Craftsman 580323602 Owner’s Manual

Owner's Manuam

Generator

®

HOURS: Mort. ° Fri. 8 a.m. to 5 p.m. {CT)

CAUTtON

Before using this product, read this

manual and follow all Safety Rules

and Operating instructions.

Sears, Roebuck and Co., Hoffman Estates, _L 60179 U.S.A.

Visit our Craftsman website: www.craftsmamcom

Part No. 193353GS Draft9 (07192005)

Antes de utilizar el producto, lea este

manual y siga todas las Reglas de
Seguridad e Instrucciones de Uso.

PRECAUC_ON

o Safety
o AssemNy
o Operation

o Maintenance
o Parts

o EspaSoN

STORAGE ............................... 17

TROUBLESHOOTING ...................... 18

SCHEMATIC/WIRING DIAGRAM ............. 19

REPLACEMENT PARTS ................. 20=28

EMISSION SYSTEM VVARRANTY ......... 30-31

ESPANOL ............................. 32_51

HOW TO ORDER PARTS .......... BACK PAGE

LIMtTED WARRANTY FOR CRAFTSMAN GENERATORS

SEARS warrants to the original purchaser that the alternator and engine for its portable 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) 1Year

Engine 2 Years (2nd year parts only) 1Year

* 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 will 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, _L 60179 U.S.A.

© Sears Brands, LLC

This is the safety alert symbol. It is used to alert you to potential personal inju_' hazards.
Obey all safety messages that foltow this symbol to avoid possible injury or death.

ii_=!_l;ijRead this manuat carefully and become

familiar with your generator. 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, wil/

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.

WARNING

The engine exhaust from this product contains
chemicams known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING

• This generator does not meet U. S. Coast Guard
Regulation 33CFRo183 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.

Hazard Symbols and Meanings

WARNING

Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).

WARNING

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.

Electrocution Electrical Shock Electrical Shock

Explosion

Fire

Toxic Fumes Hot Surface Kickback

WARNING

When starting engine, pull cord slowly until resistance is
felt and then pull rapidly to avoid kickback.

NEVER start or stop engine with electrical devices
plugged in and turned on.

WARNING

WARNING

WHEN ADDING OR DRAINmNG 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 or drain 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.

WHEN STARTING EQUIPMENT

Ensure spark plug, muffler, fuel cap and air cleaner are
in place.

DO NOT crank engine with spark plug removed.
If fuel spills, wait until it evaporates before starting

engine.

WHEN OPERATING EQUIPPv_ENT

Do not tip engine or equipment at angle which causes

fue! to spill.

DO NOT choke carburetor to stop engine.
This generator is not for use in mobile equipment or

marine applications.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.

Disconnect spark plug wire.

WHEN 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

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR

GENERATOR
+ Disconnect the spark plug wire from the spark plug and

place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

Use approved spark plug tester.
DO NOT check for spark with spark plug removed.

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".
Start generator and let engine stabilize before connecting

electrical loads.
Connect electrical loads in OFF position, then turn ON

for operation.
Turn electrical loads OFF and disconnect from generator

before stopping generator.

CAUTION

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator

for adequate cooling, maintenance and servicing.

In the State of California a spark arrester is required by
law (Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal laws
apply on federal lands. If you equip the muffler with a
spark arrester, it must be maintained in effective working
order.You can order a spark arrester through your

authorized Sears service dealer.

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.

120 Volt AC, 20 Amp
Duplex Receptacles

Fuel Tank

Rocker Switch

Recoil Starter

Choke Lever

Air

Cleaner

120/240 Volt AC, 20 Amp
Receptacles

Circuit Breakers

120 Volt AC, 20 Amp, Dupmex 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.

1201240 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 -- Protects engine by filtering dust and

debris out of intake air.
CircuEt Breakers -- Each receptacle socket is

protected against electrical overload with "push to
reset" circuit breakers.

Fuel Tank -- Tank holds 4 U.S. gallon of unleaded
fuel.

Spark Attester
Muffler

Grounding Fastener

Grounding Fastener -- If required, please consult a
qualified electrician, electrical inspector, or local
agency having jurisdiction.

OH 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 attester
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 flat, 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 helpline 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 two 1/2" or 13mm open end wrenches
or a socket wrench with 1/2" or 13mm sockets, a

15/16" 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 1/2" or 13mm
wrenches with 20mm cap screws and lock nuts.

8. Center lifting handle on generator end of cradle.
Attach handle using two 1/2" or 13mm wrenches
with 45mm capscrews and hex nuts.

Capscrew

Handle

Nut

Mounting Leg

Nut

\

Capscrew

Axle

Stud

Wheel

Jam Nut

_./_ _Nasher

Retaining Pin

BEFORE STARTING "THE

Add Engine OH

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. DO NOT use
special additives.

1. Choose a viscosity according to the table below:

J

C 30 2Q 10 0 10 20 30 40

STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT O_L CHANGE

NOTE: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol with "SJ/CF

ENERGY CONSERVING" or higher, is an acceptable
oil at all temperatures. Use of synthetic oil does not
alter required oil change intervals.

* 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.

2. Place generator on a level surface.

3. Clean area around oil fill and remove oil dipstick.

4. Wipe dipstick clean. Replace and tighten dipstick.

Remove and and check oil level.

5. Slowly pour oil into oil fill opening. Pause to permit

oil to settle. Oil level should be at "Full" mark on
dipstick. DO NOT OVERFILL. Remove and check

oil level.

NOTE: You may not need to use all the supplied oil.

6. Replace and tighten dipstick.

NOTE: Check oil often during engine break-in.

100

Add Fue{

WARNING

WHEN ADDING FUEL

Turn generator OFF and let it coo! at least 2 minutes

before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.

Fil!fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.

Keep fue! away from sparks, open flames, pilot lights,
heat, and other ignition sources.

DO NOT light a cigarette or smoke.

NOTE: This gasoline engine is certified to operate on

gasoline. Exhaust Emission Control System: EM

(Engine Modifications).

1. Use clean, fresh, regular UNLEADED fuel with a
minimum of 85 octane with equipment. DO NOT

use fuel which contains Methanol DO NOT mix oil

with fuel

2. Clean area around fuel fill cap, remove cap.

3. Slowly add regular unleaded fuel to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank

space for fuel expansion, as shown here.

4. Install fuel cap and wipe up any spilled fuel.
CAUTION! 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. Drain the
fuel tank, start the engine and let it run until the fuel

lines and carburetor are empty. Use fresh fuel next

season. See "Storage" on page 17 for additional

information.
NEVER use engine or carburetor cleaner products in

the fuel tank as permanent damage may occur.

HOW TO USE YOUR GENERATOR

if you have any problems operating your generator
after reading the manual, please call the generator
he+p+ineat 1-800-222-3136.

System Ground

The generator has a system ground that connects the
generator flame components to the ground terminals
on the AC output receptacles. The system ground is
connected to the AC neutral wire (the neutral is
bonded to the generator frame).

Spec{amRequirements
There may be Federa+ or State Occupational Safety

and Health Administration (OSHA) regulations, local
codes, or ordinances that apply to the intended use of
the generator. Please consult a qualified electrician,
electrical inspector, or the local agency having

jurisdiction.

• in some areas, generators are required to be

registered with local utility companies.

• if the generator is used at a construction site, there

may be additional regulations which must be
observed.

Connecting to a Build+rig's E_ectrica_
System

Connections for standby power to a building's
electrical system must be made by a qualified
electrician. The connection must isolate the generator
power from utility power, and must comply with all
applicable laws and electrical codes.

Generator Location

Generator Clearance

WARNtNG

Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).

The generator must be at least 5 ft. (152 cm) from
structures having combustible walls and/or other

combustible materials. Leave at least 3 ft. (92 cm) all
around generator including overhead, for adequate
cooling, maintenance and servicing.

Place generator in a well ventilated area, which will

allow for removal of deadly exhaust gas+ DO NOT

place generator where exhaust gas could accumulate
and enter inside or be drawn into a potentially
occupied building. Ensure exhaust gas is kept away
from any windows, doors, ventilation intakes or other

openings that can allow exhaust gas to collect in a

confined area. Prevailing winds and air currents
should be taken into consideration when positioning

generator.

WARNING

When usinggenerator 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 othep,,vise 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.

Typical Generator Shown

Exhaust Port

To Start The Engine

CAUTION

See "Don't Ovedoad Generator".
Start generator and let engine stabilize before connecting

electrical loads.
Connect electrical loads in OFF position, then turn ON

for operation.

Turn electrical loads OFF and disconnect from generator
before stopping generator.

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.

WARNING

When starting engine, pull cord slowly until resistance is

felt and then pull rapidly to avoid kickback.

NEVER start or stop engine with electrical devices
plugged in and turned on,

iMPORTANT: if engine floods, place choke lever in
"Run" position and crank until engine starts.

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

)rotection device.

WARNING

DO NOT touch hot surfaces,

Allow equipment to coo! before touching.
The generator must be at bast 5 feet from structures having

combustible wails and/or other combustible materials.
Keep at least 3 feet of clearance on al! sides of generator

for adequate cooling, maintenance and servicing.

In the State of California a spark arrester is required by
law (Section 4442 of the California Public Resources
Code), Other states may have similar laws. Federal laws
apply on federal lands. If you equip the muffler with a
spark arrester, it must be maintained in effective working
order,You can order a spark arrester through your

authorized Sears service dealer,

Connecting E_ectrica_ 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".

Stopping the Engine

1. Turn off and unplug all electrical loads from unit.

1

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.

DO NOT stop engine by moving choke lever to "Choke"

l CAUTION

position,Backfire,fireor engine damage could occur,

CORD SETS AND RECEPTACLES

I cAuTmo. 1

• NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply,

• DO NOT overload the generator, See "Don't Overload
Generator".

Use only high quality, weGinsulated, 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.

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

.J

(Neutral)

Y (Hot) | X (Hot)

NEMA L14-20 /_7 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).

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 foJlowing:

1. Make sure generator has clean, fresh fuel.

2. Open fuel valve (turn valve to open position).

3. Use SAE 5W-30 oiJ(synthetic preferred, see
page 7).

4. Check oil Jevel daiJyor after every eight (8) hours
of operation.

5. Maintain the generator folJowing the "Maintenance
Schedule" on page 14.

6. SheJter unit from elements.

10

inanemergency,usetheoriginalshippingcartonasa

temporaryshelter:

7. Cutoffallcartonflaps.

8. Cutoutonelongsideofcartontoexposemuffler
sideofunitasshown.

For a more permanent shelter, build a structure that

wiJl enclose three sides and the top of the generator.

7. Make sure entire muffler-side of generator is
exposed, as shown previously.

IMPORTANT: The generator must be at least 5 ft.
(152 cm) from structures having combustible walls

and/or other combustible materials. Leave at least 3 ft.
(92 cm) all around generator including overhead, for

adequate cooling, maintenance and servicing.

9. Face exposed end away from wind and elements.

10. Structure should hold enough heat created by the
generator to prevent icing problem.

11. Start and run engine outdoors.

12. Keep exhaust gas from entering a confined area
through windows, doors, ventilation intakes or
other openings.

Mufflersideexposed.Yourunitmaydifferin

appearancefromthatshownabove.

IMPORTANT:Thegeneratormustbeatleast5ft.
(152cm)fromstructureshavingcombustiblewalls

and/orothercombustiblematerials.Leaveatleast3ft.
(92cm)allaroundgeneratorincludingoverhead,for

adequatecooling,maintenanceandservicing.

9. Cutappropriateslotstoaccessreceptaclesofunit.

10.Startunit,thenplacecartonoverit.
NOTE:Removeshelterwhentemperaturesareabove

40°F[4°C].

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator

for adequate cooling, maintenance and servicing.

Remove shelter when temperatures are above 40°F [4°C].

WARNtNG

Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through

windows, doors, ventilation intakes or other openings.

DO NOT operate generator inside any building or
enclosure, including the generator compartment of a

recreational vehicle (RV).

13. DO NOT enclose generator any more than shown.

14. Remove shelter when temperatures are above
40°F [4°C].

15. Turn engine OFF and let cool two (2) minutes

before refueling.

11

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:

Too! or Appliance
Window Air

Conditioner
Refrigerator
Deep Freezer

Television
Light (75 Watts)

Rated

1200

80O
5OO
5OO

75

3075 Total

Running Watts

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

_Startin _ Watts

1800

1600

5OO

1800 Highest

Surge Watts
= 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.

Check

Additional

Surge

(Starting)

Watts

500
1200
1600

2000

1800

6OO
1300

520

1200

96O
1000
1500
1800

1800

2000
2500

tool or

Rated*

Tool or Appliance

Essentials

Bulb - 75 watt 75

Deep Freezer 500
Sump Pump 800

RefrigeratodFreezer - 18 Cu, Ft, 800
Water We!l Pump - 1/3 HP 1000
Heating/Cooling

Window AC - 10,000 BTU 1200
Window Fan 300

Furnace Fan Blower - 1/2 HP 800
Kitchen
Microwave Oven - 1000 Watt 1000
Coffee Maker 1500

El_ic Stove --Sin le Element 1500
Hot Plate 2500

Famimy Room
DVD/CD Player 100

VCR 100
Stereo Receiver 450
Color Television - 27" 500

Personal Computer w/17" 800
monitor

Other
Security S_stem 180

AM/FM Clock Radio 300
Garage Door Opener - 1/2 HP 480

Electric Water Heater - 40 4000
Gallon

DIY/Job Site
Quartz Halogen Work Light
Aidess 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)

Watts

1000

600

96o
1000
1500
1800

1800

2000
2500

*Wattages listed are approximate only.
appliance for actual wattage.

12

ENGtNE TECHNICAL INFORMATION

This is a single cylinder, overhead valve(OHV), air
cooled engine. It is a low emissions engine.

in the State of California, Model Series 120000

engines are certified by the California Air Resources

Board to meet emissions standards for 125 hours.

Such certification does not grant the purchaser, owner
or operator of this engine any additional warranties

with respect to the performance or operational life of
this engine. The engine is warranted solely according

to the product and emissions warranties stated
elsewhere in this manual.

Power Ratings

The power ratings for an individual engine model are
initially developed by starting with SAE (Society of
Automotive Engineers) code J1940 (Small Engine

Power & Torque Rating Procedure) (Revision 2002-

05). Given both the wide array of products on which
our engines are placed, and the variety of

environmental issues applicable to operating the
equipement, it may be that the engine you have

purchased will not develop the rated horsepower when
used in a piece of power equipment (actual "on-site"

power). This difference is due to a variety of factors
including, but not limited to, the following: differences
in altitude, temperature, barometric pressure, humidity,

fuel, engine lubrication, maximum governed engine
speed, individual engine to engine variability, design of

the particular peice of power equipment, the manner in
which the engine is operated, engine run-in to reduce
friction and clean out of combustion chambers,

adjustments to the valves and carburetor, and other
factors. The power ratings may also be adjusted

based on comparisons to other similar engines utilized
in similar applications, and will therefore not
necessarily match the values derived using the

foregoing codes.

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

Bore ....................... 2.69 in. (68mm)

Stroke ...................... 2.20 in. (56mm)

Displacement ................ 12.48 in. (206 cc)

Spark Plug

Type: ................. Champion RC12YC or

Equivalent

Set Gap To: ............ 0.030inch (0.76ram)

Armature Air Gap: ............ 0.010-0.014 in.

(0.25-0.36mm)

Valve clearance with valve springs installedand piston 1/4 in.

(6 mm) pasttop dead center (checkwhen engine is cold).

intake ...................... 0.004-0.006 in.

(0.10-0.15 mm)

Exhaust .................... 0.009-0.011 in.

(0.23-0.28 mm)

Fuel Capacity ................ 4 U.S. gallons

Oil Capacity ................ 20 Ounces (.6 Liters)

Oil Type:

Above 40° F ............... SAE 30

Below 40° F ............... SAE 5W-30 or 10W-30

13

MAINTENANCE SCHEDULE

Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is recuired when operating in adverse conditions noted below.

MABNTENANCE SCHEDULE

FiLL tN DATES AS YOU

COMPLETE REGULAR SERVICE

MAINTENANCE TASK

Check oil tevet

E

Clean debris
Change engine oil

Service air cleaner
Service spark plug

Service spark arrester
Clean cooiing system

Prepare for storage

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.

= Replace more often under dirty or dusty conditions.

Before Every 25 Hours

Each Use or Yearly

X

x

If unit is to remain idle for longer than 30 days.

GENERAL RECOMMENDATIONS

Regular maintenance will improve the performance

and extend the life of the generator. See any
authorized Sears dealer for service.

The generator's warranty does not cover items that
have been subjected to operator abuse or negligence.
To receive full value from the warranty, the operator

SERVICE DATES

X 2

Every 50 Hours

or Year y

X 1

Every 100

Hours or Yearly

x
x

x 2

NOTE: DO NOT use a garden hose to clean

generator. Water can enter the engine fuel system and
cause problems. In addition, if water enters the
generator through cooling air slots, some of the water

will be retained in voids and cracks of the rotor and
stator winding insulation. Water and dirt buildup on the

generator internal windings will eventually decrease
the insulation resistance of these windings.

must maintain generator as instructed in this manual.
Some adjustments will need to be made periodically to

properly maintain your generator.
All service and adjustments should be made at least

once each season. Follow the requirements in the
"Maintenance Schedule" chart 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 C_eaning

Daily or before use, clean accumulated debris from

generator. Keep linkage, spring and controls clean.

Keep area around and behind muffler free from any

combustible debris.
Generator parts should be kept clean to reduce the

risk of overheating and ignition of accumulated debris.

• Use a damp cloth to wipe exterior surfaces clean.

CAUTION

EMiSSiON CONTROL

Maintenance, replacement or repair of the emission
control devices and systems may be performed by any
non-road engine repair establishment or individual.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping the unit
clean and dry. Operate and store the unit in a clean dry
environment where it will 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.

DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.

DO NOT insert any objects through cooling slots.

Use a soft bristle brush to loosen caked on dirt, oil,

etc.

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.

SERVICE DATES

14

ENGINE MAINTENANCE

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR

Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.

WHEN TESTBNG FOR ENGINE SPARK

Use approved spark plug tester.
DO NOT check for spark with spark plug removed,

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 OH

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.

cAuTmO. 1

• Used motor oil has been shown to cause skin cancer in
certain laboratory animals,

• Thoroughly wash exposed areas with soap and water,

KEEP OUT OF REACH OF CHILDREN.
DON'T POLLUTE. CONSERVE
RESOURCES. RETURN USED OIL TO
COLLECTION CENTERS.

C[eanlRepmace Spark Plug

Change the spark plug every 100 hours of operation

or once each year, whichever comes first. This will

help your engine to start easier and run better.

1. Clean area around spark plug.

2. Remove and inspect spark plug.

3. Check electrode gap with wire feeler gauge and
set spark plug gap to 0.030 inch (0.76mm) if

necessary.

4. Replace spark plug if electrodes are pitted, burned
or porcelain is cracked. Use a recommended

replacement plug.

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 25 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

Change the oil while the engine is still warm from
running, as follows:

1. Make sure unit is on a [eve[ surface.

2. Disconnect the spark plug wire from the spark
plug and place the wire where it cannot contact
spark plug.

3. Clean area around oil drain plug. The oil drain plug
is located at base of engine, opposite carburetor.

4. Remove oil drain plug and drain oil completely into
a suitable container.

5. Reinstall oil drain plug and tighten securely.
Remove oil cap/dipstick.

6. Slowly pour oil into oil fill opening. Pause to permit
oil to settle. Oil [eve[ should be at "Full" mark on

dipstick. DO NOT OVERFILL Remove and check
oil level.

7. Reinstall oil cap/dipstick. Tighten cap securely.

8. Wipe up any spilled oil.

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.

15

Carburetor

if you think your carburetor needs adjusting, see your
nearest Sears service center. Engine performance
may be affected at attitudes above 3000 feet. For
operation at higher elevations, contact your nearest

Sears service center.

CJean Spark Arrester Screen

The engine exhaust muffler has a spark attester
screen. Inspect and clean the screen every 100 hours

of operation or once each year, whichever comes first.

NOTE: You can purchase a new spark attester screen
b calling 1-800-366°PART.

WARNING

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.

Keep at least 3 feet of clearance on all sides of generator

for adequate cooling, maintenance and servicing.

In the State of California a spark arrester is required by law

(Section4442 of the CaliforniaPublic ResourcesCode).
Otherstates may havesimilar laws. Federallawsapply on

federal lands. If you equip the mufflerwitha spark arrester,

it mustbe maintainedin effectiveworking order.

if you use your generator on any forest-covered,
brush-covered, or grass-covered unimproved land, it

must have a spark attester. The spark attester must
be maintained in good condition by the
owner/operator.

Spark Attester

Screen

_eat Shield

.

Remove four screws that attach spark attester

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.

.

Reattach screen and muffler guard.

Air Coo_ing System

Over time debris may accumulate in cylinder cooling
fins and cannot be observed without partial engine
disassembly. For this reason, we recommend you

have an authorized Sears service dealer clean the

cooling system per recommended intervals (see
"Maintenance Schedule" on page 14). Equally

important is to keep top of engine free from debris.

See "Generator Cleaning".

c[ Ak

Clean and inspect the spark attester as follows:

1. To remove muffler heat shield from muffler,
remove four screws that connect guard to muffler

bracket.

16