Craftsman 580323601 Owner’s Manual

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!.,

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.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

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

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.

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.

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.

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

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*

._ -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.

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.

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

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.

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

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.

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

SERVICE DATES

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.

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.

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

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.

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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