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"