Sears 580.32601 User manual

Sears
owners
manual
MODEL NO.
580.326010
CAUTION: READ
INSTRUCTIONS AND
RULES FOR SAFE
OPERATIONS CAR EFULLY
TO PREVENT ACCIDENTS,
GENERAL INFORMATION
INSTALLATION
OPERATING INSTRUCTIONS
MAINTENANCE
REPAIR PARTS
4500 WATT
HEAVY DUTY
PORTABLE ALTERNATOR
ALTERNATOR
Record in space provided below the Model No. and Serial No.
of the alternator, Model No, and Serial No. are both located
on the Nameplate, just below Alternator Control Panel.
Model Noo Serial No,
Retain these numbers for future reference,,
Sears, Roebuck and Co., Ct-deago, 1]1.60684 U.S.A.

FULL ONE YEAR WARRANTY
For one year from the date of purchase, Sears will repair any defect in
material or workmanship in this alternator at no charge°
If the alternator is used for commercial or rental purposes, this warranty
applies for only thirty days from the date of purchase.
Warranty service is available by contacting the nearest Sears Store or Service
Center throughout the United States.
This warranty gives you specific legal rights, and you may also have other
rights which vary from state to state. Sears, Roebuck and Co.
Sears Tower
BSC 41-3
Chicago, I L 60684
INTRODUCTION
Your Owner's Manual is meant to provide you with instructions for safe and proper operation of
the 4500 watt portable alternator, Read its contents carefully and comply with all instructions
and rules for' safe operation. With proper care, your alternator will give years of dependable elec-
tric power.
_IL CAUTION
Engines are shipped without oil. Any attempt to start your alternator before the recom =
mended oil has been properly added will result in an engine failure.
RULES FOR SAFE OPERATION
_ Your portable alternator' produces
dangerously high voltages,, Never permit un-
qualified people especially children to
operate the unit.
_Never handle electrical equipment
while standing in water, while barefoot, or
while hands are wet, This carl result in
dangerous electrical shock_
Maintain electrical power' cords in
good condition. Worn, bare or frayed elec-
trical cords are dangerous.
Make sure the wire gauge sizes of
electrical power cords are large enough to
handle the largest anticipated amperage of
electrical equipment. Using wires that are too
small to handle the amperage load is
dangerous.
Never install the alternator in any
enclosure or compartment that might
obstruct the free flow of cooling air. Severe
heat damage to the unit will occur.
_ Gasoline is highly flammable and ex-
plosive. Comply with local laws governing the
storage and handling of gasoline,
_1_ Use care when using your' alternator.
Keep clear of moving parts. Never work on the
unit while it is running. Keep equipment clean
and check frequently for loose, missing,
rusted or damaged nuts, bolts, and other
fasteners,.
_ Never try to adjust governed eng]ne
speed. High engine speed is dangerous, The
alternator will produce the required voltage
and frequency only at 3600 rpm.
Never run the alternator in any enclos-
ed area. Gasoline engines consume oxygen
and give off DEADLY carbon monoxide gas.

TABI.E OF CONTENTS
WARRANTY ....................... inside Front Cover
RULES FOR SAFE OPERATION inside Front Cover
SPECIFICATIONS ............................... 1
NOMENCLATURE ........................................... 2
WIRING DIAGRAM ............................................... 3
INSTALLATION OF STAND-BY
POWER SYSTEMS ............................... 4
REPAIR PARTS ........................................ 25-28
Section 1 -- Preparation For Use
Alternator Unpacking and Removal
From Shipping Skid .............................. 5
Parts Shipped With Alternator ......................... 5
Wheel Kit Installation ..................................... 7
Lubrication ........................................... 8
Battery Installation ................................ 9
Battery Connections .................................. 9
Fill Fuel Tank ..................................... 10
Install Fuel Tank ................................ 10
Cord Sets for 120 Volt, 15 Amp Outlets ......... 10
Optional Wiring Connections - 240 Volt
Connector Plug .......................... 11
Optional Wiring Connections - 120 Volt,
30 Amp Connector Plug ....................... 11
Grounding The Alternator .......................... 12
Section 2 -- Operating Instructions
Do and Don't Chart ...................................... 13
Before Starting the Engine ................................ 14
Starting the Engine .................................. 15
Stopping the Engine ................................ 16
Wattage and Power .................................... 16
Using the 120 Volt, 15 Amp Outlets ................. 16
Using the 120 Volt, 30 Amp Outlet ............... 16
Using the 240 Volt, 20 Amp Outlet ................. 17
Don't Overload the Alternator ....................... 17
Motor Starting Requirements ........................ 17
Charging a Battery ......................................... 18
Section 3 -- Preventive Maintenance
Maintenance Chart ....................................... 19
General Inspection ................................... 19
Change Oil ............................................. 20
Service Air Cleaner ............................... 21
Inspect 30 Amp Fuse ............................... 21
Spark Plugs ......................................... 22
Clean Fuel Tank ....................................... 22
Inspect Cooling Fins ........................... 22
De-Carbonize Muffler .................................. 23
Replace Fuel Filter .................................. 23
De-Carbonize Engine Cylinder Heads ............ 23
Storage ............................................... 23
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SPECIFICATIONS
Model Noo 58&326010
IWattage Capacity 4500 Watts Continuous (5600 watts m'omentary surgei .............
Voltage Output 120f240 Volts
Amperes (Maximum) ....................................37.,5 at 120 Voi"ts _18175at 240"Volts .......
Frequency ...... i ......................60 Hertz a{ 1800 rpm ...................
.....Phase(s) Single Phase
Driven Speed
Voltage Regulation
Electrical Outlets
Make and Model
Horsepower
No. of Cylinders
....Displacemen{ ........
Governed Speed
Fuel Tank Capacity
1800 rpm
Solid state "Voltage over Frequency" regulator maintains
2120 volts (_+ 2%) at 60 Hz.
...................... (2io' 120 Volt, 15 Amp
(1) - 120 Volt, 30 Amp
(1) - 240 Volt, 20 Amp
..... ,,, "",::',','L,,,, ......... ,,,
Briggs & Stratton Model No. 401415
Approximatei'y iO HIP. at 1800 rpm
2
Recommended Fuel
Crankcase Oil
Capacity
Spark Plug use' Champion J-8, Auto-Lite A-71i"or AC G046 ......
Set gap to .030 inch
Starting Electric Ring Gear
Cooling System .................... Forced airiCentrifugal' Blower Type) ............................
...... Air Cleaner ......................... ...............Dry paper cartridge w"it'lqoil f0ampre-cieaner '
1
40 Cubic Inches (656 cc's)
1800 rpm
5 Gallons (1&925 Liters)
........Use clean, fresh NON:LEADED gasot'ine (Leaded, REGULAR grade
gasoline is an acceptable substitute)
31/2 Pints (I.65 Liters)

NOMENCLATURE
CENTRIFUGAL
BLOWER SHROUD
CRADLE
WHEELS
(SHIPPED WITH
WHEEL KIT)
MUFFLER
ENGINE AIR
CLEANER OIL FILLER & DIPSTICK
120 VOLT, 15 AMP OUTLETS
HANDLES
(SHIPPED WITH
WHEEL KIT)
STARTER MOTOR
STARTER SOLENOID
INDICATOR
LIGHT
FUSE - 15 AMP
5 GALLON
FUEL TANK
NAMEPLATE
12 VOLT BATTERY
_IIUSTOME R SUPPLI ED
RESTING SUPPORT
(SHIPPED WITH WHEEL KIT)
2

WIRING DIAGRAM Model No. 580.326010
o !ci
_ oooooo
V)
DO
0 0

INSTALLATION OF STAND-BY POWER SYSTEMS
_I_DANGER
installation of Stand-By Electrical Power Systems should be done by a QUALIFIED electrtctam ALL APPLICABLE ELEC-
TRICAL AND BUILDING CODES MUST BE COMPLIED WITH. improper installation methods or procedures are EX-
TREMELY DANGEROUS add may damage equipment and personal property°
Alternator
F! om
Utility
Line
Meter _
Box _
1\
To Building
Circuits To.Bulid ing
Auxiliary Dist Circuits Powered
enter Circuits By Alternator
Building
Distribution I AuxiliaryBuilding
Panel _ DistributionCenter
(For-Alternator Powered
.... Circuit)
Cord Set
TYPICAL INSTALLATION
Atypical Stand-By Power System is shown above° This System uses a (1) Connection Box and
Cord Set, (2) a Transfer Switch, (3) two Building Distribution Centers, and (4) interconnecting wir-
ing.
The CONNECTION BOX and CORD SET is used with the 120/240 volt, 4-prong, 20 amp outlet. The
following Stand-By Kits are available:
Model No. Connection Box and Cord Set Transfer Switch
580.322280 120/240 Volt, 4-wire cord set 100 Amp Manual
580.322290 !201240 Volt, 4-wire cord set 200 Amp Manual
A TRANSFER SWITCH is required, to prevent electrical "feedback" between utility company
power lines and the alternator. Be sure to install the correct Transfer Switch, based on the
following:
1. if utility company input to the building is rated at LESS THAN 100 Amps, install a Switch hav-
ing a utility line connection rated at 100 Amps.
2. If utility company input to the building is rated at MORE THAN 100 Amps but LESS THAN 200
Amps, install a Switch having a utility line connection rated at 200 Amps.
3. Make sure the Transfer Switch alternator connection is rated at a higher amperage than the
alternator to be used.
4

SECTION 1
PREPARATION FOR USE
Alternator Unpacking and Removal from Shipping Skid
1 Cut Straps
2. Lift Cardboard Shtpplng
Carton Straight Up and
Off Shipping Pallet
Cardboard Insert
Alternator Localed Here
Kit Located Here
Shipping Pallet
¢"4
|Alternator Cradle
Wood Sh,pping PatIet " !.j ]
?
Washer
!
_b Bolt
1oThe alternator is bolted to a wood shipping
pallet, The cardboard is then set into position
and retained with straps., Location of alter-
nator and wheel kit in shipping carton is
shown above. To remove carton, cut the
straps and lift cardboard carton straight up
and off pallet°
PARTS SHIPPED WITH ALTERNATOR
2. Two 1/4 inch bolts and hex nuts retain the
alternator cradle to the wood shipping palleL
Use two 7/16 inch wrenches to remove bolts
and hex nuts° Alternator can then be removed
from wood pallet°
The following items are shipped with the alternator and must be installed or assembled. To order
additional items listed below, refer to REPAIR PARTS section of this manual.
1_ Battery Hold-Down Bracket with retaining hardware
2. Wheel Kit
3. One 5 gallon Fuel Tank with retaining strap
4o One 120 Volt, 3-Prong, 30 Amp Connector Plug
5. One 240 Volt, 20 Amp, 4-Prong Connector Plug
The battery retaining bracket and hardware
are shown at right° The 12 volt battery is to be
supplied by the customer° Make sure all of
the following have been received:
[_ Item
D1
N2
_3
E34
D5
Description
Bracket (1 Req'd)
Bolt -V4-20 x 7" long (2 Req'd)
Flatwasher- %" (2 Req'd)
Lockwasher - 1/4" (2 Req'd)
Wing Nut - _/4-20 (2 Req'd)
Battery Locating Bracket ITEM 5
__ ITEM 4
@_.--.f
ITEM 3
_ ITEM I
t2 Volt Battery ITEM 2
(Customer Supplied )
5

Wheel Kit parts areshownbelow,SeeWHEELKITINSTALLATIONin this section for installation
instructions. Make sure the Kit hasthe following parts:
_" Item
[] 1
[] 2
[] 3
[] 4
[] 5
[] 6
[] 7
[] 8
[] 9
[]10
Description [_ltem
Axle Shaft (1 Req'd) [] 11
U-Bolt (2Req'd) [] 12
Lock Nut - 5/16-18(4Req'd) [] 13
Axle Spacer (2Req'd) [] 14
Wheel (2 Req'd) C] 15
Flat Washer- a/4"(2 Req'd) [] 16
Cotter Pin -3/32" (2 Req'd) [] 17
Support Leg Cushion (1 Req'd)" [] 18
Flat Washer'- 7116" (1 Req'd) [] 19
Bolt - 5/16-18 x 11/4" long (1 Req'd)
Description
Nut - 5/16-18 (1 Req'd)
Support Leg (1 Req'd)
Bolt -5/16-18 x 3/4" tong (2 Req'd)
Washer, Flat - 5/16" (2 Req'd)
Nut - 5116-t8 (2 Req'd)
Handle (2 Req'd)
Bolt - 318-16 x 2s,4" long (4 Req'd)
Locknut -3/8-16 (4 Req'd)
Plastic Cap (2 Req'd)
19
ITEM 17
ITEM 16
ITEM 11
ITEM 13
ITEM 18
ITEM 12
ITEM 14
" ITEM 15
ITEM 8 __._!
T-
ITEM 4
ITEM 5
1
1
ITEM 3
ITEM 2
ALTERNATOR CRADLE
(VIEWED FROM BOTTOM)
ITEM t
/
,6

Strap Bracket Fuel Tanl<
/
,i, Rubber Strap
Check that both the 5 gallon fuel tank and its
rubber strap have been received. The rubber
strap has an "S" -Hook at each end that in-
serts into strap brackets on the alternator
cradle°
120 Volt, 30 Amp,
4-Prong Connector Plug
240 Volt, 20 Amp, 4-Prong
Connector Plug
!
Check that both the 120 Volt, 3-prong, 30 amp
and the 240 Volt, 4-prong, 20 amp connector
plug have been received. See OPTIONAL
CONNECTOR PLUGS in this section for more
information on these plugs.
WHEEL KIT INSTALLATION
1. Set Axle Shaft (Item 1) into place and retain
loosely with two U-bolts (Item 2) and 5/16-18
Lock Nuts (item 3). DO NOT TIGHTEN Lock
Nuts.
2. Slide Axle Spacer (Item 4) over end of Axle
Shaft, followed by Wheel (item 5) and 3/4" Fiat
Washer (Item 6).
3_ Retain Flat Washer, Wheel and Axle Spacer
with 3/32" Cotter Pin (Item 7).
4. Repeat Steps (2) and (3) above for other side
of Axle Shaft.
5. Center Axle Shaft so that no binding is evi-
dent and both wheels turn freely. Then
tighten U-bolt Lock Nuts (Item 3) at both ends
of Axle Shaft.
6o Slide 7116" Fiat Washer (Item 9) over 5116-18
x ! 1/4" bolt (Item t0)o
7_ Insert bolt (Item 10) through Support Leg
Cushion (Item 8) and through hole in Support
Leg (Item 12) and retain securely with 5116-i8
Lock Nut (Item 11).
Alternator Cradle
(Viewed From Bottom)
._Item 19 /
_'-_em 16
"_'3 f Item t 3
te 11 __ Item3
Item 12 ._j_ it_--em__
Item 10 'I" ( !t _Xitem 4 [,.1" item 2
Item 7 _m_j item 5
8o Install Support Leg (Item 12), withCushion (Item 8) installed, onto Alternator Cradle using two
5/16-18 x 3/4" long Bolts (Item 13), Flat Washers (Item 14), and Lock Nuts (Item 15). Tighten
securely.
9. install both Handles (Item 16)o Retain with four 3/8-16 x 23/4'' long Bolts (Item 17) and Lock Nuts
(Item 18). Tighten all four bolts.
10. Install plastic Caps (Item 19) onto end of both Handles.
7

LUBRICATION
CAUTION
Engines are shipped without oil. Any attempt to start the engine before the recommended
oil has been properly added may result in an engine failure.
Service the engine crankcase with a high quality detergent oil having a classification which in-
cludes"For Service MS, SC, SD or SE", and as recommended in the following CHART. Oil recom-
mendations are the result of extensive testing° use no special additives with the recommended
oilo Recommended Oil
l t !,
t
oFT20 o 29 49 _ ................8o mo
°C- 30 -20..............!0 ........... 010 20 30 40
"TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
*if not available, a synthetic oil may be used having- 5W-30 or 5W-40 viscosity.
Fill engine crankcase with oil as follows:
1. Remove Oil Dipstick from Oil Filler neck.
2. Make sure unit is LEVEL.
3. Pour a measured 31/2 pints (56 ounces or'
1o65 Liters) of the recommended oil into Filler'
Neck_ DO NOT OVERFILL.
CAUTION
If engine crankcase is overfilled, a smoking
condition will result as the engine tries to
discharge the surplus oil.
4. Reinstall Oil Dipstick ALL THE WAY into
Oil Filler Neck, then remove° Oil should be at
Dipstick FULL mark° if oil level is BELOW
Dipstick FULL mark, add oil as required to
bring level to FULL mark°
A
CAUTION
Do not operate engine
with oll level below
"add 1 pint" mark.
Oft Dipstick
Oii FIHer Neck
FULL
ADD 1 PINTt_
5o if oil level is ABOVE the Dipstick FULL
mark, remove Oil Drain Plug at base of engine
and drain excess oil into asuitable continer_
Then reinstall drain plug.
6. When oil level is at Dipstick FULL mark,
reinstall Dipstick into Filler Neck° MAKE
SURE DIPSTICK IS TIGHT.
8
OIL _'
DRAIN
PLUG

BATTERY INSTALLATION
A 12 Volt automotive type storage battery is
required, and must be purchased separately.
Battery should have a 32 amplhour (or higher)
capacity° Install the battery as follows:
_ CAUTION
install the battery and connect battery
cables EXACTLY as outlined in this
Manual. Incorrect battery cable connec-
tions will damage the engine ignition
system andlor the alternator battery charg-
ing circuit,
1. Set battery into place on cradle against the
battery locating bracket.
2. Set the Bracket (Item 1) onto top of battery.
MAKE SURE BRACKET DOES NOT CON*
TACT BATTERY POSTS.
3o Retain Bracket with two t/4-20 x 7" long
bolts (Item 2), Flat Washer (Item 3), Lock
Washer (item 4), and Wing Nuts (Item 5). Snug
both Wing Nuts down, but DO NOT OVER-
TIGHTEN..
BATTERY CONNECTIONS
1o The black battery cable is connected to a
grounding lug. Make sure the cable is TIGHT,
then connect the other end of black cable to
battery post indicated by a NEGATIVE, NEG
or (-)o
Battery Locating Bracket ITEM 5
h
t2 Volt Battery fl
(Customer Supplied ) ITEM 2
Grounding Lug For Negative
Battery Cable
Black Battery Cable
..To NEGATIVE, NEG or (-)
Battery Post
2. The red battery cable is connected to the
starter solenoid° Be sure the hex nut that re-
tains the cable is tight. Connect the other end
of the red cable to the battery post indicated
by a POSITIVE, POS or (4-).
Red BatteQ
Cable To
POSITIVE, POS
or ( + ) Battery
Post
To
Starter
Motor
9

FILL FUEL TANK
1_ Pull back on knurled fitting and remove fuel
line from tank filler cap.
2. Remove Fuel Tank filler cap° Fill tank with
CLEAN, FRESH, NON-LEADED gasoline.
(Leaded, REGULAR grade gasoline is an ac-
ceptable substitute.) Reinstall cover.
_DANGER
Gasoline vapors are highly flammable and
explosive. Avoid spillage. Do not permit
smoking, open flame, or sparks in the area
while filling fuel tank.
INSTALL FUEL TANK
Strap Bracket Fuel Tank
/
/ Rubber Strap
"S" - Hook
Strap Bracket
Cradle
1. Set Fuel Tank into place on alternator
cradle. Pass rubber strap UNDER fuel tank lif-
ting handles and hook into both strap
brackets.
CORD SETS FOR 120 VOLT, 15 AMP OUTLETS
Extension cords used with the two 120 volt,
15 amp outlets must be in good condition.
Wire gauge sizes of cord sets must be large
enough to handle the amperage load of tools
and equipment they power. The chart at right
lists recommended wire sizes for cord sets,
based on the amperage of equipment being
used and the length of the cord in feet.
10
2. Remove Filler Cap
1 T_NK FILLER CAP
2. To connect fuel line quick-disconnect to
tank fitting, pull back on quick-disconnect
knurled fitting. Insert open end of knurled fuel
line fitting over male fitting on tank, then let
knurled fitting snap into place to locko
AMPERAGE
RATING
2
3
4
5
6
8
!0
t2
14
t6
LENGTH OF CORD IN FEET
50 Ft j
18 Ga
18 Ga
16 Ga
16 Ga
16 Ga
16 Ga
16 Ga
14 Ga
14 Ga
12 Ga
100 Ft 150 F!
18 Ga, t8 Ga
18 Ga, t8 Ga
16 Ga 16 Ga
16 Ga 16 Ga
16 Ga. 14 Ga
14 Ga 12 Ga
14 Ga 12 Ga
14 Ga 12 Ga
12 Ga 10 Ga
12 Ga 10 Ga
Outlets

Optional Wiring Connections - 240 Volt Connector Plug
_1_ DANGER
All wiring connections should be done by a QUALIFIED electrician. Improper or unauthor-
ized wiring connections are not only dangerous, but may damage equipment. Wire gauge
sizes must be large enough to handle the maximum amperage load. All applicable elec-
trical codes must be complied with.
Ground
HOT HOT
240 Volts
A 240 volt, 4-prong, 20 amp connector plug is
included with the alternatoro If additional
plugs are required, refer to REPAIR PARTS
section of Owner's Manual. The 240 volt
outlet will supply both 120 volts a-c and 240
volts a-c, as shown above, when a 4-wire cable
is connected to the connector plug.
One method of connecting a 4-wire cable to
the connector plug, is to terminate the cable
at a connection box. See illustration above.
When a Stand-By kit is ordered, a 4-wire cord
set is included (see INSTALLATION OF
STAND-BY POWER SYSTEMS, page 4)_
Optional Wiring Connections -120 Volt, 30 Amp Connector Plug
,==,.,...- I20 Volts ,,,....,.,,_, /#i"Ground
-2--
F" 3-Wlre
! Cable
L __1
A 120 volt, 3-prong, 30 amp connector plug is
included with the alternatoro if additional
plugs are required, refer to REPAIR PARTS
section of manual° A 3-wire cable must be pur-
chased and connected to the plug as shown
above.
One method of connecting a 3-wire cable is to
terminate the cable at an outlet box, as shown
above
11

GROUNDING THE ALTERNATOR
An earth grounding lug is provided on the
alternator blower shroud. Connect a groun-
ding wire to this lug that is no smaller than a
No, 8 AWG. When using the alternator, the
free end of the grounding wire must be con-
nected to earth ground, or to a pipe or struc-
ture that is attached to earth ground°
DANGER
DO NOT, under any circumstances, attach
the grounding wire to any structure, pipe,
or container that contains a combustible
material. This can result in fire or explosion
in the event the alternator frame becomes
electrically charged.
Centrifugal
BJower Shroud
Ground
Lug
t2

Section 2
OPERATING INSTRUCTIONS
DO AND DON'T CHART
DO DON'T
1. DO read all instructions in this Manual
before operating your alternator°
2o DO unplug all power cords from alternator
outlets before starting or stopping the unit.
3_ DO add up wattages of all equipment to be
powered by the alternator at one time. This
total must not exceed 4500 watts,
4o DO remember that some electric motors re-
quire more WATTS of power for starting than
for running.
5. DO make sure that wire gauge sizes of elec-
trical cords are large enough to handle the
maximum anticipated amperage.
6. DO comply with laws pertaining to the
storage and handling of gasoline.
7. DO comply with all instructions in Section
3 of this Manual (MAINTENANCE.)
8. DO disconnect wire from engine spark plug
before working on or around the alternator.
This wilt prevent accidental starting of the
engine°
1. DON'T fill the gas tank while the engine is
running or in the dark. Gasoline spillage on a
hot engine can cause fire or an explosion.
2. DON'T run the alternator in any enclosed
space° Gasoline engines consume oxygen
and give off DEADLY carbon monoxide,
3o DON'T install the alternator in any compart-
ment that will restrict the free flow of cooling
air. Without this free flow of cooling air,
serious heat damage to the alternator wilt oc-
cur.
4,. DON'T attempt to change engine governed
speed° High operating speeds are extremely
dangerous. The alternator wilt produce the re-
quired voltage and frequency ONLY AT 1800
RPM.
5. DON'T run the engine with the air cleaner
removed. Serious damage to the engine can
result°
6. DON'T unplug or plug in electrical power
cords while standing in water, while barefoot,
or while hands are wet. Dangerous electrical
shock can result.
7. DON'T touch muffler, exhaust piping, or
engine. They become HOT and will cause
serious burns_
_ CAUTION
Engines are shipped without oil, Any attempt to start the engine before the recommended
oil has been properly added to the engine crankcase will result in an engine failure.
13

BEFORE STARTING THE ENGINE
CAUTION
Do not operate engine
wtth oll levet below
"add 1 pint" mark_
FULLADD 1 PINT
1, Disconnect
Fuel Line
2, Remove Filler Cap
t. Make sure engine crankcase has been pro-
perly filled with the recommended oil. See
LUBRICATION on Page 8.
2. Fill gas tank with clean, fresh, NON-
LEADED gasoline. (Leaded, REGULAR grade
gasoline is an acceptable substitute_)
k DANGER
Gasoline vapors are highly flammable and explosive. Do not permit smoking, open flame, or
sparks in the vicinity while filling gas tank. Do not allow gasoline to spill on any hot surface.
E
t TANK FILLER CAP
3o Connect fuel supply hose to gas tank outlet
fitting. Pull back on the knuded sleeve, insert
hose fitting over tank outlet fitting and let the
sleeve snap into place to lock.
J
Turn FILler Cap
1,_Turn Counter,
_lo_kwlse to Vent
Tank
4. Turn gas tank filler cap one-half turn
counterclockwise to vent tank,
14

5. Unplug, disconnect or turn OFF all elec-
trical equipment.
_ CAUTION
Never start the, alternator with electrical
equipment plugged in and turned ON. Cor-
rect voltage and frequency can only be ob-
tained with engine running at governed
speed of 1800 rpm. Some electrical equip-
ment can be damaged by incorrect voltage
and/or frequency.
STARTING THE ENGINE
CHOKI
OPEN
CH OK E
CLOSED
1, To Crank Engine,
Hold StoplStart
Switch To Start
Position
2. Release Switch When
Engine Starts
1. Move Choke Lever all the way down to
CLOSED position.,
NOTE
Lesser amounts of choking may be re-
quired when engine is warm.
2. Hold Start/Stop switch at START position
to crank engine. Release switch when engine
starts. Then open choke gradually as engine
warms up.
CAUTION
Do not crank engine continuously for longer than about 30 seconds at a time. Excessively
long cranking periods may result in damage to the starter motor. Each 30 second cranking
period should be followed by at least a 1 minute "cooling off" period.
t5,

STOPPING THE ENGINE
1. Unplug, disconnect, or turn OFF all electrical loads. Let the engine run for a few minutes to
cool.
2. Set the StartlStop switch to STOP position. Do not leave unit until engine has come to a com-
plete stop.
WATTAGE AND POWER
Watts is a measure of electrical POWER. In most cases, approximate watts can be found by
multiplying VOLTS times AMPSo For example, if a certain appliance requires 10 amps of current
at 120 volt:
WATTS = VOLTS x AMPS
WATTS = 120x10
WATTS = 1200
That particular appliance requires approximately 1200 watts for its operation,
USING THE 120 VOLT, 15 AMP OUTLETS
CAUTION
Make sure extension cords are large enough. Read CORD SETS FOR 120 VOLT 15 AMP
OUTLETS on Page 11.
Each of these outlets is rated at a maximum
capacity of 15 amps, or 1800 watts_ Do not at-
tempt to run equipment requiring more than
15 amps or" 1800 watts of power. Do not at-
tempt to run 240 volt equipment from either
outlet.
USING THE 120 VOLT, 30 AMP OUTLET
|
@
_J , . .....
120 VOLT, 15 AMPS
1800 WATTS 120 VOLT, 15 AMPS
1800 WATTS
A 3-prong, 30 amp connector plug for this outlet is shipped with the alternator. (See PARTS
SHIPPED WITH ALTERNATOR on Page 5.) The plug must be connected to a suitable cord set
(see Page 12.)
120 VOLT, 30 AMP
3600 WATTS
1. Align Prongs,
Insert Plug
2. Twist Plug
Clockwise
The outlet has a 30 amp or 3600 watt capacity.
Do not attempt to run equipment requiring
more than 30 amps or 3600 watts from the
outlet.
To plug the connector plug into the outlet,
line up prongs and insert plug. Then twist
plug clockwise to lock.
16

USING THE 240 VOLT, 20 AMP OUTLET
The outlet has a 20 amp capacity and can han-
dle the full 4500 watt capacity of the alter-
nator. To plug the connector plug into the
outlet, align the 4 prongs and insert plug.
Then twist the plug clockwise to lock.
A 4-prong, 20 amp connector plug for this outlet is shipped with the alternator (see PARTS SHIP-
PED WITH ALTERNATOR, Page 5)° The plug must be connected to a suitable cord set (see Page
11).
240 VOLT, 20 AMPS
4500 WATTS
DON'T OVERLOAD THE ALTERNATOR
Alternator wattage capacity is 4500 watts, with a surge capacity of 5600 watts. The 4500 watt
capacity of the unit should not be exceeded, except for momentary periods. Add up the wattage
ratings of all equipment to be powered by the alternator at one time. This total should not ex-
ceed 4500 watts.
IMPORTANT
Alternator stator windings are protected by a temperature sensitive device. Any prolonged
overloading of the unit will result in high internal temperatures, which will cause this
device to "trip". NO A-C POWER WILL BE AVAILABLE FROM ALTERNATOR OUTLETS UN-
TIL INTERNAL TEMPERATURES HAVE RETURNED TO NORMAL, If a loss of electrical output
occurs, immediately unplug, turn OFF, or disconnect electrical loads. Let unit cool for
several minutes, then reconnect loads NOT TO EXCEED 4500 watts.
MOTOR STARTING REQUIREMENTS
Some electric motors requires more watts of power for starting than for continuous on-speed
operation. To find approximate starting and running watts for these motors, locate the TYPE OF
MOTOR and its HORSEPOWER on the motor nameplate. Then find starting and running watts in
the following CHART.
MOTOR STARTING REQUIREMENTS APPROXIMATE STARTING WATTS
Motor Approx. R_ulsio. Split
H.P. Running Univ_rml Induction Capacitor Phase
Rating Watts Motor= Motors Motor= Motors
½
1
!W
2
3
5
275
400
450
6OO
1000
1600
20O0
30OO
4800
4OO
5O0
600
750
lO00
1250
o
e
6OO
85O
975
1300
1gO0
23OO
32OO
3gO0
52OO
7500
"Motom of higherhorsepowershown in th_aclassificationare not generally uaKL
850
1050
1350
1800
26O0
3OO0
42OO
5100
68OO
980O
1200
1700
1950
260O
o
t
w
o
17

CHARGING A BATTERY
The alternator battery receives a trickle charge of 0 - 8 amps as long as the engine is running.
This battery charging circuit can be used to recharge an external 12 volt battery, as well.
CAUTION
The battery charging circuit is designed for 12 volt, automotive type storage batteries only.
Do not attempt to recharge any 6 volt battery, or any other type of battery.
DANGER
A charging battery gives off EXPLOSIVE hydrogen gas. Do not permit smoking, open flame,
or sparks in the vicinity of a charging battery. Remove battery vent caps before attempting
to recharge the battery.
DANGER
Battery fluid is an extremely caustic sulfuric acid solution that can cause severe burns.
Avoid spillage of fluid, or contact with skin, eyes, wiring insulation or painted surfaces. If
spillage or contact occurs, flush immediately with clear water.
To recharge a discharged battery, proceed as follows:
1. Remove battery vent caps.
2. Connect a battery jumper cable to alter-
nator battery post indicated by a POSITIVE,
POS or (+) and to the discharged battery post
indicated by a POSITIVE, POS or (+)_
3. Connect a second battery jumper cable to
alternator battery post indicated by a
NEGATIVE, NEG or (-) and to the discharged
battery post indicated by a NEGATIVE, NEG
or (-).
4. Start the alternator engine.
5. When discharged battery has recharged,
shut alternator engine down and disconnect
battery cables.
18
Remove
Vent Caps
Alternator
Battery
Battery
Chargi ng
Cables
Discharged
Battery