Craftsman 580325650 Owner’s Manual

Operator'sManual

ectricStart

ACGenerator

®

HOURS: Mnn. - Fri. 8 a.m. to 5 p.m. (CT)

WARNING

Before usingthis product, readthis

manualand follow all SafetyRules

add OperatingInstructions.

Sears, Roebuckand Co., Roffrnan Estates,IL 60179 U.S.A.

Visit our Craftsman website:www.craftsman.com

Part No. 198712GS Draft E (06/19/2007)

Antes de utilizar el producto, lea este

ADVEBTENCIA

manualy siga todas las Reglasde

Seguridade Instrucciones de Uso.

,, Safety

• Assembly

• Operation

• Maintenance

,, Parts

,, Espafiol,p. 36

o 3

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

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

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

ASSEMBLY................................... 7-9

OPERATION................................ 10-14

SPECIFICATIONS............................... 15

MAINTENANCE.............................. 16-19

STORAGE .................................... 20

TROUBLESHOOTING............................ 21

SCHEMATIC/WIRINGDIAGRAM ................ 22-23

REPLACEMENTPARTS ....................... 24-32

NOTES....................................... 33

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

ESPANOL.................................. 36-59

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

One-YearFullWarrantyon CraftsmanGenerator

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

AdditionalOne-YearLimited Warrantyon CraftsmanGenerator

Forthe second year from the date of purchase,if any part ofthis generator fails dueto adefect in material or workmanship, a
new part will besupplied free of charge. You must paythe labor cost if you wish to haveit installed.

All warranty coverageappliesfor only 90 days from date of purchase if this generator is used for commercial or rental
purposes. Oncea generator has experiencedcommercial or rental use, it shall thereafter be considered a commercial or rental
generatorfor the purpose of this warranty.

This warranty gives you specific legal rights, andyou may also haveother rights which vary from state to state.

© SearsBrands, LLC

Sears, Roebuckand Co., D/817WA,HoffmanEstates, IL 60179 U.S.A.

,_ Thisisthe safetyalert symbol,it isused to alert youto potential personalinjuryhazards.

Obeyall safetymessagesthat follow this symbolto avoid possibleinjury ordeath.

[ _-!] Read thismanual carefully and become familiar

...................withyourgenerator. Knowits applications,its

limitations,and any hazardsinvolved.

Thesafety alert symbol (_1_)is usedwith a signal word

(DANGER,CAUTION,WARNING),a pictorial and/oFa safety

messageto alert you to hazards.DANGERindicatesa hazard
which, if not avoided, will result in deathor serious injury.
WARNINGindicates a hazardwhich, if not avoided, could

result in death or serious injury. CAUTIONindicatesa hazard
which, if not avoided, might result in minor or moderate
injury. NOTICE,indicates a situation that could result in
equipment damage.Follow safety messagesto avoid or

reducethe risk of injury or death.

WARNING

The engine exhaustfrom this productcontains chemicals

known to the State ofCalifornia to cause cancer, birth

defects, or otherreproductive harm.

HazardSymbolsand Meanings

DANGER

Contentsare HARMFULORFATALIF
SWALLOWED.Avoid contact to eyes,skin or

clothing. DONOTtake internally. Avoid breathing
the mist or vapor. Overexposureto eyes or skin
cancause irritation. Keepstabilizer out of the

reachof children.
Fuelstabilizer is a hazardouschemical.**

• FreshStartTM fuelcapisdesignedto holdacartridgewhich
containsfuelstabilizer.

. IfSWALLOWED,callphysicianimmediately.DONOTinduce

vomiting.If inhaled,removetofreshair.Incaseofeyeorskin
contact,flushwithwaterfor 15minutes.

• Storeunopenedcartridgesina cool,dry,wellventilatedarea.
Keepopencartridgeinfuelcap,andfuelcapclosedonfueltank

whennotin use.

Inthe caseofanemergency,contactaphysicianimmediately

andcall1-808-424-9308formaterialsafetyinformation.

• *Fuel stabilizer contaies: 2,6-di-tret-butylpheeol (128-39-2) and aliphatie 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 smell.

A - Explosion

B - Fire
C- ElectricShock
D- ToxicFumes
E- Kickback
F- Hot Surface

®

G - Flying Objects

H - ExplosivePressure
J - ChemicalBum

K - HazardousChemical

L - Moving Parts

M - Read Manual

A,

NEVER use inside a home

or garage,EVENIF doors
and windows are open.

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

_ reathingcarbon monoxide can cause headache,

• OperategeneratorONLYoutdoors.

fatigue, dizziness,vomiting, confusion, seizures,
nausea,fainting or death.

Installabatteryoperatedcarbonmonoxidealarmnearthe

bedrooms.
Keepexhaustgasfromenteringa confinedareathrough

windows,doors,ventilationintakes,or otheropenings.
DONOTstartor runengineindoorsorin anenclosedarea,

(evenifwindowsanddoorsareopen),includingthegenerator
compartmentof arecreationalvehicle(RV).

Only use OUTSIDE and
far away from windows,

doors, and vents.

WARNING

WARNING

Generatorproduceshazardousvoltage.

_¢ Failureto isolategenerator from power utility can

• When using generator for backup power, notify utility company.

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

• DO NOTtouch barewires or receptacles.
. DO NOTuse generator with electrical cordswhich are worn,

• DO NOThandle generator or electricalcords while standing in

• DO NOTallow unqualified persons or children to operate or

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

Use approvedtransfer equipment to isolate generator from
electric utility.

highly conductive area, such as metal decking or steel work.

frayed, bareor otherwise damaged.
DO NOToperate generator in the rain or wet weather.

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

servicegenerator.

WARNING

_,,,_ ontact with muffler areacan result in serious

_ Exhaustheat/gases can ignite combustibles,

• Allow equipment to cool beforetouching.

• Keepat least5 feet (1.5 m) of clearanceon all sides of

• Codeof FederalRegulation(CFR) Title 36 Parks,Forests,and

burns.

structures or damagefuel tank causing afire.

DONOTtouch hot parts and AVOIDhot exhaustgases.

generator including overhead.

Public Property require equipment powered by an internal
combustion engineto havea spark arrester, maintainedin
effectiveworking order, complying to USDAForest service

standard 5100-1C or later revision. Inthe Stateof California a
spark arresteris required under section4442 of the California

Public resourcescode. Otherstates may havesimilar laws.

WARNING

hands, hair, clothing, or accessories.

Starter and other rotating parts can entangle

• NEVERoperategenerator without protective housing or covers.
. DO NOTwearloose clothing, jewelry or anything that may be

caught in the starter or other rotating parts.

. Tie up long hair and removejewelry.

WARNING

Starter cord kickback (rapid retraction) can result
in bodily injury. Kickback will pull hand and arm

I1_< toward engine faster than you can let go.

Brokenbones, 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 electricaldevices plugged in
andturned on.

WARNING

Fueland its vapors are extremelyflammable and

explosive.

Fire or explosion can cause severe burns ordeath.

WHEN ADDING OR DRAINING FUEL

. Turn generator OFFand let it cool at least2 minutes before

removing fuel cap.Loosencap slowly to relievepressure in
tank.

• Fill or drain fuel tank outdoors.

. DONOToverfill tank. Allow space for fuel expansion.

• If fuel spills,wait until it evaporatesbefore starting engine.

. Keepfuel away from sparks,open flames, pilot lights, heat, and

other ignition sources.

• DONOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

• Ensure spark plug, muffler, fuel cap, and air cleanerare in place.

. DONOTcrank enginewith sparkplug removed.

WHEN OPERATING EQUIPMENT

• DONOT tip engine or equipment at anglewhich causesfuel to
spill.

. This generator is not for usein mobileequipment or marine

applications.

WHEN TRANSPORTING OR REPAIRINGEQUIPMENT

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

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL INTANK

• Store awayfrom furnaces, stoves,water heaters,clothes dryers,
or other appliances that havepilot light or other ignition source
becausethey can ignite fuel vapors.

WARNING

This generator does not meetU. S. CoastGuard Regulation
33CFR-183and should not beusedon marine applications.

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

WARNING

_ Unintentional sparking can result in fire OF

_¢ electric shock.

WHENADJUSTINGOR MAKINGREPAIRSTOYOUR GENERATOR
. Disconnectthe spark plug wire from the spark plug and place

the wire where it cannot contact sparkplug.

WHENTESTINGFORENGINESPARK

• Use approved spark plug tester.
. DO NOTcheck for spark with spark plug removed.

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 generatorin any way.

NOTICE

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

DONOTexceedthe generator's wattage/amperagecapacity. See
Don't OverloadGeneratorin the Operationsection.

Start generator and let engine stabilize beforeconnecting
electrical loads.

Connectelectrical loads in OFFposition, then turn ONfor
operation.

Turn electricalloads OFFand disconnect from generator before
stopping generator.

NOTICE

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

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
corrosive vapors.

DONOTinsert any objectsthrough 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.

KNOWYOUROEHERATOR

I!__-!i] Read the Operator'sManual and safety rulesbeforeoperating your generator.

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

FuelTank SparkArrestor Muffler

120/240 Volt AC,

/

/ 30 Amp Receptacle

Double PoleCircuit
Breaker(AC)

120 Volt AC,20 Amp
Duplex Receptacles

DataTag

Choke Lever

Air Cleaner

Recoil Starter

Engine Rocker Switch

120 Volt AC,20 Amp, DuplexReceptacles -- May be used
to supply electrical power for the operation of 120Volt AC,
20 Amp, single phase, 60 Hzelectrical, lighting, appliance,

tool and motor loads.
120/240 Volt AC,30 Amp LockingReceptacle -- May be

usedto 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 intakeair.
Battery Float Charger Jack-- Use batteryfloat charger to

keepthe starting batterycharged and readyfor use.
Choke Lever-- Used whenstarting a cold engine.
Data Tag-- Provides model, revision and serial number of

generator. Pleasehavethese readilyavailablewhen calling
for assistance.

Double Pole Circuit Breaker (AC)-- A double pole circuit
breakeris provided to protect all the receptaclesand
generatoragainst electrical overload.

Grounding Fastener

BatteryFloat ChargerJack

Oil Fill Cap/Dipstick

Start Switch

EngineRocker Switch -- Set this switch to "On"before

starting engine. Set switch to "Off"to stop engine.

FuelTank-- Capacityof five (5) U.S.gallons.
GroundingFastener-- Consultyour local agencyhaving

jurisdiction for grounding requirements in your area.

Oil Fill Cap/Dipstick -- Checkand fill enginewith oil here.
SeeOil for oil recommendations and filling instructions.

Recoil Starter-- Usedto start the engine.
SparkArrestor Muffler -- Exhaustmuffler lowers engine

noiseand is equipped with a spark arrester screen.
Start Switch -- Pushand hold in "Start" position for a

maximum of 15 seconds during eachstart attempt, until

engine starts.

StatStationTM -- Displaysthe nominal load on generator
basedon output frequency. It also has a built in maintenance

reminder.

Your Craftsmangenerator requiressome assembly andis

readyfor use only after it has beenproperly serviced with the
recommendedoil and fuel.

If you have any problemswith the assembly of your
generator, please call the generator helpline at

1-800-222-3136.

Unpacking the Generator

f. Setthe carton on a rigid fiat surface.

2. Removeeverything from carton except generator.

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

4. Leavegeneratoron carton to install wheel kit.

Carton Contents

Checkall contents against those listed below:

• Main unit

• Engineoil

• Oil bottle funnel

• Operator's manual

• Wheel kit

• Adapter cord set

If any parts are missing or damaged,call the generator

helpline at 1-800-222-3135.

install WheelKit

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

NOTtow this unit with amotorized vehicle.

You will needthe following tools to installthese
components:

• 13mmwrenches

• Socket wrench with a13mm socket

• Pliers
Safetyglasses

Install the WheelKit as Follows:
IMPORTANT: Installing the wheel kit must becompleted

prior to adding any oil or fuel.

1. Tip generator so that engine end is up.

2. Slide axlethrough both mounting brackets.

3. Place a wheel on eachside as shown in A.

4. Place a washer on axleand then placean e-ring in axle

groove.

5. Install e-ring with pliers, squeezingfrom top of e-ringto

bottom of axle.

CAUTION

E-tings cancause eye injury.

.,_ E-fings canspring back and becomeairborne

when installing or removing.

, Alwaysweareyeprotectionwheninstalling/removinge-rings.

6. Repeatstep 4 and 5 to securesecond wheel.

7. Tip generatorso that engine side is down.

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

frame and battery tray bolt.

9. Attach support leg using a capscrew, batterytray bolt

and 2 hex nuts. Tighten with a 13mm socket wrench and
13mm wrench.

10. Return generatorto normal operating position (resting
on wheels and support leg).

Capscrew

Hex Nut

Support Leg _ Hex Nut

Axle

Wheel

Axle

E-Ring

<>8

3

Wheel

Flat Washer

CheckBattery/ Attach Negative BatteryWire

Thesealedbattery on the generator is fully chargedand
pre-installed exceptfor the negative(black) battery cable.

Toinstall:

1. Cutoff tie wrap securing looseend of negative (black)
cable.

2. Attach negativebattery cable to negativebattery
terminal.

Negative

battery cable

/,

J

'\\\ /J'/

Add Fuel

Fuelmustmeet these requirements:

* Clean,fresh, unleadedgasoline.
* A minimum of 87 octane/87 AKI (91 RON). High altitude

use, see High Altitude.

* Gasolinewith up to 10% ethanol (gasohol) or upto 15%

MTBE(methyl tertiary butyl ether) is acceptable.

NOTICE

Avoid generatordamage.
Failureto follow Operator'sManualfor fuel

recommendationsvoids warranty.

DONOTuseunapprovedgasolinesuchasE85.
DONOTmixoil in gasoline.

DONOTmodifyengineto runonalternatefuels.

To protect the fuel system from gum formation, mix in a fuel
stabilizer when adding fuel. See Storage.All fuel is notthe

same. If you experiencestarting or performance problems
after using fuel, switch to a different fuel provider or change

brands. This engine is certified to operateon gasoline. The

emission control system for this engine is EM (Engine

Modifications).

BEFORESTARTINGTHEGENERATOR

AddEngineOil

1. Placegeneratoron a flat, level surface.

2. Cleanarea around oil fill and remove yellow oil fill cap.

NOTE:Seethe section Oilto reviewoil recommendations.
Verify provided oil bottle is correct viscosity for current

ambient temperature.

3. Using oil funnel (optional), slowly pour contents of
provided oil bottle into oil fill opening.

NOTICE

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

DONOTattempttocrankor startthe enginebeforeit hasbeen
properlyservicedwiththerecommendedoil.Thismayresultin

anenginefailure.

4. Replaceoil fill cap and fully tighten.

WARNING

_fl_ Fueland its vapors are extremely flammable and

explosive.

Fireor explosion can cause severe burns ordeath.

WHEN ADDINGFUEL

• TurngeneratorOFFandletitcoolatleast2 minutesbefore
removingfuelcap.Loosencapslowlyto relievepressurein

tank.

. Fillfueltankoutdoors.

• DONOToverfilltank.Allowspaceforfuelexpansion.

. Iffuelspills,waituntilit evaporatesbeforestartingengine.

• Keepfuelawayfromsparks,openflames,pilotlights,heat,and

otherignitionsources.

• DONOTlight acigaretteor smoke.

1. Cleanareaaround fuel fill cap, removecap.

2. Slowly add unleadedgasoline (A) to fuel tank (B). Be
careful not to overfill. Allow about 1.5"(4 cm) of tank
space (C) for fuel expansion.

3. Install fuel cap and let any spilled fuel evaporate before

starting engine.

FreshStartTM Fuel Cap

Adding fuel preserverhelps keepfuel fresh and carburetors
cleanfor easier starting, all season long. This newfuel cap
automatically drips concentrated fuel preserver into your fuel

tank.

DANGEB

Contentsare HARMFULORFATALIF

_ WALLOWED.Avoid contact to eyes, skin or

. If SWALLOWED,callphysicianimmediately.

• Inthecaseofanemergency,contacta physicianimmediately

• *Fuel stabilizer contains: 2,6-di-tret-butylphenol (128-39-2) and alipbatic petroleum

1. Placecartridge into fuel cap.

clothing. DONOTtake internally. Avoid breathing
the mist orvapor. Overexposureto eyesor skin

reachof children.

can cause irritation. Keepstabilizer out of the

Fuelstabilizer is a hazardouschemical.**

andcall1-808-424-9380formaterialsafetyinformation.

distillate (64742-47-8).

3. Removetab to exposemembrane.

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

4. Reinstall fuel cap on fuel tank.

5. Periodically checkthe cartridge to ensure there is still
fuel preserver inside. If it is empty, removecartridge
and replace.

2. Pushto "snap" cartridge into place.

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

85 octane / 85AKI (89 RON)gasoline is acceptable.To
remainemissions compliant, high altitude adjustment is
required. Operationwithout this adjustment will cause
decreasedperformance, increasedfuel consumption, and

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

kit is not recommended.

HOWTOUSEYOURGENERATOR Generator Location

If you haveany problems operating your generatorafter GeneratorClearance
readingthe manual, pleasecall the generator heipline at

1-800-222-3136.

System Ground

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

AOoutput receptacles.The system ground isconnectedto
the AOneutral wire (the neutral is bonded to the generator
frame).

SpecialRequirements

Theremay be Federalor StateOccupational Safety and

HealthAdministration (OSHA)regulations, local codes, or

ordinancesthat applyto the intended useof the generator.

Pleaseconsult a qualified electrician, electrical inspector, or

the local agency havingjurisdiction.

• Insome areas,generators are requiredto be registered
with local utility companies.

• Ifthe generator is used at a construction site, there may
be additional regulationswhich must beobserved.

Connecting to a Building's Electrical System

Oonnectionsfor standby power to a buiiding's electrical
system must bemadeby a qualified electrician. The
connection must isolatethe generator power from utility
power, and must comply with all applicable laws and

electricalcodes.

Placegenerator outdoors in an areathat wiil not accumulate
deadlyexhaustgas. DONOTplacegenerator whereexhaust

gas (A) could accumulate and enter inside or be drawn into a

potentially occupied building. Ensureexhaustgas is kept

away from anywindows, doors, ventilation intakes, or other

openingsthat can allow exhaustgasto collect in a confined

area. Prevailingwinds and air currents should be taken into
consideration when positioning generator.

Using a generator indoors CAN KiLL YOU iN MINUTES.

Generator exhaust contains carbon monoxide. This is
a poison you cannot see or smeJL

Exhaustheat/gases can ignite combustibles,
structures or damagefuel tank causing a fire.

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

WARNING

A

WARNING

iGeneratorproduces hazardousvoltage.

_¢ Failureto isolategenerator from power utility can

• Whenusinggeneratorfor backuppower,notifyutilitycompany.

• Useagroundfaultcircuitinterrupter(GFCI)inanydampor

• DONOTtouchbarewiresor receptacles.

, DONOTusegeneratorwithelectricalcordswhichareworn,

, DONOToperategeneratorintherainorwetweather.

• DONOThandlegeneratoror electricalcordswhilestandingin

• DONOTallowunqualifiedpersonsorchildrento operateor

result in deathor injury to electric utility workers
dueto backfeedof electrical energy.

Useapprovedtransferequipmenttoisolategeneratorfrom
electricutility.

highlyconductivearea,suchasmetaldeckingor steelwork.

frayed,bareor otherwisedamaged.

water,whilebarefoot,or whilehandsorfeetarewet.

servicegenerator.

NEVERuse inside a home

or garage,EVENIF doors
and windowsare open.

OnJy use OUTSIDE and
far away from windows,

doors, and vents.

10

To Start The Engine

Disconnectall electrical loadsfrom the generator. NEVER
start or stop engine with electrical devices plugged in and
turned ON. Followstart instruction steps innumerical order:

1. Makesure unit is on a levelsurface.

IMPORTANT:Failureto start and operate unit ona level
surfacewill cause the unit not to start orshut down during
operation.

2. Turn red fuel valveto "On" position.

3. Place choke lever in "Choke" position.

5B. For manual starting, grasp recoil handleand pull slowly

until slight resistance is felt. Then pull rapidly one time
only to start engine.

WARNING

Startercord kickback(rapid retraction) can result
in bodily injury. Kickbackwill pull hand and arm

_< toward engine fasterthan you can letgo.

T'-

Brokenbones, fractures, bruises, or sprains
could result.

• Whenstartingengine,pullcordslowlyuntilresistanceis feltand
thenpullrapidlytoavoidkickback.

, NEVERstartor stopenginewith electricaldevicespluggedin

andturnedon.

• If engine starts, proceedto step 7.

• If engine fails to start, proceedto step 6.

6. Movechoke lever to "Half" choke position, and pull
recoil handletwice.

• If engine fails to start, repeatsteps 5 thru 7.

7. Slowly move choke leverto "Run" position. If engine
falters, movechoke leverto "Half" choke position until
engine runs smoothly, and thento "Run" position.

IMPORTANT:If engine floods, placechoke lever in "Run"

)osition andcrank until engine starts.

4. Set engine rocker switch to "On" position.

EngineRockerSwitch is

shown in On position

5A. Far electric starting, push and hold the start switch in

"Start" position untilgenerator starts. To prolong the life
ofstarter components, DONOTholdstart switchin

"Start" position for morethan 15 seconds, and pause
for at least 1 minute betweenstarting attempts.

START

• If engine starts, proceedto step 7.

• If engine fails to start, proceedto step 6.

NOTE:If battery is discharged, use manual starting
instructions.

_i, WARNING

s_ Contactwith muffler areacan result in serious

_ Exhaustheat/gases can ignite combustibles,

®

o

o

NOTE:If engine starts after 3 pulls but fails to run, or if unit

shuts down during operation, makesure unit is on a level
surface and check for proper oil level in crankcase. This unit

may be equipped with a low oil protection device. If so, oil
must be at proper level for engine to start.

burns.

structures or damagefuel tank causing a fire.

DONOTtouch hot parts and AVOIDhot exhaust gases.
Allow equipment to cool beforetouching.

Keepat 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 powered by an internal
combustion engineto havea spark arrester, maintained in

effectiveworking order, complying to USDAForestservice
standard 5100-1C or later revision. In the Stateof California a

spark arrester is required under section 4442 ofthe California
Public resources code. Otherstates may havesimilar laws.

11

Connecting Electrical Loads

• Letthe engine stabilize and warm up for afew minutes
after starting.

DONOTconnect240Voltloadsto 120Voltreceptacles.
DONOTconnect 3-phase loadsto the generator.
DONOTconnect 50 Hz loadstothe generator.
Plug in andturn on the desired 120 Volt AC,single phase,

60 Hertzelectrical loads.

• DONOTOVERLOADTHEGENERATOR.SeeDon't

OverloadGenerator.

NOTICE

Exceedinggenerators wattage/amperagecapacitycan
damagegenerator and/or electrical devicesconnected to it.

DONOTexceedthe generator'swattage/amperagecapacity.See
Don'tOverloadGeneratorintheOperationsection.

Startgeneratorandletenginestabilizebeforeconnecting
electricalloads.

ConnectelectricalloadsinOFFposition,thenturn ONfor
operation.

TurnelectricalloadsOFFanddisconnectfromgeneratorbefore
stoppinggenerator.

Stopping the Engine

1. Turnoffandunplugall electricalloadsfrom unit.NEVER

start or stop engine with electrical devices plugged in
and turned on.

2. Let engine run at no-load for two minutesto stabilize

unit's internaltemperatures.

3. Move engine rocker switch to "Off" position.

WARNING

CORDSETSAND RECEPTACLES

Useonly high quality, well-insulated, grounded extension

cords with the generator's 120Volt duplex receptacle.

Inspect extension cords beforeeach use.
Checkthe ratings of all extension cords beforeyou usethem.

Extensioncord sets usedshould be rated for 125Volt AC
loadsat 20 Amps or greaterfor most electrical devices.

Somedevices, however, may not requirethis type of

extension cord. Checkthe operator's manualsof those

devicesfor the manufacturer's recommendations.
Keepextensioncords asshort as possible to minimize

voltage drop.

WARNING

_ verloadedelectrical cords can overheat,arc,

• ONLYusecordsratedforyour loads.
. Followallsafetieson electricalcords.

120/240VoltAC, 30 Amp,LockingReceptacle

Usea NEMAL14-30 plug with this receptacle.Connecta
4-wire cord set ratedfor 250 Volt ACloads at 30 Amps (or
greater). You can usethe same 4-wire cord if you plan to

run a 120 Volt load.

and burn resulting in death, bodily injury, and/or
property damage.

4-WireCordSet

:Neutral)

Backfire,fire or engine damagecould occur.

DONOTstopenginebymovingchokeleverto "Cheke"position.

4. Move fuel valve to "Off" position.
Y (Hot) | X (Hot)

NEMAL14-30 /-7L/ 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

23.3Amps for 240 Volts or two independent120 Volt loads

at 23.3 Amps each.The outlet is protected by a double pole

rocker switch circuit breaker.

NOTICE

Receptaclesmay be marked with rating value greaterthan
generator output capacity.

NEVERattemptto poweradevicerequiringmoreamperage
thangeneratoror receptaclecansupply.

DONOToverloadthegenerator.SeeDon'tOverloadGenerator.

12

120 Volt AC, 20 Amp, Duplex Receptacles

Eachduplex receptacleis protected against overload by a

double pole rocker switch circuit breaker.

Howto Use the Battery Charoer

Usebattery charger jack to keepthe starting batterycharged

and readyfor use. Battery charging should be done ina dry

location, such as inside a garage.

1. Plug charger into unit's "12V DO Battery Charger"jack,
which is located on generator side panel. Plug battery
charger into a120 Volt ACwall receptacle.

Useeachreceptacleto operate 120 Volt AO,single-phase,
60 Hzelectrical loads requiring up to 2,400 watts (2.4 kW) at
20 Amps of current. Usecord sets that are rated for 125 Volt
AOloadsat 20Amps (or greater).

Generator Adapter Cord Set

Thegenerator comeswith a 25' generatoradapter cord set
designedto provide two sets of 120 Volt, 20 Amp outlets
from one120 Volt, 20 Amp duplex receptacle.

The maximum load oneach outlet is 20 Amps. The maximum
total load on both blackwire outlets or white stripe wire
outlets is 20 Amps.

NOTE:Follow all safety precautions when connecting any
extensioncord or deviceto the generator.

2. Unplug charger from unit and wall outlet when generator'
is being started and while in operation.

3. Keepcharger plugged in when generator is not in useto
prolong battery life. Thecharger hasa built infloat

equalizerand will not overcharge battery,evenwhen

plugged in for an extendedperiod of time.

IMPORTANT:SeeBatteryMaintenancefor additional
information.

13

DOH'TOVERLOADGENERATOR

Capacity

You must make sureyour generator cansupply enough rated

(running) and surge (starting) watts for the itemsyou will

power at the sametime. Followthese simple steps:

1. Selectthe itemsyou will power at the same time.

2. Total the rated(running) watts of these items.This isthe
amount of power your generator must produce to keep
your items running.

3. Estimate how manysurge (starting) watts you will need.
Surge wattage is the short burst of power neededto
start electric motor-driven tools or appliancessuch as a
circular saw or refrigerator. Becausenot all motors start
at the sametime, total surge watts can be estimated by
adding only the item(s) with the highest additional surge
watts to the total ratedwatts from step 2.

Example:

Tool or Appliance
Window Air

Conditioner
Refrigerator

Deep Freezer
Television

Light (75 Watts)

Rated

(Running) Watts

1200

8OO
5OO

5OO

75

3075 Total

Running Watts

Total Rated(Running) Watts

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

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

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 benothing connected to 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 described in this manual.

2. Plug in and turn on the first load, preferablythe largest
load you have.

3. Permit the generatoroutput to stabilize (engine runs
smoothly and attached deviceoperates properly).

Additional Surge

(Starting) Watts

1800

1600

5OO

1800 Highest

Surge Watts

=3075
= 1800
=4875

4. Plugin and turn onthe nextload.

5. Again, permit the generatorto stabilize.

6. Repeatsteps 4 and 5 for each additional load.

Additional

Surge

Watts

Tool or Appliance

Essentials
Light Bulb - 75 watt

Deep Freezer
Sump Pump

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

Heating/Cooling
Window AC - 10,000 BTU

Window Fan
Furnace Fan Blower- I/2 HP

Kitchen

Microwave Oven - 1000 Watt
Coffee Maker

Electric Stove - Single Element
Hot Plate

Family Room
DVD/CD Player

VCR
Stereo Receiver
Color Television - 27"

Personal Computer w/17"
monitor

Other
Security System

AM/FM Clock Radio
Garage Door Opener - I/2 HP

Electric Water Heater - 40
Gallon

DIY/Job Site
Quartz Haloqen Work Light

Airless Sprayer- I/3 HP
Reciprocating Saw

Electric Drill- I/2 HP
Circular Saw - 7 1/4"
Miter Saw - 10"
Table Planer - 6"

Table Saw/Radial Arm Saw - 10"
Air Compressor - I-1/2 HP

Rated*

(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

NEVERadd more loadsthan the generator capacity.Take

special care to consider surge loads in generatorcapacity,as

describedabove.
*Wattageslisted are approximateonly. Checktool or

appliancefor actual wattage.

14

EHGINETECHNICALIHFORMATION

This isa single cylinder, overheadvaive(OHV),air coded
engine, it is a low emissions engine.

Inthe Stateof California, 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
additional warranties with respectto the performance or
operational life of this engine.Theengine is warranted solely
according to the product and emissions warranties stated

elsewherein this manual.

Power Ratings

Thegross power rating for individual gas engine models is
labeledin accordancewith SAE(Societyof Automotive

Engineers)code J1940 (Small Engine Power & Torque

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

(Revision2002-05). Torque values are derived at3060 RPM;
horsepower values are derivedat 3600 RPM. Actual gross

engine power will be lower andis affected by, among other
things, ambient operating conditions andengine-to-engine

variability. Givenboth the wide array of products on which
enginesare placed and the variety of environmental issues

applicableto operating the equipment, the gas engine will 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.), application limitations,
ambient operating conditions (temperature,humidity,
altitude), and engine-to-engine variability. Dueto

manufacturing and capacity limitations, Briggs & Stratton

maysubstitute anengine of higher rated power for this
Seriesengine.

PRODUCTSPECIFICATIOHS

Generator Specifications

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

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

RatedACVoltage ...................... 120/240 Volts

RatedACCurrent

at 240 Volts ........................ 23.3Amperes

at 120 Volts ........................ 46.6 Amperes

RatedFrequency ................... 60 Hzat 3600 rpm

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

FuelCapacity ......................... 5 U.S.gallons

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

Engine Specifications

Bore .............................. 3.12 in. (79 mm)

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

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

SparkPlug

Type: .................... Briggs & Stratton 491055

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

Armature Air Gap: ........ 0.008-0.012 in. (0.20-0.30mm)

Valveclearancewith valvesprings installed and piston 1/4 in.

(6 mm) past top deadcenter (check whenengine is cold).

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

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

Oil Capacity ............................... 28fl. oz.

NOTE:For practical operation, the generator load should not

exceed 85% of rated wattage. Enginegross horsepower will

decrease3-1/2% for each 1,000feet (300 meters) abovesea
leveland 1% for each 10° F (5.6° C) above 77° F (25° C). It

should operate satisfactorily at an angle up to 15°.

15

MAINTENANCESCHEDULE

Followthe hourly or calendar intervals, whichever occurs first.

Morefrequent service is required when operating in adverseconditions noted below.

MAINTENANCESCHEDULE

FILL IN DATESAS YOU

COMPLETEREGULARSERVICE SERVICEDATES

MAINTENANCETASK Every25 Hours

Checkoil level
Cleandebris
Service air cleaner

Change engine oil
Service spark plug
Service spark arrester

Cleancooling system
Checkvalve clearance

Preparefor 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 ordusty conditions.

2 Replacemore often under dirty ordusty conditions.

Before

Each Use

X
×

or Yearly

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

SERVICEDATES

Every50 Hours Every 100 Every250

or Yearly Hours or Yeary Hours or Yeary

X1

×
X

X_

×

GENERALRECOMMENDATIONS

Regularmaintenancewill improvethe performanceand
extendthe life of the generator. Seea Searsor other qualified

dealerfor service.
Thegenerator's warranty does not cover items that have

been subjected to operator abuseor negligence.To receive
full value from the warranty,the operator must maintain
generatoras instructed in this manual.

Someadjustments will needto be madeperiodically to
properly maintain your generator.

All serviceand adjustments should be madeat least once
eachseason.Follow the requirementsin the Maintenance

Schedulechart above.
NOTE:Oncea year you should clean or replacethe 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.

EMiSSiONSCONTROL

[Vlaintellance, replacement,or repair of the emissions con-

trol devicesand systems may be performedby any non-
roadengine repairestablishment or individual. However,

to obtain "no charge" emissions control service,the work

must be performed by a qualified servicecenter. Seethe

Emissions Warranty.

GENERATORMAINTENANCE

Generatormaintenanceconsists of keepingthe unit clean and
dry. Operateandstore the unit in a cleandry environment
whereit will not be exposedto excessivedust, dirt, moisture
or anycorrosive vapors. Coolingair slots in the generator

must not becomeclogged with snow, leaves,or any other

foreign material.
Checkthe cleanlinessof the generator frequently and clean

when dust, dirt, oil, moisture or other foreign substancesare
visible on its exterior surface.

NOTE:DO NOTusea garden hose to cleangenerator. Water
can enterthe engine fuel system and causeproblems. In
addition, if water enters the generatorthrough cooling air

slots, some of the water will beretainedin voids and cracks
of the rotor and stator winding insulation. Water and dirt

buildup onthe generator internal windings will eventually
decreasethe insulation resistance of these windings.

Generator Cleaning

Daily or before use,clean accumulated debrisfrom
generator. Keeplinkage,spring andcontrols clean. Keeparea
around and behind muffler free from anycombustible debris.

Inspect cooling air slots and openings on the generator.
Theseopenings must be kept clean and unobstructed.

Generatorparts should bekept cleanto reducethe risk of
overheating and ignition of accumulated debris.

• Usea dampcloth to wipe exterior surfaces clean.

NOTICE

Improper treatment of generator candamageit and
shorten its life.

DONOTexposegeneratorto excessivemoisture,dust,dirt, or
corrosivevapors.

DONOTinsertanyobjectsthroughcoolingslots.

,, Usea soft bristle brush to loosencaked on dirt, oil, etc.

• Useavacuumcleanerto pick uploose dirt and debris.

16

BatteryMaintenance

Otherthan trickle charging, describedelsewhere, no

maintenanceis required for the battery. Keepthe battery and

terminals cleanand dry.
IMPORTANT:Battery charging should be performed in a dry

location, such as inside a garage.

ENGINEMAIHTENANCE

WARNING

_ Unintentionalsparking can result in fire or

StatStation TM

TheStatStationTM displaysthe nominal load on generator
basedon output frequency. It also has a built in maintenance

reminder.

Wattage Monitor Operation
Thedisplay is two seven-segmentLEDsthat provide an easy-

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

output as a percentage.
As generatorload increases,the display values will increase.

Whenthe displayedvalues begin flashing, the user should
stop adding electrical loads to the generator.

If the power usage becomestoo high, the letters "OL" (for
Over Load)will flash on the display. The usershould reduce
the amount of load attachedto the generator.

Maintenance Reminder
TheLEDwill displaycertain codesto alert you to checkoil,

changeoil, check or replaceair filter and check or replace
spark plug. The following codes will display:

"C1" Checkoil at 8 hour increments
"62" Changeoil at 50 hour increments

"63" Checkor replaceair filter at 25 hour increments
"C4" Checkor replacespark plug at 100 hour increments
Totake advantage ofthe StatStation"maintenance reminder"

capabilities, the user must pressthe resetbutton after
completing the maintenancecalled for in the displayedcode

(Cl, C2,03, or C4). This results in a display of "Co" or "CA",
depending on how long the button is pressed:

1) "Co" - Pressingthe reset button once quickly will display
"Co"(clearingto zero).This will clearany maintenance
codes that have elapsed up to that point and they will
begin timing again from zero.

2) "CA" - Pressing and holding the resetbutton for
2 secondswill display "CA"(clearing all). This clears all

maintenancecodes, even if they havenot yet reached

their service point, and they will begin timing again from

ze re.

If nominal loadand maintenancecodes appear

simultaneously, the LEDshall display,alternately, the
nominal load and code as follows:

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

_¢ electricshock.

WHENADJUSTINGORMAKINGREPAIRSTOYOURGENERATOR
. Disconnectthesparkplugwirefromthesparkplugandplace

thewirewhereit cannotcontactsparkplug.

WHENTESTINGFORENGINESPARK

• Useapprovedsparkplugtester.
. DONOTcheckforsparkwithsparkplugremoved.

Oil

Oil Recommendations
We recommend the use of Briggs & Stratton Warranty

Certifiedoils for bestperformance. Other high-quality
detergentoils areacceptableif classifiedfor service SF,SG,
SH,SJ or higher. DONOTusespecial additives.

Outdoortemperatures determinethe properoil viscosity for

the engine. Usethe chart to select the best viscosity for the

outdoor temperature range expected.

oF

104 m _, __ ,

°C

o6- I-.-

20
10

m 0

L-- o

-22

* Below40°F(4%) theuseof SAE30will resultinhardstarting.
** Above80°F(27°0)theuseof 10W30maycauseincreasedoil

consumption.Checkoil levelmorefrequently.

@t0 OTE:Synthetic oil meeting ILSACGF-2,API

certification mark and APIserv,!cesymbol with
"SJ/CFENERGYCONSERVINGor higher, is an

acceptableoil atall temperatures. Use of synthetic oil
does not alter required oil change intervals.

2- --3o

17

CheckingOil Level

Oil levelshould bechecked prior to each use or at leastevery
5 hoursof operation.Keepoil levelmaintained.

1. Make sure generatoris ona levelsurface.

2. Cleanarea around oil fill and remove oil fill cap.

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

4. Replaceand tighten oil fill cap.

AddingEngineOil

1. Make sure generatoris ona levelsurface.

2. Check oil level as described in Checking Oil Level

3. If needed, slowly pour oil into oil fill openingto the point

of overflowing at oil fill.

4. Replaceand tighten oil fill cap.

Service Air Cleaner

Your enginewill not run properly and may be damagedif you

run it with a dirty air cleaner.

Replacethe air cleanerevery 25 hours of operation or once
eachyear, whichever comes first. Replacemore often if
operating under dirty or dusty conditions.

To servicethe air cleaner, folJew these steps:

1. Loosen screws (A) and removeair cleaner cover (B).

ChangingEngineOil

Changethe oil after the first 5 hours of operation. Changeoil

every 50 hours thereafter. If you are using your generator

under extremely dirty or dusty conditions, or in extremely hot

weather, changethe oil more often.

CAUTION

Avoid prolonged or repeatedskin contact with usedmotor
oil.

Usedmotoroil hasbeenshownto causeskincancerin certain
laboratoryanimals.

Thoroughlywashexposedareaswith soapandwater.

KEEPOUTOFREACHOF CHILDREN.DON'T
POLLUTE.CONSERVERESOURCES.RETURN
USEDOILTOCOLLECTIONCENTERS.

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

follows:

1. Makesure unit is on a levelsurface.

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

3. Cleanareaaround oil drain plug.The oil drain plug is
locatedat base of engine, opposite carburetor.

4. Removeoil drain plug and drain oil completely into a

suitable container.

5. Reinstalloil drain plug and tighten securely. Removeoil

fill cap.

6. Slowlypour oil (about 28 oz.) into oil fill openingto the
point of overflowing at oil fill. DONOToverfill.

7. Reinstall oil fill cap. Fingertighten capsecurely.

8. Wipe upanyspilled oil.

2. Carefully removecartridge (C) from base(D).

3. Install clean(or new)air cleanerassembly insidecover.
Disposeof old filter properly.

4. Assemble air cleaner cover onto baseand tighten screws.

NOTE:You can purchase newair cleanerelementsby calling
1-SOO-4-MY-HOME(46g-4663).

CleanlReplace Spark Plug

Changethe spark plug every 100 hours of operation or once

eachyear, whichever comes first. This will helpyour engine
to start easierand run better.

1. Cleanareaaround spark plug.

2. Removeand inspect spark plug.

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

jjJ -- -. f .....

4. Replacespark plug if electrodesare pitted, burned or
porcelainis cracked. Usea recommended replacement
plug.

5. install spark plug andtighten firmly.

NOTE:You canpurchase anew spark plug bycalling
1-800-4-NIY-HOME(469-4663).

18