Craftsman 919.670041 User manual

SEA FIS
Model No.
919.670041
i,,CRRFTSMRNI
120/240 VOLT • 4250 WATT
GENERATOR
IMPORTANT:
Read the Safety Guidelines
and All Instructions Care-
fully Before Operating
• SAFETY GUIDELINES
• ASSEMBLY
•OPERATION
•MAINTENANCE
•TROUBLESHOOTING
•REPAIR PARTS
Sold by Sears Canada, Inc., Toronto, Ont. M5B2B8
MGP-670041 Rev. 0 1/11/00

Warranty ................................................... 2
Safety Guidelines .................................. 3-8
Assembly ............................................. 9-10
Operation .......................................... 11-15
Maintenance ..................................... 16-18
Service Adjustments ............................. 18
Storage ................................................... 19
Troubleshooting Guide .......................... 19
Generator Parts ................................ 20-26
Engine Parts ..................................... 27-36
How To Order Parts ................. Back Cover
DATEPURCHASED:
MODEL NO:
SERIAL NO:
STOREWHERE PURCHASED:
ADDRESS:
CITY:
TELEPHONE:
Record the above information about your unit
so that you will be able to provide it incase of
loss or theft.
GHORSEPOWER 9 HP l
ASOLINE CAPACITY 7 GALLON/26.5 LITERS
IL CAPACITY 37.1OZ./1.1 L TERS
MAINTENANCE AGREEMENT
The Sears Warranty, plus aMaintenance Agreement, pro-
vide maximum value for your Sears products. Contact
your nearest Sears store for details.
CUSTOMER RESPONSIBILITIES
Read and observe the safety rules.
Follow a regular schedule in maintaining, caring for and
using your generator.
Follow the instructions under "Customer Responsibili-
ties" and "Storage" sections of this owner's manual.
FULL ON£ YEAR WARRANTY ON CRAFTSMAN GENERATORS
For one year from the date of purchase, when this Craftsman generator is maintained and operated according to the instruc-
tions in this owner's manual, Sears will repair, free of charge, any defect in material and workmanship.
If your Craftsman Generator is used for commercial or rental purposes, this warranty applies for only 90 days from the original
date of purchase.
FULL ONE YEAR WARRANTY ON CRAFTSMAN ENGINE
For one year from the date of purchase, when this Craftsman engine is maintained and operated according to the instructions
in this owner's manual, Sears will repair, free of charge, any defect in material and workmanship.
If your Craftsman engine is used for commercial or rental purposes, this warranty applies only for 90 days from thedate of
purchase. This warranty does not cover: Expendable items such as spark plugs and air filters, which become worn during
normal use.
Repairs necessary because of operator abuse or negligence, including damage resulting from no oil being supplied to
the engine or failure to maintain the equipment according to the instructions contained in this owner's manual, are not
covered under warranty.
WARRANTY SERVICE IS AVAILABLE BY RETURNING THE GENERATOR TO THE NEAREST SEARS SERVICE CENTER. This
warranty gives you specific legal rights and you may also have other rights, which vary from PROVINCE TO PROVINCE.
Sold by Sears Canada, Inc., Toronto, Ont.
MGP*670041 2 -- ENG

This manual contains information that is important for you to know and understand. This information relates to
protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information,
we use the symbols to the right. Please read the manual and pay attention to these sections.
DANGER indicates an imminently hazardous situation CAUTION indicates apotentially hazardous situation
which, if not avoided, wirl result in death or serious which, if not avoided,_ result in minor or moderate
in_juE, iniuw.
WARNING indicates a potentially hazardous situation CAUTION used without the safety alert symbol indicates a
which, if not avoided, could result in death of serious potentially hazardous situation which, if not avoided,
inEig__. result in property damaqe.
This product is not equipped with a spark arresting muffler. If the product will be used around flammable
materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or other similar items,
then an approved spark attester must be installed and may be legally required in other countries.
• SAVE THESE INSTRUCTIONS "
When using this product basic precautions should always be
followed including the following:
RISK OF ELECTROCUTION AND FIRE
HAZARD WHAT COULD HAPPEN
Attempting to connect generator di-
rectly to the electrical system of any
building structure.
Back feeding electricity through a
building's electrical system to the
outside utility feed )ines cou)d en-
danger repair persons attempting to
restore service.
Attempting to connect to the incom-
ing utility service could result in
electrocution.
Restoration of electrical service while
the generator is connected to the
incoming utility could result in a fire or
serious damage if aisolator switch is
not installed.
Failure to use a double throw transfer
switch when connecting to a struc-
tures electrical system can damage
appliances and WILL VOID the
manufacturers warranty.
HOW TO PREVENT IT
Never backfeed electricity througt
a structure's electrical system.
To connect to astructure's electri
cat system in a safe manner,
always have a Double-Throw
Transfer Switch installed by a
qualified electrician and in compli
ance with local ordinances. (Whel
installing a Double-Throw
I Transfer Switch, a minimum of
10 gauge wiring must be used.)
3-- ENG MGP-670041

READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
HAZARD
Operation of generator in rain, wet,
icy, or flooded conditions.
Use of worn damaged, undersized
or ungrounded extension cords.
Placing generator on or against
highly conductive surface, such as
a steel walkway or metal roof.
Improper connection of items to
generator.
Operation of unit when damaged, or
with guards or panels removed.
RISK OF ELECTROCUTION AND F!RE (cont'd)
WHAT COULD HAPPEN
Water is an excellent conductor of elec-
tricity! Water which comes in contact
with electrically charged components
can transmit electricity to the frame and
other surfaces, resulting in electrical
shock to anyone contacting them.
Contact with worn or damaged exten-
sion cords could result in electrocution,
Use of undersize extension cords could
result in overheating of the wires or at-
tached items, resulting in fire.
Use of ungrounded cordsets could pre-
vent operation of circuit breakers and
result in electrical shock.
Accidental leakage of electrical current
could charge conductive surfaces in
contact with the generator.
Exceeding the load capacity of the gen-
erator by attaching too many items, or
items with very high load ratings to it
could result in overheating of some
items or their attachment wiring result-
ing in fire or electrical shock.
Attempting to use the unit when it has
been damaged, or when it is not func-
tioning normally could result in fire or
electrocution.
Removal of guarding could expose
electrically charged components and
result in electrocution.
HOW TO PREVENT IT
Operate generator in a clean, dry,
well ventilated area. Make sure
hands are dry before touching unit.
Inspect extension cords before use
and replace with new cord if re-
quired.
Use proper size (wire gauge) cordset
for application see chart in the As-
sembly section of this manual.
Always use acordset having a
grounding wire with an appropriate
grounding plug. DO NOT use an
ungrounded plug.
Place generator on low conductiv-
ity surface such as a concrete
slab.
ALWAYS operate generator a
minimum of six feet from any
conductive surface.
Read the load rating chart and in-
structions in the Wattage Calcula-
tion section. Make sure that the
summation of electrical loads for all
attachments does not exceed the
load rating of the generator.
Do not operate generator with me-
chanical or electrical problem, Have
unit repaired by an Authorized Ser-
vice Center.
Do not operate gene:'ator with pro-
tective guarding removed.
MGP-670041 4-- ENG

READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF FIRE
WHAT COULD HAPPENHAZARD
Attempting to fill the fuel tank while
the engine is running.
Sparks, fire, hot objects
Improper storage of fuel
Inadequate ventilation for genera-
tor
Tampering with factory set engine
speed settings.
Overfilling the fuel tank -
fuel spillage.
Gasoline and gasoline vapors can
become ignited by coming in contact
with hot components such as the
muffler, engine exhaust gases, or from
an electrical spark,
Cigarettes, sparks, fires, or other hot
objects can cause gasoline or gaso-
line vapors to ignite.
Improperly stored fuel could lead to
accidental ignition. Fuel improperly
secured could get into the hands of
children or other unqualified persons.
Materials placed against or near the
generator or operating the generator
_nareas where the temperature
exceeds 104 ° F. ambient (such as
storage rooms or garages) can
interfere with its proper ventilation
features causing overheating and
-possible ignition of the materials or
buildings.
Engine speed has been factory set to
:)rovide safe operation. Tampering
with the engine speed adjustment
could result in overheating of attach-
ments and could cause afire.
Spilled fuer and its vapors can be-
come ignited from hot surfaces or
sparks.
5-- ENG
HOW TO PREVENT IT
Turn engine off and allow it to cool
before adding fuel to the tank.
Equip area of operation with a fire
extinguisher certified to handle
gasoline or fuel fires.
Add fuel to tank in well ventilated
area. Make sure there are no
sources of ignition near the
generator.
Store fuel in a OSHA approved
container designed to hold gaso-
line. Store container in secure
location to prevent use by others.
Operate generator in a clean, dry,
well ventilated area a minimum of
four feet from any building, object
or wall. DO NOT OPERATE UNIT
INDOORS OR IN ANY CON-
FINED AREA.
Never attempt to "speed-up" the
engine to obtain more perfor-
mance. Both the output voltage
and frequency will be thrown out
of standard by this practice,
endangering attachments and the
user.
Use care in filling the tank to avoid
spilling fuel Make sure fuel cap is
secured tightly and check engine
for fuel leaks before starting
engine. Move generator away
from refueling area or any spillage
before starting engine. Allow for
fuel expansion. Keep maximum
fuel level ¼ inch below the tip of
the fuel tank. Never refuel with the
engine running.

READ AND UNDERSTAND ALL WARNINGS BEFORE
Risk of Injury and Property Damage When
Transportina Generator
HAZARD
Fire, Inhalation, Damage to Vehicle
Surfaces
WHAT COULD HAPPEN
Fuel or oil can leak or spill and could
result in fire or breathing hazard,
serious injury or death can result. Fuel
or oil leaks will damage carpet, paint
or other surfaces in vehicles or
trailers.
HOW TO PREVENT IT
If generator is equipped with a fuel
shut-off valve, turn the valve to the
off position before transporting to
avoid fuel leaks. If generator is not
equipped with a fuel shut-off valve,
drain the fuel from tank before
transporting. Transport fuel only in
an OSHA approved container.
Always place generator on a
protective mat when transporting
to protect against damage to
vehicle from leaks. Remove
generator from vehicle immedi-
ately upon arrival at your destina-
tion
RISK OF BREATHING - INHALATION HAZARD
HAZARD
Gasoline engines produce toxic
carbon monoxide exhaust fumes.
WHAT COULD HAPPEN
Breathing exhaust fumes will cause
serious injury or death.
HOW TO PREVENT IT
Operate generator in clean, dry,
well ventilated area. Never
operate unit in enclosed areas
such as garages, basements,
storage, sheds, or in any location
occupied by humans or animals.
Keep children, pets and others
away from area of operating unit.
MGP-670041 6-- ENG

READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF UNSAFE OPERATION
HAZARD
Operation of generator in careless
manner.
Operation of voltage sensitive appli-
ances without a voltage surge pro-
tector.
Raising or suspending generators
equipped with lift rings improperly
Operating generator while suspended
WHAT COULD HAPPEN
All sources of energy include the
)otential for injury. Unsafe operation
or maintenance of your generator
could lead to serious injury or death
to you or others.
Any gasoline operated household
generator will incur voltage variations
causing damage to voltage sensitive
appliances or could result in fire.
Generator could fall causing serious in-
jury or death to you or others.
Improper raising or suspending can
cause damage to the generator.
Generator will not operate properly
and will cause damage to the genera-
tor and could cause serious injury or
death to you or others.
HOW TO PREVENT IT
• Review and understand all of
the operating instructions and
warnings in this manual.
•Become familiar with the
operation and controls of the
generator. Know how to shut it
off quickly.
• Equip area of operation with a
fire extinguisher certified to
handle gasoline or fuel fires.
• Keep children or others away
from the generator at all times.
Always use a U.L. listed voltage
sensitive surge protector to
connect voltage sensitive appli-
ances such as TV, computer, or
stereo equipment. Failure to use
a U.L. listed voltage surge
protector will void the warranty
on your generator.
Notice: A multiple outlet strip is
not a surge protector make sure
you use a U.L. listed voltage surge
)rotector.
Always use proper connecting
)rocedures as described in this
manual when connecting cables,
chains, or straps for raising or
suspending generators equipped
with lift rings.
Always use cables, chains, or
straps rated at 2000 Ibs working
load or more to raise or suspend
generator.
Never operate generator while
suspended or in an unlevel posi-
tion. Always operate generate on
a flat, level surface.
7 -- ENG MGP-670041

READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF HOT SURFACES
HAZARD
Contact with hot engine and
generator components.
WHAT COULD HAPPEN
Contact with hot surfaces, such as
engines exhaust components, could
result in serious burns.
HOW TO PREVENT IT
During operation, touch only the
control surfaces of the generator.
Keep children away from the
generator at all times. They may
not be able to recognize the
hazards of this product.
RISK OF MOVING PARTS
HAZARD
Contact with moving parts can
result in serious injury.
WHAT COULD HAPPEN
The generator contains parts which
t_otateat high speed during operation.
These parts are covered by guarding
to prevent injury.
HOW TO PREVENTIT
Never operate generator with
guarding or cover plates removed.
Avoid wearing loose fitting clothing
or jewelry which could be caught
by moving parts.
HAZARD
Lifting a very heavy object.
RISK FROM LIFTING
WHAT COULD HAPPEN
Serious injury can result from at-
tempting to lift too heavy an object.
HOW TO PREVENT IT
The generator is too heavy to be
lifted by one person. Obtain
assistance from others before you
try to move it.
MGP-670041 8 -- ENG

CARTON CONTENTS
1-Generator
1 - Parts Box
1 - Handle
- Parts Bag
"1 -Twlstlock Plug L5-2OP
1 - Owner's Manual
"1 - Twlstlock Plug L14-20P
To be installed and/or used in
accordance with appropriate local electrical codes
and regulations. Refer to enclosed instructions for
proper installation.
_2 - Wheels
2 - Bracket
2-Shoulder
Bolts
_l-Foot Bracket
©
2 - Handle Caps
1 - Isolator Foot 7 - 5/16-18 x 3/4"
CapScrews
(6 used)
2 - 5/16-18 x 1 3/4 "
Cap Screws
9 - 5/16-18
Lock Nuts
2-Washers 2 -318-16
Lock Nuts
Read owner's manual. Do not attempt to operate equipment until you have read Owner's
Manual for Safety, Assembly, Operation, Maintenance, Storage Instructions.
NOTE: Left and right describes the location of a part
with the operator facing the outlet panel,
TOOLS NEEDED FOR ASSEMBLY
1- Box Cutter or Knife
2 - 1/2" Wrenches
2 - 9/16" Wrenches
1 - 1" thick x 1' square piece of wood
REMOVE GENERATOR FROM CARTON
* Open carton from top.
•Cut carton along dotted lines.
• Remove all carton inserts.
• Remove generator through opening in carton.
IMPORTANT: Before any attempt to start your genera-
tor be sure to check engine oil (See Adding Engine Oil
paragraph in the Operation section on page 13 of this
manual.)
9 -- ENG MGP-670041

GROUNDING THE GENERATOR
A grounding lug is supplied with the generator for use
when required by local electrical ordinances. Refer to
article 250 of the National Electrical Code to clarify
any needed grounding information. Your local electric
company or a certified electrician should be able to
help you with this information.
NOTE: Your engine is already grounded to the frame
by a grounding strap.
Grounding Lug
INSTALLING WHEEL KIT
The Craftsman Wheel Kit was designed to greatly
improve the portability of your generator.
Drain gas and oil before
assembling the port;ability
kit. Failure to do so will cause damage to the
engine.
NOTE: Always follow state regulations for proper oil
disposal.
•Place generator on level ground; qrain all gas and
oil from the engine (see engine manual for correct
procedure).
• Place a 1" thick x 1' square piece of wood on the
ground in front of the engine. With the help of
another person, tilt the generator and rest the
recoil starter on the wood. NOTE: This wil!
support the gasoline engine during assembly and
make assembly easier.
• Place a handle cap (7) onto each end of handle
prior to installation.
•The handle should be installed on the electrical
outlet end of the generator. Place one washer
(12) on long cap screws (11). Align the handle
brackets with the upper holes pre-drilled in the
generator frame. Place mentioned screws through
frame and handle brackets. Secure with lock nuts
(8) and tighten.
2
Locate the engine support. Place one wheel
bracket (4) on top of support as shown in illustra-
tion. Align with the pre-drilted holes in support.
Place 2 cap screws (9) through holes in bracket
and support. Secure with 2 lock nuts (8) and
tighten.
Insert one shoulder bolt (2) into wheel (1). Insert
threaded end of bolt through wheel bracket,
secure with lock nut (3) and tighten. NOTE: The
wheel will not rub frame if installed properly.
Repeat the above steps for the opposite side.
Insert the threaded stud of rubber foot (10)
through the middle hole of the foot bracket (5).
Secure with lock nut (8) and tighten.
Locate the support under the electrical outlet end
of the generator. Position foot bracket (5), with
rubber foot installed, under the support and align
the holes in the foot bracket (5) with the slots in
the support. Place one cap screw (9) through
each slot in the support and the holes in the foot
bracket. Secure with the lock nuts (8) and tighten.
Once completed, the wheel kit is ready for use.
11
12
8
10
MGP-670041 10- ENG

KNOW YOUR GENERATOR
IRead this Owner's Manual and Safety Rules before operation of your Generator, Compare this illustra-
tion with your generator to familiarize yourself with the location of various controls and adjustments. Save the
manual for future references.
FOUR FUEL TANK
CIRCUIT
BREAKERS FUEL CAP \
MUFFLER
SPARK PLUG_
AIR CLEANER "
FUEL VALVE
LEVER CHOKE
CONTROL
ENGINE ON/OFF
SWITCH
(notshown)
120 VOLT
DUPLEX --
RECEPTACLE FUEL SHUT OFF VALVE
(not shown)
120 VOLT 3-PRONG
TWISTLOCK
RECEPTACLE
240 VOLT4-PRONG
TWlSTLOCK
RECEPTACLE
FULL POWER
SWITCH
FUEL TANK- Capacity of 7 US gallons/26.5 Liters.
CHOKE CONTROL- Used to start cold engine.
ENGINE ON/OFF SWITCH- Sets engine in starting
mode for recoil starter - Stops running engine.
FUEL VALVE LEVER (located on engine) - Used to
shut off the flow of fuel to the engine.
FUEL SHUT OFF VALVE (located under gas tank) -
Used to shut off the flow of fuel to the engine.
ENGINE OIL FILL- Check and fill engine with oil.
AIR CLEANER- Includes filter element cartridge and
foam pre-cleaner that limits the amount of dirt that
enters the engine.
FULL POWP2R SWITCH - Allows the operator to dis-
tribute power across the outlets.
FILL
ENGINE OIL DRAIN
CIRCUIT BREAKER- Each receptacle has acircuit
breaker to protect the generator from overloading.
120 VOLT RECEPTACLES- Used to supply 4250
watts of electrical power per receptacles when the
Full Power Switch is in the 120V position and 2125
watts with the Full Power Switch in the 120/240V
position. Protected by 15 amp circuit breaker.
240 VOLT TWlSTLOCK RECEPTACLE -Used to
supply 4250 watts of electrical power per receptacles
when the Full Power Switch is in the 120V position
and 4250 watts with the Full Power Switch is in the
120/240V position. Protected by 15 amp circuit
breaker.
11 -- ENG MGP-67CO41

RECEPTACLES
Your generator is equipped with:
•one 120 volt duplex receptacle protected by a 15
amp circuit breaker
• one 120 volt 3-prong twistlock receptacle pro-
tected by a two 15 amp circuit breakers
• one 240 volt 4-prong twistlock receptacle pro-
tected by two 15 amp circuit breakers
The circuit breakers are provided to protect the
generator against electrical overload. If the circuit
breaker trips, unplug electrical load from receptacle.
Let circuit breaker cool clown and then push circuit
breaker button to reset.
®
®
FULL POWER SWITCH
When placed in the 120V position it allows you to
receive the full capacity of the generator by using all
120 volt receptacles. When in the 120/240 position,
you will only be able to receive 2125 watts when using
the 120 volt receptacles and the full 4250 watts when
using the 240 4-prong twistlock receptacle.
Full Power Switch in the 120V/240V position
®
NEMA 5-20R
Duplex
2125 Watts
120V 15A 12OV 24OV 15A
NEMA LS-2OR . ®
3-prong 4-prong
Twistlock Twistlock
2125 Watts 4250 Watts
r-i
120V 120/240V
Full Power Switch in the 12OV position
120V 15A 12OV 240V tSA
0@@0
® . ®
NEMA 5-20R 3-prong 4-prong
Duplex Twistlock Twistlock
4250 Watts Surge
2125 continuos 4250 Watts surge together
2125 Watts continuous together
No 240V available
12OV 12(_240V
LOW OIL SHUTDOWN
Your Craftsman generator engine is equipped with Low
Oil Shutdown. Low Oil Shutdown is asafety device
designed to protect your engine from damage in the
event the oil level in the crankcase is low.
If while the engine is running, the oil gets low, it will
automatically shut itself down and will not restart until
the oil is added. If the oil is low before start-up, the
generator will not start until oil is added.
NOTE: The Low Oil Shutdown mechanism isvery sensi-
tive. You must fill the engine to the full mark on the dip-
stick to inactivate this safety device.
GENERATOR CAPACITY
Exceeding the rated capacity of your generator can
result in serious damage to your generator and con-
nected electrical devices. You should observe the
following to prevent overloading the unit:
• Starting and running wattage requirements should
always be calculated when matching a generators
wattage capacity to the appliance or tool.
• There are two types of electrical appliances that
can be powered by your generator:
A. Items such as radios, light bulbs, television
sets, and microwaves have a "resistive load".
Starting wattage and running wattage are the
same.
B, Items such as refrigerators, air compressors,
washer, dryer, and hand tools that use an
electrical motor have an "inductive load".
Inductive load appliances and tools require
approximately 2 to 4 times the listed wattage
for starting the equipment. This initial load
only lasts for a few seconds on start-up but is
very important when figuring your total watt-
age to be used.
MGP*670041 12 -- ENG

NOTE: Some inductive appliances and tools will list
on the motor name plate, the starting and running
voltage and amperage requirements. Use the following
formula to convert voltage and amperage to wattage:
(Volts X Amp = Watts)
•Always start your largest electric motor first, and
then plug in other items, one at a time.
NOTE: On 120-volt loads the maximum starting watt-
age should NOT exceed one half of the rated generator
wattage. Example: a 4250 rated wattage generator =
2125 maximum starting wattage.
The guide is provided to assist you in determining the
appliances and tools that can be ran with the wattage
capacity of your generator.
OBTAINING ELECTRICITY FROM
GENERATOR
There are basically two ways to obtain electricity from
a generator:
• Use of extension cords directly from the genera-
tor to the appliance, lights, tools, etc.
• Use of a double-throw transfer switch installed
directly to the main electrical supply outside of
the house.
Extension Cord
When using an appliance or tool at a considerable
distance from the generator, a 3-wire extension cord
that has a 3-blade grounding plug and a 3-slot
receptacle that accepts the tool's plug MUST be
used in order to reduce the risk of electrical shock. A
cord of adequate size must be used. A minimum of 12
gauge wire size with at least a 20 amp draw can be
used. When amperage exceeds 20 amps a 10 gauge
wire size should be used.
on cord that is hot
touch is overloaded.
Repair or replace damaged extension cords
immediately.
Connecting Generator To Main Electrical
Supply
Potential hazards exist when a electrical generator is
connected to the main electrical supply coming into
the house. It is at that point that the generator could
feed back into the utility company's system causing
possible electrocution of workers who are repairing
electrical lines. To avoid back feeding of electricity into
utility systems, a double-throw transfer switch
should be installed between the generator and utility
power. This device should be installed by a licensed
electrician and in compliance with all local electrical
codes.
NOTE: When installing a Double-ThrowTransfer
Switch, a minimum of 10 gauge wiring must be used.
13 -- ENG MGP-670041

BEFORE STARTING ENGINE
_Always check engine oil level
before every start. Running
engine low of oil or out of oil could result in
set ous damage to the engine.
Adding Engine Oil
Your generator has been shipped without oil in the
engine.
To add oil:
• Remove the filler cap/dipstick.
• Fill to the edge of the oil filler hole. Oil capacity is
37.1 ounces/1.1 liters.
• Replace filler cap/dipstick and tighten securely.
Filler Cap/Dipstick
Full
Never fill fuel tank indoors.
Never fill fuel tank when engine is running or
hot. Do not smoke when filling fuel tank.
To Start Your Generator
Never run engine indoors or
in enclosed, poor ventilated areas. Engine
exhaust contains carbon monoxide, an odor-
less and deadly gas.
Open the fuel shut-off valve located under the gas
tank. Turn counter clockwise until the valve stops.
Move fuel valve lever to ON position.
Lower Limit
SAE 10W-30 (4 stroke automotive detergent oil) is
recommended for general use. Other viscosities
shown in the chart may be used when the average
temperature in your area is within the recommended
range.
II El]!
Upper Limit
-20 0
IKIIII I I
*30 -20 -10 0 t0 20 30 40"C
AMBIENT TEMPERATURE
The SAE oil viscosity and service classifications are in
the API label on the oil container. API SERVICE
category SF or SG oil is recommended.
Gasoline
Remove gas cap.
Add unleaded gasoline with a pump octane rating
of 86 or higher, slowly, to fuel tank. Do not mix oil
with gasoline.
Never fill fuel tank com-
pletely. Fill tank to 1/2" below the bottom of the
filler neck to provide space for fuel expansion.
Wipe any fuel spillage from engine and equip-
ment before starting engine.
• Do not overfill.
• Move choke control lever to CLOSED position.
NOTE: To restart a warm engine, move choke control
to OPEN position.
CHOKE CHOKE
OPEN
• Turn engine switch to ON position.
MGP-670041 14 -- ENG

IYou MUST unplug any load
from the generator before starting to prevent
permanent damage to any appliances.
Pull starter grip slowly until you feel resistance,
then pull briskly. Return starter grip gently. Pull
rope with a rapid full arm stroke. Let rope rewind
slowly. Repeat if necessary.
Starter Grip
NOTE: IF ENGINE OIL LEVEL IS TOO LOW, EN-
GINE WILL NOT START. CHECK OIL LEVEL AND
ADD IF NECESSARY.
• If choke control lever is in CLOSED position, move
lever to OPEN position as engine warms up.
IMPORTANT: Allow generator to run at no load for 5
minutes upon each initial start-up to allow engine and
generator to stabilize.
STOPPING ENGINE
• Disconnect all electrical loads.
• Turn engine switch to "OFF" position.
• Close fuel shut-off valve located under gas tank.
IMPORTANT: Never store engine with fuel in tank,
indoors, or in enclosed, poorly ventilated areas or
where fuel fumes may reach an open flame.
CONNECTING ELECTRICAL LOADS
•Let engine run and warm up for five minutes after
starting with no electrical load.
Connect loads in the following manner to prevent
damage to equipment:
Connect inductive load equipment first, inductive
loads consist of refrigerators, freezers, water
pumps, air conditioners, or small hand tools.
Connect the items that require the most wattage
first.
Connect the lights next.
Voltage sensitive equipment should be the last
equipment connected to the generator. Plug
voltage sensitive appliances such at "IV's, VCR's,
microwaves, ovens, computers, and cordless
telephones into a UL listed voltage sbrge protec-
tor, then connect the UL listed voltage surge
protector to the generator.
IMPORTANT: You should always add up the rated
watts of all lights, tools and appliances you are
powering at one time. This total should not
exceed the rated capacity of you generator or
circuit breaker rating of the receptacle supplying
power.
Move the fuel valve lever to the "OFF" position.
Fuel
Valve
Lever
15 -- ENG MGP-67CO4_

CUSTOMER RESPONSIBILITIES TABLE
Perform task at every indicated
month or operating hour
interval, whichever comes first.
MAINTENANCE TASK
Engine Oil Check
Change
Air Filter Check
Clean
Replace
Sediment cup Clean
Check Spark Plug Clean-Readjust
Replace
Clean
Before
each
1
2
use
First month or
every 20 Hrs. Every 3 months
or 50 Hrs. Every 6 months or 100 Hrs.
X
XX
x(1)
X
X
X
Every year or
300 Hrs.
X _
Every 2 years (Replace if necessary) (2)
Prepare unit for storage if it is to remain idle for more than 30 days.
Service more frequently when used in dusty areas.
These items should be service by your authorized service dealer.
Replace the paper air filter element only.
X
Spark arrester X (2)
(optional part)
Fuel line Check
Prepare Unit for Storage
GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items
that have been subjected to operator abuse or negli-
gence. To receive full value from the warranty, opera-
tor must maintain the generator as instructed in this
manual.
Some adjustments will need to be made periodically to
maintain your generator.
GENERATOR MAINTENANCE
Your generator should be kept clean and dry at all
times. The generator should not be stored or oper-
ated in environments that include excessive moisture,
dust or any corrosive vapors. If these substances are
on the generator, clean with a cloth or soft bristle
brush. Do not use a garden hose or anything with
water pressure to clean the generator. Water may
enter the cooling air slots and could possibly damage
the rotor, stator and the internal windings of the
generator head.
All adjustments in the Maintenance section of this
manual should be made at least once each season.
ENGINE MAINTENANCE
Improperly maintaining this
engine, or failure to correct a problem before
operation, can cause a malfunction in which
you can be seriously hurt or killed.
Always follow the inspection and maintenance
recommendations and schedules in this
owner's manual.
MGP-670041 16 -- ENG

Oil
• Oil level should be checked prior to each use and
at least every 5 hours of operation.
To check oil:
• Remove the filler cap/dipstick and wipe it clean.
• Insert and remove the dipstick without screwing it
into the filler neck. Check the oil level shown on
the dipstick,
• If the oil level is tow, fill to the edge of the oil filler
hole with the recommended oil. See the Adding
Oil paragraph on page 14 of this manual.
• Screw in the filler cap/dipstick securely.
edge of the oil filler hole with the recommended
oil. See the Adding Oil paragraph on page 14 of
this manual.
Air Filter
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If you operate the
engine in very dusty areas, clean the air filter more
often than specified in the Owner's Responsibilities
• Remove the wing nut from the air cleaner cover,
and remove the cover.
Air Cleaner Cover,
ap/Dipstick
Upper Limit
o O
Changing Engine Oil
For a new engine, change oil after the first 20 operat-
ing hours. Thereafter, change oil after every 100
hours of operation.
Change the oil while the engine is still warm. The oil
will flow freely and carry away more impurities. Make
sure the engine is level when filling, checking or
changing oil.
Change the oil as follows:
• To keep dirt, grass clippings, etc. out of the
engine, clean the area around the drain plug and
dipstickbefore removing it.
• Place a suitable container below the engine to
catch the used oil, then remove the filler cap/
dipstick and the drain plug.
• _ IJ /
\ _._-_4_ ./" Filler Cap/
oipst,ck
o.
Dr&in_" Level
Plug
Allow the used oil to drain completely, then
reinstall the drain plug, and tighten it securely.
Please dispose of used motor oil in a manner that
is compatible with the environment. We suggest
you take used oil in a sealed container to your
local recycling center or service station fro recla-
mation. Do not throw it in the trash, pour it on the
ground, or down a drain.
With the engine in a level position, fill to the outer
17 -- ENG
Paper Filter
Element _
Foam Filter
Element
Gasket
Remove the wing nut from the air filter and remove
the filter.
Remove the foam filter from the paper fitter.
Inspect both air filter elements and replace them if
the are damaged. Always replace the paper air
filter element at the scheduled interval. See
Customer's Responsibilities on page 16 of this
manual
Clean the air filter elements if they are to be
reused.
To clean the paper element:
• Tap the filter element several times on a hard
surface to remove dirt, or blow compressed
air (not exceeding 30 psi, 207kPa, 2.1kg/cm 2)
through the filter element from the inside.
Never try to brush off dirt; brushing with force
dirt into the fibers.
To clean the foam air filter element:
Clean in warm in warm soapy water, rinse, and
allow to dry thoroughly. Or clean in nonflam-
mable solvent and allow to dry. Dip the filter
element in clean engine oil, then squeeze out
all excess oil. The engine will smoke when
started if too much oil is left in the foam.
MGP-670041

• Wipe dirt from the inside of the air cleaner base
and cover, using a moist rag. Be careful to
prevent dirt from entering the air duct that leads
to the carburetor.
• Place the foam air filter element over the paper
element, and reinstall the assembled air filter. Be
sure the gasket is in place beneath the air filter.
Tighten the air filter wing nut securely.
• Install the air cleaner cover, and tighten the cover
wing nut securely.
Sediment Cup Cleaning
•Move the fuel valve lever to the "OFF" position,
then remove the fuel sediment cup and O-Ring.
Fuel Valve
Lever
OFF
Gasoline is highly flam-
mable and explosive.
You can be burned or seriously injured when
handling fuel.
•Keep heat, sparks, and flame away.
•Handle fuel only outdoors.
•Wipe up spills immediately.
-- )O':_nnumg;nt
• Wash the sediment up and O-Ring in nonflam-
mable solvent, and dry them thoroughly.
• Place the O-ring in the fuel valve, and install the
sediment cup. Tighten the sediment cup securely.
•Move the fuel valve to the "ON" position and
check for leaks. Replace the O-ring if there is any
leakage.
Clean and Replace Spark Plug
Check spark plug yearly or every t00 operating hours.
• Clean area around spark plug.
• Remove and inspect spark plug.
• Replac e spark plug if electrodes are pitted, burned
or porcelain is cracked.
• Check electrode gap with wire feeler gauge and
set gap .030 if necessary.
• Install spark, tighten securely.
.030" (0.76MM)
o
Spark Plug
CARBURETOR
The carburetor of your generator is pre-set at the fac-
tory. The carburetor should net be tampered with. If your
generator is used at an altitude in excess of 4000 feet
performance may be affected. If so consult with your
nearest Sears Service Center regarding high altitude set
changes.
GOVERNOR
Your engine governor maintains the constant operating
speed of your generator. DO NOT tamper with the en-
gine governor which is factory set for proper engine
speed.
Over-speeding your engine above factory high speed set-
ting can be dangerous and could possibly cause per-
sonal injury or property damage. If you believe the en-
gine is running too fast or slow, take your generator to a
Authorized Sears Service Center for repair and adjust-
ment.
I
Low engine speeds impose a I
heavy load on the engine and
when sufficient power is not available the engine
fe cou d be shortened.
MGP-67004_ 18 -- ENG

If you are going to store your generator for more than
30 days, use the following information as a guide to
prepare the generator for storage.
Never store generator with
in the tank indoors or in
enclosed, poorly ventilated areas, where fumes
can reach an open flame, spark or pilot light as
on a furnace, water heater, clothes dryer or
other gas appliances.
Engine Preparation
•Add fuel stabilizer to fuel tank to minimize the
formation of fuel gum deposits during storage.
•Run engine at least 10 minutes after adding
stabilizer to allow it to enter the fuel system.
• Disconnect the spark plug wire and remove the
spark plug.
• Add one teaspoon of oil through the spark plug
hole.
• Place rag over spark plug hole and pull the recoil a
few times to lubricate the combustion chamber.
Replace the spark plug, but do not connect the
spark plug wire.
NOTE: If a fuel stabilizer is not used, all gasoline must
be drained from the tank and carburetor to prevent gum
deposits from forming on these parts and causing pos-
sible malfunction of the engine.
Generator
Clean the generator as outlined in the Generator
Maintenance paragraph on page 16.
Check that cooling air slots and openings on
generator are open and unobstructed.
PROBLEM
Engine will not start
No electrical output
CAUSE
1. Low on fuel or oil
2. Ignition switch in "Off" position.
3. Faulty spark plug.
4. Choke in wrong position.
5. Fuel shut-off valve in closed
position.
6. Unit loaded during start-up.
7. Spark plug wire loose.
1. Faulty receptacle.
2. Circuit breaker kicked out.
3. Defective capacitor.
4. Faulty power cord.
1. Overload
2. Faulty cords or equipment.
CORREC_ON
1. Add fuel or oil.
2. Turn to "ON" position
3. Replace spark plug.
4. Adjust choke accordingly.
5. Open fuel shut-off valve.
6. Remove load from unit.
7. Attach wire to spark plug.
1. Have Authorized Sears Service
Center replace.
2. Depress and reset.
3. Have Authorized Sears Service
Center replace capacitor.
4. Repair or replace cord.
Repeated circuit breaker trip- 1. Reduce load.
ping 2. Check for damaged, bare, or
frayed wires on equipment.
Replace.
Generator overheating the 1. Generator overloaded. 1. Reduce toad.
circuit breaker depressed 2. Insufficient ventilation. 2. Move to adequate supply of
fresh air.
19 -- ENG MGP-610041

CRAFTSMAN 4250 GENERATOR 919.670040 GENERATOR ASSEMBLY
4
12
TORQUE 96-120 IN-LBS
KEY
NO,
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
DESCRIPTION PART NUMBER
FUELTANK GS-0795
FUEL TANK SCREWS 91895680
WASHER SSN-632
FUEL CAP GS-0443
FRAME ASSEMBLY GS-0909
PANELASSEMBLY GS-0844
ISOLATOR GS-0433
FUEL HOSE GS-0225
HEATSHIELD GS-0675
ISOLATOR GS-0033
LOCK NUT 5/16-18 SSF-8150
SCREW 5/16-18 x 1 SSF-605
LOCK WASHER SSN-1619-ZN
SCREW 5/16-18 x 3/4 SS-12-CD
GROUND STRAP GS-0118
ENGINE (model # GX270VWN2)
HOSE CLAMP .301 ID GS-0560
UNION REDUCER 1/4 TO 3/8 GS-0535
SCREW 1/4 x 5/8 39124607
LOCK WASHER SS-1503-CD
* SEE ENGINE PAGES 27-36
MGP-670041 20 -- ENG