Craftsman 580.329130 User Manual
Owner's Manual
CRRFTSMRN°
3800 Watt
AC Generator
Model No.
580.329130
CusGemn:/at°lpl ine_ "
HOURS: Mon.- Fri. 8 a.m. to 5 p.m. (CT)
CAUTION:
Before using this product, read this
manual and follow all its Safety Rules
and Operating Instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
Visit our Craftsman website: www.sears.com/craftsman
Part No. 187144 Draft 0 (9/6/2000)
• Safety
• Assembly
• Operation
• Maintenance
• Parts
• Espahol
WARRANTY ................................... 2
SAFETY RULES ............................... 3
ASSEMBLY ................................... 4
OPERATION ................................ 4-8
MAINTENANCE ............................. 9-11
SPECIFICATIONS .............................. 9
STORAGE ................................... 12
TROUBLESHOOTING .......................... 13
SCHEMATIC DIAGRAM ......................... 14
WIRING DIAGRAM ............................. 15
REPLACEMENT PARTS ..................... 16-22
EMISSION CONTROL WARRANTY ................ 23
ESPANOL ................................. 24-39
HOW TO ORDER PARTS ............... BACK PAGE
LIMITED WARRANTY FOR DELUXE PORTABLE GENERATORS
SEARS warrants to the original purchaser that the alternator and engine for its portable generator will be free
from defects in materials or workmanship for the items and period set forth below from the date of original
purchase. This warranty is not transferable and applies only to portable generators driven by the Sears
warranted engine.
CONSUMER* COMMERCIAL*
Alternator 2 years (2nd year parts only) 1 year
Engine 2 years (2nd year parts only) 1 year
* NOTE: For the purpose of this warranty "Consumer Use" means personal residential household and
emergency use by original purchaser, not to be used as a primary source of power. "Commercial Use" means all
other uses, including rental, construction, commercial, and income producing purposes. Once a generator has
experienced commercial use, it shall thereafter be considered a commercial use generator for the purpose of
this warranty.
During said warranty period, SEARS will, at its option, repair or replace any part which, upon examination by
SEARS, is found to be defective under normal use and service**. Starting batteries are not warranted by
SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by
the purchaser and prepaid by him. This warranty does not cover normal maintenance and service and does not
apply to a generator set, alternator or engine, or parts which have been subjected to improper or unauthorized
installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair
or storage so as, in SEARS's judgment, to adversely affect its performance and reliability.
** NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to
perform well. This warranty will not cover repair when normal use has exhausted the life of a part or engine.
THERE IS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE
DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO
THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR
CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES
IS EXCLUDED.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest SEARS authorized warranty service facility. Warranty service can be performed
only by a SEARS authorized service facility. This warranty will not apply to service at any other facility. At the
time of requesting warranty service, evidence of original purchase date must be presented.
SEARS, ROEBUCK AND CO., Hoffman Estates, IL 60179 U.S.A
The engine exhaust from this product contains
chemicals known to the State of California
to cause cancer, birth defects, or other
reproductive harm.
CAUTION! Always disconnect spark plug wire
and place the wire where it cannot contact the
spark plug to prevent accidental starting when
setting up, transporting, adjusting or making
repairs to your generator.
DANGER! This generator is designed for
outdoor use only. Do Not use this generator
inside any building or enclosure, including the
generator compartment of a recreational vehicle
(RV). Fire or an explosion may result. No user
performed modifications, including venting of
exhaust and/or cooling ventilation, will eliminate
the danger. Allow at least two feet of clearance
on all sides of the generator while operating the
unit.
,_ CAUTION! Before using this product, read this
manual and follow all Safety Rules and
Operating Instructions.
• The generator produces dangerously high voltage
that can cause extremely hazardous electrical
shock. Avoid contact with bare wires, terminals,
etc. Never permit an unqualified person to operate
or service the generator.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet. Dangerous electrical shock
will result.
• The National Electric Code requires the frame and
external electrically conductive parts of generator
be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the generator. Consult with a
local electrician for grounding requirements in your
area.
• Do Not use worn, bare, frayed or otherwise
damaged electrical cord sets with the generator.
Using any defective cord set may result in
electrical shock or damage to equipment and/or
property.
• Operate generator only on level surfaces and
where it will not be exposed to excessive moisture,
dirt, dust or corrosive vapors.
• Never add fuel while unit is running.
• Allow at least 2 feet of clearance on all sides of
generator while operating unit or damage could
result. Read "Cold Weather Operation" on page 7.
• Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do Not permit smoking, open
flames, sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine.
Comply with all laws regulating storage and
handling of gasoline.
• Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can
overflow onto a hot engine and cause FIRE or an
EXPLOSION.
Never store generator with fuel in tank where
gasoline vapors might reach an open flame or
spark (as on a furnace, water heater or clothes
dryer). FIRE or an EXPLOSION might result.
Generator exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air where adequate
ventilation is available.
• The unit requires an adequate flow of cooling air
for its continued proper operation. Never operate
the unit inside any room or enclosure where the
free flow of cooling air into and out of the unit
might be obstructed. Without sufficient cooling air
flow, the unit quickly overheats, damaging the
generator or nearby property.
• Never start or stop the unit with electrical loads
connected to receptacles AND with the connected
devices turned ON. Start the engine and let it
stabilize before connecting electrical loads.
Disconnect all electrical loads before shutting
down the generator.
• Never operate generator:
in rain; in any enclosed compartment; when
connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if
flames or smoke are observed while unit is
running; if unit vibrates excessively.
NOTE: Your generator is equipped with a spark
arrester muffler, the spark arrester must be
maintained in effective working order by the
owner/operator.
In the State of California a spark arrester is required
by law (Section 4442 of the California Public
Resources Code). Other states may have similar
laws. Federal laws apply on federal lands.
,_ 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.
CARTON CONTENTS
• Main unit
• Owner's manual
• Engine oil
Check all contents. If any parts are missing or
damaged, call the generator helpline at
1-800-222-3136.
TO REMOVE GENERATOR FROM
CARTON
• Slice two corners at end of carton from top to
bottom so the panel can be folded down fiat, then
remove all packing material.
• Read "Cold Weather Operation" on page 7.
• Remove the generator from the shipping carton.
KNOW YOUR GENERATOR
Read the owner's manual and safety rules before operating your generator.
Compare the illustrations with your Generator to familiarize yourself with the locations of various controls and
adjustments. Save this manual for future reference.
Fuel Tank
120 Volt AC, 30 Amp,
Locking Receptacle
120/240 Volt AC,
20 Amp Receptacle
120 Volt AC, 20 Amp
Receptacles
Grounding Wing Nut
120 Volt AC, 20 AC Amp 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 Volt AC, 30 Amp, Locking Receptacle -- May
be used to supply electrical power for the operation of
120 Volt AC at 30 Amp, single phase, 60 Hz, electrical
lighting, appliance, tool and motor loads.
120/240 Volt AC, 20 Amp Receptacle -- May be
used to supply electrical power for the operation of
120 and/or 240 Volt AC, 20 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
Air Cleaner- Filters air as it is drawn into the engine
carburetor.
Choke Lever- Used when starting a cold engine.
Circuit Breakers -- Each receptacle is provided with
a "push to reset" circuit breaker to protect the
Fuel Shut Off
Air Cleaner
Run/Stop Switch
Choke Lever
Oil Filter
Spark Arrester Muffler
Circuit Breakers
generator and any connected tools or appliances
against electrical overload.
Fuel Shut Off -- Make sure fuel shut off is open
before starting engine. Close when engine is shut off
Fuel Tank -- Tank holds 4 U.S. gallons of unleaded
gasoline.
Grounding Wing Nut -- Provides a convenient tie
point for connecting generator to earth ground.
Oil Filter -- Filters engine oil for longer engine life.
Run/Stop Switch -- Set this switch to "Run" before to
set in starting mode. Set the switch to "Stop" to shut
off a running engine. Located on the engine block.
Spark Arrester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester
screen.
4
RECEPTACLES
Use only high quality, well-insulated, extension cords
with the generator's electrical receptacles. Check the
ratings of all extension cords before you use them.
Extension cords should be rated for 125 Volt AC loads
at 20 Amps or greater for most electrical devices.
Some devices, however, may not require this type of
extension cord. Check the owner's manuals of those
devices for the manufacturer's recommendations.
Keep extension cords as short as possible, preferably
less than 15 feet, to prevent voltage drop and possible
overheating of wires.
120 Volt AC, 20 Amp Receptacles
Each receptacle of this pair is protected against
overload by a single 20 Amp push-to-reset type of
circuit breaker.
4-Wire Cord Set
240V
qF-120V--_ 120V-_
i
Neutral)
Y (P_ot)_ X (Hot)
NEMA L14-20 /--/I-7 _rr°Uenn_
As shown above, connect a suitable 4-wire cord set to
a NEMA L14-20 plug and to the desired load. The
cord set should be rated for 250 Volt AC loads at
20 Amps (or greater).
,_ CAUTION! Although this receptacle is rated for
240 Volt AC loads at 20 Amps (4,800 watts or
4.8 kW), this generator is rated for a total output
of 3,800 watts. Powering loads that exceed the
generator's wattage capacity can damage it or
cause serious injuries. The total number of
240 Volt loads powered through this receptacle
should not exceed 20 Amps.
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.
_ AUTION! Although each receptacle socket is
rated for 120 Volt AC loads at 20 Amps
(2,400 watts or 2.4 kW), this generator is rated
for a total output of 3,800 watts. Powering loads
that exceed the generator's wattage capacity
can damage it or cause serious injuries. The
total number of 120 Volt loads powered through
these receptacles should not exceed 20 Amps.
120/240 Volt AC, 20 Amp Receptacle
This is a full capacity receptacle, which means you
can take the generator's full rated wattage from this
single receptacle. The outlet is protected by a 20 Amp
push-to-reset circuit breaker.
120 Volt AC, 30 Amp Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect
a 3-wire cord set rated for 125 Volts AC at 30 Amps to
the plug.
3-Wire Cord Set
Neutral
120V
Hm
/__ Ground
NEMA L5=30 (Green)
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3,600 watts
(3.6 kW) of power at 30 Amps. The outlet is protected
by a 30 Amp push-to-reset circuit breaker.
HOW TO USE YOUR GENERATOR
If you have any problems operating your generator,
please call the generator helpline at 1-800-222-3136.
Grounding the Generator
The National Electrical Code requires that the frame
and external electrically conductive parts of this
generator be properly connected to an approved earth
ground. Local electrical codes may also require proper
grounding of the unit. For that purpose, a grounding
wing nut is provided on the base of the cradle (note:
typical unit shown may not look like your unit).
k
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding wing
nut and to an earth-driven copper or brass grounding
rod (electrode) provides adequate protection against
electrical shock. However, local codes may vary
widely. Consult with a local electrician for grounding
requirements in your area.
Proper grounding of generator will help prevent
electrical shock in the event of a ground fault condition
in the generator or in connected electrical devices.
Proper grounding also helps dissipate static electricity,
which often builds up in ungrounded devices.
BEFORE STARTING THE
GENERATOR
To operate the engine you must do the following:
Although multi-viscosity oils (5W30, 10W30, etc.)
improve starting in cold weather, these multi-viscosity
oils will result in increased oil consumption when used
above 32°F. Check your engine oil level more
frequently to avoid possible damage from running low
on oil.
• Place generator on a level surface.
• Clean area around yellow oil fill cap. Remove the
oil fill cap.
• Slowly fill engine with oil through the oil fill opening
until the oil level is to the point of overflowing.
• Install yellow oil fill cap and finger tighten securely.
• Check engine oil level before starting each time
thereafter. If the oil level is below the point of
overflowing, fill to the proper level.
Add Gasoline
,_ WARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot. Do
Not light a cigarette or smoke when filling the
fuel tank.
,_ CAUTION! Do Not overfill the fuel tank.
Always leave room for expansion.
• Use regular UNLEADED gasoline with the
generator engine. Do Not use premium gasoline.
Do Not mix oil with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank.
Be careful not to overfill. Allow about 1/2" of tank
space between bottom of fill opening and top of
fuel for fuel expansion, as shown here.
1/2" Air Space Tank
Fuel
Add Engine Oil
NOTE: When adding oil to the engine crankcase in
the future, use only high quality detergent oil rated
with API service classification SF or SG SAE 30
weight. Use no special additives.
Select the oil's viscosity grade according to your
expected operating temperature. Do Not use
SAE 10W-40.
• Above 40°F, use SAE 10W-30 or SAE 30.
• Below 40°F, use synthetic 5W-20 or 5W-30.
_F -20
C-30
0 20 32 40 60 80 100
-2'0 -io 6 i'o 2'0 4'0
TemperatureRangeof Expected Use
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels
(called gasohol, ethanol or methanol) can attract
moisture, which leads to separation and formation of
acids during storage. Acidic gas can damage the fuel
system of an engine while in storage. To avoid engine
problems, the fuel system should be emptied before
storage of 30 days or longer. See "Storage" on
page 12. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may
Occur.
TO START THE ENGINE
_ AUTION! Never run engine indoors or in
enclosed poorly ventilated areas. Engine
exhaust contains carbon monoxide, an odorless
and deadly gas.
,_ WARNING! temperature of muffler and nearby
areas may exceed 150°F (65°C). Avoid these
areas.
Disconnect all electrical loads from the generator. Use
the following start instruction steps by numerical order:
1. Turn the fuel valve to the "On" position.
_ FUELTAN_
2. Set the Run/Stop switch to "Run" position.
TO STOP THE ENGINE
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with
electrical devices plugged in AND turned on.
• Let engine run at no-load for several minutes to
stabilize the internal temperatures of engine and
generator.
• Move Run/Stop switch to "Stop" position.
COLD WEATHER OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] and a high dew point), your generator may
experience icing of the carburetor and/or the
crankcase breather system.
In an emergency, use the original shipping box as a
temporary shelter:
• Cut off all flaps.
• Cut out one of the long sides of the box to expose
exhaust side of unit. Ensure a minimum of two feet
clearance between open side of box and nearest
object.
• Cut appropriate slots to access receptacles and
clear handles.
• Start unit, then place box over it.
3. Place the choke lever in the "Full" choke position.
//
4. Grasp the recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly one time only
to start engine.
• If engine starts, proceed to step 6.
• If engine fails to start, proceed to step 5.
5. Move the choke lever to "Half" choke position,
and pull recoil handle twice.
• If engine fails to start, repeat steps 3 thru 5.
6. Move choke lever to "Run" position. If engine
falters, move choke lever to "Half" choke position
until the engine runs smoothly and then to "Run"
position.
NOTE: If engine still fails to start after 3 pulls, check
for proper oil level in crankcase. This unit is equipped
with a Low Oil Shutdown System (see page 8).
IMPORTANT: Remove shelter when temperature is
above 40°F [4°C].
For a more permanent shelter, build a structure that
will enclose three sides and the top of the generator:
• Make sure entire muffler-side of generator is
exposed. Note that your generator may appear
different from that shown here.
• Ensure a minimum of two feet clearance between
open side of box and nearest object.
• Face exposed end away from wind and elements.
• Enclosure should hold enough heat created by the
generator to prevent icing.
,_ CAUTION! Never run unit indoors; Do Not
enclose generator any more than shown.
Remove shelter when temperatures are above
40°F [4°C].
LOW OIL PRESSURE SHUTDOWN
SYSTEM
The engine is equipped with a low oil pressure sensor
that shuts down the engine automatically when the oil
pressure drops below 6 psi. If the engine shuts down
by itself and the fuel tank has enough gasoline, check
engine oil level.
Initial Start-up
A delay built in the low oil shutdown system allows oil
pressure to build during starting. The delay allows the
engine to run for about 10 seconds before sensing oil
pressure.
Sensing Low Pressure
If the system senses low oil pressure during operation,
the engine shuts down. As the system shuts down, the
low oil light comes ON. However, once the engine has •
stopped rotating, this lightwill go OFF.
Restarting
If you try to restart the engine within 10 seconds after
it shuts down, the engine may NOT start. The system
needs 5 to 10 seconds to reset.
If you do restart the engine after such a shutdown and
have not corrected the low oil pressure, the engine
runs for about 10 seconds as described above and
then stops.
DON'T OVERLOAD THE
GENERATOR
Overloading a generator in excess of its rated wattage
capacity can result in damage to the generator and to
connected electrical devices. Observe the following, to
prevent overloading the unit:
• Add up the total wattage of all electrical devices to
be connected at one time. This total should NOT
be greater than the generator's wattage capacity.
• The rated wattage of lights can be taken from light
bulbs. The rated wattage of tools, appliances and
motors can usually be found on a data plate or
decal affixed to the device.
If the appliance, tool or motor does not give
wattage, multiply volts times ampere rating to
determine watts (volts x amps = watts).
Some electric motors, such as induction types,
require about three times more watts of power for
starting than for running. This surge of power lasts
only a few seconds when starting such motors.
Make sure you allow for this high starting wattage
when selecting electrical devices to connect to your
generator. First, figure the watts needed to start the
largest motor. Add to that figure the running watts
of all other connected loads.
The Wattage Reference Guide below is provided to
assist you in determining how many items your
generator can operate at one time.
WATTAGE REFERENCE GUIDE
Recreational/Home Uses
Tool/Appliance ...................... Watts
AM/FM clock radio ....................... 50
Light bulb ............................. 100
Fan .................................. 200
20" color TV ........................... 400
*Deep freezer .......................... 500
Personal computer and 15" monitor ......... 800
"1/3 hp furnace fan blower ................ 800
Microwave oven ........................ 800
"18 cuft refrigerator ..................... 800
Sump pump .......................... 1000
Electric skillet ......................... 1250
*½ hp water well pump .................. 1400
"12,000 Btu window air conditioner ......... 1400
Space heater ......................... 1800
Electric water heater .................... 4000
Professional/Contractor Uses
Tool/Appliance ...................... Watts
"1/3 hp airless sprayer ................... 600
3/8" hammer drill ....................... 600
Variable speed Sawzall® ................. 960
½" power drill ......................... 1000
Quartz-halogen work light ................ 1000
Belt sander ........................... 1200
7 ¼" circular saw ...................... 1500
7 ¼" worm drive saw .................... 1600
"1½ hp air compressor .................. 1800
"10" power miter saw ................... 1800
6" bench grinder ....................... 1800
*6" table planer ........................ 1800
"10" table/radial arm saw ................ 2000
Wire feed welder ....................... 2400
*=allow 3 times listed watts for starting surge
MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is required when operating in adverse conditions noted below.
Maintenance Operation Every 8 Hours 25 Hours or 50 Hours or 100 Hours or
Check oil level X
Change oil & oil filter:l:
Clean spark arrester screen
Service air filter pre-cleaner
Service air cleaner cartridge
Adjust valve clearance
Replace spark plugs
Retorque head bolts
:1: Change oil & oilfilter after first 8 hours of operation, then after every 50 hours.
* Change oil & oilfilter every 25 hours when operating under heavy load or in high temperatures.
** Clean more often under dirty or dusty conditions. Replace filter parts if very dirty.
*** Perform this task only after first 50 hours of operation. Head bolts will not need further retorquing.
PRODUCT SPECIFICATIONS
Generator Specifications
Rated MaximumPower ........ 3,800 Watts (3.8kW)
Surge Maximum Power ........ 4,750 Watts (4.75kW)
Rated AC Voltage ............ 120/240 Volts
Rated MaximumAC Current:
at 240 Volts ............... 15.8 Amperes
at 120 Volts ............... 31.6 Amperes
Rated Frequency ............ 60 Hz at 3600 rpm
Phase ..................... Single Phase
Gasoline Capacity ............ 4 U.S. gallons
Engine Specifications
Rated Horsepower ........... 7.8 at 3600 rpm
Spark Plug
Type: ................ Champion RC12YC or
Set Gap To: ........... 0.030inch (0.76mm)
Oil Type:
Above 32° F .............. SAE 30 or 10W-30
Below 32° F............... Synthetic 5W-20 or
GENERAL RECOMMENDATIONS
The warranty of the Generator does not cover items that
have been subjected to operator abuse or negligence.
To receive full value from the warranty, operator must
maintain Generator as instructed inthis manual.
Some adjustmentswill need to be made periodically to
properlymaintain your generator. All adjustmentsin the
Service and Adjustments section of thismanual should
be made at least once each season. Followthe
requirements inthe "Maintenance Schedule" chart above.
or Daily Every Season Every Season Every Season
NOTE: Once a year you should clean or replace the
spark plug and replace the air filter. A new spark plug
and clean air filter assure proper fuel-air mixture and
help your engine run better and last longer.
GENERATOR 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.
Equivalent
5W-30
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.
CLEAN THE GENERATOR
_ AUTION! Never Insert any object or tool
through the air cooling slots, even if the engine
is not running.
• Use a damp cloth to wipe exterior surfaces clean.
• A soft, bristle brush may be used to loosen caked
on dirt, oil, etc.
Yearly
Avacuumcleanermaybeusedtopickuploose
dirtanddebris.
Lowpressureair(nottoexceed25psi)maybe
usedtoblowawaydirt.Inspectcoolingairslots
andopeningsonthegenerator.Theseopenings
mustbekeptcleanandunobstructed.
ENGINE MAINTENANCE
Retorque Head Bolts
After 50 hours of operation, retorque the head bolts for
this engine to 3.1 kg/m (22 foot-pounds). The torque
sequence is A, B, C, D, E (star pattern).
D B
,_ DANGER! When working on the generator,
always disconnect spark plug wire from spark
plug and keep it away from spark plug.
Checking Oil Level
Oil level should be checked prior to each use or at
least every 8 hours of operation. Keep oil level
maintained.
Changing Engine Oil and Oil Filter
Change oil after first 8 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 oil more often.
Change oil while engine is still warm from running, as
follows:
• Clean area around oil drain plug.
• Remove oil drain plug and oil fill plug and drain oil
completely into a suitable container.
• When oil has completely drained, install oil drain
plug and tighten securely.
• Place a suitable container beneath the oil filter and
turn filter counterclockwise to remove. Discard
according to local regulations.
• Coat gasket of new filter (p/n 70185) with engine
oil. Turn filter clockwise until gasket snugs against
the filter adapter. Then tighten filter an additional
3/4 turn.
• Filloil sump with recommended oil (see page 6).
• Installthe oil fill plug and tighten securely.
A E
C
IMPORTANT: If you feel uncomfortable about doing
this procedure or you don't have the proper tools,
please take your generator in to the nearest Sears
service center to have the head bolts retorqued. This
is a very important step to insure the longest life for
your engine.
Service Air Cleaner
Your engine will not run properly and may be
damaged if you run it using a dirty air cleaner.
Clean or replace the air cleaner paper filter once every
25 hours of operation or once a year, whichever
comes first. Clean or replace more often if operating
under dusty or dirty conditions. Clean foam
pre-cleaner every 25 hours of operation or sooner
under dusty conditions.
To clean or replace foam pre-cleaner:
• Remove air cleaner cover, then foam pre-filter.
PAPER
FILTER
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.
Replace with recommended spark plug, as follows.
• Clean area around spark plug, then remove and
inspect it. Replace spark plug ifelectrodes are
pitted, burned or porcelain is cracked.
• Check new spark plug electrode gap with wire
feeler gauge and set gap to 0.030 inch (0.76mm).
FOAM
PRE-FILTER
• Wash pre-cleaner in soapy water. Squeeze pre-
filter dry in clean cloth (DO NOT TWIST).
• Clean air cleaner cover before installing it.
To clean or replace paper air filter:
• Remove air cleaner cover; then remove foam pre-
filter (service if necessary) and remove paper filter.
• Clean paper filter by tapping it gently on a solid
surface. If the filter is too dirty, replace it with a new
one. Dispose of the old filter properly.
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Clean air cleaner cover then insert pre-cleaner into
cover. Next insert new paper filter into cover to
hold pre-cleaner in place and assemble all of them
to the base of the air cleaner.
NOTE: If you need to order a new air filter, please call
1-800-366-PART.
Clean Spark Arrester Screen
The engine exhaust muffler has a spark arrester
screen. Inspect and clean the screen every 100 hours
of operation or once each year, whichever comes first.
NOTE: 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.
Clean and inspect the spark arrester asfollows:
• To remove the muffler guard from the muffler,
remove the four screws that connect the guard to
the muffler bracket.
• Remove the four screws attaching the valve cover
with a #2 or #3 phillips screwdriver.
• Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To
get the piston to TDC, pull on the recoil handle
slowly while watching the piston through the spark
plug hole. As you pull on the recoil handle, the
piston should move up and down. The piston is at
TDC when it is up as high as it can go.
• Loosen the rocker arm jam nut. Use an 8 mm allen
wrench to turn the pivot ball stud while checking
clearance between the rocker arm and the valve
stem with a feeler gauge. Correct clearance is
0.002-0.004 inch (0.05-0.1mm). NOTE: You must
hold the rocker arm jam nut in place as you turn
the pivot ball stud.
Feeler
Allen Wrench Gauge
SPARK ARRESTER
SCREEN
MUFFLER
HEAT SHIELD
Remove four screws that attach the spark arrester
screen.
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 the screen and the muffler guard.
Adjusting Valve Clearance
After the first 50 hours of operation, you should adjust
the valve clearance in the engine.
IMPORTANT: If you feel uncomfortable about doing
this procedure or you don't have the proper tools,
please take your generator in to the nearest Sears
service center to have the valve clearance adjusted.
This is a very important step to insure the longest life
for your engine.
To adjust valve clearance:
• Make sure the engine is at room temperature.
• Make sure that the spark plug wire is removed from
the spark plug and out of the way.
• Remove the breather tube from the valve cover.
Loosen
Jam Nut
When valve clearance is correct, hold the pivot ball
stud in place with the allen wrench and tighten the
rocker arm jam nut to 65-85 inch-pounds torque.
After tightening the jam nut, recheck valve
clearance to make sure it did not change.
• Reattach the valve cover. Start all four screws
before tightening or you will not be able to get all
the screws in place. Make sure the gasket between
the valve cover and cylinder head is in place.
• Reattach the breather tube.
• Reattach the spark plug wire to the spark plug.
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GENERAL
The generator should be started at least once every
seven days and allowed to run at least 30 minutes. If
this cannot be done and you must store the unit for
more than 30 days, use the following information as a
guide to prepare it for storage.
Long Term Storage Instructions
,_ WARNING! Never store engine with fuel in
tank indoors or in enclosed, poorly ventilated
areas where fumes may reach an open flame,
spark or pilot light as on a furnace, water heater,
clothes dryer or other gas appliance.
It is important to prevent gum deposits from forming in
essential fuel system parts, such as the carburetor,
fuel filter, fuel hose or tank during storage. Also,
experience indicates that alcohol-blended fuels (called
gasohol, ethanol or methanol) can attract moisture,
which leads to separation and formation of acids
during storage. Acidic gas can damage the fuel
system of an engine while in storage.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. Follow
these instructions:
_ WARNING! Drain fuel into approved container
outdoors, away from open flame. Be sure
engine is cool. Do Not smoke.
Protect Fuel System
• Remove all gasoline from the fuel tank to prevent
gum deposits from forming on these parts and
causing possible malfunction of engine.
• Run engine until engine stops from lack of fuel.
Engine
Change Oil
While engine is still warm, drain oil from crankcase.
Refill with recommended grade.
Oil Cylinder Bore
,_ CAUTION! Avoid spray from spark plug hole
when cranking engine slowly.
• Remove spark plug and pour about 1/2 ounce
(15ml) of engine oil into the cylinder. Cover spark
plug hole with rag. Crank slowly to distribute oil.
• Install spark plug. Do Not connect spark plug wire.
Generator
• Clean the generator as outlined on page 9 ("Clean
the Generator").
• Check that cooling air slots and openings on
generator are open and unobstructed.
Other Storage Tips:
• Do Not store gasoline from one season to another.
• Replace your gasoline can if it starts to rust.
Contaminated gasoline will cause engine problems.
• If possible, store your unit indoors and cover itto
give protection from dust and dirt. BE SURE TO
EMPTY THE FUEL TANK.
• Cover your unit with a suitable protective cover that
does not retain moisture.
,_ DANGER! Never cover your generator while
engine and exhaust area are warm.
• Store generator in clean, dry area.
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