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Owner's Manual
ICRRFTSMRN+I
AC Generator
3600 Watt
Model No.
580.323601
CusGemn:/at°lplin e_
HOURS: Mon. - Fri. 8 a.m. to 5 p.m. (CT)
CAUTION:
Before using this product, read this
manual and follow all its Safety Rules
and Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
Visit our Craftsman website: www.sears.comlcraftsman
Past No. 192788GS Drai'_0 (03/07/2003)
• Safety
• Assembly
• Operation
• Maintenance
• Parts
• Espafiol
01!!!U!!!!U!.,
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WARRANTY ............................. 2
SAFETY RULES ........................ 3-4
KNOW YOUR GENERATOR ................ 5
ASSEMBLY ............................ 6-7
OPERATION .......................... 8-10
SPECIFICATIONS ....................... 11
MAINTENANCE ....................... 11-13
STORAGE ............................. 13
TROUBLESHOOTING .................... 14
NOTES ............................ 15 & 26
SCHEMATIC/WIRING DIAGRAM ............ 16
REPLACEMENT PARTS ................ 17-25
EMISSION SYSTEM WARRANTY ........... 27
ESPANOL ........................... 28-43
HOW TO ORDER PARTS .......... BACK PAGE
LIMITED WARRANTY FOR CRAFTSMAN GENERATORS
SEARS warrants to the original purchaser that the alternator and engine for itsportable 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.
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, over-speeding, 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 states 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 wilt 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.
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This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
A
Obey all safety messages that follow this symbol to avoid possible injury or death.
_Read this manual carefully and become
familiar with your pressure washer. Know its
applications, its limitations, and any hazards
involved.
The safety alert symbol (,_) is used with a signal
word (DANGER, CAUTION, WARNING), a pictorial
and/or a safety message to alert you to hazards.
DANGER indicates a hazard which, if not avoided, will
result in death or serious injury. WARNING indicates a
hazard which, if not avoided, could result in death or
serious injury. CAUTION indicates a hazard which, if
not avoided, might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in equipment
damage. Follow safety messages to avoid or reduce
the risk of injury or death.
In the State of California a spark arrester is required
3y taw (Section 4442 of the California Public
Resources Code). Other states may have similar laws.
;ederal laws apply on federal lands. If you equip the
"nuffter with a spark arrester, it must be maintained in
_=ffective working order.You can order a spark arrester
through your authorized Sears service dealer.
A WARNING I
The engine exhaust from this product contains I
chemicals known to the State of California to cause
cancer, b rth defects, or other reproduct ve harm,
WARNING
This generator does not meet U. S. Coast Guard
Regulation 33CFR-183 and should not be used on
marine applications.
Failure to use the appropriate U. S. Coast Guard
approved generator could result in bodily injury and/or
property damage.
DANGER
DANGER
Operate generator ONLY outdoors.
Keep at least 2 feet of clearance on all sides of
generator for adequate ventilation.
DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).
kDANGER
National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an
electrician for local grounding requirements.
DANGER
When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp
or highly conductive area, such as metal decking or steel
work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
DO NOT operate generator in the rain.
DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or feet
are wet.
DO NOT allow unqualified persons or children to operate
or service generator.
DO NOT allow any open flame, spark, heat, or lit cigarette
during and for several minutes after charging a battery.
Wear protective goggles, rubber apron, and rubber gloves.
WARNING
;ENERATOR
Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.
3
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WARNING
WHEN ADDING FUEL
Turn generator OFF and let it cool at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fill fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.
Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
_/HEN OPERATING EQUIPMENT
Do not tip engine or equipment at angle which causes
fuel to spill.
This generator is not for use in mobile equipment or
marine applications.
_/HEN TRANSPORTING OR REPAIRING EQUIPMENT
Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
Disconnect spark plug wire.
_/HEN STORING FUEL OR EQUIPMENT WITH FUEL IN
TANK
Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite fuel vapors.
WARNING
DO NOT touch hot surfaces.
Allow equipment to cool before touching,
CAUTION
DO NOT tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
DO NOT modify generator in any way.
CAUTION
See "Don't Overload Generator" on page 10.
Start generator and let engine stabilize before connectin
electrical loads.
Connect electrical loads in OFF position, then turn ON
for operation.
Turn electrical loads OFF and disconnect from generatol
before stopping generator.
CAUTION
Use generator only for intended uses.
If you have questions about intended use, ask dealer or
contact Sears.
Operate generator only on level surfaces.
DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.
If connected devices overheat, turn them off and
disconnect them from generator.
Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
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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.
Oil Fill Cap/Dipstick
120 Volt AC, 20 Amp
Duplex Receptacles
FuetTank
Rocker Switch
Recoil Starter
Choke Lever
Air
120/240 Volt AC, 20 Amp
Receptacles
Circuit Breake_
120 Volt AC, 20 Amp, Duplex Receptacles -- May
be used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical,
lighting, appliance, tool and motor loads.
120/240 Volt AC, 20 Amp Locking Receptacle --
May be used to supply electrical power for the
operation of 120 and/or 240 Volt AC, 20 Amp, single
phase, 60 Hz electrical, lighting, appliance, tool and
motor loads.
Air Cleaner -- Filters intake air as it is drawn into the
engine.
Circuit Breakers -- Each receptacle socket is
protected against electrical overload with "push to
reset" circuit breakers.
Spark Arrester
Muffler
Grounding Fastener
Fuel Tank -- Tank holds 4 U.S. gallon of unleaded
fuel.
Grounding Fastener-- Ground the generator to an
approved earth ground here.
Oil Fill Cap/Dipstick -- Check and fill engine with oil
here. See page 7 for oil recommendations and filling
instructions.
Choke Lever -- Used when starting a cold engine.
Recoil Starter -- Used for starting the engine.
Rocker Switch -- Set switch to "On" prior to using
recoil starter. Set switch to "Off" to switch off engine.
Spark Attester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester
screen.
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TO REMOVE GENERATOR FROM
CARTON
Open top flaps of shipping carton.
Slice two corners at end of carton from top to
bottom so the panel can be folded down fiat, then
remove all packing material.
Remove the generator and contents from the
shipping carton.
CARTON CONTENTS
Check all contents against those listed below:
Main unit
Engine oil
Owner's manual
Wheel Kit
If any parts are missing or damaged, call the
generator hetpline at 1-800-222-3136.
INSTALL WHEEL KIT
NOTE: While the wheel kit is designed to greatly
improve the portability of your generator, it is not
intended for over-the-road use.
You will need a socket wrench with 1/2" or 13mm
sockets, a 5/16" wrench and a needle-nose pliers to
install this kit.
Install the Wheel Kit as Follows:
1. Place bottom of generator cradle on a flat surface.
2. Place axle stud through wheel retainer on cradle
frame, as shown below.
3. Use 15/16" wrench to secure axle stud to frame
with 5/8-18 jam nut.
4. Install other axle stud in same manner.
NOTE: Be sure to install wheel with raised hub inboard.
5. Tip unit and install wheel. Place flat washer over
axle stud.
6. Retain wheel on axle stud with retaining pin.
Install other wheel on remaining axle stud the
same way.
7. Attach support leg using two 13mm wrenches with
20mm cap screws and lock nuts.
8. Center lifting handle on generator end of cradle.
Attach handle using two 13mm wrenches with
capscrews and hex nuts.
Mountin
Capscrew
Jam Nut
Axle
Stud
\ / /
Capscrew /
Wheel Retaining Pin
Washer
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BEFORE STARTING THE
GENERATOR
Add Engine Oil
IMPORTANT: Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine failure.
NOTE: When adding oil to the engine crankcase, use
only high quality detergent oil rated with API service
classification SF, SG, SH, SJ or higher rated
SAE 30 weight. Do Not use special additives.
1. Choose a viscosity according to the table below:
**mm
IE*
J
._ -2o, o 2o 3_ 4o _o _o _oo
STARTING TEMPERATURE RANGE ANTiCiPATED BEFORE NEXT OiL CHANGE
* The use of multi-viscosity oils (5W-30, 10W-30, etc.)
in temperatures above 40°F (4°C) will result in higher
than normal oil consumption. When using a multi-
viscosity oil, check oil more frequently.
** If using SAE 30 oil in temperatures below 40°F
(4°C), it will result in hard starting and possible engine
bore damage due to inadequate lubrication.
1. Place generator on a level surface.
2. Clean area around oil fill and remove oil dipstick.
3. Wipe dipstick clean. Pour oil into oil fill opening.
Replace and tighten dipstick.
4. Pause to permit oil to settle. Remove and and
check oil level. Oil level should be at "Full" mark
on dipstick. DO NOT OVERFILL.
Add Fuel
,_ WARNINGI NEVER fill fuel tank indoors.
NEVER fill fuel tank when engine is running or
hot. Allow unit to cool for two minutes before
refueling. DO NOT light a cigarette or smoke
when filling the fuel tank.
,_ WARNINGI DO NOT overfill the fuel tank.
Always leave room for expansion.
1. Use regular UNLEADED fuel with generator
engine. DO NOT use premium fuel. DO NOT mix
oil with fuel.
2. Clean area around fuel fill cap, remove cap.
3. Slowly add unleaded regular fuel to fuel tank. Be
careful not to overfill. Allow about 1.5 of tank
space for fuel expansion, as shown here.
Fuel
_NNNN_N_NN_NNNN_
_NNNNNNNNNN_NNNN,
4. Install fuel cap and wipe up any spilled fuel.
IMPORTANT: It is important to prevent gum deposits
from forming in fuel system parts such as the
carburetor, fuel hose or tank during storage. 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 13. NEVER use engine or
carburetor cleaner products in the fuel tank as
permanent damage may occur.
NOTE: You may not need to use all the supplied oil.
5. Install oil dipstick, hand tighten securely.
NOTE: Check oil often during engine break-in.
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HOW TO USE YOUR GENERATOR
If you have any problems operating your generator
after reading the manual, please call the generator
hetpline at 1-800-222-3136.
Grounding 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
fastener is provided on the generator housing.
Grounding
Fastener _ \_\
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding
fastener and to an earth-driven copper or brass
grounding rod (electrode) provides adequate
protection against electrical shock. However, local
codes 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,
especially if the unit is equipped with a wheel kit.
Proper grounding also helps dissipate static electricity,
which often builds up in ungrounded devices.
To Start The Engine
CAUTION! NEVER start or stop the engine with
electrical loads connected to the receptacles AND with
the connected devices turned ON.
Disconnect all electrical loads from the generator.
Follow start instruction steps in numerical order:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a
level surface will cause the unit not to start or shut
down during operation.
2. Turn fuel valve to "On" position. Fuel valve handle
should be vertical (pointing toward ground) for fuel
to flow.
Fuel Valve is shown
in the On position
3. Place choke lever in "Choke" position.
4. Set rocker switch to "On" position.
Rocker Switch is
shown in On position
5. Grasp recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly to start engine.
6. Move choke lever to "Run" position a short
distance at a time over several seconds in warm
weather or minutes in cold weather. Let engine
run smoothly before each change. Operate with
choke in "Run" position.
NOTE: If engine starts after 3 pulls but fails to run, or
if unit shuts down during operation, make sure unit is
on a level surface and check for proper oil level in
crankcase. This unit may be equipped with a low oil
protection device.
Connecting Electrical Loads
Let the engine stabilize and warm up for a few
minutes after starting.
DO NOT connect 240 Volt loads to 120 Volt
receptacles.
DO NOT connect 3-phase loads to the generator.
DO NOT connect 50 Hz loads to the generator.
Plug in and turn on the desired 120 Volt AC, single
phase, 60 Hertz electrical loads.
DO NOT OVERLOAD THE GENERATOR. See
"Don't Overload Generator" on page 10.
Stopping the Engine
1. Unplug all electrical loads from unit. NEVER start
or stop engine with electrical devices plugged in
and turned on.
2. Let engine run at no-load for two minutes to
stabilize unit's internal temperatures.
3. Move rocker switch to "Off" position.
4. Move fuel valve to "Off" position.
CORD SETS AND RECEPTACLES
Use only high quality, well-insulated, extension cords
with the generator's 120 Volt electrical receptacles.
Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
for 125 Volt AC loads at 20 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.
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Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
120 Volt AC, 20 Amp Duplex Receptacle
Each receptacle is protected against overload by a
single 15 Amp push-to-reset circuit breaker. Use each
receptacle to operate 120 Volt AC, single phase 60 Hz
electrical loads requiring up to 2,400 watts (2.4 kW) at
20 Amps of current.
1. Make sure generator has clean, fresh fuel.
2. Open fuel tank valve (turn valve to open position).
3. Use SAE 5W-30 oil (synthetic preferred, see
page 7).
4. Check oil level daily or after every eight (8) hours
of operation.
5. Change oil every 24 hours of operation.
6. Shelter unit from elements.
In an emergency, use the original shipping carton as a
temporary shelter:
1. Cut off all carton flaps.
2. Cut out one of the tong sides of carton to expose
muffler side of unit as shown below. Ensure a
minimum of two feet clearance between open side
of carton and nearest object.
120/240 Volt AC, 20 Amp Receptacle
This is a full capacity receptacle; it can supply the
generator's full rated output from this sole outlet. The
outlet is protected by two 15 Amp push-to-reset
circuit breakers.
4-Wire Cord Set
(Neutral)
Y (Hot) / X (Hot)
NEMA L14-20 _ Ground (Green)
A NEMA L14-20 plug is used with this 240 Volt
receptacle. Connect a suitable 4-wire cord set to the
plug and to the desired load. The cord set should be
rated for 250 Volt AC loads at 20 Amps (or greater).
CAUTION! Although this receptacle is rated for
A
120/240 Volts at 20 Amps (4,800 watts or
4.8 kW), the generator is rated for a total of
3,600 watts at 15 Amps. Powering loads that
exceed the wattage capacity of the generator
can damage it or cause serious injuries. See
"Don't Overload Generator" on page 10.
/
COLD WEATHER OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] combined with high humidity), your
Craftsman generator may experience icing of the
carburetor and/or the crankcase breather system. To
reduce this problem, you need to perform the
following:
/
Muffler side exposed. Your unit may differ in
appearance from that shown above.
3. Cut appropriate slots to access receptacles of unit.
4. Start unit, then place carton over it.
NOTE: Remove carton when temperature is above
40°F [4°C].
For a more permanent shelter, build a structure that
will enclose three sides and the top of the generator.
1. Make sure entire muffler-side of generator is
exposed, as shown.
2. Ensure a minimum of two feet clearance between
open side of structure and nearest object.
3. Face exposed end away from wind and elements.
4. Structure should hold enough heat created by
generator to prevent icing problem.
,_ WARNING! Engines give off carbon monoxide,
an odorless, colorless, poison gas. Breathing
carbon monoxide can cause nausea, fainting or
death.
5. Start and run engine outdoors.
6. DO NOT start or run engine in enclosed area,
even if doors or windows are open.
7. DO NOT enclose generator any more than shown.
8. Remove shelter when temperatures are above
40°F [4°C].
9. Turn engine OFF and let cool two (2) minutes
before refueling.
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DON'T OVERLOAD GENERATOR
Capacity
You must make sure your generator can supply
enough rated (running) and surge (starting) watts for
the items you will power at the same time. Follow
these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items. This
is the amount of power your generator must
produce to keep your items running.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time,
total surge watts can be estimated by adding only
the item(s) with the highest additional surge watts
to the total rated watts from step 2.
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated
(Running) Watts
1200
8O0
5O0
500
75
3075 Total
RunningWatts
Total Rated (Running) Watts
Highest Additional Surge Watts
Total Generator Output Required
Power Management
To prolong the life of your generator and attached
devices, it is important to take care when adding
electrical loads to your generator. There should be
nothing connected to the generator outlets before
starting it's engine. The correct and safe way to
manage generator power is to sequentially add loads
as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the
largest load you have.
3. Permit the generator output to stabilize (engine
runs smoothly and attached device operates
properly).
Additional Surge
(Starting)Wa_s
1800
1600
5O0
1800 Highest
Su_eWatts
= 3075
= 1800
= 4875
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
NEVER add more loads than the generator capacity.
Take special care to consider surge loads in generator
capacity, as described above.
Rated* Additional
Tool or Appliance
Essentials
Light Bulb - 75 watt
Deep Freezer
Sump Pump
Refrigerator/Freezer - 18 Cu, Ft,
Water Well Pump- 1/3 HP
HeatinglCeeling
Window AC - 10,000 BTU
Window Fan
Furnace Fan Blower - 1/2 HP
Kitchen
Microwave Oven - 1000 Watt
Coffee Maker
Electric Stove - Single Element
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television - 27"
Personal Computer w/17"
monitor
Other
Security System
AM/FM Clock Radio
Garage Door Opener - 1/2 HP
Electric Water Heater - 40
Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - 1/2 HP
Circular Saw - 7 1/4"
Miter Saw - 10"
Table Planer - 6"
Table Saw/Radial Arm Saw - 10"
Air Compressor - 1-1/2 HP
(Running) Sure
Wa_s (Starting)
75
500 500
800 1200
800 1600
1000 2000
1200 1800
300 600
800 1300
1000
1500
1500
2500
100
100
450
500
800
180
300
480 520
4000
1000
600 1200
960 960
1000 1000
1500 1500
1800 1800
1800 1800
2000 2000
2500 2500
Wa_s
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
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MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is required when operating in adverse conditions noted below.
MAINTENANCE SCHEDULE
FILL IN DATES AS YOU COMPLETE
REGULAR SERVICE
MAINTENANCE TASK
ENGINE
Check oil level
Change engine oil X= I
Service air cleaner I X_ I
Service spark plug I X I
Service spark attester X I
Prepare for storage I If unit is to remain idle for
HOURLY OPERATING
INTERVAL
Before
Each Use
X
SERVICE DATES
I
I longer than 30 days. I
Clean if clogged. Replace if perforated or torn.
2 Change oil after the first (5) operating hours and every 50 hours or every year, whichever occurs first, thereafter.
Change sooner when operating under dirty or dusty conditions.
3 Replace more often under dirty or dusty conditions.
PRODUCT SPECIFICATIONS
Generator Specifications
Rated Running Watts ......... 3,600 Watts (3.6kW)
Rated Surge Watts ........... 5,300 Watts (5.3kW)
Rated AC Voltage ............ 120/240 Volts
Rated Maximum AC Current
at 240 Volts .............. 15.0 Amperes
at 120 Volts .............. 30.0 Amperes
Rated Frequency ............ 60 Hz at 3600 rpm
Phase ..................... Single Phase
Shipping Weight ............. 127 Ibs.
Engine Specifications
Rated Horsepower ........... 7.0 at 3600 rpm
Displacement ............... 206cc
Spark Plug Type: ............ Champion RC-12YC
or Equivalent
Set Gap To: ................ 0.030inch (0.76mm)
Fuel Capacity ............... 4 U.S. gallon
Oil
Above 40°F .......... SAE 30
0°F -4O°F ........... SAE 5W-30 or 10W-30
GENERAL RECOMMENDATIONS
The generator warranty 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.
All adjustments in this section should be made at least
once each season. Follow the requirements in the
"Maintenance Schedule" chart shown above.
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.
GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit
clean and dry. Operate and store the unit in a clean
dry environment where it witl 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.
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
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NOTE:DONOTuseagardenhosetoclean
generator.Watercanentertheenginefuelsystemand
causeproblems.Inaddition,ifwaterentersthe
generatorthroughcoolingairslots,someofthewater
willberetainedinvoidsandcracksoftherotorand
statorwindinginsulation.Wateranddirtbuilduponthe
generatorinternalwindingswilteventuallydecrease
theinsulationresistanceofthesewindings.
To Clean the Generator
Use a damp cloth to wipe exterior surfaces clean.
Use a soft bristle brush to loosen caked on dirt, oil,
etc.
,_ CAUTIONI NEVER insert any object or tool
through the air cooling slots, even ifthe engine
is not running.
Use a vacuum cleaner to pick up loose dirt and
debris.
Use low pressure air (not to exceed 25 psi) to blow
away dirt. Inspect cooling air slots and openings on
the generator. These openings must be kept clean
and unobstructed.
ENGINE MAINTENANCE
,_ CAUTIONI When working on the generator
always disconnect spark plug wire from spark
plug and keep it away from spark plug.
Checking Oil Level
Oil level should be checked prior to each use or at least
every 5 hours of operation. Keep oil level maintained.
Changing Engine Oil
Change the oil after the first 5 hours of operation.
Change oil every 50 hours thereafter. If you are using
your generator under extremely dirty or dusty
conditions, or in extremely hot weather, change the oil
more often.
Change the oil while the engine is still warm from
running, as follows:
1. Clean area around oil drain plug. The oil drain
plug is located at base of engine, opposite
carburetor.
2. Remove oil drain plug and drain oil completely into
a suitable container.
3. Install oil drain plug and tighten securely.
4. Fill oil sump with recommended oil. See page 7
for oil recommendations.
5. Install oil cap/dipstick. Check oil level. Tighten cap
securely.
6. Wipe up any spilled oil.
Clean/Replace Spark Plug
Change the spark plug every 100 hours of operation
or once each year, whichever comes first. This wilt
help your engine to start easier and run better.
1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Replace spark plug ifelectrodes are pitted or
burned or porcelain is cracked. For replacement
use Champion RC-12YC or equivalent.
4. Check electrode gap with wire feeler gauge and
set spark plug gap to 0.030 inch (0.76mm) if
necessary.
5. Install spark plug and tighten firmly.
NOTE: You can purchase a new spark plug by calling
1-800-366-PART.
Service Air Cleaner
Your engine will not run properly and may be
damaged if you run it with a dirty air cleaner.
Replace the air cleaner every 100 hours of operation
or once each year, whichever comes first. Replace
more often if operating under dirty or dusty conditions.
To service the air cleaner, follow these steps:
1. Loosen screw and tilt cover down.
CARTRIDGE BASE -_
COVER
SLOTS AND
SCREW----_ TABS
2. Carefully remove cartridge assembly.
3. To clean cartridge, gently tap pleated paper side
on a flat surface.
4. Reinstall clean or new cartridge inside cover.
5. Insert cover's tabs into slots in bottom of base.
6. Tilt cover up and tighten screw securely to base.
NOTE: You can purchase new air filter elements by
calling 1-800-366-PART.
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Carburetor
If you think your carburetor needs adjusting, see your
nearest Sears service center. Engine performance
may be affected at attitudes above 3000-5000 feet.
For operation at higher elevations, contact your
nearest Sears service center.
Clean Spark Arrester Screen
The engine exhaust muffler has a spark arrester
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
NOTE: If you use your generator on any forest-
covered, brush-covered, or grass-covered unimproved
land, it must have a spark arrester. The spark arrester
must be maintained in good condition by the
owner/operator.
Clean and inspect the spark arrester as follows:
1. To remove muffler heat shield from muffler,
remove four screws that connect guard to muffler
bracket.
Spark Arrester
Screen
Muffler
Heat Shield
2. Remove four screws that attach spark arrester
screen.
3. 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.
4. Reattach screen and muffler guard.
GENERAL
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.
Long Term Storage Instructions
WARNINGI NEVER store engine with fuel in
A
tank indoors or in enclosed, poorly ventilated
areas where fumes may reach an open flame,
spark or pilot light as on a furnace, water heater,
clothes dryer or other gas appliance.
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. Follow
these instructions:
Protect Fuel System
,_ WARNINGI Drain fuel into approved container
outdoors, away from open flame. Be sure
engine is cool. DO NOT smoke.
Remove all fuel from the fuel tank to prevent gum
deposits from forming on these parts and causing
possible engine malfunction.
Run engine until engine stops from lack of fuel.
Change Oil
While engine is still warm, drain oil from crankcase.
Refill with recommended grade.
Oil Cylinder Bore
Remove spark plug and pour about 1 ounce (30ml)
of clean engine oil into the cylinder.
,_ CAUTIONI Avoid spray from spark plug hole
when cranking engine slowly.
Cover spark plug hole with rag. Crank slowly to
distribute oil.
Install spark plug. DO NOT connect spark plug
wire.
Generator
Clean the generator as outlined on page 12 ("To
Clean the Generator").
Check that cooling air slots and openings on
generator are open and unobstructed.
Other Storage Tips
DO NOT store fuel from one season to another.
Replace your fuel can if the can starts to rust. Rust
and/or dirt in your fuel wilt 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.
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Problem
Engine is running, but no AC
output is available.
Engine runs good at no-load but
"bogs down" when loads are
connected,
Engine will not start; or starts
and runs rough.
Engine shuts down when
running.
Engine lacks power.
Engine "hunts" or falters.
Cause
1. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
1. Short circuit in a connected
load.
2. Engine speed is too slow.
3. Generator is overloaded.
4. Shorted generator circuit.
1. Rocker Switch set to "Off".
2. Fuel Valve is in "Off' position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
6. Spark plug wire not connected
to spark plug.
7. Bad spark plug.
8. Water in gasoline.
9. Flooded.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or
closed.
12. Engine has lost compression.
Out of gasoline.
1. Load is too high.
2. Dirty air filter.
Carburetor is running too rich or
too lean.
Correction
1. Reset circuit breaker.
2. Contact Sears service facility.
3. Check and repair.
4. Connect another device that is
in good condition.
1. Disconnect shorted electrical
load.
2. Contact Sears service facility.
3. See "Don't Overload
Generator".
4. Contact Sears service facility.
1. Set switch to "On".
2. Turn fuel valve to "Open"
position.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank and carburetor;
fill with fresh fuel.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank and carburetor;
fill with fresh fuel.
9. Wait 5 minutes and re-crank
engine.
10. Contact Sears service facility.
11. Contact Sears service facility.
12. Contact Sears service facility.
Fill fuel tank.
1. See "Don't Overload
Generator".
2. Replace air filter.
Contact Sears service facility.
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