Craftsman 580.323602 User manual

Owner's Manuam
®
Generator
HOURS: Mort. ° Fri. 8 a.m. to 5 p.m. {CT)
CAUTtON
Before using this product, read this
manual and follow all Safety Rules
and Operating instructions.
PRECAUC_ON
Antes de utilizar el producto, lea este
manual y siga todas las Reglas de
Seguridad e Instrucciones de Uso.
Sears, Roebuck and Co., Hoffman Estates, _L 60179 U.S.A.
Visit our Craftsman website: www.craftsmamcom
Part No. 193353GS Draft9 (07192005)
o Safety
o AssemNy
oOperation
o Maintenance
o Parts
o EspaSoN

STORAGE ............................... 17
TROUBLESHOOTING ...................... 18
SCHEMATIC/WIRING DIAGRAM ............. 19
REPLACEMENT PARTS ................. 20=28
EMISSION SYSTEM VVARRANTY ......... 30-31
ESPANOL ............................. 32_51
HOW TO ORDER PARTS .......... BACK PAGE
LIMtTED WARRANTY FOR CRAFTSMAN 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. 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, over-speeding, 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, _L 60179 U.S.A.
© Sears Brands, LLC

This is the safety alert symbol. It is used to alert you to potential personal inju_' hazards.
Obey all safety messages that foltow this symbol to avoid possible injury or death.
ii_=!_l;ijRead this manuat 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, wil/
result in death or serious injury. WARNING indicates a
hazard which, if not avoided, could result in death or
serious injury. CAUTION indicates a hazard which, if
not avoided, might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in equipment
damage. Follow safety messages to avoid or reduce
the risk of injury or death.
WARNING
The engine exhaust from this product contains
chemicams 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 33CFRo183 and should not be used on
marine applications.
• Failure to use the appropriate U. S. Coast Guard
approved generator could result in bodily injury and/or
property damage.
Hazard Symbols and Meanings
Electrocution Electrical Shock Electrical Shock
Explosion Fire
Toxic Fumes Hot Surface Kickback
WARNING
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).
WARNING
When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp
or highly conductive area, such as metal decking or steel
work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
DO NOT operate generator in the rain.
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
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
WHEN ADDING OR DRAINmNG 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.
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.
If fuel spills, wait until it evaporates before starting
engine.
WHEN OPERATING EQUIPPv_ENT
Do not tip engine or equipment at angle which causes
fue! 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
DO NOT touch hot surfaces.
Allow equipment to cool before touching.
The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.
Keep at least 3 feet of clearance on all sides of generator
for adequate cooling, maintenance and servicing.
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. If you equip the muffler with a
spark arrester, it must be maintained in effective working
order.You can order a spark arrester through your
authorized Sears service dealer.
WARNING
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR
+Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.
WHEN TESTING FOR ENGINE SPARK
Use approved spark plug tester.
DO NOT check for spark with spark plug removed.
CAUTION
DO NOT tamper with governed speed. Generator
supplies correct rated frequency and voltage when
running at governed speed.
DO NOT modify generator in any way.
CAUTION
See "Don't Overload Generator".
Start generator and let engine stabilize before connecting
electrical loads.
Connect electrical loads in OFF position, then turn ON
for operation.
Turn electrical loads OFF and disconnect from generator
before stopping generator.
CAUTION
Use generator only for intended uses.
If you have questions about intended use, ask dealer or
contact Sears.
Operate generator only on level surfaces.
DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.
If connected devices overheat, turn them off and
disconnect them from generator.
Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.

KNOW YOUR GENERATOR
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.
120 Volt AC, 20 Amp
Duplex Receptacles
Fuel Tank Rocker Switch
Recoil Starter
Choke Lever
Air
Cleaner
120/240 Volt AC, 20 Amp
Receptacles
Circuit Breakers
120 Volt AC, 20 Amp, Dupmex 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.
1201240 Volt AC, 20 Amp Locking 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 -- Protects engine by filtering dust and
debris out of intake air.
CircuEt Breakers -- Each receptacle socket is
protected against electrical overload with "push to
reset" circuit breakers.
Fuel Tank -- Tank holds 4 U.S. gallon of unleaded
fuel.
Spark Attester
Muffler
Grounding Fastener
Grounding Fastener -- If required, please consult a
qualified electrician, electrical inspector, or local
agency having jurisdiction.
OH Fill Cap/Dipstick -- Check and fill engine with oil
here. See page 7 for oil recommendations and filling
instructions.
Choke Lever -- Used when starting a cold engine.
Recoil Starter -- Used for starting the engine.
Rocker Switch -- Set switch to "On" prior to using
recoil starter. Set switch to "Off" to switch off engine.
Spark Attester Muffler- Exhaust muffler lowers
engine noise and is equipped with a spark attester
screen.

TO REMOVE GENERATOR FROM
CARTON
• Open top flaps of shipping carton.
• Slice two corners at end of carton from top to
bottom so the panel can be folded down flat, then
remove all packing material.
• Remove the generator and contents from the
shipping carton.
CARTON CONTENTS
Check all contents against those listed below:
• Main unit
• Engine oil
• Owner's manual
• Wheel Kit
if any parts are missing or damaged, call the
generator helpline at 1-800-222-3136.
INSTALL WHEEL KIT
NOTE: While the wheel kit is designed to greatly
improve the portability of your generator, it is not
intended for over-the-road use.
You will need two 1/2" or 13mm open end wrenches
or a socket wrench with 1/2" or 13mm sockets, a
15/16" wrench and a needle-nose pliers to install this
kit.
Install the Wheel Kit as Follows:
1. Place bottom of generator cradle on a flat surface.
2. Place axle stud through wheel retainer on cradle
frame, as shown below.
3. Use 15/16" wrench to secure axle stud to frame
with 5/8-18 jam nut.
4. Install other axle stud in same manner.
NOTE: Be sure to install wheel with raised hub inboard.
5. Tip unit and install wheel. Place flat washer over
axle stud.
6. Retain wheel on axle stud with retaining pin.
Install other wheel on remaining axle stud the
same way.
7. Attach support leg using two 1/2" or 13mm
wrenches with 20mm cap screws and lock nuts.
8. Center lifting handle on generator end of cradle.
Attach handle using two 1/2" or 13mm wrenches
with 45mm capscrews and hex nuts.
Capscrew
Handle
Nut
Mounting Leg
Nut
Axle
Stud
\
Capscrew Wheel
Jam Nut
_./_ _Nasher
Retaining Pin

BEFORE STARTING "THE
Add Engine OH
IMPORTANT: Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine failure.
NOTE: When adding oil to the engine crankcase, use
only high quality detergent oil rated with API service
classification SF, SG, SH, SJ or higher. DO NOT use
special additives.
1. Choose a viscosity according to the table below:
J
100
C 30 2Q 10 0 10 20 30 40
STARTING TEMPERATURE RANGE ANTICIPATED BEFORE NEXT O_L CHANGE
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.
* The use of multi-viscosity oils (5W-30, 10W-30, etc.)
in temperatures above 40°F (4°C) will result in higher
than normal oil consumption. When using a multi-
viscosity oil, check oil more frequently.
** If using SAE 30 oil in temperatures below 40°F
(4°C), it will result in hard starting and possible engine
bore damage due to inadequate lubrication.
2. Place generator on a level surface.
3. Clean area around oil fill and remove oil dipstick.
4. Wipe dipstick clean. Replace and tighten dipstick.
Remove and and check oil level.
5. Slowly pour oil into oil fill opening. Pause to permit
oil to settle. Oil level should be at "Full" mark on
dipstick. DO NOT OVERFILL. Remove and check
oil level.
NOTE: You may not need to use all the supplied oil.
6. Replace and tighten dipstick.
NOTE: Check oil often during engine break-in.
Add Fue{
WARNING
WHEN ADDING FUEL
Turn generator OFF and let it coo! at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fil!fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.
Keep fue! away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
NOTE: This gasoline engine is certified to operate on
gasoline. Exhaust Emission Control System: EM
(Engine Modifications).
1. Use clean, fresh, regular UNLEADED fuel with a
minimum of 85 octane with equipment. DO NOT
use fuel which contains Methanol DO NOT mix oil
with fuel
2. Clean area around fuel fill cap, remove cap.
3. Slowly add regular unleaded fuel to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank
space for fuel expansion, as shown here.
4. Install fuel cap and wipe up any spilled fuel.
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 problems, the fuel system should be
emptied before storage of 30 days or longer. Drain the
fuel tank, start the engine and let it run until the fuel
lines and carburetor are empty. Use fresh fuel next
season. See "Storage" on page 17 for additional
information.
NEVER use engine or carburetor cleaner products in
the fuel tank as permanent damage may occur.

HOW TO USE YOUR GENERATOR
if you have any problems operating your generator
after reading the manual, please call the generator
he+p+ineat 1-800-222-3136.
System Ground
The generator has a system ground that connects the
generator flame 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).
Spec{amRequirements
There may be Federa+ 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 Build+rig's E_ectrica_
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.
WARNING
When usinggenerator 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 othep,,vise damaged.
DO NOT operate generator in the rain.
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.
Generator Location
Generator Clearance
WARNtNG
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).
The generator must be at least 5 ft. (152 cm) from
structures having combustible walls and/or other
combustible materials. Leave at least 3 ft. (92 cm) all
around generator including overhead, for adequate
cooling, maintenance and servicing.
Place generator in a well ventilated area, which will
allow for removal of deadly exhaust gas+ DO NOT
place generator where exhaust gas could accumulate
and enter inside or be drawn into a potentially
occupied building. Ensure exhaust gas is kept away
from any windows, doors, ventilation intakes or other
openings that can allow exhaust gas to collect in a
confined area. Prevailing winds and air currents
should be taken into consideration when positioning
generator.
Typical Generator Shown
Exhaust Port

To Start The Engine
CAUTION
See "Don't Ovedoad 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.
Disconnect all electrical loads from the generator.
Follow start instruction steps in numerical order:
1. Make sure unit is on a level surface.
IMPORTANT: Failure to start and operate unit on a
level surface will cause the unit not to start or shut
down during operation.
2. Turn fuel valve to "On" position. Fuel valve handle
should be vertical (pointing toward ground) for fuel
to flow.
Fuel Valve is shown
in the On position
3. Place choke lever in "Choke" position.
/
4. Set rocker switch to "On" position.
Rocker Switch is
shown in On position
5. Grasp recoil handle and pull slowly until slight
resistance is felt. Then pull rapidly to start engine.
WARNING
When starting engine, pull cord slowly until resistance is
felt and then pull rapidly to avoid kickback.
NEVER start or stop engine with electrical devices
plugged in and turned on,
iMPORTANT: if engine floods, place choke lever in
"Run" position and crank until engine starts.
1
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
)rotection device.
WARNING
DO NOT touch hot surfaces,
Allow equipment to coo! before touching.
The generator must be at bast 5 feet from structures having
combustible wails and/or other combustible materials.
Keep at least 3 feet of clearance on al! sides of generator
for adequate cooling, maintenance and servicing.
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. If you equip the muffler with a
spark arrester, it must be maintained in effective working
order,You can order a spark arrester through your
authorized Sears service dealer,
Connecting E_ectrica_ 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 rocker switch to "Off" position.
4. Move fuel valve to "Off" position.
lCAUTION
DO NOT stop engine by moving choke leverto "Choke"
position,Backfire,fireor engine damage could occur,

CORD SETS AND RECEPTACLES
I cAuTmo. 1
• NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply,
• DO NOT overload the generator, See "Don't Overload
Generator".
Use only high quality, weGinsulated, extension cords
with the generator's 120 Volt electrical receptacles.
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 owner'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 Volt AC, 20 Amp Duplex Receptacle
Each receptacle is protected against overload by a
single 15 Amp push-to-reset 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.
120/240 Volt AC, 20 Amp Receptacle
This is a full capacity receptacle; it can supply the
generator's full rated output from this sole outlet. The
outlet is protected by two 15 Amp push-to-reset
circuit breakers.
4-Wire Cord Set
.J
(Neutral)
Y (Hot) | X (Hot)
NEMA L14-20 /_7 Ground (Green)
A NEMA L14-20 plug is used with this 240 Volt
receptacle. Connect a suitable 4-wire cord set to the
plug and to the desired load. The cord set should be
rated for 250 Volt AC loads at 20 Amps (or greater).
COLD WEATHER OPERATION
Under certain weather conditions (temperatures below
40°F [4°C] combined with high humidity), your
Craftsman generator may experience icing of the
carburetor and/or the crankcase breather system. To
reduce this problem, you need to perform the foJlowing:
1. Make sure generator has clean, fresh fuel.
2. Open fuel valve (turn valve to open position).
3. Use SAE 5W-30 oiJ(synthetic preferred, see
page 7).
4. Check oil Jevel daiJy or after every eight (8) hours
of operation.
5. Maintain the generator folJowing the "Maintenance
Schedule" on page 14.
6. SheJter unit from elements.
10

inanemergency,usetheoriginalshippingcartonasa
temporaryshelter:
7. Cutoffallcartonflaps.
8. Cutoutonelongsideofcartontoexposemuffler
sideofunitasshown.
Mufflersideexposed.Yourunitmaydifferin
appearancefromthatshownabove.
IMPORTANT:Thegeneratormustbeatleast5ft.
(152cm)fromstructureshavingcombustiblewalls
and/orothercombustiblematerials.Leaveatleast3ft.
(92cm)allaroundgeneratorincludingoverhead,for
adequatecooling,maintenanceandservicing.
9. Cutappropriateslotstoaccessreceptaclesofunit.
10.Startunit,thenplacecartonoverit.
NOTE:Removeshelterwhentemperaturesareabove
40°F[4°C].
DO NOT touch hot surfaces.
Allow equipment to cool before touching.
The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.
Keep at least 3 feet of clearance on all sides of generator
for adequate cooling, maintenance and servicing.
Remove shelter when temperatures are above 40°F [4°C].
For a more permanent shelter, build a structure that
wiJl enclose three sides and the top of the generator.
7. Make sure entire muffler-side of generator is
exposed, as shown previously.
IMPORTANT: The generator must be at least 5 ft.
(152 cm) from structures having combustible walls
and/or other combustible materials. Leave at least 3 ft.
(92 cm) all around generator including overhead, for
adequate cooling, maintenance and servicing.
9. Face exposed end away from wind and elements.
10. Structure should hold enough heat created by the
generator to prevent icing problem.
11. Start and run engine outdoors.
12. Keep exhaust gas from entering a confined area
through windows, doors, ventilation intakes or
other openings.
WARNtNG
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure, including the generator compartment of a
recreational vehicle (RV).
13. DO NOT enclose generator any more than shown.
14. Remove shelter when temperatures are above
40°F [4°C].
15. Turn engine OFF and let cool two (2) minutes
before refueling.
11

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:
Too! or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated
1200
80O
5OO
5OO
75
3075 Total
Running Watts
Total Rated (Running) Watts
Highest Additional Surge Watts
Total Generator Output Required
Power Management
Additional Surge
_Startin _ Watts
1800
1600
5OO
1800 Highest
Surge Watts
= 3075
= 1800
= 4875
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.
Tool or Appliance Rated* (Running)
Watts
Essentials
Bulb -75 watt 75
Deep Freezer 500
Sump Pump 800
RefrigeratodFreezer -18 Cu, Ft, 800
Water We!l Pump -1/3 HP 1000
Heating/Cooling
Window AC -10,000 BTU 1200
Window Fan 300
Furnace Fan Blower -1/2 HP 800
Kitchen
Microwave Oven -1000 Watt 1000
Coffee Maker 1500
El_ic Stove --Sin le Element 1500
Hot Plate 2500
Famimy Room
DVD/CD Player 100
VCR 100
Stereo Receiver 450
Color Television -27" 500
Personal Computer w/17" 800
monitor
Other
Security S_stem 180
AM/FM Clock Radio 300
Garage Door Opener -1/2 HP 480
Electric Water Heater -40 4000
Gallon
DIY/Job Site
Quartz Halogen Work Light
Aidess Sprayer -1/3 HP
Reciprocating Saw
Electric Drill -1/2 HP
Circular Saw -7 1/4"
Miter Saw -10"
Table Planer -6"
Table Saw/Radial Arm Saw -10"
Air Compressor -1-1/2 HP
*Wattages listed are approximate only.
appliance for actual wattage.
1000
600
96o
1000
1500
1800
1800
2000
2500
Check
Additional
Surge
(Starting)
Watts
500
1200
1600
2000
1800
6OO
1300
520
1200
96O
1000
1500
1800
1800
2000
2500
tool or
12

ENGtNE 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 120000
engines are certified by the California Air Resources
Board to meet emissions standards for 125 hours.
Such certification does not grant the purchaser, owner
or operator of this engine any additional warranties
with respect to the performance or operational life of
this engine. The engine is warranted solely according
to the product and emissions warranties stated
elsewhere in this manual.
Power Ratings
The power ratings for an individual engine model are
initially developed by starting with SAE (Society of
Automotive Engineers) code J1940 (Small Engine
Power & Torque Rating Procedure) (Revision 2002-
05). Given both the wide array of products on which
our engines are placed, and the variety of
environmental issues applicable to operating the
equipement, it may be that the engine you have
purchased will not develop the rated horsepower when
used in a piece of power equipment (actual "on-site"
power). This difference is due to a variety of factors
including, but not limited to, the following: differences
in altitude, temperature, barometric pressure, humidity,
fuel, engine lubrication, maximum governed engine
speed, individual engine to engine variability, design of
the particular peice of power equipment, the manner in
which the engine is operated, engine run-in to reduce
friction and clean out of combustion chambers,
adjustments to the valves and carburetor, and other
factors. The power ratings may also be adjusted
based on comparisons to other similar engines utilized
in similar applications, and will therefore not
necessarily match the values derived using the
foregoing codes.
PRODUCT SPECIFICATIONS
Generator Specifications
Rated Running Watts .......... 3,600 Watts (3.6kW)
Rated Surge Watts ........... 5,300 Watts (5.3kW)
Rated AC Voltage ............ 120/240 Volts
Rated Maximum AC Current
at 240 Volts ............... 15.0 Amperes
at 120 Volts ............... 30.0 Amperes
Rated Frequency ............ 60 Hz at 3600 rpm
Phase ...................... Single Phase
Shipping Weight .............. 127 Ibs.
Engine Specifications
Rated Horsepower ............ 7.0 at 3600 rpm
Bore ....................... 2.69 in. (68mm)
Stroke ...................... 2.20 in. (56mm)
Displacement ................ 12.48 in. (206 cc)
Spark Plug
Type: ................. Champion RC12YC or
Equivalent
Set Gap To: ............ 0.030inch (0.76ram)
Armature Air Gap: ............ 0.010-0.014 in.
(0.25-0.36mm)
Valve clearance with valve springs installedand piston 1/4 in.
(6 mm) past top dead center (checkwhen engine iscold).
intake ...................... 0.004-0.006 in.
(0.10-0.15 mm)
Exhaust .................... 0.009-0.011 in.
(0.23-0.28 mm)
Fuel Capacity ................ 4 U.S. gallons
Oil Capacity ................ 20 Ounces (.6 Liters)
Oil Type:
Above 40° F ............... SAE 30
Below 40° F ............... SAE 5W-30 or 10W-30
13

MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is recuired when operating in adverse conditions noted below.
MABNTENANCE SCHEDULE
FiLL tN DATES AS YOU
COMPLETE REGULAR SERVICE
MAINTENANCE TASK
Check oil tevet
EClean debris
Change engine oil
Service air cleaner
Service spark plug
Service spark arrester
Clean cooiing system
Prepare for storage
SERVICE DATES
Before Every 25 Hours
Each Use or Yearly
X
x
X 2
Every 50 Hours
or Year y
X 1
Every 100
Hours or Yearly
x
x
x 2
If unit is to remain idle for longer than 30 days.
SERVICE DATES
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
authorized Sears 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.
EMiSSiON CONTROL
Maintenance, replacement or repair of the emission
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 C_eaning
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.
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.
CAUTION
DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.
Use a soft bristle brush to loosen caked on dirt, oil,
etc.
Use a vacuum cleaner to pick up loose dirt and debris.
Use low pressure air (not to exceed 25 psi) to blow
away dirt. Inspect cooling air slots and openings on
the generator. These openings must be kept clean
and unobstructed.
14

ENGINE MAINTENANCE
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 TESTBNG 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.
Changing Engine OH
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. cAuTmO. 1
• Used motor oil has been shown to cause skin cancer in
certain laboratory animals,
• Thoroughly wash exposed areas with soap and water,
KEEP OUT OF REACH OF CHILDREN.
DON'T POLLUTE. CONSERVE
RESOURCES. RETURN USED OIL TO
COLLECTION CENTERS.
C[eanlRepmace Spark Plug
Change the spark plug every 100 hours of operation
or once each year, whichever comes first. This will
help your engine to start easier and run better.
1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Check electrode gap with wire feeler gauge and
set spark plug gap to 0.030 inch (0.76mm) if
necessary.
4. Replace spark plug if electrodes are pitted, burned
or porcelain is cracked. Use a recommended
replacement plug.
5. Install spark plug and tighten firmly.
NOTE: You can purchase a new spark plug by calling
1-800-366-PART.
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 screw and tilt cover down.
CARTRIDGE BASE
Change the oil while the engine is still warm from
running, as follows:
1. Make sure unit is on a [eve[ 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 cap/dipstick.
6. Slowly pour oil into oil fill opening. Pause to permit
oil to settle. Oil [eve[ should be at "Full" mark on
dipstick. DO NOT OVERFILL Remove and check
oil level.
7. Reinstall oil cap/dipstick. Tighten cap securely.
8. Wipe up any spilled oil.
COVER /
SLOTS AND
SCREW _ TABS
2. Carefully remove cartridge assembly.
3. To clean cartridge, gently tap pleated paper side
on a flat surface.
4. Reinstall clean or new cartridge inside cover.
5. Insert cover's tabs into slots in bottom of base.
6. Tilt cover up and tighten screw securely to base.
NOTE: You can purchase new air filter elements by
calling 1-800-366-PART.
15

Carburetor
if you think your carburetor needs adjusting, see your
nearest Sears service center. Engine performance
may be affected at attitudes above 3000 feet. For
operation at higher elevations, contact your nearest
Sears service center.
CJean Spark Arrester Screen
The engine exhaust muffler has a spark attester
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 attester screen
b calling 1-800-366°PART.
WARNING
DO NOT touch hot surfaces.
Allow equipment to cool before touching.
The generator must be at least 5 feet from structures having
combustible walls and/or other combustible materials.
Keep at least 3 feet of clearance on all sides of generator
for adequate cooling, maintenance and servicing.
In the State of California a spark arrester is required by law
(Section4442 of the CaliforniaPublic ResourcesCode).
Otherstates may havesimilar laws. Federallawsapply on
federal lands. If you equip the mufflerwith a spark arrester,
it mustbe maintainedin effectiveworking order.
if you use your generator on any forest-covered,
brush-covered, or grass-covered unimproved land, it
must have a spark attester. The spark attester must
be maintained in good condition by the
owner/operator.
Clean and inspect the spark attester as follows:
1. To remove muffler heat shield from muffler,
remove four screws that connect guard to muffler
bracket.
.
3.
.
Spark Attester
Screen
_eat Shield
Remove four screws that attach spark attester
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 screen and muffler guard.
Air Coo_ing 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 an authorized Sears service dealer clean the
cooling system per recommended intervals (see
"Maintenance Schedule" on page 14). Equally
important is to keep top of engine free from debris.
See "Generator Cleaning".
c[ Ak
16

Thegeneratorshouldbestartedatleastonceevery
sevendaysandallowedtorunatleast30minutes.If
thiscannotbedoneandyoumuststoretheunitfor
morethan30days,usethefollowinginformationasa
guidetoprepareitforstorage.
Long Term Storage Instructions
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 fuel 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
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.
WHEN DRAINBNG FUEL
Turn generator OFF and let it cool at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Drain fuel tank outdoors.
Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
Protect Fuel System
1. Remove all gasoline from fuel tank to prevent gum
deposits from forming on these parts and causing
possible malfunction of engine.
2. Run engine until engine stops from lack of fuel.
Change OH
While engine is still warm, drain oil from crankcase.
Refill with recommended grade.
Oil Cylinder Bore
• Remove spark plug and pour about 1 ounce (30ml)
of clean engine oil into the cylinder.
• Install spark plug and crank slowly to distribute oil.
WARNING
NEVER crank enqine with spark plug removed,
Generator
1. Clean generator as outlined in "Generator Cleaning".
2. Check that cooling air slots and openings on
generator are open and unobstructed.
Other Storage Tips
1. DO NOT store fuel from one season to another.
2. Replace fuel can if it starts to rust. Contaminated
fuel will cause engine problems.
3. If possible, store unit indoors and cover it to give
protection from dust and dirt. BE SURE TO
EMPTY FUEL TANK.
.
5.
Cover unit with a suitable protective cover that
does not retain moisture.
Store generator in clean, dry area.
WARNING
DO NOT place a storage cover over a hot generator,
Let equipment coo! for a sufficient time before placing
the cover on the equipment.
17

Problem
Engineis running, but no AC
output is available.
Engine runs good at noqoad but
"bogs down" when loads are
connected.
Engine will not start; or starts
and runs rough.
Engine shuts down when
running.
Cause
One of the circuit breakers is
open.
Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
.
Short circuit in a connected
load.
Engine speed is too slow.
Generator is overloaded.
4. Shorted generator circuit.
Rocker Switch set to "Off".
Fuel Valve is in "Off" position.
Correction
Reset circuit breaker.
Contact Sears service facility.
3. Check and repair.
4. Connect another device that is
in good condition.
Disconnect shorted electrical
load.
Contact Sears service facility.
3. See "Don't Overload
Generator".
4. Contact Sears service facility.
Set switch to "On".
Turn fuel valve to "Open"
position.
3. Dirty air cleaner.
4. Out of gasoline.
5. Stale gasoline.
3. Clean or replace air cleaner.
4. Fill fuel tank.
5. Drain gas tank and carburetor;
fill with fresh fuel.
Engine lacks power.
.
to spark plug.
7. Bad spark plug.
8. Water in gasoline.
Spark plug wire not connected
9. Flooded.
6. Connect wire to spark plug.
7. Replace spark plug.
8. Drain gas tank and carburetor;
fill with fresh fuel.
9. Wait 5 minutes and re-crank
engine.
Engine "hunts" or falters.
10. Excessively rich fuel mixture.
11. Intake valve stuck open or
closed.
12. Engine has lost compression.
Out of gasoline.
Low oil level.
Load is too high.
Dirty air filter.
Carburetor is running too rich or too
lean.
0. Contact Sears service facility.
1. Contact Sears service facility.
2. Contact Sears service facility.
Fill fuel tank.
Fill crankcase to proper level or
place generator on level
surface.
See "Don't Overload
Generator".
Replace air filter.
Contact Sears sewice facility.
18

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P_ER
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22
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19

CRAFTSMAN 3600 Watt AC Generator 580.323602
Main Unit _ Exploded View
/+4
52 /
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58
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25
24
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22
4\
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900
15
31
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