Craftsman 580326310 Owner’s Manual
Operator's Manual
Watt Electric Start
AC Generator
Model No.
580.326310
®
HOURS: Mort. =Fri. 8 a.m. to 5 p.m. (CT)
_1i IllWARNING
Before using this product, read this
manual and follow all Safety Rules
and Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit our Craftsman website: www.craftsman.com
Part No. 198737GS Draft D (06,07,2006)
I] ADVERTENCIA
Antes de utilizar el producto, lea este
manual y siga todas las Reglas de
Seguridad e Instrucciones de Uso.
. Safety
• Assembly
• Operation
• Maintenance
• Parts
. EspaSol, p. 36
WARRANTY .............................. 2
SAFETY RULES ......................... 3-4
FEATURES AND CONTROLS ................ 5
ASSEMBLY ............................. 6-8
OPERATION ........................... 9-13
SPECIFICATIONS ......................... 14
MAINTENANCE ........................ 15-18
STO RAG E ............................... 19
TROUBLESHOOTING ...................... 20
NOTES ............................. 21 & 33
SCHEMATIC/WIRING DIAGRAM .......... 22-23
REPLACEMENT PARTS ................. 24-32
EMISSIONS SYSTEM WARRANTY ........ 34-35
ESPANOL ............................. 36-59
HOW TO ORDER PARTS .......... BACK PAGE
ONE=YEAR FULL WARRANTY ON CRAFTSMAN GENERATOR
If this generator fails due to a defect in material or workmanship within one year from the date of purchase,
return it to any Sears store, other Craftsman outlet, or Sears Parts & Repair Center in the United States for free
repair (or replacement if repair proves impossible).
Additional One=Year Limited Warranty on Craftsman Generator
For the second year from the date of purchase, if any part of this generator fails due to a defect in material or
workmanship, a new part will be supplied free of charge. You must pay the labor cost if you wish to have it
installed.
All warranty coverage applies for only 90 days from date of purchase if this generator is used for commercial or
rental purposes. Once a generator has experienced commercial or rental use, it shall thereafter be considered a
commercial or rental generator for the purpose of this warranty.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Sears, Roebuck and Co., D/817WA, Hoffman Estates, IL 60179 U.S.A.
© Sears Brands, LLC
_iL This is the safety alert symbol, it is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
[ =_-!] Read this manual carefully and become
...................familiar with your generator. Know its
applications, its limitations, and any hazards
involved.
The safety alert symbol (,A) is used with a signal
word (DANGER, CAUTION, WARNING), a pictorial
and/or a safety message to alert you to hazards.
DANGER indicates a hazard which, if not avoided, will
result in death or serious injury. WARNING indicates a
hazard which, if not avoided, could result in death or
serious injury. CAUTION indicates a hazard which, if
not avoided, might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in equipment
damage. Follow safety messages to avoid or reduce
the risk of injury or death.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
• This generator does not meet U. S. Coast Guard
Regulation 33CFR-183 and should not be used on
marine applications.
• Failure to use the appropriate U. S. Coast Guard
approved generator could result in bodily injury and/or
property damage.
Hazard Symbols and Meanings
Explosion Fire Electrical Shock
'W,
Toxic Fumes
Hot Surface Kickback
WARNING
DANGER
Fresh Start TM fuel cap is designed to hold a cartridge
which contains fuel stabilizer.
If SWALLOWED, call physician immediately. DO NOT
induce vomiting. If inhaled, remove to fresh air. In case
of eye or skin contact, flush with water for 15 minutes.
Store unopened cartridges in a cool, dry, well ventilated
area. Keep open cartridge in fuel cap, and fuel cap
closed on fuel tank when not in use.
In the case of an emergency, contact a physician
immediately and call 1-800-424-9300 for material safety
information.
'Fuei stabilizer contains: 2,6-di-tret-butylphenol (128-39-2) and aliphatic
petroleum distillate (64742-47-8)
WARNING
When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp
or highly conductive area, such as metal decking or steel
work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
DO NOT operate generator in the rain or wet weather.
DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or feet
are wet.
DO NOT allow unqualified persons or children to operate
or service generator.
WARNING
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure (even if doors or windows are open), including
the generator compartment of a recreational vehicle (RV).
When starting engine, pull cord slowly until resistance is
felt and then pull rapidly to avoid kickback.
NEVER start or stop engine with electrical devices
plugged in and turned on.
WARNING
WARNING
WHEN ADDING OR DRAINING FUEL
Turn generator OFF and let it cool at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fill or drain fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.
If fuel spills, wait until it evaporates before starting
engine.
Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
WHEN STARTING EQUIPMENT
Ensure spark plug, muffler, fuel cap and air cleaner are
in place.
DO NOT crank engine with spark plug removed.
WHEN OPERATING EQUIPMENT
Do not tip engine or equipment at angle which causes
fuel to spill.
DO NOT choke carburetor to stop engine.
This generator is not for use in mobile equipment or
marine applications.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
Transport/repair with fuel tank EMPTY or with fuel shutoff
valve OFF.
Disconnect spark plug wire.
WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN
TANK
Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that have pilot light or other
ignition source because they can ignite fuel vapors.
WARNING
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.
WHEN TESTING FOR ENGINE SPARK
Use approved spark plug tester.
DO NOT check for spark with spark plug removed.
CAUTION
DO NOT tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
DO NOT modify generator in any way.
CAUTION
See "Don't Overload Generator".
Start generator and let engine stabilize before connecting
electrical loads.
Connect electrical loads in OFF position, then turn ON
for operation.
Turn electrical loads OFF and disconnect from generator
before stopping generator.
CAUTION
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Title 36 Parks,
Forests, and Public Property require equipment powered
by an internal combustion engine to have a spark
arrester, maintained in effective working order, complying
to USDA Forest service standard 5100-1C or later
revision. In the State of California a spark arrester is
required under section 4442 of the California Public
resources code. Other states may have similar laws.
Use generator only for intended uses.
If you have questions about intended use, ask dealer or
contact Sears.
Operate generator only on level surfaces.
DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.
If connected devices overheat, turn them off and
disconnect them from generator.
Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
KNOW YOUR GENERATOR
RoodthoOperotor'sMoouolo°dso otyroio bofo oope otiogyoo gooe otor,
Compare the illustrations with your generator to familiarize yourself with the locations of various controls
and adjustments, Save this manual for future reference,
Fuel Tank
120 Volt AC, 20 Amp
Duplex Receptacles
120/240 Volt AC,
30 Amp Receptacle
Circuit Breakers (AC)
Double Pole Circuit
Breaker (AC)
StatStation 7"M
Spark Arrester Muffler
Grounding
Fastener
Data Tag
120 Volt AC, 20 Amp, Duplex Receptacles -- May be
used to supply electrical power for the operation of 120 Volt
AC, 20 Amp, single phase, 60 Hz electrical, lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle -- May be
used to supply electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical, lighting, appliance, tool and motor loads.
Air Cleaner i Protects engine by filtering dust and debris
out of intake air.
Battery Float Charger Jack i Use battery float charger to
keep the starting battery charged and ready for use.
Choke Lever -- Used when starting a cold engine.
Circuit Breakers (AC) i Push to reset circuit breakers are
provided to protect the 120 VAC, 20A duplex receptacles
against electrical overload.
Data Tag i Provides model, revision and serial number of
generator. Please have these readily available when calling
for assistance.
Air Cleaner
Recoil Starter
Choke
Lever Battery Float
Start Switch Charger Jack
Double Pole Circuit Breaker (AC) -- A double pole circuit
breaker is provided to protect all the receptacles and
generator against electrical overload.
Engine Rocker Switch -- Set this switch to "On" before
starting engine. Set switch to "Off" to stop engine.
Fuel Tank i Capacity of seven (7) U.S. gallons.
Grounding Fastener i Consult your local agency having
jurisdiction for grounding requirements in your area.
Oil Fill Cap -- Check and fill engine with oil here. See page
16 for oil recommendations and filling instructions.
Recoil Starter -- Used to start the engine.
Spark Arrester Muffler -- Exhaust muffler lowers engine
noise and is equipped with a spark arrester screen.
Start Switch -- Push and hold in "Start" position for a
maximum of 15 seconds during each start attempt, until
engine starts.
StatStationTM i Displays the nominal load on generator
based on output frequency. It also has a built in
maintenance reminder.
Engine
Rocker Switch
Oil Fill Cap
Your Craftsman generator requires some assembly
and is ready for use only after it has been properly
serviced with the recommended oil and fuel.
if you have any problems with the assembly of
your generator, please call the generator helpline
at 1-800-222-3136.
Unpacking the Generator
1. Set the carton on a rigid flat surface.
2. Remove everything from carton except generator.
3. Open carton completely by cutting each corner
from top to bottom.
4. Leave generator on carton to install wheel kit.
Carton Contents
Check all contents against those listed below:
Main unit
Engine oil
Oil bottle funnel
Operator's manual
Wheel kit
Adapter cord set
If any parts are missing or damaged, call the
generator helpline at 1-800-222-3136.
install Wheel Kit
NOTE: Wheel kit is not intended for over-the-road
use. DO NOT tow this unit with a motorized vehicle.
You will need the following tools to install these
components:
• 13mm wrench
• Socket wrench with a 13mm socket
• Pliers
• Safety glasses
install the Wheel Kit as Follows:
IMPORTANT: Installing the wheel kit must be
completed prior to adding any oil or fuel.
1. Tip generator so that engine end is up.
2. Slide axle through both mounting brackets.
3. Place a wheel on each side as shown.
4. Place a washer on axle and then place an e-ring
in axle groove.
5. Install e-ring with pliers, squeezing from top of
e-ring to bottom of axle.
CAUTION
Always wear eye when
6. Repeat step 4 and 5 to secure second wheel.
7. Tip generator so that engine side is down.
8. Attach support leg with M8 x 20 mm cap screws
and M8 hex nuts.
9. Return generator to normal operating position
(resting on wheels and support leg).
10. Raise handles and insert handle pins to move
generator.
Handle Pin
Support Leg --
Your unit may vary slightly
from that shown here
Wheel
Flat Washer
Axle
20 mm Cap Screw
E-Ring
Check Battery / Attach Negative Battery
Wire
The sealed battery on the generator is fully charged and
pre-installed except for the negative (black) battery cable.
You will need an 8mm wrench to install the negative
battery cable.
To install:
1. Cut off tie wrap securing loose end of negative
(black) cable.
2. Remove screw, lock washer and flat washer on
negative battery terminal.
3. Slide lock washer, flat washer and negative
battery cable over screw.
Negative
battery cable
Flat Washer,
Lock Washer
Positive battery cable
4. Reattach screw to negative battery terminal and
tighten.
5. Verify that connections to battery and generator
are tight and secure.
BEFORE STARTING THE
GENERATOR
Add Engine OIl
CAUTION! Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine failure.
1. Place generator on a level surface.
2. Clean area around oil fill and remove yellow oil fill
cap.
NOTE: See the section "Oil" on page 16 to review oil
recommendations. Verify provided oil bottle is correct
viscosity for current ambient temperature.
3. Using oil funnel (optional), slowly pour entire
contents of provided oil bottle (26 oz.) into oil fill
opening.
4. Replace oil fill cap and fully tighten.
Add Fuel
All fuel is not the same. If a starting or performance
problem is encountered immediately after new fuel has
been used, try another service station or change brands.
NOTE: This engine is certified to operate on gasoline.
Exhaust Emissions Control System: EM (Engine
Modifications).
WARNING
WHEN ADDING FUEL
Turn generator OFF and let it cool at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fill fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.
Wait for spilled fuel to evaporate before starting engine.
Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
Type of Fuel
1. Always use clean, fresh, unleaded gasoline with a
minimum of 87 octane/87 AKI (91 RON). DO NOT
mix oil with fuel. DO NOT modify the engine fuel
system or carburetor to run on alternative fuels.
NOTE: Fuel with up to 10% ethanol (gasohol) or up to
15% MTBE (methyl tertiary butyl ether), is acceptable.
IMPORTANT: Use of any fuel other than those
approved above will void warranty. Some areas
require that fuel pumps be marked if the fuel contains
alcohols or ethers. If you are not sure if your fuel
contains alcohol or ethers that are different than those
approved above, then check with the service station
operator.
2. Clean area around fuel fill cap, remove cap.
3. Slowly add regular unleaded fuel to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank
space for fuel expansion, as shown here.
4. Install fuel cap and let any spilled fuel evaporate
before starting engine.
CAUTION!Alcohol-blendedfuels(calledgasohol,
ethanolormethanol)canattractmoisture,whichleads
toseparationandformationofacidsduringstorage.
Acidicgascandamagethefuelsystemofanengine
whileinstorage.
Toavoidengineperformanceissues,thefuelsystem
shouldbetreatedwithafuelpreserveroremptied
beforestorageof30daysor longer.Toprotectthe
fuelsystemfromgumformation,useBriggs&Stratton
FRESHSTARTTM fuel stabilizer plus, or FRESH
START TM continuous fuel preserver (concentrated
liquid cartridge). If fuel preserver is not used, drain the
fuel tank, start the engine and let it run until the fuel
lines and carburetor are empty. Use fresh fuel next
season. See "Storage" on page 19 for additional
information.
NEVER use engine or carburetor cleaner products in
the fuel tank as permanent damage may occur.
1. Place cartridge into fuel cap.
2. Push to "snap" cartridge into place.
3. Remove tab to expose membrane.
Fresh Start TM Fuel Cap
Adding fuel preserver helps keep fuel fresh and
carburetors clean for easier starting, all season long.
This new fuel cap automatically drips concentrated
fuel preserver into your fuel tank.
DANGER
If SWALLOWED, call physician immediately.
In case of emergency, contact a physician immediately
and call 1-800-424-9300 for material safety information.
**Fuel stabilizer contains: 2,6-dFtret-butylphenol (128-39-2) a_d aEiphatic
petroleum distillate (64742-47-8).
-_-_..
IMPORTANT: DO NOT remove the silver foil seal on
the opposite side of the cartridge.
4. Reinstall fuel cap on fuel tank.
©
5. Periodically check the cartridge to ensure there is
still fuel stabilizer inside. If it is empty, remove
cartridge and replace.
High-altitude use
Operation at high altitude (over 5,000 feet), may
require a high-altitude carburetor jet kit to improve
performance and decrease fuel consumption. See any
Sears or other qualified dealer for more information.
HOW TO USE YOUR GENERATOR Generator Location
If you have any problems operating your generator
after reading the manual, please call the generator
helpline at 1-800-222-3136.
System Ground
The generator has a system ground that connects the
generator frame components to the ground terminals
on the AC output receptacles. The system ground is
connected to the AC neutral wire (the neutral is
bonded to the generator frame).
Special Requirements
There may be Federal or State Occupational Safety
and Health Administration (OSHA) regulations, local
codes, or ordinances that apply to the intended use of
the generator. Please consult a qualified electrician,
electrical inspector, or the local agency having
jurisdiction.
• In some areas, generators are required to be
registered with local utility companies.
• If the generator is used at a construction site, there
may be additional regulations which must be
observed.
Connecting to a Building's ElectricaR
System
Connections for standby power to a building's
electrical system must be made by a qualified
electrician. The connection must isolate the generator
power from utility power, and must comply with all
applicable laws and electrical codes.
Generator Clearance
_ WARNING
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Place generator in a well ventilated area, which will
allow for removal of deadly exhaust gas. DO NOT
place generator where exhaust gas could accumulate
and enter inside or be drawn into a potentially
occupied building. Ensure exhaust gas is kept away
from any windows, doors, ventilation intakes or other
openings that can allow exhaust gas to collect in a
confined area. Prevailing winds and air currents
should be taken into consideration when positioning
generator.
Using a generator indoors WiLL KiLL YOU
iN MINUTES.
Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
[]
_, WARNING
When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp
or highly conductive area, such as metal decking or steel
work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
DO NOT operate generator in the rain or wet weather.
DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or feet
are wet.
DO NOT allow unqualified persons or children to operate
or service generator.
NEVER use in the home
or in partly enclosed
areas sucn as garages.
ONLY use outdoors and
far from open windows,
idoors, and vents.
Typical Generator Shown
Exhaust Port
To Start The Engine
Disconnect all electrical loads from the generator.
NEVER start or stop engine with electrical devices
plugged in and turned ON. Follow start instruction
steps in numerical order:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a
level surface will cause the unit not to start or shut
down during operation.
2. Turn fuel valve to "On" position. Fuel valve handle
should be vertical (pointing toward the ground) for
fuel to flow.
Fuel Valve is shown
in the On position
3. Place choke lever in "Choke" position.
5B. For manual starting, grasp recoil handle and pull
slowly until slight resistance is felt. Then pull
rapidly one time only to start engine.
WARNING
When starting engine, pull cord slowly until resistance is
felt and then pull rapidly to avoid kickback.
NEVER start or stop engine with electrical devices
plugged in and turned on.
• If engine starts, proceed to step 7.
• If engine fails to start, proceed to step 6.
6. Move choke lever to "Half" choke position, and
pull recoil handle twice.
• If engine fails to start, repeat steps 5 thru 7.
7. Slowly move choke lever to "Run" position. If
engine falters, move choke lever to "Half" choke
position until engine runs smoothly, and then to
"Run" position.
IMPORTANT: If engine floods, place choke lever in
"Run" position and crank until engine starts.
4. Set engine rocker switch to "On" position.
Engine Rocker Switch
is shown in On position
5A. For electric starting, push and hold the start
switch in "Start" position until generator starts. To
prolong the life of starter components, DO NOT
hold start switch in "Start" position for more than
15 seconds, and pause for at least 1 minute
between starting attempts.
START
* Ifengine starts, proceed to step 7.
. Ifengine fails to start, proceed to step 6.
NOTE: If battery is discharged, use manual starting
instructions.
WARNING
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Title 36 Parks,
Forests, and Public Property require equipment powered
by an internal combustion engine to have a spark
arrester, maintained in effective working order, complying
to USDA Forest service standard 5100-1C or later
revision. In the State of California a spark arrester is
required under section 4442 of the California Public
resources code. Other states may have similar laws.
NOTE: If engine starts after 3 pulls but fails to run, or
if unit shuts down during operation, make sure unit is
on a level surface and check for proper oil level in
crankcase. This unit may be equipped with a low oil
protection device. If so, oil must be at proper level for
engine to start.
10
Connecting Electrical Loads
* Let the engine stabilize and warm up for a few
minutes after starting.
* DO NOT connect 240 Volt loads to 120Volt receptacles.
* DO NOT connect 3-phase loads to the generator.
* DO NOT connect 50 Hz loads to the generator.
* Plug in and turn on the desired 120 Volt AC, single
phase, 60 Hertz electrical loads.
* DO NOT OVERLOAD THE GENERATOR. See
"Don't Overload Generator".
CAUTION
See "Don't Overload Generator".
Start generator and let engine stabilize before connecting
electrical loads.
Connect electrical loads in OFF position, then turn ON
for operation.
Turn electrical loads OFF and disconnect from generator
before stopping generator.
CORD SETS AND RECEPTACLES
CAUTION
NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply.
DO NOT overload the generator. See "Don't Overload
Generator".
Use only high quality, well-insulated, grounded
extension cords with the generator's 120 Volt electrical
receptacles. Inspect extension cords before each use.
Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
for 125 Volt AC loads at 20 Amps or greater for most
electrical devices. Some devices, however, may not
require this type of extension cord. Check the
operator's manuals of those devices for the
manufacturer's recommendations.
Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
Stopping the Engine
1. Turn off and unplug all electrical loads from unit.
NEVER start or stop engine with electrical devices
plugged in and turned on.
2. Let engine run at no-load for two minutes to
stabilize unit's internal temperatures.
3. Move engine rocker switch to "Off" position.
i WARNING I
DO NOT stop engine by moving choke lever to "Choke"
position.
4. Move fuel valve to "Off" position.
1201240 Volt AC, 30 Amp, Locking
Receptacle
Use a NEMA L14-30 plug with this receptacle.
Connect a 4-wire cord set rated for 250 Volt AC loads
at 30 Amps (or greater). You can use the same 4-wire
cord if you plan to run a 120 Volt load.
4-Wire Cord Set
Y (Hot) | X (Hot)
NEMA L14-30 /_ Ground (Green)
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 6,300 watts of power
(6.3 kW) at 26.2 Amps for 240 Volts or two
independent 120 Volt loads at 26.2 Amps each. The
outlet is protected by a double pole rocker switch
circuit breaker.
11
120 Volt AC, 20 Amp, Duplex Receptacles
Each duplex receptacle is protected against overload
by a double pole rocker switch circuit breaker.
How to Use the Battery Charger
Use battery charger jack to keep the starting battery
charged and ready for use. Battery charging should be
done in a dry location, such as inside a garage.
1. Plug charger into unit's "12V DC Battery Charger"
jack, which is located on the start switch bracket.
Plug battery charger into a 120 Volt AC wall
receptacle.
FS..f _ -_. ,
Use each receptacle to operate 120 Volt AC,
single-phase, 60 Hz electrical loads requiring up to
2,400 watts (2.4 kW) at 20 Amps of current. Use cord
sets that are rated for 125 Volt AC loads at 20 Amps
(or greater).
GENERATOR ADAPTER CORD SET
The generator comes with a 25' generator adapter
cord set designed to provide two sets of 120 Volt,
20 Amp outlets from one 120 Volt, 20 Amp duplex
receptacle.
\
2. Unplug charger from unit and wall outlet when
generator is being started and while in operation.
3. Keep charger plugged in when generator is not in
use to prolong battery life. The charger has a built
in float equalizer and will not overcharge battery,
even when plugged in for an extended period of
time.
IMPORTANT: See "Battery Maintenance" on page 16
for additional information.
The maximum load on each outlet is 20 Amps. The
maximum total load on both black wire outlets or white
stripe wire outlets is 20 Amps.
NOTE: Follow all safety precautions when connecting
any extension cord or device to the generator.
12
DON'T OVERLOAD GENERATOR
Capacity
You must make sure your generator can supply
enough rated (running) and surge (starting) watts for
the items you will power at the same time. Follow
these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items. This
is the amount of power your generator must
produce to keep your items running.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time,
total surge watts can be estimated by adding only
the item(s) with the highest additional surge watts
to the total rated watts from step 2.
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated
(Running) Watts
1200
800
500
500
75
3075 Total
Running Watts
Total Rated (Running) Watts
Highest Additional Surge Watts
Total Generator Output Required
NOTE: The rated (running) watts cannot exceed 6300.
Also, given the 6300 watt rated limit, additional surge
(starting) watts cannot exceed 9100.
Power Management
To prolong the life of your generator and attached
devices, it is important to take care when adding
electrical loads to your generator. There should be
nothing connected to the generator outlets before
starting it's engine. The correct and safe way to
manage generator power is to sequentially add loads
as follows:
1. With nothing connected to the generator, start the
engine as described in this manual.
2. Plug in and turn on the first load, preferably the
largest load you have.
3. Permit the generator output to stabilize (engine
runs smoothly and attached device operates
properly).
Additional Surge
(Starting) Watts
1800
1600
5OO
1800 Highest
Surge Watts
= 3075
= 1800
= 4875
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
NEVER add more loads than the generator capacity.
Take special care to consider surge loads in generator
capacity, as described above.
Check
Additional
Surge
(Starting)
Watts
5OO
1200
1600
2000
1800
600
1300
520
1200
96O
1000
1500
1800
1800
2000
2500
tool or
Rated*
Tool or Appliance
Essentials
Light Bulb - 75 watt 75
Deep Freezer 500
Sump Pump 800
Refrigerator/Freezer - 18 Cu. Ft. 800
Water Well Pump - 1/3 HP 1000
Heating/Cooling
Window AC - 10,000 BTU 1200
Window Fan 300
Furnace Fan Blower - 1/2 HP 800
Kitchen
Microwave Oven - 1000 Watt 1000
Coffee Maker 1500
Electric Stove - Single Element 1500
Hot Plate 2500
Family Room
DVD/CD Player 100
VCR 100
Stereo Receiver 450
Color Television - 27" 500
Personal Computer w/17" 800
monitor
Other
Security System 180
AM/FM Clock Radio 300
Garage Door Opener- 1/2 HP 480
Electric Water Heater - 40 4000
Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - 1/2 HP
Circular Saw - 7 1/4"
Miter Saw - 10"
Table Planer - 6"
Table Saw/Radial Arm Saw - 10"
Air Compressor - 1-1/2 HP
(Running)
Watts
1000
6oo
96o
1000
1500
1800
1800
2000
2500
*Wattages listed are approximate only.
appliance for actual wattage.
13
ENGINE TECHNICAL INFORMATION
This is a single cylinder, overhead valve(OHV), air
cooled engine. It is a low emissions engine.
In the State of California, Model Series 210000
engines are certified by the California Air Resources
Board to meet emissions standards for 250 hours.
Such certification does not grant the purchaser, owner
or operator of this engine any additional warranties
with respect to the performance or operational life of
this engine. The engine is warranted solely according
to the product and emissions warranties stated
elsewhere in this manual.
Power Ratings
* The power ratings for an individual engine model are
initially developed by starting with SAE (Society of
Automotive Engineers) code J1940 (Small Engine
Power & Torque Rating Procedure) (Revision 2002-
05). Given both the wide array of products on which
our engines are placed, and the variety of
environmental issues applicable to operating the
equipment, it may be that the engine you have
purchased will not develop the rated horsepower when
used in a piece of power equipment (actual "on-site"
power). This difference is due to a variety of factors
including, but not limited to, the following: differences
in altitude, temperature, barometric pressure, humidity,
fuel, engine lubrication, maximum governed engine
speed, individual engine to engine variability, design of
the particular piece of power equipment, the manner in
which the engine is operated, engine run-in to reduce
friction and clean out combustion chambers,
adjustments to the valves and carburetor, and other
factors. The power ratings may also be adjusted
based on comparisons to other similar engines utilized
in similar applications, and will therefore not
necessarily match the values derived using the
foregoing codes.
PRODUCT SPECIFICATIONS
Generator Specifications
Wattage ................... 6300 Watts (6.3 kW)
Starting Wattage ............ 9100 Watts (9.1 kW)
Rated AC Voltage ................ 120/240 Volts
Rated AC Current
at 240 Volts .................... 26.2 Amperes
at 120 Volts .................... 52.5 Amperes
Rated Frequency ............. 60 Hz at 3600 rpm
Phase .......................... Single Phase
Fuel Capacity .................... 7 U.S. gallons
Unit Weight .......................... 198 Ibs.
Engine Specifications
Gross* Horsepower .............. 11 at 3600 rpm
Bore ....................... 3.3 in. (83.81 mm)
Stroke .................... 2.438 in. (61.67 mm)
Displacement ................. 20.85 in. (342 cc)
Spark Plug
Type: ......... Champion RC12YC or Equivalent
Set Gap To: ............... 0.030inch (0.76mm)
Armature Air Gap: . .. 0.008-0.012 in. (0.20-0.30mm)
Valve clearance with valve springs installed and piston
1/4 in. (6 mm) past top dead center (check when
engine is cold).
Intake ............ 0.004-0.006 in. (0.10-0.15 mm)
Exhaust ........... 0.004-0.006 in. (0.10-0.15 mm)
Oil Capacity ......................... 28 ft. oz.
NOTE: For practical operation, the generator load
should not exceed 85% of rated wattage. Engine
gross horsepower will decrease 3-1/2% for each
1,000 feet (300 meters) above sea level and 1% for
each 10° F (5.6° C) above 77° F (25 ° C). It should
operate satisfactorily at an angle up to 15°.
14
MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is required when operating in adverse conditions noted below,
MAINTENANCE SCHEDULE
FILL IN DATES AS YOU SERVICE DATES
COMPLETE REGULAR SERVICE SERVICE DATES
Before Every 25 Hours Every 50 Hours Every 100
MAINTENANCE TASK Each Use or Year y or Yearly Hours or Yearly
Check oil level X
Clean debris X
Service air cleaner X2
Change engine oil X1
Service spark plug X
Service spark arrester X
Clean cooling system X2
Check valve clearance X
Prepare for storage If unit is to remain idle for longer than 30 days.
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.
GENERAL RECOMMENDATIONS
Regular maintenance will improve the performance
and extend the life of the generator. See a Sears or
other qualified dealer for service.
The generator's warranty does not cover items that
have been subjected to operator abuse or negligence.
To receive full value from the warranty, the operator
must maintain generator as instructed in this manual.
Some adjustments will need to be made periodically to
properly maintain your generator.
All service and adjustments should be made at least
once each season. Follow the requirements in the
"Maintenance Schedule" chart above.
NOTE: Once a year you should clean or replace the
spark plug and replace the air filter. A new spark plug
and clean air filter assure proper fuel-air mixture and
help your engine run better and last longer.
EMISSIONS CONTROL
Maintenance, replacement or repair of the emissions
control devices and systems may be performed by any
non-road engine repair establishment or individual.
GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit
clean and dry. Operate and store the unit in a clean dry
environment where it will not be exposed to excessive
dust, dirt, moisture or any corrosive vapors. Cooling air
slots in the generator must not become clogged with
snow, leaves, or any other foreign material.
Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
NOTE: DO NOT use a garden hose to clean
generator. Water can enter the engine fuel system and
cause problems. In addition, if water enters the
generator through cooling air slots, some of the water
will be retained in voids and cracks of the rotor and
stator winding insulation. Water and dirt buildup on the
generator internal windings will eventually decrease
the insulation resistance of these windings.
Generator Cleaning
Daily or before use, clean accumulated debris from
generator. Keep linkage, spring and controls clean.
Keep area around and behind muffler free from any
combustible debris. Inspect cooling air slots and
openings on the generator. These openings must be
kept clean and unobstructed.
Generator parts should be kept clean to reduce the
risk of overheating and ignition of accumulated debris.
• Use a damp cloth to wipe exterior surfaces clean.
• Use a soft bristle brush to loosen caked on dirt, oil,
etc.
• Use a vacuum cleaner to pick up loose dirt and debris.
CAUTION
DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.
15
Battery Maintenance
Other than trickle charging, described elsewhere, no
maintenance is required for the battery. Keep the
battery and terminals clean and dry.
iMPORTANT: Battery charging should be performed
in a dry location, such as inside a garage.
StatStation TM
The StatStation TM displays the nominal load on
generator based on output frequency. It also has a
built in maintenance reminder.
Wattage Monitor
The LED display will indicate 0-95% nominal load.The
display will flash at 90% nominal load and above. If
above 95% nominal load the display will flash "OL"
(meaning 'overload'). When load returns to within
normal range, the display will automatically resume
nominal load indication. See the table below for
operation functions.
Frequency Range
62.5-62.0
61.9-61.5
61.4-61.0
60.9-60.5
60.4-60.0
59.9-59.5
59.4-59.0
58.9-58.5
58.4-58.0
57.9-57.5
57.4-57.0
57.0 and below
Maintenance Reminder
The LED will display certain codes to alert you to
check oil, change oil, check or replace air filter and
check or replace spark plug. The following codes will
display:
"C1"
"C2"
"C3"
Check oil at 8 hour increments
Change oil at 50 hour increments
Check or replace air filter at 25 hour
increments
"C4"
Check or replace spark plug at 100 hour
increments
Pushing "Reset" will set the indicated code timer to
zero.
If nominal load and maintenance codes appear
simultaneously, the LED shall display, alternately, the
nominal load and code as follows:
The code will display for 3 seconds, then 1/2 second
off. The load will display for 6 seconds and then
1/2 second off.
LED Display
0
0
10
20
40
60
70
8O
Flash 90
Flash 95
Flash OL
Flash OL
ENGINE MAINTENANCE
WARNING
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR
• Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.
WHEN TESTING FOR ENGINE SPARK
Use approved spark plug tester.
DO NOT check for spark with spark plug removed.
Oil
Oil Recommendations
NOTE: When adding oil to the engine crankcase, use
only high quality detergent oil classified "For Service
SF, SG, SH, SJ" or higher. DO NOT use special
additives.
1. Choose a viscosity according to the following
table:
86
68
50
32
104 F_
14
4
_ 0
-22
NOTE: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol with "SJ/CF
ENERGY CONSERVING" or higher, is an acceptable
oil at all temperatures. Use of synthetic oil does not
alter required oil change intervals.
SAE 30:40 °F and higher (5 °C and higher) is good
for all purpose use above 40°F, use below 40°F will
cause hard starting.
10W-30:0 to 100 °F (-18 to 38 °C) is better for
varying temperature conditions. This grade of oil
improves cold weather starting, but may increase oil
consumption at 80°F (27°C) or higher.
*Check oil level frequently at higher temperatures.
Synthetic 5W-30:-20 to 120 °F (-30 to 40 °C)
provides the best protection at all temperatures as well
as improved starting with less oil consumption.
5W-30:40 °F and below (5 °C and below) is
recommended for winter use, and works best in cold
conditions.
40 C
30
10
-10
-20
-30
16
CheckingOilLevel
Oillevelshouldbecheckedpriortoeachuseoratleast
every5hoursofoperation,Keepoillevelmaintained,
1. Makesuregeneratorisonalevelsurface.
2. Cleanareaaroundoilfillandremoveoilfillcap.
3. Verifyoil isatthepointofoverflowingatoilfill
opening.
4. Replaceandtightenoilfillcap.
Changing Engine Oil
Change the oil after the first 5 hours of operation.
Change oil every 50 hours thereafter. If you are using
your generator under extremely dirty or dusty
conditions, or in extremely hot weather, change the oil
more often.
CAUTION
AddingEngineOil
1. Makesuregeneratorisonalevelsurface.
2. Checkoillevelasdescribedin"CheckingOil
Level".
3. If needed,slowlypouroilintooilfillopeningtothe
pointofoverflowingatoilfill.
4. Replaceandtightenoilfillcap.
Service Air Cleaner
Your engine will not run properly and may be
damaged if you run it with a dirty air cleaner.
Replace the air cleaner every 25 hours of operation or
once each year, whichever comes first. Replace more
often if operating under dirty or dusty conditions.
To service the air cleaner, follow these steps:
1. Loosen screws and remove air cleaner cover.
Remove paper filter.
Cartridge
Cover
\
\
Used motor oil has been shown to cause skin cancer in
certain laboratory animals.
Thoroughly wash exposed areas with soap and water.
KEEP OUT OF REACH OF CHILDREN.
DON'T POLLUTE. CONSERVE
RESOURCES. RETURN USED OIL TO
COLLECTION CENTERS.
Change the oil while the engine is still warm from
running, as follows:
1. Make sure unit is on a level surface.
2. Disconnect the spark plug wire from the spark
plug and place the wire where it cannot contact
spark plug.
3. Clean area around oil drain plug. The oil drain plug
is located at base of engine, opposite carburetor.
4. Remove oil drain plug and drain oil completely into
a suitable container.
5. Reinstall oil drain plug and tighten securely.
Remove oil fill cap.
6. Slowly pour oil (about 28 oz.) into oil fill opening to
the point of overflowing at oil fill. DO NOT overfill.
7. Reinstall oil fill cap. Finger tighten cap securely.
8. Wipe up any spilled oil.
Base
2. Install clean (or new) air cleaner assembly inside
cover. Dispose of old filter properly.
3. Assemble air cleaner cover onto base and tighten
screws.
NOTE: You can purchase new air cleaner elements by
calling 1-800-4-MY-HOME (469-4663).
Clean/Replace Spark Plug
Change the spark plug every 100 hours of operation
or once each year, whichever comes first. This will
help your engine to start easier and run better.
1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Check electrode gap with wire feeler gauge and
set spark plug gap to 0.030 inch (0.76mm) if
necessary.
4. Replace spark plug if electrodes are pitted, burned
or porcelain is cracked. Use a recommended
replacement plug.
17
5. Installsparkplugandtightenfirmly.
NOTE:Youcanpurchasea newsparkplugbycalling
1-800-4-MY-HOME(469-4663),
Clean Spark Attester Screen
The engine exhaust muffler has a spark arrester
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
NOTE: You can purchase a new spark arrester screen
by calling 1-800-4-MY-HOME (469-4663).
If you use your generator on any forest-covered, brush-
covered, or grass-covered unimproved land, it must
have a spark arrester. The spark arrester must be
maintained in good condition by the owner/operator.
WARNING
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Title 36 Parks,
Forests, and Public Property require equipment powered
by an internal combustion engine to have a spark
arrester, maintained in effective working order, complying
to USDA Forest service standard 5100-1C or later
revision. In the State of California a spark arrester is
required under section 4442 of the California Public
resources code. Other states may have similar laws.
Clean and inspect the spark an'ester as follows:
1. To remove muffler heat shield from muffler,
remove four screws that connect guard to muffler
bracket.
Air Cooling System
Over time debris may accumulate in cylinder cooling
fins and cannot be observed without partial engine
disassembly. For this reason, we recommend you
have a Sears or other qualified service dealer clean
the cooling system per recommended intervals (see
"Maintenance Schedule" on page 15). Equally
important is to keep top of engine free from debris.
See "Generator Cleaning".
CLEAN
Check Valve Clearance
Regular valve clearance check and adjustment will
improve performance and extend engine life. This
procedure cannot be done without partial engine
disassembly and the use of special tools. For this
reason we recommend that you have a Sears or other
qualified service dealer check and adjust valve
clearance at recommended intervals.
Carburetor Adjustment
The carburetor on this engine is low emission. It is
equipped with a non-adjustable idle mixture valve and
governed idle, if equipped. Governed idle and top
speed have been set at the factory. If adjustment is
required, see a Sears or other qualified service dealer.
i
CAUTION
MUFFLER"-.
,
Remove four screws that attach spark arrester
screen.
3.
Inspect screen and replace if torn, perforated or
otherwise damaged. DO NOT use a defective
screen. If screen is not damaged, clean it with
commercial solvent.
,
Reattach screen and muffler guard.
DO NOT tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
DO NOT modify generator in any way.
18
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