Craftsman 580.675610 Operator's Manual

AC Generator 5600 Watt

Model No.

580.675610

Part No. 200656GS Draft A (10/04/2006)

Generator

Customer Helpline

1-800-222-3136

Operator’s Manual

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

Sears Canada, Inc.

Visit our Craftsman website: www.sears.ca

• Safety

• Assembly

• Operation

• Maintenance

• Parts

• Français, p. 36

AVERTISSEMENT

Avant d’utiliser ce produit, veuillez lire le

manuel et suivre toutes les directives

relatives à la sécurité et à l’utilisation.

WARNING

Before using this product, read this

manual and follow all Safety Rules

and Operating Instructions.

TABLE OF CONTENTS

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

SAFETY RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 6

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

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

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

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

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

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

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SCHEMATIC/WIRING DIAGRAM. . . . . . . . . . . . . . . . . . 22-23

REPLACEMENT PARTS. . . . . . . . . . . . . . . . . . . . . . . . . 24-33

EMISSIONS SYSTEM WARRANTY . . . . . . . . . . . . . . . . 34-35

FRANÇAIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 or Canada 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 ever used for commercial or rental purposes.

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

Sears, Roebuck and Co., Hoffman Estates, IL 60179

Sears Canada Inc., Toronto, Ontario, Canada M5B 2B8

WARRANTY

SAFETY RULES

Read this manual carefully and become familiar with your generator. Know its applications, its limitations, and any hazards involved.

The safety alert symbol ( ) 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. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

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.

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.

Fire

Explosion

Toxic Fumes

Hot Surface

Moving Parts

Electrical Shock

Kickback

Flying Objects

Hazardous Chemical

Operator’s Manual

DANGER

Contents are harmful or fatal if swallowed. Avoid contact to eyes, skin or clothing. DO NOT take internally. Avoid breathing the mist or vapor. Overexposure to eyes or skin can cause irritation. Keep stabilizer out of the reach of children.

Fuel stabilizer is a hazardous chemical.**

• Fresh Start™ 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.

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

distillate (64742-47-8).

WARNING

Running engines give off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near the bedrooms.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

• DO NOT start or run engine indoors or in an enclosed area, even if windows and doors are open, including the generator compartment of a recreational vehicle (RV).

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

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

Generator produces powerful voltage. Failure to isolate generator from power utility can

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

• 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

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

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

• 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

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

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

• 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.

WARNING

Unintentional sparking can result in fire or electric shock.

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.

WARNING

Starter and other rotating parts can entangle hands, hair, clothing, or accessories.

• NEVER operate generator without protective housing or covers.

• DO NOT wear loose clothing, jewelry or anything that may be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

NOTICE

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

• 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

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

Excessively low speeds impose a heavy load.

• 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.

NOTICE

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

• 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.

• This equipment is designed to be used with Sears authorized parts ONLY. If equipment is used with parts that DO NOT comply with minimum specifications, user assumes all risks and liabilities.

KNOW YOUR GENERATOR

Read the Operator’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.

FEATURES AND CONTROLS

Stat Station™

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 — Protects engine by filtering dust and debris out of intake air.

Choke Lever — Used when starting a cold engine. Data Tag — Provides model, revision and serial number of

generator. Please have these readily available when calling for assistance.

Double Pole Circuit Breaker (AC) — A double pole circuit breaker is provided to protect all the receptacles and generator against electrical overload.

Fuel Tank — Capacity of five (5) U.S. gallons. Fuel Valve — Used to turn fuel supply on and off to engine. Grounding Fastener — 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. On/Off Switch — Set this switch to "On" before using recoil

starter. Set switch to "Off" to switch off engine.

Recoil Starter — Used to start the engine. Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen. StatStation™ — Displays the electrical load on generator

based on output frequency. It also has a built in maintenance reminder.

120 Volt AC, 20 Amp Duplex Receptacles

Fuel Tank

Choke Lever

Recoil Starter

On/Off Switch

Double Pole Circuit Breaker (AC)

120/240 Volt AC, 30 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Fastener

Oil Fill Cap

Data Tag

Fuel Valve

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

• 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 wrenches

• 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 in A.

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.

6. Repeat step 4 and 5 to secure second wheel.

7. Tip generator so that engine side is down.

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

9. Attach support leg using 2 capscrews (M8 x 16 mm) and 2 hex nuts. Tighten with a 13mm socket wrench and 13mm wrench.

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

ASSEMBLY

Support Leg

Axle

Flat Washer

Wheel

E-Ring

Axle

Wheel

Hex Nut

Capscrew

CAUTION

E-rings can cause eye injury. E-rings can spring back and become airborne

when installing or removing.

• Always wear eye protection when installing/removing e-rings.

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 “Oil Recommendations” in Maintenance section.

Verify provided oil bottle is the 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

Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.

• A minimum of 87 octane/87 AKI (91 RON). High altitude

use, see “High Altitude”.

• Gasoline with up to 10% ethanol (gasohol) or up to 15%

MTBE (methyl tertiary butyl ether) is acceptable.

To protect the fuel system from gum formation, mix in a fuel stabilizer when adding fuel. See Storage. All fuel is not the same. If you experience starting or performance problems after using fuel, switch to a different fuel provider or change brands. This engine is certified to operate on gasoline. The emission control system for this engine is EM (Engine Modifications).

1. Clean area around fuel fill cap, remove cap.

2. Slowly add regular unleaded fuel to fuel tank. Be careful not to overfill. Allow at least 1.5" of tank space for fuel expansion, as shown here.

3. Install fuel cap and wait for any spilled fuel to evaporate.

CAUTION! 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 performance issues, the fuel system should be treated with a fuel preserver or emptied before storage of 30 days or longer. To protect the fuel system from gum formation, use Briggs & Stratton FRESH START™ fuel stabilizer plus, or FRESH START™ 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” for additional information.

NEVER use engine or carburetor cleaner products in the fuel tank as permanent damage may occur.

Fuel

Tank

1.5” Air Space

NOTICE

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

• DO NOT attempt to crank or start the engine before it has been properly serviced with the recommended oil. This may result in an engine failure.

NOTICE

Avoid generator damage. Failure to follow Operator’s Manual for fuel

recommendations voids warranty.

• DO NOT use unapproved gasoline such as E85.

• DO NOT mix oil in gasoline.

• DO NOT modify engine to run on alternate fuels.

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

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.

• 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.

Fresh Start™ 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.

1. Place cartridge into fuel cap.

2. Push to “snap” cartridge into place.

3. Remove tab to expose membrane.

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

At higher altitudes (over 5,000 feet), 85 octane/85 AKI (89 RON) gasoline is recommended. High-altitude use may require a carburetor jet kit to improve performance and decrease fuel consumption. See any Sears or qualified dealer for more information.

DANGER

Fuel stabilizer is a hazardous chemical.**

• If SWALLOWED, call physician immediately.

• In the case of an emergency, contact a physician immediately and call 1-800-424-9300 for material safety information.

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

distillate (64742-47-8).

HOW TO USE YOUR GENERATOR

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 Electrical 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 Location

Generator Clearance

Place generator outdoors in an area that will not accumulate 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.

OPERATION

Exhaust Port

Typical Generator Shown

WARNING

Generator produces powerful voltage. Failure to isolate generator from power utility can

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

• 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

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• Keep at least 5 ft. (1.5 m) clearance on all sides of generator including overhead.

WARNING

Running engines give off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near the bedrooms.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

• DO NOT start or run engine indoors or in an enclosed area, even if windows and doors are open, including the generator compartment of a recreational vehicle (RV).

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 red fuel valve to “On” position.

3. Place choke lever in “Choke” position.

4. Set On/Off switch to “On” position.

5. Grasp recoil handle and pull slowly until slight resistance is felt. Then pull rapidly to start engine.

IMPORTANT: If engine floods, place choke lever in “Run” position and crank until engine starts.

6. Move choke lever to “Run” position a short distance at a time over several seconds in warm weather or minutes in cold weather. Let engine run smoothly before each change. Operate with choke in “Run” position.

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.

Connecting Electrical Loads

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

• 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.

• 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”.

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 On/Off switch to “Off” position.

4. Move fuel valve to “Off” position.

On/Off Switch is shown in On position

“Off” Position

“On” Position

WARNING

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

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

• 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

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

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

NOTICE

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

• 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.

WARNING

Backfire, fire or engine damage could occur.

• DO NOT stop engine by moving choke lever to “Choke” position.

CORD SETS AND RECEPTACLES

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.

120/240 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.

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

23.3 Amps for 240 Volts or two independent 120 Volt loads at 23.3 Amps each. The outlet is protected by a double pole rocker switch circuit breaker.

120 Volt AC, 20 Amp, Duplex Receptacles

Each duplex receptacle is protected against overload by a double pole rocker switch circuit breaker.

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). Inspect cord sets before each use.

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.

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. If an extension cord is used with adapter cord set, be sure extension cord is rated for 125V at 20 Amps.

NOTE: Follow all safety precautions when connecting any extension cord or device to the generator.

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

NOTICE

Receptacles may be marked with rating value greater than generator output capacity.

• 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”.

WARNING

Overloaded electrical cords can overheat, arc, and burn resulting in death, bodily injury, and/or property damage.

• ONLY use cords rated for your loads.

• Follow all safeties on electrical cords.

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:

Total Rated (Running) Watts = 3075 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875

NOTE: The rated (running) watts cannot exceed 5600. Also, given the 5600 watt rated limit, additional surge (starting) watts cannot exceed 8600.

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).

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.

*Wattages listed are approximate only. Check tool or appliance for actual wattage.

Tool or Appliance

Rated

(Running) Watts

Additional Surge

(Starting) Watts Window Air Conditioner

1200

1800

Refrigerator

800

1600

Deep Freezer

500

Television

500

Light (75 Watts)

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt

Deep Freezer

500

Sump Pump

800

1200

Refrigerator/Freezer - 18 Cu. Ft.

800

1600

Water Well Pump - 1/3 HP

1000

2000

Heating/Cooling

Window AC - 10,000 BTU

1200

1800

Window Fan

300

600

Furnace Fan Blower - 1/2 HP

800

1300

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” monitor

800

Other

Security System

180

AM/FM Clock Radio

300

Garage Door Opener - 1/2 HP

480

520 Electric Water Heater - 40 Gallon

4000

DIY/Job Site

Quartz Halogen Work Light

1000

Airless Sprayer - 1/3 HP

600

1200

Reciprocating Saw

960

960 Electric Drill - 1/2 HP

1000

Circular Saw - 7 1/4”

1500

Miter Saw - 10”

1800

Table Planer - 6”

1800

Table Saw/Radial Arm Saw - 10”

2000

Air Compressor - 1-1/2 HP

2500

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 200000 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 gross power rating for individual gas engine models is labeled in accordance with SAE (Society of Automotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure), and rating performance has been obtained and corrected in accordance with SAE J1995 (Revision 2002-05). Actual gross engine power will be lower and is affected by, among other things, ambient operating conditions and engine-to-engine variability. Given both the wide array of products on which engines are placed and the variety of environmental issues applicable to operating the equipment, the gas engine will not develop the rated gross power when used in a given piece of power equipment (actual "on-site" or net horsepower). This difference is due to a variety of factors including, but not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application limitations, ambient operating conditions (temperature, humidity, altitude), and engine-toengine variability. Due to manufacturing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

PRODUCT SPECIFICATIONS

Generator Specifications

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

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

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

AC Current

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

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

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

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

Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 U.S. gallons

Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 lbs.

Engine Specifications

Gross* Horsepower . . . . . . . . . . . . . . . . . . . . . 10 at 3600 rpm

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

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

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

Spark Plug

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

491055S or 5066D

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

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

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 Ounces (0.8 Liters)

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°.

SPECIFICATIONS

MAINTENANCE SCHEDULE

Follow the hourly or calendar intervals, whichever occurs first. More frequent service is required when operating in adverse conditions noted below.

MAINTENANCE

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.

Replace more often under dirty or dusty conditions.

GENERAL RECOMMENDATIONS

Regular maintenance will improve the performance and extend the life of the generator. See any 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.

MAINTENANCE SCHEDULE OPERATING INTERVALS

SERVICE DATES

FILL IN DATES AS YOU COMPLETE

REGULAR SERVICE

MAINTENANCE TASK

Before

Each Use

Every 25 Hours or

Yearly

Every 50 Hours or

Yearly

Every 100 Hours

or Yearly

Check oil level

Clean debris

Change engine oil

Service air cleaner

Service spark plug

Service spark arrester

Clean cooling system

Check valve clearance

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

NOTICE

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

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

StatStation™

The StatStation™ 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.

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” Check oil at 8 hour increments “C2” Change oil at 50 hour increments “C3” 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.

ENGINE MAINTENANCE

Oil

Oil Recommendations

NOTE: Use a 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 table below:

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 viscosity improves cold weather starting, but may increase oil consumption above 80°F (27°C).

*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.

Frequency Range LED Display

62.5-62.0 0

61.9-61.5 0

61.4-61.0 10

60.9-60.5 20

60.4-60.0 40

59.9-59.5 60

59.4-59.0 70

58.9-58.5 80

58.4-58.0 Flash 90

57.9-57.5 Flash 95

57.4-57.0 Flash OL

57.0 and below Flash OL

WARNING

Unintentional sparking can result in fire or electric shock.

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.

Checking Oil Level

Oil level should be checked prior to each use or at least every 5 hours of operation. Keep oil level maintained.

1. Make sure generator is on a level surface.

2. Clean area around oil fill and remove oil fill cap.

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

4. Replace and tighten oil fill cap.

Adding Engine Oil

1. Make sure generator is on a level surface.

2. Check oil level as described in “Checking Oil Level”.

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

4. Replace and tighten oil fill cap.

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.

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).

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.

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 recommended oil (about 28 oz.) into oil fill opening to the point of overflowing at oil fill cap.

7. Reinstall oil fill cap. Finger tighten cap securely.

8. Wipe up any spilled oil.

9. Reconnect spark plug wire to spark plug.

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. Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use a recommended replacement plug.

4. Check electrode gap with wire feeler gauge and set spark plug gap to 0.030 inch (0.76mm) if necessary.

5. Install spark plug and tighten firmly.

NOTE: You can purchase a new spark plug by calling 1-800-4-MY-HOME (469-4663).

Cartridge

Screw

Cover

Base

CAUTION

Avoid prolonged or repeated skin contact with used motor oil.

• Used motor oil has been shown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

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: 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, brushcovered, 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 as follows:

1. To remove muffler heat shield from muffler, remove four screws that connect guard to muffler bracket.

2. 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.

4. Reattach screen and muffler guard.

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”.

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.

Muffler

Spark Arrester

Screen

Heat Shield

WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (152 cm) of clearance on all sides of generator including overhead.

CAUTION

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

Excessively low speeds impose a heavy load.

• 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.

+ 42 hidden pages

Craftsman 580.675610 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual