tank.
2.Fillcrankcaseto properlevel.
Enginelackspower.
1. Loadis too high.
2. Dirtyair filter.
1.See"Don't Overloadthe Generator"
2.Replaceair filter.
Engine"hunts"or falters.
1. Chokeis openedtoo soon.
1.Movechoketo halfwaypositionuntil
enginerunssmoothly.
2.ContactSearsServiceFacility.
2. Carburetoris runningtoo rich
or too lean.
No batterychargeDC output
1. Batterypostsare corroded.
2. Batteryfluid level is low.
3. Batterycable is bad.
4. Batteryis defective.
5. Receptacleis bad.
15
1.Clean batteryposts
2.Add distilledwater to battery.
3.Replacecable.
4.Checkbatterycondition;replaceif
defective.
5.ContactSearsServiceFacility.
16
ill
CRAFTSMAN
Wiring
7500 Watt AC Generator
580.327181
Diagram
1
1
17
CRAFTSMAN
7500 Watt AC Generator
Main Unit --
Exploded
580.327181
View
7O
66
51
65
67
DETAIL OF ELECTRIC
START SWITCH
J
TO + TERMINAL
ON BA]WERY
900.
10
51
21
22
5O
72
\
'\
27
\
2O
\
29
9
58
/
17
/
7O
55
I
55
18
TO
STARTER
CRAFTSMAN
7500 Watt AC Generator
Main Unit -- Parts List
580.327181
DESCRIPTION
ITEM
PART #.
1
92432
1
CRADLE
47
85000
2
92531
1
SUPPORT,
Engine
48
3
92731
1
SUPPORT,
Engine & Muffler
49
4
92247
1
HOUSING,
Engine Adapter
5
B1342G
1
ASSEMBLY,
Rotor
6
B1897G
1
ASSEMBLY,
Stator
7
65791
1
8
96796
1
9
22129
12
WASHER,
10
86307
4
11
47481
1
12
92609
13
82857
14
ITEM
QTY.
DESCRIPTION
1
CLIP, Insulation
143-53621
1
WIRE, Ground
26850
2
LW, EXT, M6 Shakeproof
50
57593
1
MOUNT, Cable Tie
51
92982
1
DECAL, Danger
52
B1899
2
DECAL, Heat Shield
BEARING
53
B4901
1
DECAL, 1-800-4MyHome
WASHER, Special M8 Flat
55
25244
12
57
B1898
1
DECAL, Control Panel
HHMS, 5/16 - 24 x 3/4 Lg. Sems
58
B1332A
1
ASSEMBLY,
HHCS, 5/16 - 24 x 10 - 5/8 Lg.
60
22531
2
HHCS, 5/16 - 18 x 1-3/4" Lg.
2
MOUNT, Vibration
62
93826
1
DECAL, Start Instructions
2
MOUNT, Vibration
63
77282
1
SWITCH,
40976
2
SCREW, M8 - 1.25 x 20mm
64
22287
2
SCREW, 1/4 - 20" x 3/4"
15
66476
2
CAPSCREW,
65
22097
2
WASHER,
16
92532
1
BRACKET, Muffler
66
22127
2
NUT, 1/4 - 20" Hex
17
22142
2
SCREW, 5/16 - 18 x 3/4"
67
77283
1
ASSY, Starter Switch
18
91153
1
MUFFLER
68
96068
1
SHIELD, Heat
19
90239
1
GASKET, Muffler
1
PIN, 4 mm x 10 Roll
56893
B2153
CRIMPTITE,
81917
69
70
5
20
8
HHCS, 12 - 14 x 7/8 Self Driller
21
81887J
1
WRAP, Stator
71
23762
1
SHAKEPROOF,
Ext #10
22
52618
2
HHCS, M5 - 0.8 x12 Lg.
72
22097
4
LOCKWASHER,
1/4 - M6
23
52856
2
NUT, M5 Locking
900
NSP
1
25
66825C
1
CARRIER, Rear Bearing
ENGINE, 15 HP, Generac Power
Systems, EHF 00935
26
74908
4
TAPTITE, M5 - 0.8 x 10 Lg.
27
66449L
4
BOLT, M6 - 1 x 190 mm Stator
28
65795
2
RECTIFIER, Battery Charge
B1901
1
Owner's Manual
AB3061
2
28oz. Engine Oil
37806
1
120V 30A Locking Plug
43438
1
120/240V 30 A Locking Plug
65787
1
Battery Charge Cables
84882
1
Spark Plug Wrench/Driver
29
30
31
PART #.
66849C
67022
84132
QTY.
1
1
1
M8 Lock
M6 - 1.0 x 12mm
Power Regulator
32
66386
1
33
66849
2
TAPTITE, M5 - 0.8 x 16 Lg.
34
78388
1
COVER, Bearing Carrier
35
22769
1
WASHER, Shakeproof
ASSEMBLY,
Control Box
Starter
M6 Lock
10 - 24 x 1/2
Parts Not Illustrated
TAPTITE, M5 - 0.8 x 30 Lg.
GROMMET, Rubber
ASSEMBLY,
NUT, Hex 5/16 - 18
Brush Holder
Optional Accessories
Int. #10
36
86494
1
SCREW, M6 - 1.0 x 16 Lg. Wing
09-32688
37
86292
1
HHCS, #10 Self Driller
09-32687
38
77395
4
NUT, M6 Flange Lock
39
83465
4
GROMMET, Tank
40
78831B
4
HHMS, M6 - 1.0 x 60 Black
41
80270
1
42
78299
1
43
94834
44
93595
45
46
Not Illustrated
Cord Wrap Kit
120V 30A Locking Plug
Battery Tray Kit Not Illustrated
VALVE, Tank
96923
22129
1
2
Battery Tray
Lockwasher
BUSHING, Plastic Tank
45771
2
Hex Nut
1
CAP, Fuel Gauge
96925
1
Battery Tie-down
1
TANK, Fuel
96924
2
J-Bolt
92039
1
SHIELD, Heat
154-53621
1
Battery Cable Positive
92665
1
INSULATION, #2 -1/4" Thick
155-53621
22145
1
2
Battery Cable Negative
Flat Washer
19
CRAFTSMAN
Control
7500 Watt AC Generator
Panel -- Exploded
580.327181
View and Parts List
19
21
2O
25
19
8
\
17
10
10
6
13
11
18
16
7
/
I
18
25
8
11
8
_0
I
31
\
17
16
5
52
27
ITEM PART#
QTY.
DESCRIPTION
ITEM PART #
QTY.
DESCRIPTION
1
B1331
1
PANEL, Control
17
22264
10
WASHER, #8 M4 Lock
2
23897
4
WASHER, #10 M5 Flat
18
51715
10
NUT, M4 - 0.7 Hex
3
49226
4
WASHER,
19
64526
8
SCREW, #6-32 x 3/8"
4
91526
4
SCREW, M5-0.8 x 12 mm
20
83970
1
5
82538
1
SWITCH, Idle Control
21
64525
4
BOARD, System Control
3/4" Hex Standoff
6
82881
4
WASHER, 7/16" Int. Lock
22
87962
1
7
43181
4
SCREW, M3- 0.5 x 10 mm
CIRCUIT BREAKER,
(automatic), 12V
8
43182
4
WASHER,
23
84335
1
ASSEMBLY,
Wire Harness
Rubber Connector
M5 Lock
M3 Lock
10
75207A
2
CIRCUIT BREAKER, 30 AMP
24
84134
1
GROMMET,
11
75207
2
CIRCUIT BREAKER, 20 AMP
25
92069
1
BOX, Control Panel
12
23365
10
WASHER, #8 Shakeproof
26
84028
1
TRANSFORMER,
10A
Idle Control
13
68868
1
OUTLET, 30A, 120V Locking Type
27
75475
9
SCREW, M4- 0.7 x 10 mm
14
43437
1
OUTLET, 30A, 120V/240V Locking
Type
30
31
74191
90418
1
1
OUTLET, 50A, 240V
32
75476
1
PPHMS, M4 - 0.7 x 16
15
68759
1
OUTLET, 20A,120V
16
43180
10
WASHER,
M4 Flat
2O
OUTLET, 10A, 12VDC
CRAFTSMAN
Wheel
7500 Watt AC Generator
Kit --
Exploded
/
/
/
/
580.327181
View and Parts List
/
3
l/
13
/
/
/
/
/
/
/
/
/
10
9
/
5
I
6
4
ITEM
PART NO.
QTY.
1
93393A
1
DESCRIPTION
2
89742
2
WHEEL
3
93693A
1
AXLE
4
87005
2
5
89635
2
PIN, Retaining
SPACER, Wheel
6
93696
1
LEG, Support
7
27007
2
MOUNT, Vibration
8
42909
2
CAPSCREW,
9
52858
8
NUT, Lock M8
10
22247
2
WASHER, Wheel
11
39253
2
CAPSCREW,
12
22145
2
WASHER, Vibration Mtg.
13
39287
4
HHCS, M8 - 1.25 x 45 Lg GR 10.9
HANDLE
2!
Hex Hd. M8 - 1.25 x 30 Lg.
Hex Hd. - M8 - 1.25 x 20 Lg.
/
/
/
GENERAC Power Systems Engine, Model EHF 00935
Low Oil Shutdown And GovernorExploded View
7
13
14
White
/
\
15
8
\15
9
10
/-25
21
\
24
\
\
\
\
29
27
28
\\
5O
ITEM
7
8
9
10
12
13
14
15
16
PART NO. QTY.
DESCRIPTION
78653
85272
93104
93611
84329
92981
22097
92079
84542
Run/Stop Switch
Led Assembly
L.O.S. Decal
Black Sleeving
3 Pin Male Hsg.
Wire Asm.
M6 Lockwasher
M6 x 30 Taptite
Ignition Coil
1
1
1
1
1
1
2
2
1
ITEM
20
21
23
24
25
27
28
29
30
22
PART NO. QTY.
DESCRIPTION
72347
72734
83502
83512
73100
83503
73101
72735
72789
Sparkplug
Governor Lever
Adjust Screw
M8 x 15 Taptite
60Hz Gov. Spring
M5 Lock Nut
Governor Bracket
Governor Rod
Anti-Lash Spring
1
1
1
2
1
1
1
1
1
GENERAC Power Systems Engine, Model EHF 00935
Low Oil Shutdown And GovernorExploded View
91
92
89
_79
83
/
/80
ITEM
86
PART NO. QTY.
DESCRIPTION
78
79
82774
91222C
1
1
80
81
67198N
67890
1
1
Woodruff Key
Flywheel w/Ring Gear
(410)
Conical Washer
M20 Hex Nut
17.
ITEM
82
83
84
85
86
87
88
89
90
91
92
93
22
93
ITEM
17
22
26
93
PART NO. QTY.
DESCRIPTION
21544
40976
22129
B2160
Starter Motor
SHCS M8-1.25 x 20
Lock Washer M8
Rubber Spacer
1
2
2
1
\
82
81 Z
PART NO. QTY.
DESCRIPTION
88433
45756
78609
73104A
1
7
2
1
Top Wrapper
M6 x 10 Taptite
Cover Bolt
Air Box Cover
92437
88434
66476
96195
96196
73116A
81668
1
1
4
1
1
1
5
Blower Housing
Lower Wrapper
M6 x 12mm cap screw
Recoil Assembly
Recoil Cup
Back plate, E. SRT
M6 x 10 HHCS
83512
1
M8 x 15 Taptite
WITH
ITEM
2
3
4
5
6
23
92
OIL
FILTER
PART NO. QTY.
DESCRIPTION
86999
94683
49821
60108
70185
Oil
Oil
M8
Oil
Oil
1
1
2
1
1
Filter Gasket
Filter Adapter
x 30 SHCS
Press Switch
Filter
GENERAC Power Systems Engine, Model EHF 00935
Carburetor, Air Cleaner, Oil Switch and Oil Blockoff-Exploded
34
View and Parts List
33
/
43
38
46
48
5O
49
37
38
ITEM
PART NO. QTY.
DESCRIPTION
31
32
33
34
35
72745
91039
40945
81647
66476
1
1
2
2
2
Breather Hose
Head/Manifold Gasket
M6 x 20 SHCS
Carb. Bolt
M6 x 12 HHCS
36
37
38
39
40
91028
22097
49813
90970
93873
1
3
2
1
2
41
42
91204
89228
1
1
ITEM
PART NO. QTY.
DESCRIPTION
43
44
45
46
47
A4600
73108A
49811
59635
73111
410 Nikki Carb.
Air Cleaner Base
M6 Flatwasher
#8 x 3/8 Plastite
Air Filter
K Adapter
M6 Lock Washer
M6 Hex Nut
Carb./Airbox Gasket
M6 Ribbed Lockwasher
48
49
50
51
60
81646
83504
47411
90827
30340
Spitback Plate
Carb/Manifold Gasket
61
48031C
24
1
1
4
1
1
1
1
2
1
12"
1
Pre-cleaner
Choke Knob
M6 x 16 HHCS
Brkt. Air Box
1/4" ID Hose
Hose Clamp
GENERAC Power Systems Engine, Model EHF 00935
Long Block - Exploded View and Parts List
1
46
25
14
5O
48
43
19
31
ITEM
1
2
3
4
5
6
7
8
9
10
12
13
14
15
19
20
21
22
23
24
25
26
27
28
29
DESCRIPTION
47
PART NO. QTY.
Connecting Rod
71978
with Cap and Bolt
Piston Pin
71980
Piston Ring Set (410)
21533
Piston (410)
96699
Piston Pin Retainer
71983
Crank Shaft Assembly
78666A
With Gears (Small Taper)
Governor Arm
83948
Governor Arm "R" Pin
78658
Governor Arm Washer
78659
Crankcase H.S. W/Taper
88261E
Plugs (410)
Crankshaft Seal
72655
Gov. Gear Assembly
83912
Governor Retainer
78645
("C" Ring)
Governor Spool
76365
Camshaft Assembly
83932
Crankcase Gasket
76701
Cylinder Head Gasket (410) 21713B
Oil Pressure Relief
78691
Cover
Press. Relief Spring
83918
Press. Relief Ball
76362
Thrust Washer
76361
Gear Cover
88260B
Valve Spring Retainer
86514
Valve Spring
91308
Gerotor Set
86025
/ / \12
ITEM
1
30
31
1
1
1
2
1
32
33
34
35
36
37
38
39
40
41
42
43
1
1
2
1
2
1
1
44
46
47
48
1
1
1
1
1
50
51
1
1
1
1
2
2
1
52
53
54
55
25
10
DESCRIPTION
Balancer
Cylinder Head With
Valve Seats & Guides
Exhaust Valve
Intake Valve
Push Rod
Tappet
Oil Pick-Up Assembly
Rocker Cover Gasket
Pivot Ball Stud
Rocker Arm
Jam Nut (Rocker Arm)
Push Rod Guide Plate
M10 x 108 Head Bolt
Rocker Cover Breather
Assembly
Oil Fill Plug
O-ring 17.8 I.D. x 2.4 THK.
3/8" NPT Pipe Plug
M5-0.8 x 8mm Screw
(Thread Forming)
Valve Spring Keeper
M6-1 x 12mm Pan Head
Screw and Lockwasher
Hex Head flange Bolt
M8 1.25 x 42mm
Valve Stem Seal
Valve Spring Washer
Long Block Assm.
F
PART NO.
QTY.
84430
21714
1
1
86516
86517
88396B
83897
77158
71987
72694
83907
72696
78694
21742
83938
1
1
2
2
1
1
2
2
2
1
4
1
76329
86254
26925
74908
1
1
2
1
86515
78606
4
4
A1442
8
78672
89673
A1044
1
2
0
CALIFORNIA
AND FEDERAL EMISSION
CONTROL WARRANTY
STATEMENT
Your Warranty
As the ULGE engine owner, you should be aware that
Sears may deny any and/or all warranty coverage or
responsibility if your ULGE engine or a
part/component of it has failed due to abuse, neglect,
improper maintenance, unapproved modifications, or
the use of counterfeit and/or 'grey-market' parts not
made, supplied or approved by the original equipment
manufacturer.
Rights and Obligations
The California Air Resources Board (CARB), United
States Environmental Protection Agency (EPA), and
Sears Roebuck and Co. USA (Sears) are pleased to
explain the emissions control system warranty on your
1997 and later utility and lawn and garden equipment
engine. New Utility and Lawn and Garden Equipment
(ULGE) engines must be designed, built, and
equipped to meet both the State of California and
Federal stringent anti-smog standards. Sears must
warrant the emission control system on your ULGE
engine for the periods of time listed below provided
there has been no abuse, neglect, or improper
maintenance of your ULGE engine.
You are responsible for presenting your ULGE engine
to a Sears authorized service center as soon as a
problem occurs. Warranty repairs should be
completed in a reasonable amount of time, not to
exceed 30 days.
If you have any questions regarding your warranty
rights and responsibilities, you should contact your
nearest authorized service center or call Sears at
1-800-473-7247.
The emissions control system may include parts such
as the carburetor, ignition and exhaust systems. When
a warrantable condition occurs, Sears will repair your
lawn and garden equipment engine at no cost to you.
Expenses covered under warranty include diagnosis,
replacement parts and labor.
Manufacturer's
Warranty
Warranty
Warranty
Date
Length of Coverage
Sears warrants to the initial owner and each
subsequent purchaser that the engine is free from
defects in materials and workmanship which cause the
failure of a warranted part for a period of two years.
Coverage
The 1997 and later ULGE engines are warranted for
two years. If any emission related component or
system on your engine (as listed below) is found to be
defective, repairs or replacement will be performed by
an authorized Sears service center.
Owner's
Commencement
The warranty period begins on the date the ULGE
engine is delivered to the original, end-use purchaser.
What is Covered
Repair or Replacement of Parts
Responsibilities
Repair or replacement of any warranted part will be
performed at no charge to the owner at an approved
Sears service center. If you have any questions
regarding your warranty rights and responsibilities, you
should contact your nearest authorized service center
or call Sears at 1-800-473-7247.
As the ULGE engine owner, you are responsible for
the completion of all required maintenance as listed in
your factory supplied Owner's Manual. For warranty
purposes Sears recommends that you retain all
receipts covering maintenance on your ULGE engine.
However, Sears cannot deny warranty solely because
of the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
26
Warranty
How to File a Claim
Period
Any warranted part which is not scheduled for
replacement as required maintenance shall be
warranted for 2 years. Any warranted part which is
scheduled only for regular inspection and/or has
instructions to the effect of "repair or replace as
necessary" shall also be warranted for 2 years. Any
warranted part which is scheduled for replacement as
required maintenance shall be warranted either for the
period of time up to its first scheduled replacement, or
for 2 years, whichever comes sooner.
If you have any questions regarding your warranty
rights and responsibilities, you should contact your
nearest authorized service center or call Sears at
1-800-473-7247.
Where
to get Warranty
Warranty services or repairs shall be provided at all
Sears authorized service centers.
Maintenance,
Replacement
Emission Related Parts
Diagnosis
and Repair of
Any Sears approved replacement part used in the
performance of any warranty maintenance or repair on
emission related parts will be provided without charge
to the owner if the part is under warranty.
When the ULGE engine is inspected by an authorized
Sears service center, the owner shall not be held
responsible for diagnostic costs if the repair is deemed
warrantable.
Emission
Consequential
Service
Damages
Control Warranty
Parts List
1. Fuel Metering System:
Sears may be liable for damages to other engine
components caused by the failure of a warranted part
if the failed part was still under warranty.
a. Carburetor assembly
b. Fuel filter
2. Air Induction System:
a. Intake manifold
What is not covered
b. Air cleaner
Owner Responsibilities
3. Catalytic Muffler Assembly (if so equipped),
including:
Any failures caused by abuse, neglect, or improper
maintenance will not be covered.
a. Muffler gasket
b. Exhaust manifold
Add-On or Modified Parts
The use of add-on, unauthorized or modified parts
constitutes sufficient reason for denial of submitted
warranty repairs. Sears will not be held liable for
repairs of this type.
4. Ignition System
a. Spark plug
b. Ignition module
5. Crankcase Breather Tube
2?
For in-home major brand repair service"
Call 24 hours a day, 7 days a week
1-800-4-MY-HOME
Para pedir servicio de reparacibn
sM
(1-800-469-4663)
a domicilio
- 1-800-676-5811
In Canada for all your service and parts needs call - 1-800-665-4455
Au Canada pour tout le service ou les pieces
For the repair or replacement parts you need:
Call 7 am - 7 pm, 7 days a week
1-800-366-PART
Para ordenar
(1-800-366-7278)
piezas con entrega a domicilio
- 1-800-659-7084
For the location of a Sears Parts and Repair Center in your area:
Call 24 hours a day, 7 days a week
1-800-488-1222
For information on purchasing a Sears Maintenance Agreement
or to inquire about an existing Agreement:
Call 9 am - 5 pm, Monday-
Saturday
1-800-827-6655
The ServiceSideof Sears"