Craftsman 580.325601 User Manual

Owner's Manual

®

o Safety
o Assembly

o Operation

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.craftsman.com

Part No. 197127GS Draft 1 (07/29/2005) 0 7

Antes de utilizar el producto, lea este

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

PRECAUCI6N

o Maintenance
o Parts

o Espa_oN

WARRANTY .................................... 2

SAFETY RULES ............................... 3-4

FEATURES AND CONTROLS ...................... 5

ASSEMBLY ................................... 6-7

OPERATION ................................. 8-1 1

SPECIFICATIONS ............................... 12

MAINTENANCE .............................. 13-15

STORAGE ..................................... 16

TROUBLESHOOTING ............................ 17

SCHEMATIC DIAGRAM .......................... 18

WIRING DIAGRAM .............................. 19

REPLACEMENT PARTS ....................... 20-28

NOTES ....................................... 29

EMISSION CONTROL WARRANTY .............. 30-31

ESPAI_OL ................................... 32-51

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

LIMtTED WARRANTY FOR DELUXE PORTABLE 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 and applies only to portable generators driven by the Sears
warranted engine.

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, overspeeding, 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., Dept. DI817 WA, Hoffman Estates, IL 60179 U.S.A

@Sears Brands, LLC

Thisis 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.

,¢'_ I_Read 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
chemicals 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 33CFR=183and should not be used on
marine applications.

• Failure to use the appropriate U. S. Coast Guard

approved generator could result in death, serious 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

Explosion

Fire

Toxic Fumes Hot Surface Kickback

WARNING

When starting engine, pull cord slowly until resistance is
felt and then pul! 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.

Choke Lever

Air Cleaner

Recoil Starter

Rocker Switch

(on engine shroud)

.J

.J

Circuit

Breakers (AC)

FuelTank

120/240 VAC,

30A Receptacle

Fuel Valve

(2) 120 VAC, 20A
Duplex Receptacles

120 VomtAC, 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, 30 Amp LocHng Receptacle --

May be used to supply electrical power for the
operation of 120 and/or 240 Volt AC, 30 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.
Choke Lever -- Used when starting a cold engine.
Circuit Breakers (AC) -- Push to reset circuit

breakers are provided to protect the generator against
electrical overload.

Grounding Fastener

Spark Arrester Muffler

Fuel Tank -- Capacity of five (5) U.S. gallons.
Fuel Valve -- Used to turn fuel on and off to engine.

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

Oil Fill -- Add engine oil here.

Recoil Starter -- Used to start the engine.

Rocker Sw{tch -- Set this switch to "On" before 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.

YourCraftsmangeneratorrequiressomeassembly
andisreadyforuseonlyafterithasbeenproperly

servicedwiththerecommendedoilandfuel.
Ifyou haveanyproblemswith theassemMyof

your generator,pleasecallthegeneratorhelpline

at1-800-222-3136.
IMPORTANT:Anyattempttoruntheenginebeforeit

hasbeenservicedwiththerecommendedoilwillresult
inanenginefailure.

REMOVE GENERATOR FROM
CARTON

1. Set the carton on a rigid flat surface.

2. Remove everything from carton except generator.

3. Open carton completely by cutting each corner
from top to bottom.

4. Leave generator on carton to install wheel kit.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged,
call the generator helpline at 1-800-222-3136.

• The main unit

• Owner's manual

• Engine oil

• 120/240 Volt, 30 Amp locking plug

• Wheel Kit

ASSEMBLING THE WHEEL KIT

NOTE: Wheel kit is not intended for over=the=road use.
You will need the following tools to install these

components:

• 1/2" or 13mm wrench

• Socket wrench with a 1/2" or 13mm socket

• Pliers
Refer to imlustrationshown below and install the wheel

kit as fol!ows:

1. Tip generator so that engine end is up.

2. Slide axle through both mounting brackets.

3. Place a wheel on each side with air valve facing
out.

4. Place a washer on axle and then place an e-ring
in axle groove.

5. Install e-dng with pliers, squeezing from top of e-
ring to bottom of axle.

6. Repeat step 3 through 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Line up holes in support leg with holes in
generator frame.

9. Attach support leg using two short (M8 x 16mm)
cap screws and two locking hex nuts. Tighten with

a 1/2" or 13mm socket and wrench.

10. On support leg end of generator, slide handle onto
center of top of frame.

11. Attach handle using two long (M8 x 45mm) cap
screws and two locking hex nuts. Tighten with a

1/2" or 13mm socket and wrench.

12. Return generator to normal operating position
(resting on wheels and support leg).

13. Check that tires are inflated to value marked on
tire or within 15 and 40 psi.

Handle Assembly,

Hex

Support Leg

Cap Screw

Hex Nut _

Whee_ Kit Assembly View

\

\,

Cap Screw

Axle

Wheel

Flat Washer

/

/

E=Ring

BEFORE STARTING THE

GENERATOR

To operate the generator you will need to first add
engine oil and gasoline, as follows:

Add Engine Oim

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:

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.

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

ENERGY CONSERVING" or higher, is an acceptable
o11at all temperatures. Use of synthetic oil does not
alter required oil change intervals.

2. Place generator on a level surface.

3. Clean area around yellow oil fill cap. Remove oil

fill cap.

4. Slowly fill engine with oil through oil fill opening

until oil level is to the point of overflowing.

5. Install yellow oil fill cap and finger tighten securely.

6. Check engine oil level before starting each time

thereafter. If oil level is below the point of
overflowing, fill to proper level.

NOTE: Check oil often during engine break-in.

Add Fue_

WARNING

WHEN ADDING FUEL

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

before removing fue! 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.

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.

Tank

\\\\\\\

4. Install fuel cap and wipe up any spilled fuel.
CAUTmON! 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 16 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,

please call the generator helpline at 1o800o222o3136.

System Ground

The generator has a system ground that connects the
generator frame 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 Federal 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 BuHding'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
appJicable laws and electrical codes.

Generator Location

Generator Clearance

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).

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 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.

Typical Generator Shown

Exhaust Port

TO START THE ENGINE

Disconnect alJelectrical loads from the generator. Use

the foiJowing start instruction steps by numerical order:

1. Make sure unit is on a level surface.
iMPORTANT: FaiJure to start and operate unit on a

leveJ surface wilJ cause the unit not to start or shut

down during operation.

2. Turn the fueJ vaJve to the "On" position.

+t/t_-

3. Place the choke Jever in the "Choke" position.

+

Set the rocker switch to "On" position.

-, Rocker Switch
is shown in the

On position

WARNING

DO NOT touch hot surfaces.

Allow equipment to cool before touching.
The generator must be at least 5 feet from structures having

combustible wails 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.

To Stop the Engine

1. UnpJug aJJeJectricaJ loads from generator paneJ
receptacles. NEVER start or stop engine with
electrical devices plugged in and turned on+

2+ Let engine run at no-load for several minutes to

stabilize internal temperatures of engine and
generator.

5+

Grasp the recoil handJe and puJJsJowJyuntiJslight
resistance is felt. Then puJJrapidly 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 Jever in

"Run" position and crank untiJ engine starts.

6. Move choke Jever to "Run" position a short
distance at a time over several seconds in warm

weather or minutes in coJd weather. Let engine

run smoothly before each change. Operate with
choke in "Run" position.

NOTE: Jfengine starts after 3 puJJsbut fails to run, or
if unit shuts down during operation, make sure unit is

on a leveJ surface and check for proper oil JeveJin

crankcase. This unit may be equipped with a low oiJ
protection device.

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

I CAUTION

position. Backfire, fire or engine damage could occur.

3+ Move rocker switch to "Off' position.

1

4+ Move fuel vaJve to "Off' position.

Connecting Electrica_ Loads

• DO NOT connect 240 Volt loads to 120 Volt
receptacles.

• DO NOT connect 3-phase Joads to generator.

• DO NOT connect 50 Hz loads to generator.

• Let engine stabilize and warm up for a few minutes
after starting.

• PJug in and turn on desired 120 and/or 240 Volt
AC, singJe phase, 60 Hz eJectricaJ loads.

• DO NOT OVERLOAD THE GENERATOR. See
"Don't OverJoad Generator".

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.

CORD SETS AND RECEPTACLES

CAUTION

• 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, 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 20 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.

1201240 Volt AC, 30 Amp Receptacle

This is a full capacity receptacle; it can supply the

1

generator's full rated output from this sole outlet. The
outlet is protected by two 20 Amp push-to-reset

circuit breakers.

4-Wire Cord Set

_j_ Y (Hot) X (Hot)

NEMA L14-30 /_ Ground (Green)

A NEMA L14-30 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 30 Amps (or greater).

10

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. See the table
on the right.

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
Dee£ Freezer

Television

Light (75 Watts)

Rated

_Runnin _ VVatts

1200

8OO
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

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.

Rated*

Too! or Appliance

Essentials
Light Bulb - 75 watt

Deep Freezer
Sump Pump

Refrigerator/Freezer- 18 Cu. Ft.
Water Well Pump - 1/3 HP

Heating/Cooling
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 C!ock Radio

Garage Door Opener - 1/2 HP
Electric Water Heater - 40

Gallon
D_Y/Job Site

Quartz Haloqen Work Light

Airless Sprayer - 1/3 HP

Reci rocatin 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) (Starting)

Watts

75

500 500

800 1200
800 1600

1000 2000

1200 1800

300 600

800 1300

1000
1500
1500
2500

100
100

45O

5OO

8OO

180
3OO

480 520

4000

1000

600 1200

960 960
1000 1000
1500 1500
1800 1800
1800 1800

2000 2000

2500 2500

*Wattages listed are approximate only.

appliance for actual wattage.

Additional

Surge

Watts

Check tool or

11

ENGINE 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 200000

engines are certified by the California Air Resources

Board to meet emissions standards for 250 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 emmisions 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 peice 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

utilizedin similar applications, and will thereforenot
necessarily match the values derived using the
foregoing codes.

PRODUCT SPECIFICATIONS

Generator Specifications

Starting Wattage .............. 8600 Watts (8.6 kW)

Wattage ..................... 5600 Watts (5.6 kW)

AC Voltage ........................ 120/240 Volts

AC Current

at 240 Volts ........................ 23,3 Amps

at 120 Volts ........................ 46,6 Amps

Frequency ..................... 60 Hz at 3600 rpm

Phase ............................. Single Phase

Unit Weight ............................. 170 Ibs,

Engine Specifications

Horsepower ...................... 10 at 3600 rpm

Bore ............................ 3,12 in. (79mm)

Stroke .......................... 2.44 in. (62mm)

Displacement ................... 18.64 in. (305 cc)

Spark Plug

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

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

Armature Air Gap: .................. 0,008-0,0!2 in.

(0,20-0,30ram)

Valve clearance withvalve springs installedand piston I/4 in.

(6 mm) past top dead center (check when engine is cold).

Intake ........................... 0,004-0,006 in.

(0,10-0,15 mm)

Exhaust .......................... 0,004-0,006 in.

(0,10-0,15 mm)

Fuel Capacity ...................... 5 U.S. gallons

Oil Capacity ................ 28 Ounces (.8 Liters)

Oil Type:

Above 40° F ........................ SAE 30

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

12

OWNER'S RESPONSIBILITIES

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

MABNTENANCE SCHEDULE

FILL tN DATES AS YOU SERVICI= DATES

COMPLETE REGULAR SERVICE SERVICE DATES

Before Every 25 Hours Every 50 Hours Every 100

MAINTENANCE TASK Each Use or Year y or Year y Hours or Yearly

Check oil level X
Clean debris X

Change engine oil X1
Service air cleaner X2

Service spark plug X
Service spark arrester X

Clean cooting system X2
Prepare for storage If unit is to remain idle for longer than 30 days.

Change oit 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.

2 Clean or reptace more often under dirty or dusty conditions.

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
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.

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.

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.

Generator Cleaning

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

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.

13

ENGINE MAINTENANCE

VVARNJNG

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,

Checking Oi_ Leve_

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 oHevery 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.

j cAuTmo.

CJean/Rep_ace Spark P_ug

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.

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 using a dirty air cleaner. Clean
or replace the air cleaner paper filter once every

1

25 hours of operation or once a year, whichever
comes first. Clean or replace more often if operating
under dusty or dirty conditions.

• 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.

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 oil fiJJcap and drain oil
completely into a suitable container.

3. Install oil drain plug and tighten securely.

4. FiJJoil sump with recommended oil to the point of

overflowing. See page 7 for oil recommendations.

5. Install oil cap. Tighten cap securely.

6. Wipe up any spilled elk

Service Air FHter

1. Loosen screws and remove air cleaner cover.
Remove paper filter.

Cartridge

Cover

Base

S crew

2. Install clean (or new) air cleaner assembly inside
cover. Dispose of old filter properly.

3. Assemble air cleaner cover onto base and tighten
screws.

NOTE: You can purchase new air cleaner elements by
calling 1-800-366-PART.

14

Carburetor

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

Sears service center.

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.

CJean 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.

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
(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.

NOTE: You can purchase a new spark arrester screen

by calling 1-800-366-PART.

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 ownerloperator.

_._park Arrester Screen

eat Shield

.

Remove four screws that attach spark attester

screen.

3.

inspect screen and replace if torn, perforated or
othepMse damaged. DO NOT use a defective
screen. If screen is not damaged, clean it with

commercial solvent.

4. Reattach screen and muffler guard.

Air Cooming 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 13). Equally
important is to keep top of engine free from debris.

See "Generator Cleaning".

C[ AN

15

Thegeneratorshouldbestartedatleastonceevery
sevendaysandallowedtorunatleast30minutes.If
thiscannotbedoneandyoumuststoretheunitfor
morethan30days,usethefollowinginformationasa
guidetoprepareitforstorage.

Long Term Storage _nstructions

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 fuel 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:

WARNING

WHEN STORING FUELOR EQUIPMENTWITH FUEL IN
TANK

Store away fromfurnaces, stoves, water heaters, clothes

dryers or other appliances that havepilot light or other
ignition source because they can ignite fuel vapors.

WHEN DRAiNiNG FUEL

Turn generator OFF and let itcool at least 2 minutes

before removing fuel cap. Loosen cap slowly to relieve
pressure intank.

Drain fuel tank outdoors.

Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources,

DO NOT light a cigarette or smoke.

Protect Fuet System

1. Remove all gasoline from fuel tank to prevent gum
deposits from forming on these parts and causing

possible malfunction of engine.

2. Run engine until engine stops from lack of fuel.

Change OH

While engine is still warm, drain oil from crankcase.

Refill with recommended grade.
OHCylinder Bore

• Remove spark plug and pour about 1 ounce (30ml)
of clean engine oil into the cylinder.

• Install spark plug and crank slowly to distribute oil.

WARNING

NEVER crank enqine with spark plug removed,

Generator

1. Clean generator as outlined in "Generator Cleaning".

2. Check that cooling air slots and openings on
generator are open and unobstructed.

Other Storage Tips

1. DO NOT store fuel from one season to another.

2. Replace fuel can if it starts to rust. Contaminated
fuel will cause engine problems.

3. If possible, store unit indoors and cover it to give
protection from dust and dirt. BE SURE TO

EMPTY FUEL TANK.

4. Cover unit with a suitable protective cover that
does not retain moisture.

WARNING

DO NOT place a storage cover over a hot generator.
Let equipment coo! for a sufficient time before placing

the cover on the equipment.

.

Store generator in clean, dry area.

16