Craftsman 580329180 Owner’s Manual

Owner's Manual

[CRAFTSHAN+I

120/240 Volt Electric Start

7500 Watt

AC GENERATOR

Model No 580.329180

CusGemneraHt°lpline_

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. 186936 Draft 0 (8/16/2000) Printed in the U.S.A.

• Safety

• Assembly

• Operation

• Maintenance

• Parts

• Espan_l

Warranty .................................. 2

Safety Rules ............................... 3

Assembly ............................... 4-5

Operation .............................. 6-12

Product Specifications ....................... 13

Maintenance ........................... 13-16

Storage .................................. 17

Troubleshooting ............................ 18

Schematic/Wiring Diagram ................. 20-21

Replacement Parts ...................... 22-29

Emissions Warranty ......................... 30

EspaSol ............................... 31-51

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 GN-Series 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., D/817WA, Hoffman Estates, IL 60179

The engine exhaust from this product contains

chemicals known to the State of California

to cause cancer, birth defects,

or other reproductive harm.

,_ CAUTION! Before using this product, read this

manual and follow all Safety Rules and Operating Instructions.

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. Also, allow at least two feet of clearance on all sides of the generator while operating the unit.

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.

• The generator produces dangerously high voltage that can cause extremely hazardous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit any 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.

• Use a ground fault circuit interrupter in any damp or highly conductive area (such as metal decking or steel work).

• Do Not use worn, bare, frayed or otherwise damaged electrical cord sets with the generator.

• Operate generator only on level surfaces and where it will not be exposed to excessive moisture,

dirt, dust or corrosive vapors.

• 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.

• Never add fuel while unit is running.

• 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 or pilot light (as on a furnace, water heater or clothes dryer). FIRE or EXPLOSION may 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.

• Allow at least 2 feet of clearance on all sides of

generator or you could damage the unit. 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. Review "Cold Weather Operation" on page 10.

• Never start or stop the unit with electrical loads

connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads.

Disconnect all electrical loads before shutting down

the generator.

• Do Not insert objects through units cooling slots.

• 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.

,_ LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. IT MEANS"ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED."

Your generator requires some assembly and is ready for use 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.

IMPORTANT: Any attempt to run the engine before it has been serviced with the recommended oil will result

in an engine failure.

TO REMOVE GENERATOR FROM

CARTON

• Slice two corners at end of carton from top to bottom so the panel can be folded down flat.

• Remove all packing material, carton fillers, etc.

• Remove the generator and tranfer switch container

from the shipping carton.

CARTON CONTENTS

• Generator

• Wheel kit

• Locking plug

• Engine oil

• Transfer switch components

• Battery tray components

• Battery charge cable

• Manual

Check all contents. If any parts are missing or

damaged, call the generator helpline at

1-800-222-3136.

• Remove the 4 battery tray screws from cradle.

• Position the battery tray and install with supplied hardware.

Set battery onto tray. Position hold-down bracket. Retain battery to tray with two J bolts, two lock

washers, two flat washers and two hex nuts, as shown.

Connect the red battery cable from the engine starter switch to the positive (+) terminal on the battery.

INSTALLING TRAY AND BATTERY

NOTE: The generator can be started manually. If you

choose not to use the electric start feature of this generator, you do not need to install the battery.

You must purchase and install a 12 Volt DC battery

(Sears p/n 28-27145). The battery should be serviced

with electrolyte fluid and fully charged prior to

installation.

• Find the battery tray and fasteners shipped loose in the carton. Included are: one hold-down bracket, two 7" J bolts, two lock washers, two flat washers

and two hex nuts.

RED (+) wire from J

battery

BLACK (-) wire from battery

• Connect the black battery cable to the negative (-) terminal on the battery.

• Connect the other end of the black cable to the engine as shown.

A ARNING! Do Not connect the black battery

cable to any other location.

• Double check all connections to ensure they are in the correct locations and secure.

ASSEMBLING THE WHEEL KIT

The wheel kit is designed to greatly improve the portability of your generator.

NOTE: Wheel kit is not intended for over-the-road use. You will need a socket wrench with 1/2" or 13mm

sockets and a needle-nose plier to install this kit.

Refer to illustration shown below and install the wheel kit as follows:

• Place the generator on a hard flat surface.

• Stand at the engine end of the generator and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle. This will allow you to add the wheels.

• Slide the axle through the holes in the brackets provided on the generator cradle.

• Slide one wheel and flat washer on each end of the

axle. Make sure the air inflation valve is outward.

Insert both retaining pins using the needle-nose plier. Remove the wooden blocks.

• Attach the vibration mounts to the support leg with

30mm capscrews, washers and lock nuts.

• With the wheels on, you can now lift up the handle

end and attach the support leg with 20mm cap screws and lock nuts.

• Check each fastener to ensure it is secure.

Support

Vibration

Flatwasher

Locknut

30mm Capscrew

__.20mm

Capscrew

Flatwasher

Retaining Pin

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

Circuit Breakers (AC)

Choke Lever

12 Volt DC, 10 Amp Receptacle

Idle Control Switch

120 Volt AC, 30 Amp Locking Receptacle

Run/Stop

Cleaner

120/240 Volt AC, 30 Amp

Locking Receptacle

120 Volt AC, 20 Amp

Duplex Receptacle

12 Volt DC, 10 Amp Receptacle --This receptacle allows you to recharge a 12 Volt DC storage battery with provided battery charge cables.

120 Volt AC, 20 Amp, Duplex Receptacle -- Supplies 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 -- Supplies electrical power for the operation of 120 Volt

AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle -- Supplies 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.

120/240 Volt AC, 50 Amp Receptacle -- Supplies electrical power for the operation of 120/240 Volt AC, 50 Amp, single phase, 60 Hz, welder or motor loads.

120/240 Volt AC,

50 Amp Receptacle Grounding Lug

Spark A"_resterMuffler

Air Cleaner -- Filters intake air as it is drawn into the engine.

Choke Lever-- Used when starting a cold engine. Circuit Breakers (AC) -- Each receptacle is provided

with a push-to-reset circuit breaker to protect the generator against electrical overload.

Fuel Tank -- Tank holds 8 U.S. gallons of fuel. Grounding Lug -- Ground the generator to an

approved earth ground here. See page 8 for details.

Idle Control Switch -- The idle control runs the

engine at normal (high) speeds when there is an electrical load present and runs the engine at idle

(low) speeds the rest of the time. Run/Stop Switch -- Must be in "Run" position to start

engine. Set to "Stop" to stop a running engine. Spark Arrester Muffler -- Muffler lowers engine

noise and is equipped with a spark arrester screen.

CONNECTOR PLUGS

120 Volt AC, 20 Amp, Duplex Receptacle

This is a 120 Volt outlet protected against overload by a 20 Amp push-to-reset circuit breaker. Use each socket to power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to a combined 2,400 watts (2.4 kW) or 20 Amps of current. Use only high quality, well-insulated, 3-wire grounded cord sets rated for

125 Volts at 20 Amps (or greater).

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.

120/240 Volt AC, 30 Amp Receptacle

Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4-wire grounded cord set to the plug and to the desired load. The cord set should be rated for 250 Volts AC at 30 Amps (or greater).

4-Wire Cord Set

120V--_

(Neutral)

Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires.

120 Volt AC, 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

(or greater) to the plug.

3-Wire Cord Set

Neutral

120V

Hot

Y (Hot)

Ground

NEMA L14-30

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 or 240 Volt AC, 60 Hz, single phase loads requiring up to 7,200 watts (7.2 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

(Green)

X (Hot)

12 Volt DC, 10 Amp Receptacle

This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the

battery charge cables provided. This receptacle can not recharge 6 Volt batteries and can not be used to

crank an engine having a discharged battery. See the

section "Charging a Battery" (page 11) before

attempting to recharge a battery.

NEMA L5-30

/__ Ground

(Green)

120/240 Volt AC, 50 Amp Receptacle

Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts AC at 50 Amps to the plug.

240 Volts AC

Frame Ground

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 generator.

Y (Hot)

120 Volts _ 120 Volts

W (Neutral)

X (Hot)

NEMA 14-50

Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads requiring up to 7,500 watts (7.5 kW) of

power.

_ AUTION! Although this outlet states it has a

240 Volt 50 Amp rating (up to 12,500 watts), the generator is only rated for 7,500 watts.

Powering loads that exceed the wattage/ amperage capacity of the generator can damage it and cause serious injuries.

Grounding Wing Nut

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 the 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.

Connecting Electrical Loads

• Do Not connect 240 Volt loads to 120 Volt receptacles.

• Do Not connect 3-phase loads to the generator.

• Do Not connect 50 Hz loads to the generator.

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

• Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60 Hz electrical loads.

• Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be

greater than (a) the rated wattage/amperage capacity of the generator or (b) circuit breaker rating of the receptacle supplying the power. See "Don't Overload the Generator" on page 12.

BEFORE STARTING THE

GENERATOR

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

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.

E,,._h"r_ r_E,."kvlv_5,'.[oL_kvlv_:tll

°F -20 0 20 32 40 60 80 100

°C_ o -2'0 -io 6 i'o 5o 4'0

TemperatureRangeofExpectedUse

• Above 40°F, use SAE 10W-30 or SAE 30.

• Below 40°F, use synthetic 5W-20 or 5W-30. 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.

Slowly add unleaded regular gasoline to fuel tank. Be careful not to overfill. Allow about 1/2" of tank

space for fuel expansion, as shown here.

1/2" Air Space Tank

Fuel

• Install fuel cap and wipe up any spilled gasoline. IMPORTANT: It is important to prevent gum deposits

from forming in fuel system parts such as the

carburetor, fuel hose or tank during storage. 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 17. Never use engine or carburetor

cleaner products in the fuel tank as permanent damage may occur.

TO START THE ENGINE

A ARNING! Never start or stop engine with

electrical devices plugged into the receptacles AND devices turned ON.

Unplug all electrical loads from units receptacles before starting the engine.

Make sure the unit is in a level position. Open the fuel shut-off valve.

Add Gasoline

A ARNING! 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.

A 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.

FUEL TANK

FuelValveshown in "_--_ II

Open Position

Locate the Idle Control ON/OFF switch on the control panel and set it to the "OFF" position.

IDLE

OFF position

PlacetheRun/StopSwitchinthe"Run"position.

Move engine Choke lever to "Full" choke position.

"Full" Choke Position

• For electric starting: Press start switch on

generator cradle. To prolong the life of the starter components, press the starter button for no more

than 15 seconds, and pause for 30 seconds.

• For manual starting: Grasp the recoil handle and

pull slowly until slight resistanceis felt. Then pull rapidly one time only to start engine.

• If engine starts, skip the next step. If engine fails to start, proceed to the next step.

• Move choke lever to "Half" choke position, and pull

recoil twice.

• If engine fails to start, repeat all steps in "To Start The Engine" beginning on page 9.

• Move choke lever to "Run" position. Ifengine falters, move choke lever to "Half" choke position until the engine runs smoothly and then to "Run"

position.

NOTE: If engine fails to start after 3 pulls (or

15 seconds cranking), check for proper oil level in

crankcase. This unit is equipped with a Low Oil Shutdown System (see page 11).

STOPPING THE ENGINE

• Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned on.

• Turn "Off" the Idle Control switch (if 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.

• Close fuel valve. IMPORTANT: Do Not overload the generator. Also,

Do Not overload individual panel receptacles. These

outlets are protected against overload with push-to-

reset-type circuit breakers. If amperage rating of any

circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read "Don't

Overload the Generator" on page 12 carefully.

AUTOMATIC IDLE CONTROL

This feature is designed to greatly improve fuel economy. When this switch is turned "On," the engine will only run at its normal fast governed engine speed

when an electrical load is connected. When the load is removed, the engine will run at a reduced speed. With

the switch "Off," the engine runs at the normal fast engine speed all the time. Always have the switch OFF when starting and stopping the engine.

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 and one of the long sides of the box to expose exhaust side of unit. Cut appropriate

slots to access receptacles of unit.

• Start unit, then place box over it. Ensure a minimum of two feet clearance between open side

of box and nearest object.

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,

with two feet clearance between open side of box and

nearest object. Face exposed end away from wind

and elements, as shown.

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 into 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.

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.

CHARGING A BATTERY

Your generator has the capability of recharging a discharged 12 Volt automotive or utility style storage

battery. Do Not use the unit to charge any 6 Volt batteries. Do Not use the unit to crank an engine having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

• Check fluid level in all battery cells. If necessary,

add ONLY distilled water to cover separators in battery cells. Do Not use tap water.

• If the battery is equipped with vent caps, make sure they are installed and are tight.

• If necessary, clean battery terminals.

• Connect battery charge cable connector plug to panel receptacle identified by the words

"12 Volt DC".

• Connect battery charge cable clamp with red handle to the positive (+) battery terminal.

12 VOLT D.C.

RECEPTACLE

POS NEG

DANGER! Storage batteries give off explosive

hydrogen gas while recharging. An explosive mixture will remain around the battery for a long

time after it has been charged. The slightest

spark can ignite the hydrogen and cause an

explosion. Such an explosion can shatter the

battery and cause blindness or other serious injury.

DANGER! Do Not permit smoking, open

flame, sparks or any other source of heat around a battery. Wear protective goggles,

rubber apron and rubber gloves when working around a battery. Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can

cause severe burns. If spill occurs, flush area with clear water immediately.

12 VOLT BATTERY

• Connect battery charge cable clamp with black handle to the negative (-) battery terminal.

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine.

NOTE: Use an automotive hydrometer to test battery

state of charge and condition. Follow the hydrometer

manufacturer's instructions carefully. Generally, a battery is considered to be at 100% state of charge

when specific gravity of its fluid (as measured by

hydrometer) is 1.260 or higher.

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.

• Ifthe appliance, tool or motor does not give wattage, multiply volts times ampere rating to determine watts (volts x amps = watts).

WATTAGE REFENCE GUIDE

• 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:

1. Figure the watts needed to start the largest motor.

2. 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.

NOTE: All figures are approximate. See data plate on

appliance for wattage requirements.

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 cu ft 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 this device

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

Check Oil Level Service Air Pre-Cleaner

Change Oil And Oil Filters Clean Spark Arrestor Screen

Adjust Valve Clearance Retorque Head Bolts

Service Air Cleaner Replace Spark Plugs

Change oil after first 8 hours of operation then after every 50 hours or every season.

* Change oil and oil filter every 25 hours when operating under heavy load or in high temperatures. ** Clean more often under dirty or dusty conditions. Replace air cleaner parts if very dirty. *** Retorque head bolts only after the first 50 hours. Head bolts will not need further retorquing.

Every 8 Hours

or Daily

PRODUCT SPECIFICATIONS

Generator Specifications

Rated Maximum Power ....... 7,500 Watts (7.5 kW)

Surge Power ............... 9,375 Watts (9.3 kW)

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

Rated Maximum AC Load Current

at 240 Volts .............. 31.2 Amperes

at 120 Volts .............. 62.5 Amperes

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

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

Rated DC Voltage ........... 12 Volts

Rated Maximum DC Load Current

at 12 Volts ............... 10.0 Amperes

Engine Specifications

Rated Horsepower ........... 15 at 3600 rpm

Displacement ............... 410 cc

Spark Plug

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

Equivalent

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

Gasoline Capacity ........... 8 U.S. gallons

Oil Type:

Above 32° F .............. SAE 30 or 10W-30

Below 32° F............... Synthetic 5W-20 or

5W-30

25 Hours or 50 Hours or 100 Hours or

Every Season Every Season Every Season

x**

× ×

GENERAL RECOMMENDATIONS

The generator 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 the generator as instructed in this manual.

Some adjustments will need to be made periodically to properly maintain the generator.

All adjustments in the Service and Adjustments

section of this manual 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.

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.

X**

,_ CAUTION! Never insert any object or tool

through the air cooling slots, even if the engine

is not running.

NOTE:DoNotuseagardenhosetocleangenerator.

Watercanentertheenginefuelsystemandcause

problems.Inaddition,ifwaterentersthegenerator

throughcoolingairslots,somewaterwillberetained

invoidsandcracksoftherotorandstatorwinding insulation.Wateranddirtbuilduponthegenerator internalwindingswilleventuallydecreasethe insulationresistanceofthesewindings.

ToCleantheGenerator:

• Usea dampclothtowipeexteriorsurfacesclean.

• Asoft,bristlebrushmaybeusedto loosencaked ondirt,oil,etc.

• Avacuumcleanermaybeusedtopickuploose dirtanddebris.

• Lowpressureair(nottoexceed25psi)maybe

usedtoblowawaydirt.Inspectcoolingairslots

andopeningsonthegenerator.Theseopenings

mustbekeptcleanandunobstructed.

Engine Maintenance

_ ANGER! When working on the generator,

always disconnect negative cable from battery.

Also disconnect spark plug wires from spark

plug and keep wire away from spark plug.

• Coat gasket of new filter with fresh clean engine oil. Turn filter clockwise until gasket contacts tightly with filter adapter. Then tighten 3/4 turn more.

• Fill engine with recommended oil. (See "BEFORE STARTING THE Generator" on page 9 for oil recommendations).

• Install the oil fill cap and tighten securely.

• Wipe up any spilled oil.

Replacing the Spark Plug Use the recommended spark plug gapped to 0.76 mm

(0.030 in.). Replace the plug every 100 hours of operation or once each year, whichever comes first. This will help your engine start easier and run better.

1. Stop the engine and pull the spark plug wire off of the spark plug.

2. Clean the area around the spark plug and remove it from the cylinder head.

3. Set the spark plug's gap to 0.76 mm (0.030 in.).

Install the correctly gapped spark plug into the

cylinder head.

Checking Oil Level See "BEFORE STARTING THE GENERATOR" on

page 9 for information on checking the oil level. The

oil level should be checked before each use, or at

least every eight hours of operation. Keep the oil level maintained.

Changing the Oil and Oil Filter Change the oil and filter after the first eight hours of

operation. Change the oil every 50 hours thereafter. If you are running this unit under dirty or dusty conditions, or in extremely hot weather, change

the oil more often.

Use the following instructions to change the oil

while the engine is still warm:

• Clean area around oil drain plug and oil fill cap.

• Remove oil fill cap and oil drain plug. 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.

Retorque Head Bolts

After the first 50 hours of operation, you must retorque the head bolts to 6.9 kg.-m. (44 ft.-Ibs.).

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 re-torqued. This

is a very important step to insure the longest life for your engine.

NOTE: Only perform this adjustment after the first 50 hours of operation. The head bolts will need no

further adjustment.

• Torque sequence is as follows: A, B, C, D, (alternating pattern).

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 50 hours of operation or once a year, whichever

comes first. Clean or replace more often if operating

under dusty conditions. Clean foam precleaner every

25 hours of operation or sooner under dusty conditions.

To clean or replace foam precleaner:

• Remove air cleaner cover, then foam pre-filter.

Foam

Pre-Filter

Clean Spark Plugs

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 equipped with a spark arrester. The spark arrester must be maintained in good condition by the

owner/operator. Clean and inspect the spark arrester as follows:

• To remove the muffler guard from the muffler, remove the four screws that connect the guard to

the muffler bracket.

SPARK ARRESTOR SCREEN

Paper Filter

• Wash precleaner 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.

• Clean air cleaner cover then insert precleaner into cover. Next insert new paper filter into cover to hold precleaner 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.

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 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.

• 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 at 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 8mm 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 (0.05-0.1 mm).

NOTE: You must hold the rocker arm jam nut in place

as you turn the pivot ball stud.

When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the

rocker arm jam nut. Tighten the 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. NOTE: Start all four screws before tightening or you

will not be able to get all the screws in place.

NOTE: 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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