Ironton 504000 Owner's Manual
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Ironton 504000 Owner's Manual

4000 watt generator
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4000 Watt Generator
Owner's Manual
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #504000
READ & SAVE THESE INSTRUCTIONS

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Summary of Contents for Ironton 504000

  • Page 1 4000 Watt Generator Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury. Item #504000 READ & SAVE THESE INSTRUCTIONS...
  • Page 2 ™ Thank you very much for choosing an Ironton product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it.

  • Page 3: Table Of Contents

    Table of Contents Intended Use ............................4 Technical Specifications ........................4 Important Safety Information ....................... 4 Before Each Use ............................ 6 Operating Instructions ........................12 Maintenance ............................20 Parts Diagram for Engine ........................22 Parts List for Engine ........................... 23 Parts Diagram for Generator ......................

  • Page 4: Intended Use

    Intended Use Ironton’s 4000 Watt Generator can be used to power individual appliances plugged directly into the generator’s outlets Wheel kit (item #45719) is available and sold separately. Technical Specifications Property Specification Surge Watts 4000 Watts Rated Watts 3200 Watts...
  • Page 5 situations that could occur. Exercise common sense and caution when using this tool. Always be aware of the environment and ensure that the tool is used in a safe and responsible manner.  Do not allow persons to operate or assemble the product until they have read this manual and have developed a thorough understanding of how it works.

  • Page 6: Before Each Use

    inattention while operating the tool may result in serious personal injury.  Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in dusty work conditions.
  • Page 7 ⚠WARNING  A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise:  When your generator is running, its output will back feed into the utility power line and transformer that are normally used to provide you with power.
  • Page 8 Note: Regardless of whether you use your generator as a back-up power source or as a portable power source, you must not overload it. Overloading the generator may cause serious damage to the unit and any attached electrical devices. Extension Cords Extension cords may be used to power devices that are located at a distance from the generator.
  • Page 9 2. Outdoors Only ⚠WARNING The exhaust from your generator contains carbon monoxide (CO), a poisonous gas that can kill. You cannot smell it, see it, or taste it. Carbon monoxide exhaust is given off whether you are using gasoline, natural gas, or propane as the fuel source to power the generator. Follow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning.
  • Page 10 ⚠WARNING Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures.  Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up. ...
  • Page 11 ⚠WARNING Never attempt to attach ductwork to the muffler system to lower noise levels. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator. Grounding the Generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1.

  • Page 12: Operating Instructions

    Operating Instructions Once you have set up the generator for use, it is time to start the unit. The following are the procedures necessary for safe, successful operation of your generator. General Safety Rules for Operation ⚠WARNING Failure to follow safety rules may result in serious injury or death to the operator or bystanders. Before starting the generator, review the following general safety rules for operation: Know proper use/how to stop.
  • Page 13  Engine misfire  Excessive vibration  Flame or smoke  Abnormal noise Adjusting / repairing. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the generator to prevent accidental starting. Always discharge the capacitor before working on the generator head to prevent electrical shock.
  • Page 14  Use a portable container to fill tank. Never fill the generator's gas tank directly from the fuel pump -the generator's tank is not grounded and the high velocity flow of gasoline from a fuel pump can cause static electric build-up. Use an approved portable container to transfer gasoline to the generator's tank.
  • Page 15 ⚠WARNING Carbon monoxide poisoning hazard. Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from air intakes. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats.
  • Page 16 Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: • Gas vapor collection inside enclosures • Static electric sparks • Sparks from electric wiring, batteries, or running engines • Sources of heat (such as a hot engine or exhaust) •...
  • Page 17 5. Clean up gasoline spills/splashed immediately.  If possible, move the generator away from spilled gasoline on the ground.  Wipe up spilled gasoline, and wait 5 minutes for excess gasoline to evaporate before starting engine.  Gasoline soaked rags are flammable and should be disposed of properly. ...
  • Page 18 iii. Allow starter cord to return slowly. 5. When engine starts, move choke lever to RUN position. 6. Under long, continuous-run operating conditions, be prepared to: a. Check and refuel the engine on a regular basis. A tank of gas should last about 9.5 hours under 50% load.
  • Page 19 generator cycle on or off. The slight variation has no appreciable effect in the operation of motors, lights, and most appliances. Connecting Electrical Loads (Portable Power Generation) You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load.

  • Page 20: Maintenance

    2. Turn the engine key switch to the OFF position. 3. Store the generator properly 4. Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Disconnect loads and turn off fuel supply. When you are finished using the generator, disconnect all loads and turn off fuel supply: 1.
  • Page 21 Read and follow these safety rules whenever you will be servicing the generator:  Turn off generator. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the engine or generator to prevent accidental starting. ...

  • Page 22: Parts Diagram For Engine

    Parts Diagram for Engine Page 22 of 29...

  • Page 23: Parts List For Engine

    Parts List for Engine Code Part Description Qty. Code Part Description Qty. 240214 Crank Case 246102 Lifter, Valve 93009 Ball Bearing 96041 Packing, Case Cover 93507 Oil Seal 242003 Camshaft Assembly 244302 Governor Assembly 240905 Pin, Dowel 243901 Shaft, Governor Arm 91347 Bolt M8X30 Washer, Governor Arm...
  • Page 24 Code Part Description Qty. Code Part Description Qty. 91007 Bolt, Stud M8X34 242920 Air Cleaner Assembly 242819 Carburetor Assembly 95604 Tube, Breather 95409 Fuel Line 94401 Rubber, Fuel 94403 Clip, Fuel Line 244103 Spring, Governor 244001 Governor ARM 245104 Amplifier 91822 Bolt, Governor Arm 245601...

  • Page 25: Parts Diagram For Generator

    Parts Diagram for Generator Page 25 of 29...

  • Page 26: Parts List For Generator

    Parts List for Generator Code Part Description Qty. Code Part Description Qty. 770168-010 Frame 21.1 6080 Switch Assembly Double Receptacle, 531201 Isolator A 21.2 6032 America 20A/125V Thermal Protector 531204 Isolator B 21.3 6246 13.5A UL 30A/125V/250V 90011 Nut M8 21.4 6241 91325...

  • Page 27: Replacement Parts

    Code Part Description Qty. Code Part Description Qty. 96054 Packing Exhaust 544303 Grounding Wire Rubber Damping 705326 Muffler Comp 531112 Bracket 710185 Panel Comp Replacement Parts  For replacement parts and technical questions, please call Customer Service at 1-877-234-6869.  Not all product components are available for replacement.

  • Page 28: Limited Warranty

    Northern Tool and Equipment Company, Inc. ("We'' or ''Us'') warrants to the original purchaser only (''You'' or ''Your'') that the Ironton product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of 90 days from date of purchase.
  • Page 29 Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.com Made in China Page 29 of 29...

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