Craftsman 580.325610 User Manual

Operator'sManual

®

HOURS: Man. =Fri. 8 a.m. to 5 p.m. (CT)

WARNING

Before usingthis product, readthis

manualand foiiow ali Safety Rules

and Operatinginstructions.

Sears, Roebuck and Co., Hoffman Estates, JL 68179 U.S.A.

Visit our Craftsman website: www.craftsman.cem

Part No. 198451GS Draft F (04/09/2007)

Antes de utiiizar et producto, iea este

ADVERTENCIA

manualy siga todas las Reglasde

Seguridade Instrucciones de Uso.

® Safety
,, Assembly

,, Operation
,, Maintenance

® Parts

® Espa_oi, p. 36

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

SAFETYRULES ............................... 3-5

FEATURESAND CONTROLS....................... 6

ASSEMBLY................................... /-9

OPERATION................................ 1O-f3

SPECIFICATIONS............................... 14

MAINTENANCE.............................. 15-18

STORAGE .................................... 19

TROUBLESHOOTING............................ 20

NOTES .................................. 21 & 33

SCHEMATIC/WIRiNGDIAGRAM ................ 22-23

REPLACEMENTPARTS ....................... 24°32

EMISSIONSSYSTEMWARRANTY............... 34-35

ESPANOL.................................. 36°59

HOWTOORDERPARTS ................. BACKPAGE

One-Year FuMMWarranty on Craftsman Generator

If this generator fails dueto a defectin materiai or workmanship within oneyear from the dateof purchase,return it to any
Searsstore, other Craftsmanoutlet, or Sears Parts & RepairCenter in the United States for free repair (or replacementif
repair proves impossible).

Additional One-YearLimitedWarranty on Craftsman Generator

Forthe second year from the dateof purchase, if any part ofthis generator faiis dueto adefect in material or workmanship, a
new part wiii be supplied free of charge. You must paythe labor cost if you wish to haveit installed.

Atiwarranty coverageappiiesfor only 90 days from date of purchase if this generator is usedfor commercial or rental
purposes. Oncea generatorhas experiencedcommercial or rental use, it shall thereafter beconsidered a commercial or rental
generatorfor the purpose of this warranty.

This warranty gives you specific legal rights, and you may atso have other rights which vary from state to state.

© SearsBrands, LLC

Sears, Roebuck and Ca., D/817WA, Haffman Estates, _L60179 U.S.A.

This isthe safety alert symbol, tt isused to alert youto potential personalinjuryhazards.
Obeyall safety messages that fallow this symbamto avoid passibleinjuryor death.

ii_!-j_j Read this manual carefui(y and become familiar

with your generator. }(now its applications, its

(imitations, and any hazardsinvolved.

Thesafety alert symbol (_) is used with a signal word

(DANGER,CAUTIOr/,WARNIr/G), a pictorial and/or a safety

messageto alert you to hazards.BANGERindicatesa hazard
which, if not avoided, wi/fresult in deathor serious injury.
WARNINGindicates a hazardwhich, if not avoided, could

result in death or serious injury. CAUTIONindicatesa hazard
which, if not avoided, might resuIt in minor or moderate
injury. CAUTION,when usedwithout the alert symbol,
indicatesa situation that could result in equipment damage.

Foiiowsafety messagesto avoid or reducethe risk of injury
or death.

WARNING

The engine exhaust from this productcontains chemicals

known to the State of California to cause cancer, birth

defects, or other reproductive harm.

Hazard Symheis and Nteanings

DANGFR

Contentsare HARMFULORFATALiF
SWALLOWED.Avoid contact to eyes, skin or

clothing. DOriOTtake internaIiy. Avoid breathing
the mist or vapor. Overexposureto eyesor skin
cancause irritation. Keepstabiiizer out of the

reachof children.
Fuelstabilizer is a hazardouschemical/*

®

FreshStartTM fuelcapisdesignedto holdacartridgewhich
containsfuelstabilizer.

• IfSWALLOWEDcallphysicianimmediately.DONOTinduce
vomiting.If inhaledremovetofreshair. Incaseofeyeorskin

contacLflushwithwaterfor 15minutes.

o Storeunopenedcartridgesina cool,d% wellventilatedarea.

Keepopenca!tridgeinfuel cap,andfuel capclosedonfueltank
whennotin use.

o Inthecaseofanemergency,contacta physicianimmediately

andcall1-800-424-9300forrnateria!safetyinformation.

• *Fuel stabilizer contains: 2,6-di-tret-butylphenol (128=39-2) and aliphatic petroleum
distillate (64742-47-8).

Using a generator indoors CAN KiLL YOU iN MINUTES,
Generator exhaust contains carbon monoxide, This is

a poison you cannot see or smemmo

A =Explosion

B =Fire
C=ElectricShock
D=ToxicFumes
E=Kickback

F =Hot Surface

G =Flying Objects

H =Moving Parts
J =HazardousChemical

K =ReadManual

NEVER use inside a home
or garage, EVEN mF doors

and wiedows are open,

Only use OUTSIDE and
far away from windows,
doors, and vents,

WARNSNG

Running enginegives off carbon monoxide,an
odorless,colorless, poison gas.

Breathingcarbon monoxide cancause headache,
fatigue, dizziness,vomiting, confusion, seizures,
nausea,fainting or death.

o OperategeneratorONLYoutdoors.

• Installabatteryoperatedcarbonrnonoxideahrrn nearthe
bedroorns.

• Keepexhaustgasfromenteringa confinedareathrough
windows_doors,ventilationintakes,or otheropenings.

• DONOTstartor runengineindoorsorin anenclosedarea,
(evenifwindowsanddoorsareopen) includingthe generator
compa!tmentof arecreationalvehicle(RV).

WARNING

3enerator produces hazardous voltage.
Faiiure to isoiate generator from power utiiity can

result in death or injury to etectric utiiity workers
due to backfeed of electrical energy.

• Wben using generator for backuppower_notify utility company.
Use approvedtransfer equipment to isolate generator frorn
electric utility.

• Use a ground fault circuit interrupter (GFCI)in any damp or
bigbly conductive area, such as metaldeckingor steel work.

• DO NOTtouch barewires or receptacles.

o DO NOTuse generator with ebctrical cordswhich are worn,

frayed, bareor otherwise damaged.

• DO NOToperate generator in the rain or wet weather.

• DO NOTbandle generator or ebctrica! cords while standing in
water, while barefoot, or wbile hands or feet are wet.

• DO NOTallow unqualified persons or children to operate or
servicegenerator.

WARNING

Contactwith muffler areacan result in serious
burns.

Exhaustheat/gases can ignite combustibles,

structures or damagefuel tank causing a fire.

DONOTtouch hot parts and AVOIDbot exhaustgases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearanceon all sides of
generator including overhead.

• Codeof FederalRegulation (CFR) Title 36 Parks,Forests,and
Public Property require equipment poweredby an internal
combustion engineto have a spark arrester, rnaintainedin
effectiveworking order, complying to USDAForest seP,dce

standard 5100-10 or laterrevision. Inthe Stateof California a
spark arrester is required under section 4442 of the California

Public resourcescode. Otherstates may havesimilar laws.

WARNING

Starter and other rotating parts can entangie
hands, hair, ciothing, or accessories.

• NEVERoperate generator without protective housing or covers.

o DO NOTwear loose c!othing, jewelry'or anythingthat may'be

caught in the starter or other rotating parts.

o Tie up long hair and removejewelry'.

WARNING

Starter cord kickback (rapid retraction) can result
in bodiiy injury. Kickback wiii puff hand and arm

_< toward engine faster than you can bt go.

Broken bones, fractures, bruises, or sprains
could result.

• When starting engine, pull cord slowly until resistanceis felt and
then pull rapidly'to avoid kickback.

• NEVERstart or stop enginewith electrica!devices plugged in
andturned on.

WARNING

Fuel and its vapors are extremely flammable and

explosive.

Fire or explosion can cause severe burns ordeath.

WNENADDING ORDRA_NINGFUEL
o Turn generator OFFand let it cool at least2 rninutes before

removing fuel cap.Loosen cap slowly to re%ve pressure in
tank.

• Fill or drain fuel tank outdoors.

o DONOToverfill tank. Allow space for fuel expansion.

• Iffue! spills, wait until it evaporates before starting engine.

o Keep rue!awayfrom sparks_open flames, pilot lights, beat,and

other ignition sources.

o DONOTlight acigarette or smoke.
WHENSTARTBNGEQUIPMENT

• Ensure sparkplug_muffler, fue!cap, and air charier are in place.

o DONOTcrank enginewith sparkplug removed.
WNENOPERATmNGEQUmPLNIENT

• DONOTtip engine or equipment at anglewbich causesfuel to
spill.

o This generator is not for usein rnobileequipment or rnarine

applications.

WNENTRANSPORTINGORREPAIRmNGEQUmPI_IENT

• Transport/repair witb fuel tank EMPTYor with fuel shutoff valve
OFF.

• Disconnect spark plug wire.

WNENSTORmNGFUELOR EQUmPIVlENTWITH FUEL iN TANK
o Store away'from furnaces, stoves,water heaters,clothes dryers,

or otherappliances that bavepilot light or other ignition source
becausethey can ignite fuel vapors.

WARNING

This generator does not rneetU. S. CoastGuard Regulation
33CFR-183and should not beused on rnarineapplications.

Failureto usethe appropriate U. S. CoastGuard approved
generator could result in death or serious iniury and/or
property damage.

WARNING

Unintentionaisparking can result in fire or

electric shock.

WHENADJUSTINGOR[VIAKINOREPAIRSTOYOURGENERATOR
, Disconnectthesparkplugwirefromthe sparkplugandplace

thewirewhereit camotcontactsparkplug.

WHEN TESTINGFOR ENGINESPARK

• Useapprovedsparkplugtester.
o DONOTcheckforsparkwithsparkplugremoved.

CAUTION

Excessively high operating speeds increase risk of injury
and damage to generator.

Excessively low speeds impose a heavy load.

DO NOTtamper with governed speed.Generatorsupplies
correct rated frequency and voltage when running at governed
speed.

DO NOTmodify generator in anyway.

NOTICE

Exceeding generators wattage/amperage capacity can
damage generator and/or eiectricai devices connected to it.

DONOTexceedthe generator's wattage/amperage capacity, See
Don't OverloadGeneratorin the Operationsection.

Stat generator and letengine stabilize before connecting
ebctrical loads,

Connectebctrical loads in OFFposition, thenturn ONfor
operation.

Turn electrical loads OFFand disconnect from generator before
stopping generator.

NOTICE

Improper treatment of generator can damage it and
shorten its iife.

Use generator only for intended uses,

Ifyou havequestions about intended use,ask dealeror contact

local service center.
Operategenerator only on level surfaces.

DONOTexpose generator to excessivemoisture, dust, dirt, or
conosive vapors.

DONOTinsert any obiectsthrough cooling slots.

Ifconnected 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.

KNOWYOURGENERATOR

_Read the operator's manaamand safety rules before operatingyour generator,

Comparethe illustrations with your generatorto familiarize yourself with the locations of various controls and
adjustments. Savethis manual for future reference.

A =120 VoltAC,20 Amp, DuplexReceptacles-- May be

usedto supply electricaI power for the operation of
120 Voit AC, 20 Amp, single phase,60 Hzeiectricat,

lighting, appliance,tooi, and motor loads.

B =120/240VoltAC, 30Amp LockingReceptacle-- May be

usedto supply electricai power for the operation of
120 and/or 240 Voit AC, 30 Amp, single phase, 60 Hz

electrical, lighting, appliance,toot and motor ioads=

C- Air Cleaner -- Protects engine by filtering dust and

debris out of intake air.

D - Choke Lever -- Usedwhen starting a cold engine.
E - Data Tag -- Provides model, revision, andserial number

of generator. Pleasehavethese readily available when

calling for assistance.

F= DoablePoleCircuit Breaker(AC)-- A doublepole

circuit breaker is providedto protect ali the receptacies
and generatoragainst electrical overload.

G - Engine Identification -- Provides model, type and code

of engine. Pleasehavethese readily availableif calling for
assistance.

H =Fuel Tank -- Capacityof five (5) U.S.gallons (18.9 L).

J - Fael VaNe -- Usedto turn fuel supply on and off to

engine.

K =Groanding Fastener -- Consuityour iocai agency having

jurisdiction for grounding requirements in your area.

L - Oil Drain Plag -- Drain engine oii here.

Ni- Oil Fill Cap -- Checkand fiii engine with oii here. See

Offin Maintenancefor oil recommendations and filling

instructions.

N =ReooiJStarter -- Usedto start the engine.
P - Rocker Switch -- Setthis switch to "On" before using

recoii starter. Setswitch to "Off" to stop engine.

R =Spark Arrestor I_]affier -- Exhaustmuffler lowers engine

noise and is equippedwith a spark arrestor screen,

S - StatBtationTM -- Dispiaysthe nominat load on generator

basedon output frequency. It also has a built in
maintenancereminder.

YourCraftsmangeneratorrequiressomeassemblyandis

readyforuseonlyafterithasbeenproperlyservbedwiththe
recommendedoilandfuel.

tfyouhaveanyprobbmswiththeassemMyofyour
generator,please call the generater heb]ine at

1-80e-222-3136.

Unpacking the Generater

1. Set the carton on a rigid fiat surface.

2. Removeeverything from carton exceptgenerator.

3. Opencarton completely by cutting eachcorner from top
to bottom.

4. Leavegenerator on carton to install wheel kit.

Carten Centents

CheckalIcontents against those listed below:
o Main unit

o Engineoii
o Operator's manuai

Wheel kit

o Adapter cord set

If any parts are missing or damaged,call the generator

helpline at 1=800=222=3136.

nstall Wheel Kit

NOTE:Wheel kit is not intended for over-the-road use. DO

NOTtow this unit with a motorized vehicte.

You wiii needthe following tools to install these
components:

o 13ramwrench
o Socketwrench with a 13ram socket
o Pliers

o Safetygtasses

Install the Wheel }(it as Folbws:

1. Tip generatorso that engine end is up.

2. Slide axle (A) through both mounting brackets.

3. Placea wheel (B) on each side as shown.

4. Macea washer (C)on axieand then place an e-ring (g)
in axlegroove.

5. InstalI e-ring with pliers, squeezingfrom top of e-ring to
bottom of axle.

CAUTION

E-rings cancause eyeinjury.
E-rings canspring backand become airborne

when installing or removing.

• Alwaysweareyeprotectionwheninstalling/removinge-rings

6. Repeatsteps 4 and 5 to securesecond wheei.

7. Tip generatorso that engine side is down.

8. Line up holes in support leg (E) with holes ingenerator
frame.

9. Attach support ieg using two short capscrews (MS x
16 ram) (F) and two iocking hex nuts (G).Tighten with

a 13 mm socket and wrench.

10. Returngenerator to normat operating position (resting
on wheels and support leg).

BEFORESTARTINGTHEGENERATOR

Add Engine Oil

1. Place generator on a levelsurface.

2. Cleanareaaround oii fiii and removeyellow oii fiii cap.

NOTE:Seethe section Oi/to reviewoii recommendations.
Verify provided oii bottie is correct viscosity for current

ambient temperature.

3. Using oil funne! (optional), slowly pour entire contents
of provided oil bottle (26 oz.) into oil fill opening.

NOTICE

improper treatment of generator can damage it and
shorten its iife.

DONOTattempttocrankor startthe enginebeforeit hasbeen
properlyservicedwiththerecommendedoil.Thismayresultin
anenginefailure.

4. Replaceoil fill cap and fuIly tighten.

AddFuel

Fuel must meet these requirements:

o Clean,fresh, unleadedgasoline.
° A minimum of 87 octane/87AKi (91 RON).Highaltitude

use, see High-A/titude.

° Gasoiinewith up to 10% ethanol (gasohoi) or up to

15% MTBE(methyl tertiary butyl ether) is acceptable.

NOTICE

Avoid generatordamage.
Faiiureto foilow Operator's Manuaifor fuel

recommendations voids warranty.

DONOTuseunapprovedgasolinesuchasE85.
DONOTmixoil in gasoline.
DONOTrnodifyengineto runonalternatefuels.

WARNING

Fueland its vapors are extremely flammable and

explosive.

Fireor explosion can cause severe burns or

death.

WHENADDINGFUEL
o TurngeneratorOFFandletitcoolatleast2 rninutesbefore

removingfuelcap.Loosencapslowlyto relievepressurein
tank.

* Fillfue!tankoutdoors.
o DONOToverfilltank.Allowspaceforfuelexpansion.

* Iffue!spills,waituntil it evaporatesbeforestartingengine.
o Keepfuelawayfromsparks_openflames,pilot lights,heat,and

otherignitionsources.

o DONOTlight acigaretteor smoke.

To protect the fuei system from gum formation, mix in a fuel
stabiiizer when adding fuel. See Storage.AJifuel is notthe
same. if you experiencestarting or performance probiems
after using fuel, switch to adifferent fuei provider or change

brands. This engine is certified to operate on gasoline. The

emission controi system for this engine is EM (Engine

Modifications).

1. Cleanareaaround fuei fiii cap, removecap.

2. Slowly add unieadedgasoline (A) to fuei tank (B). Be
careful not to overfill. Allow about 1.5"(4 cm) of tank

space (C) for fuel expansion.

3. Instali fuei cap and let any spifled fuel evaporate before
starting engine.

CAUTISN! Alcohol-blendedfuels (calledgasohoI,ethanol or
methanol) can attract moisture, which ieads to separation and
formation of acids during storage, Acidic gas can damagethe
fuei system of an enginewhiie in storage,

Toavoidengineproblems,thefuel system should betreated
with a fuel preserver or emptied beforestorageof 30 daysor
longer,if adding a fuel preserver, fiii the fuel tank with fresh
fuel. if only partialiy tiffed, air in the tank wiii promote fuel
deterioration during storage, if fuei preserver is not used,
drainthe fuel tank, start theengineand let it run untiithe fuel
linesand carburetorareempty. Usefresh fuelnext season.See
Storagefor additionaiinformation.

NEVERuseengine or carburetor cleaner products in the fuel

tank as permanent damagemay occur.

Fresh StarlTM Fuel Cap
Adding fuel preserver helps keepfuei fresh and carburetors

cieanfor easier starting, ali season iong. This new fuel cap
automatically drips concentrated fuel preserver into your fuel

tank.

3. Removetab to expose membrane.

)

IMPORTANT:DONOTremove the silver foil seal on the
opposite side.

4. Reinstallfuei cap on fuel tank.

_/////i_V/b;

contact to eyes,skin or c!othing. DONOTtake
internaiiy.Avoid breathingthe mist or vapor.
Overexposureto eyesor skin can causeirritation.
Keepstabilizerout of the reach of chiidren.

Fueistabiiizer is a hazardouschemical.**

If SWALLOWED,callphysicianimmediately.
h_thecaseof anemergency,contacta physicianimmediately

andcall1-800-424-9300for materialsafetyinformation.

*Fuel stabilizer contains: 2.6-di-tret-butylphenol (128-39-2) and aliphatic petroleum

distillate (64742-47-8),

1. Place cartridge into fuel cap.

2. Push to "snap" cartridge into place.

5. Periodicaliy check the cartridge to ensurethere is stiil
fuel preserver inside. If it is empty, removecartridge
and replace.

At altitudes over 5,000 feet (1524 meters), a minimum

85 octane / 85AKI (89 RON)gasoline is acceptable.To
remainemissions compiiant, high aititude adjustment is
required. Operationwithout this adjustment wiii cause

decreasedperformance, increasedfuel consumption, and

increasedemissions. Seea qualified Searsdealerfor high
altitude adjustment information. Operationof the engine at
altitudes below 2,500 feet (762 meters)with the high altitude

kit is not recommended.

HOWTOUSEYOURGENERATOR

If you haveany problems operatingyour generator after
readingthe manual, pleasecall the generator helpiine at

1o800o222o3136.

System Ground

Thegenerator hasa system ground that connects the
generatorframe components to the ground terminals onthe

ACoutput receptacbs. Thesystem ground is connectedto
the ACneutral wire (the neutral is bonded to the generator
frame),

Special Requirements
Theremay be Federator StateOccupationalSafetyand

HealthAdministration (OSHA)regulations, local codes, or

ordinancesthat appiyto the intended useof the generator.

Pieaseconsult a quaiifbd eiectrician, electrical inspector, or

the local agency having jurisdiction.
, In some areas,generators are requiredto be registered

with iocai utiiity companies.

o If the generator is usedat aconstruction site, there may

be additional regulations which must be observed.

Cennecting te a Building's Electrical System

Connectionsfor standby power to abuiiding's electrical
system must bemadeby a quaiified electrician. The
connection must isoiatethe generator power from utiiity
power, and must comply with alI appficabb laws and

electrbaI codes.

Generater Lecatien

Generater Clearance

WARNING

_,_5 Exhaustheat/gases can ignite combustibles,

structures or damage fuel tank causing a fire.

Keepatleast5 ft. (1.5rn)clearanceonall sidesof generator
includingoverhead.

Macegenerator outdoors in an areattsatwiii not accumuiate

deadiyexhaustgas. DONOTpiacegenerator whereexhaust
gas (A) couid accumulate and enter inside or be drawn into a

potentialiy occupied buiiding. Ensure exhaust gas is kept
away from any windows, doors, ventiiation intakes, or other

openingsthat can ailow exhaust gas to coiiect in a confined
area. Prevaiiingwinds and air currents shouid be taken into

consideration when positioning generator.

Using a generator indoors CAN KiLL YOU mNMINUTES,
Generator exhaust contains carbon monoxide, This is

a poison you cannot see or smell,

WARNING

3enerator produces hazardous voltage.

_¢ aiiure to isoiate generator from power utiiity can

• Wher_using generator for backuppower, notify utility company

• Use a ground fault circuit interrLipter(GFCI)in any damp or

• DO NOTtouch barewires or receptacles

o DO NOTuse generator with ebetrical cords which areworn,

• DO NOToperate generator in the rain or wet weather

• DO NOThandle generator or ebctrica! cords while standing in

• DO NOTallow Lmqualifiedpersons or children to operate or

result in death or injury to electric utility workers
due to backfeed of electricai energy.

Use approvedtralssfer equipment to isolate generator frorn
electric utility

highly conductive area, such as metaldeckingor steel work.

frayed bareor otherwise damaged.

water, while barefoot, or while hands or feet are wet

servicegenerator.

Only use OUTSIDE and
far away from windows,
doors, and vents,

10

To Start The Engine

DisconnectatI ebctricai loadsfrom the generator. NEVER
start or stop engine with electricai devices piugged in and
turned ON. Foilow start instruction steps in numerical order:

1. Make sure unit is on a ieveisurface.

iMPORTANT:Failureto start and operateunit on a level
surfacewiii cause the unit not to start or shut down during
operation.

2. Turn redfuei vaiveto "On" position.

3. Placechoke lever in "Choke" position.

4. Set rocker switch to "Off' position.

WARNING

Contactwith muffler areacan result in serious
burns.

_ Exhaustheat/gases can ignite combustibies,

structures or damagefue! tank causing a fire.

o

DONOTtouch hotpartsandAVOIDhotexhaustgases.

®

Allowequipmentto coolbeforetouching.

o

Keepatleast5 feet(1.5m) of clearanceonall sidesof
generatorincludingoverhead.

Codeof FederalRegulation(CFR)Title36 Parks,Forests,and
PublicPropertyrequireequipmentpoweredbyaninternal
combustionengineto haveasparkanester,maintainedin
effectiveworkingorder,complyingto USDAForestservice

standard5100-1Cor laterrevision.IntheStateofCaliforniaa
sparkarresterisrequiredundersection4442ofthe CaBornia

Publicresourcescode.Otherstatesrnayhavesimilarlaws.

Connecting Electrical Loads

* Letthe engine stabiiizeand warm up for a few minutes

after starting.
o DONOTconnect240Voltloadsto 120Voitreceptacbs.
* DONOTconnect 3-phase ioadsto the generator.
o DONOTconnect 50 Hzioads to the generator.

o Mug in and turn on the desired 120 Volt AC, singie

phase,60 Hertzeiectricai ioads.

o DONOTOVERLOADTHEGENERATOR.SeeDon't

OverloadGenerator.

5. Grasprecoil handleand pulI slowly until slight
resistance is felt. Then pull rapidty to start engine.

WARNING

Startercord kickback(rapid retraction) can result
n bodiiy injury. Kickbackwiii puli handand arm
toward engine fasterthanyou can bt go.

Brokenbones, fractures, bruises, or sprains
sould result.

• Whenstartingengine,pul!cordslowlyuntil resistanceisfelt and
thenpullrapidlytoavoidkickback.

o NEVERstartorstopenginewith ebctricaldevicespluggedin

andturnedon.

t_IPORTANT:If enginefloods, place choke lever in "Rue"
position and crank untii engine starts.

6. Move choke iever to "Rue" position a short distanceat
a time over severaiseconds in warm weather or

minutes in cold weather.Let engine run smoothly
before eachchange.Operatewith choke in "Rue"
position.

NOTE:if engine starts after 3 pulls but faiis to run, or if unit
shuts down during operation, makesure unit is on a level
surfaceand checkfor proper oii ieveI in crankcase.This unit
may beequipped with a iow oii protection device. If so, oil
must be at proper level for engineto start.

NOTICE

Exceedinggeneratorswattage/amperagecapacitycan
damagegenerator and/or ebctricaI devicesconnected to it.

DONOTexceedthe generator'swattage/amperagecapacity.See
Don?OverloadGeneratorinthe Operationsection.

Startgeneratorandletenginestabilizebeforeconnecting
electricalloads.

ConnectebctricalloadsinOFFposition,thenturn ONfor
operation.

TurnelectricalloadsOFFanddisconnectfromgeneratorbefore
stoppinggenerator.

Stopping the Engine

1. Turn off and unpiug ati eiectricai ioads from unit.
NEVERstart or stop enginewith ebctricat devices
ptuggedin andturned on.

2. Letengine run at nooioadfor two minutesto stabilize
unit's internal temperatures.

3. Move rocker switch to "Off" position.

i wAR. .G

Backfre,fire or engine damagecould occur.

Io DONOTstopenginebymovingchokeleverto "Choke"position.

4. Move fuel valveto "Off" position.

11

CSBDSETSANDRECEPTACLES

Useonty high quality, welPinsulated, grounded extension

cords with the generator's 120 Volt electrical receptacles.

Inspectextension cords before eachuse.

Checkthe ratings of aii extensioncords beforeyou usethem.

Extensioncord sets used should be rated for 125Voit AC

loads at 20 Amps or greater for most electrical devices.
Some devices,however, may not require this type of
extensioncord. Checkthe operator's manuals of those

devicesfor the manufacturer's recommendations.

Keepextensioncords as short as possible, preferably Iess
than 15 feet iong, to prevent voltage drop and possible
overheating of wires.

WARNING

Overloadedelectrical cords can overheat,arc,
and burn resulting in death, bodily injury, and/or

property damage.

* ONLYusecordsratedforyour loads.
o Followallsafetiesonebctricalcords.

128/248 VeJt AC, 38 Amp, Locking Receptacle

Usea NEMAL14-30 piug with this receptacle.Connecta
4-wire cord set ratedfor 250 Voit ACioadsat 30 Amps (or
greater). You can usethe same4-wire cord if you plan to

run a 120 Volt load.

4-WheCordSet

J

128 Volt AC, 28 Amp, #uplex Receptacles

Eachduplex receptacleis protected against overload by a
double pole rocker switch circuit breaker.

Useeach receptacieto operate120 Volt AC,singb-phase, 60
Hzelectrical loads requiring upto 2,400 watts (2.4 kW) at 20

Amps of current. Usecord sets that are rated for 125 Volt AC

loadsat 20 Amps (or greater).

BENERAT{)RADAPTER CORD SET

Thegenerator comes with a 25' generatoradapter cord set

designedto provide two sets of 120 Voit, 20 Amp outiets

from one 120 Volt, 20 Amp dupiex receptacle.

(Neutral)

Y (Hot) | X (Hot)

NEMAL14-30 /-7L7 Ground(Green)

This receptaclepowers 120/240 Volt AC, 60 Hz,single phase
loads requiring up to 5,600 watts of power (5.6 kW) at

23.3 Amps for 240 Volts or two independent 120Voit ioads
at 23.3 Amps each. Theoutbt is protected by a double pole

rocker switch circuit breaker.

NOTICE

Receptaclesmay be marked with rating vaiue greater than
generatoroutput capacity.

NEVERattemptto poweradevicerequiringrnoreamperage

thangeneratoror receptaclecansupply,

DONOToverloadthegenerator,SeeDon'tOverloadGenerato,_

The maximum load on eachouttet is 20 Amps. The maximum
totai ioad on both biack wire outiets or white stripe wire

outiets is 20Amps.
NOTE:Foliowaii safety precautions when connecting any

extension cord or deviceto the generator.

12

DON'TOVERLOADGENERATOR

Capacity

You must make sureyour generator cansupply enough rated

(running) and surge (starting) watts for the items you will
power at the sametime. Foliowthese simple steps:

1. Selectthe items you wiii 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

keepyour items running.

3. Estimate how many surge (starting) watts you wiii need.
Surge wattage isthe short burst of power neededto

start electric motor-driven toois or appliancessuch as a
circular saw or refrigerator. Becausenot aii motors start

atthe sametime, totai surge watts can be estimated by
adding onlythe item(s) with the higilest additional

surge watts to the total ratedwatts from step 2.

Example:

Tool or Appliance
Window Air

Conditioner
Refrigerator
Deep Freezer

Television
U,ht _75 Watts'

Rated

(Running) Watts

1200

8OO
5O0
50O

75

3075 Total

Running Watts

Total Rated(Running) Watts

HighestAdditional Surge Watts
Total Generator Output Required
NOTE:The rated (running) watts cannot exceed5600. Also,

giventhe 5600 watt rated iimit, additional surge (starting)
watts cannot exceed8600.

Pewer Management
To prolong the iife of your generator and attacheddevices, it

is important to take carewhen adding electrical loads to your
generator. There shouid be nothing connectedto the
generator outlets before starting it's engine.Thecorrect and
safe way to managegenerator power is to sequentiallyadd

loads asfollows:

1. With nothing connectedto the generator, start the
engine as describedin this manual.

2. Hug in and turn on the first ioad,preferably the largest
load you have.

3. Permit the generatoroutput to stabiiize (engineruns
smoothly and attached deviceoperates properly).

Additional Surge

(Starting) Watts

1800

1600

5OO

1800 Highest

Surge Watts

=3075
= 1800

=4875

4. Hug in and turn onthe nextioad.

5. Again, permit the generatorto stabiiize.

6. Repeatsteps 4 and 5 for each additional load.

NEVERadd more loadsthan the generator capacity. Take

speciai care to consider surge loads in generator capacity, as

describedabove.

Additional

Watts

Tool or Appliance

Essentials

L_ht Bulb - 75 watt

Deep Freezer

Sump Pump
Refrigerator/Freezer- 18 Cu. Ft.

Water Well Pump- 1/3 HP

Rated*

(Running) Surge

Watts (Starting)

75
500 500
800 1200
800 1600

1000 2000

Heating/Cooling
Window AC - 10,000BTU
Window Fan

Furnace Fan Blower- 1/2 HP

1200 1800

300 600
800 1300

Kitchen
Microwave Oven- 1000Watt
Coffee Maker

Electric Stove - Sinqle Element
Hot Plate

Family Room
DVD/CD Player

VCR
Stereo Receiver
Color Television - 27"

Personal Computer w/17"

1000
1500
1500

2500

100
100
45O
50O
8O0

monitor
Other

Security Svstem
AM/FM Clock Radio

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

180
30O

480 520

4000

Gallon
DIY/Job Site

Quartz HaloqenWork Light
Airless Sprayer- 1/3 HP

Reciprocating Saw
Electric Drill- 1/2 HP

Circular Saw- 7 1/4"
Miter Saw- 10"

Table Planer- 6"
TableSaw/RadialArmSaw- 10"

Air Compressor - 1-1/2 HP

*Wattages listed are approximate0nly,

1000

600 1200
960 960

1000 1000
1500 1500
1800 1800

1800 1800
2000 2000
2500 2500

Checktool or

appliancefor actual wattage.

13

ENGINETECHNICALiNFORMATiON

This is a single cylinder, overheadvalve(OH\/), air cooled
engine, it is a iow emissions engine.

Inthe Stateof Caiifornia, Model200000 enginesare certified
by the California Air Resources Boardto meet emissions
standardsfor 250 hours. Such certification does not grant
the purchaser, owner or operator of this engine any
additiona] warranties with respectto the performance or
operational iife of this engine.Theengine is warranted solety
according to the product and emissions warranties stated

elsewherein this manual.

Power Ratings

Thegross power rating for individuai gas engine models is
labeledin accordancewith SAE(Society of Automotive

Engineers)code J1940 (Small Engine Power & Torque

Rating Procedure),and rating performance has been
obtained andcorrected in accordancewith SAEJ1995

(Revision2002=05).Torque values are derived at 3060 RPM;
horsepower values are derivedat 3600 RPM. Actuai gross
engine power wiii be lower andis affected by, among other
things, ambient operating conditions and engine-to-engine

variability. Givenboth the wide array of products on which
enginesare piaced and the variety of environmentai issues

appiicabteto operatingthe equipment, the gas engine wiii not
developthe rated gross power when used in a given pieceof
power equipment (actual "on-site"or net power). This

difference is due to a variety of factors including, but not
limited to, accessories (air cleaner, exhaust,charging,

cooling, carburetor, fuel pump, etc.), appiication iimitations,
ambient operating conditions (temperature,humidity,
altitude), and engine-to-engine variabiiity. Due to

manufacturing and capacity iimitations, Briggs & Stratton

maysubstitute anengine of higher rated power for this
Seriesengine.

PRODUCTSPECiFiCATiONS

Generator $pe¢ificatiens

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

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

ACVoltage ........................... 120/240 Volts

AC Current

at 240 Volts ........................... 23.3 Amps

at 120 Volts ........................... 46.6 Amps

Frequency ........................ 60 Hzat 3600 rpm

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

FuelCapacity ......................... 5 U.S.gailons

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

EngineSpecifications

Sore .............................. 3.12 in. (79mm)

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

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

SparkPlug

ResistorType: ............. Briggs & Stratton 491055S

Long Life Piatinum: .......... Briggs & Stratton 5066D

SetGapTo: ................... O.030inch(0.76ram)

Armature Air Gap: ........ 0.008-0.012 in. (O.20-O.30mm)

Valveclearancewith valvesprings installed and piston 1/4 in.

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

Intake ................. 0.004-0.006 in. (0.10=0.15mm)

Exhaust ............... 0.004-0.006 in. (0.10=0.15mm)

OiICapacity .................... 28 Ounces(0.8 Liters)

NOTE:For practical operation, the generator load should not
exceed 85% of rated wattage. Enginegross horsepower wiii

decrease3-I/2% for each 1,000feet (300 meters) above sea

leveland 1% for each 10° F (5.6° C)above 77° F (25° C). It
shouid operate satisfactorily at an angie up to 15°,

14

MAINTENANCESCHEDULE

Foiiowthe hourly or calendarintervals, whichever occurs first=
Morefrequent service is required when operating in adverseconditions noted beiow.

MAINTENANCESgNEDULE

FILL IN DATESAS YOU COMPLETE

REGULARSERVICE

MAINTENANCETASK

Checkoil level
Cleandebris

Change engine oil
Service air cleaner

Service spark plug
Service spark arrester

Cleancooling system
Preparefor storage

1 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,

2 Replace more often under dirty or dusty conditions,

Before j Every25 Hours Every50 Hours Every 100 Hours

EachUse J or Yearly or Yearly orYearly

×

X

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

GENERALBECOMMENDATIONS

Regularmaintenancewill improve the performanceand
extendthe iife of the generator. Seeany Sears or other
qualified dealerfor service.

Thegenerator's warranty does not cover items that have
been subjected to operator abuseor negligence.To receive

SERVICEDATES

X1

X2

X
X

X2

NOTE:DO NOTusea garden hose to cleangenerator. Water
can enterthe engine fuel system and causeproblems, in
addition, if water enters the generator through cooiing air

slots, some of the water wiii be retained in voids and cracks
of the rotor and stator winding insulation. Water and dirt

buiidup on the generator internai windings wiii eventually
decreasethe insuiation resistance of thesewindings.

fuiI vaiuefrom the warranty, the operator must maintain
generatoras instructed in this manual

Someadjustments wili needto bemadeperiodically to
properly maintain your generator.

AtI service and adjustments should be made at least once
eachseason.Follow the requirementsin the Maintenance

Schedulechart above.
NOTE:Oncea year you should clean or replace the spark

ptug and repiacethe air filter. A new spark plug and clean air
fiiter assure proper fuel-air mixture and help your engine run

Generater Cleaning

Daiiy or before use,ctean accumuiated debris from

generator. Keepiinkage,spring and controts clean. Keeparea
around and behind muffler free from anycombustibie debris=

Inspect cooiing air siots and openings on the generator=

Theseopenings must be kept ctean and unobstructed.
Generatorparts shouid be kept cleanto reducethe risk of

overheating and ignition of accumulated debris.
o Usea damp cloth to wipe exterior surfaces clean.

better and last longer.

EMISSIONSCONTBOL

Maintenance,replacementor repair of the emissions control
devicesand systems may be performed by any non-road
engine repair establishment or individual.

Improper treatment of generator can damage it and
shorten its iife.

DONOTexposegeneratorto excessivemoisture,dust,dirt, or
corrosivevapors.

DONOTinsertanyobjectsthroughcoolingslots.

BENEBATOBMAINTENANCE

Generatormaintenanceconsists of keepingthe unit cteanand
dry. Operateandstore the unit in a clean dry environment
whereit wiii not be exposedto excessivedust, dirt, moisture
or anycorrosive vapors. Cooiing air slots in the generator

must not becomecloggedwith snow, leaves,or any other
foreign material.

Checkthe cleanliness of the generatorfrequently and ctean
when dust, dirt, oii, moisture or other foreign substances are

visible on its exterior surface.

, Usea soft bristle brush to loosencaked on dirt, oil, etc.
, Usea vacuumcleanerto pick uploose dirt and debris.

SERVICEDATES

NOTICE

15

TheStatStationTM displaysthe nominai ioad on generator

basedon output frequency. It also has a built in maintenance

reminder.

ENGINEMAINTENANCE

WARNING

Wattage Monitor Operatian
Thedispiay is two seven-segmentLEDsthat provide an easy-

to-read indication of the amount of power being suppiied by
the generator. Theioad monitor displays the generator's

output as a percentage.
As generatorioad increases,the dispiay vaiues wiii increase.

Whenthe dispiayedvalues begin flashing, the user should
stop adding electricaI ioads to the generator.

If the power usage becomestoo hi@l,the ietters "OL" (for
Over Load)will flash on the display. The usershould reduce

the amount of load attached to the generator.
_laintenanee Reminder

The LEDwill display certain codes to aiert you to check oii,
changeoff,check or replaceair fiiter and check or replace

spark piug. Thefoliowing codes wiii display:
"C1" Checkoii at 8 hour increments

"C2" Changeoil at 50 hour increments
"C3" Checkor repiaceair fiiter at 25 hour increments
"C4" Checkor repiacespark piug at 100 hour increments
Totake advantage ofthe StatStation"maintenance reminder"

capabilities, tile user must presstile resetbutton after
compieting the maintenancecatied for in the dispiayedcode

(Cl, C2, C3, or C4). This results in a display of "Co" or "CA",
depending on how iong the button is pressed:

1) "Co" = Pressingthe reset button oncequickiy wiii
display "Co"(clearingto zero). This wilI clear any

maintenancecodes that haveelapsed up to that point
and they wiii begin timing againfrom zero.

2) "CA" - Pressing and hoiding the resetbutton for
2 seconds wilI display "CA"(clearing all). This clearsalI

maintenancecodes, evenif they have not yet reached

their service point, and they will begin timing again

from zero.

If nominal Ioadand maintenancecodes appear

simuItaneously,the LEDshall display,alternately, the
nominal Ioadand codeas follows:

Thecode wilI display for 3 seconds, then 1/2 second off. The
load will display for 6 seconds andthen 1/2 second off.

Unintentionaisparking can result in fire or
electricshock.

WHEN ADJUSTINGOR _IAKBNOREPAIRSTOYOUR GENERATOR

,', Disconnectthe sparkplugwhefromthe sparkplugandplace

thewirewhereit cannotcontactsparkplug.

WHENTESTINGFORENGINESPARK
, Useapprovedsparkplugtester.

• DONOTcheckforsparkwithsparkplugremoved.

8il

oimBecemmendatiens

NOTE:When adding oiI to the engine crankcase,useonly
high quality detergent oii classified "For Service SF,SG, SH,
SJ" or higiler. DONOTusespeciai additives.

1. Choosea viscosity according to the foiiowing table:
40 C

86
68

50
32

104 F_

14

4

-22

NOTE:Synthetic oii meeting iLSACGF=2,API certification
mark and APi servicesymboi with "SJ/CFENERGY

CONSERVING"or higiler, is an acceptabieoii ataii
temperatures. Use of synthetic oil does not alter required oil
change intervals.

$AE30:40 °Fand h@her(5 °Cand h,{qher)is good for ati

purpose useabove40°F, use below 40°F will causehard
starting.

10W-30:0 to 100 °F(=18to 38 °C)is better for varying
temperature conditions. This grade of oii improves coid
weather starting, but may increaseoil consumption at 80°F

(27°C) or higher.

*Check oii ievei frequently at higher temperatures.

Synthetic 5W-30:=20 to 120 °F(=30to 40 °5')provides the

best protection atall temperatures as weii as improved
starting with iess oii consumption.

5W-31}: 40 °Fand be_;ow(5 °Cand be/ow) is recommended
for winter use, and works best in cold conditions.

30

10

0

-10

-20

-30

16

Checking Oil Level
Oii level should be checked prior to each useor at least every

5 hours of operation=Keepoii ievetmaintained.

1. Make suregenerator is on a ieve!surface=

2. Cleanareaaround oii fiii and remove oii fiii cap=

3. Verify oii is at the point of overflowing at oil fill opening.

4. Replaceand tighten oil fill cap=

Adding Engine Oil

1. Make suregenerator is on a level surface.

2. Check oii ievei as described in Checking OffLevel

3. If needed,siowiy pour oii into oil fill opening to the
point of overflowing at oil %.

4. Replaceand tighten oil fill cap.

Changing Engine Oil
Changethe oil after the first 5 hours of operation. Changeoil

every 50 hours thereafter, if you are using your generator

underextremely dirty or dusty conditions, or in extremely hot

weather,changethe oil more often.

CAUTION

or rep_

oil.

Usedmotoroil hasbeenshownto causeskincancelin certain
laboratoryanimaB
Thoroughlywashexposedareaswithsoapandwater

KEEPOUTOFREACHOFCHILDREN.DON'T
POLLUTE.CONSERVERESOURCES.RETURN
USEDOiL TO COLLECTIONCENTERS.

4. Removeoil drain plug and drain oil completely into a
suitabie container.

5. Reinstailoil drain plug and tighten securely. Removeoil
fill cap.

6. Slowiy pour oil (about 28 oz.) into oil fill opening (B) to
the point of overflowing (C)at oil fill cap. DO NOT

overfill.

7. Reinstatioii fiii cap. Fingertigilten cap securely.

8. Wipe up any spiiied oil.

Service Air Cleaner

Your engine wiil not run properiy and may be damagedif you

run it with a dirty air cleaner.
Repiacethe air cieanerevery 25 hours of operation or once

eachyear, whichever comes first. Repiacemore often if

operating under dirty or dusty conditions.

To servicethe aircteaner,foiiow these steps:

1. Loosenscrews (A) and remove air cleanercover (B).

Changethe oil while the engine is still warm from running, as
foflows:

1. Make sure unit is on a levelsurface.

2. Disconnect the spark piug wire from the spark piug and
placethe wire whereit cannot contact spark plug.

3. Cban areaaround oil drain ptug (A). Theoii drain plug
is located at base of engine,opposite carburetor.

2. Carefullyremove cartridge (C) from base (O),

3. Instaii ctean (or new) air cieaner assembly inside cover.
Disposeof old fiiter properly.

4. Assembteair cleanercover onto baseand tighten

screws.

NOTE:You canpurchase new air cleaner elements by calling
l=800=4=MY=NOME(46go4663),

17

CJean_epJace Spark PJu9

Changethe spark piug every 100 hours of operation or once
eachyear, whichever comes first. This wifl help your engine

to start easierand run better.

1. Cleanarea around spark piug.

2. Remove and inspect spark piug.

3. Checkelectrode gap with wire feeler gaugeand set
spark plug gap to 0.030 inch (0.76ram) if necessary.

4. Replacespark plug if electrodes are pitted, burnedor
porcelain is cracked. Use a recommended replacement
plug.

5. Install spark plug and tighten firmly.

NOTE:You can purchasea newspark plug by calling
l=800-4=MY=NONiE(469=4663),

Ctean Spark Attester Screen

Theengine exhaust muffler has a spark arrestor screen.

Inspectand cleanthe screen every 100 hours of operation or

once eachyear, whichever comes first.
NOTE:You can purchasea newspark arrester screen by

calling 1-800-4-MY-HOME (469-4663).

If you useyour generatoron any forest-covered, brush-
covered,or grass-coveredunimproved iand, it must havea
spark arrestor. The spark arrestor must be maintainedin good
condition bythe owner/operator.

2. Removefour screwsthat attachspark arrestorscreen(C).

3. Inspect screen and obtain a repiacementif torn,
perforated or otherwise damaged. DO NOTusea
defectivescreen, if screen is not damaged,cleanit with

commercial soivent.

4. Reattachscreenand muffler guard.

Air Cooling System

Overtime debris may accumulate in cyiinder cooiing fins and
cannot be observed without partial engine disassembly. For
this reason,we recommendyou havea Sears or other

quaiifiedservice deaierclean the cooiing system (A) per

recommendedintervais (see Maintenance Schedub). Equally

important is to keeptop of engine free from debris=See

GeneratorC/eaning.

WARNING

_,_ Contactwith muffler areacan result in serious

* DONOTtouchhot partsandAVODhotexhaustgases.
, Allowequipmentto coolbeforetouching.
o Keepatleast5 feet(1.5m) of clearanceonall sidesof

o Codeof Federa!Regulation(CFR)Title36 Parks,Forests,and

Clean and inspect the spark arrestor as fellows:

1. To removemufflerheatshield(A) from muffler (B),

burns.
Exhaustheat/gases can ignite combustibles,

structures or damagefuel tank causing a fire.

generatorincludingoverhead.

PublicPropertyrequireequipmentpoweredbyan internal
combustionengineto haveasparkattester,maintainedin

effectiveworkingorder,complyingto USDAForestservice
standard5100-1Cor laterrevision.IntheStateofCaliforniaa

sparkarresteris requiredundersection4442oftheCalifornia
Publicresourcescode.Otherstatesmayhavesimilarlaws.

removefour screwsthat connectguardto muffler bracket.

CarburetorAdjustment

Thecarburetor on this engine is iow emission, it is equipped
with a non-adjustable idle mixture valve and governed idJe,if
equipped. Governedidie and top speed havebeenset at the
factory, if adjustment is required, see any Searsor other

ualified dealer.

CAUTION

Excessivelyhigh operatingspeeds increase risk of injury
and damageto generator.

Excessivelyiow speeds impose a heavyioad.

DONOTtamperwithgovernedspeed.Generatorsupplies
correctratedfrequency'andvoltagewhenrunningatgoverned
speed.

DONOTmodify'generatorinanyway'.

18