Craftsman 580.323610 User manual

Operator's Manual
®
AC Generator
3600 Watt
Model No.
580.323610
HOURS: Mort. -Fri. 8 a.m. to 5 p.m. (CT)
! ii_[iWARNING
Before using this product, read this
manual and follow all Safety Rules
and Operating Instructions.
[i1 .,,ADVERTENCIA
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, IL 60179 U.S.A.
Visit our Craftsman website: www.craftsman.com
Part No. 198138GS [)]'aft ((05'08,2006)
.Safety
•Assembly
•Operation
•Maintenance
• Parts
. EspaSol, p. 36

WARRANTY .............................. 2
SAFETY RULES ......................... 3-4
FEATURES AND CONTROLS ................ 5
ASSEMBLY ............................. 6-8
OPERATION ........................... 9-13
SPECIFICATIONS ......................... 14
MAINTENANCE ........................ 15-18
STO RAG E ............................... 19
TROUBLESHOOTING ...................... 20
NOTES ............................. 21 & 33
SCHEMATIC/WIRING DIAGRAM .......... 22-23
REPLACEMENT PARTS ................. 24-32
EMISSIONS SYSTEM WARRANTY ........ 34-35
ESPANOL ............................. 36-59
HOW TO ORDER PARTS .......... BACK PAGE
ONE-YEAR FULL WARRANTY ON CRAFTSMAN GENERATOR
If this generator fails due to a defect in material or workmanship within one year from the date of purchase,
return it to any Sears store, other Craftsman outlet, or Sears Parts & Repair Center in the United States for free
repair (or replacement if repair proves impossible).
Additional One=Year Limited Warranty on Craftsman Generator
For the second year from the date of purchase, if any part of this generator fails due to a defect in material or
workmanship, a new part will be supplied free of charge. You must pay the labor cost if you wish to have it
installed.
All warranty coverage applies for only 90 days from date of purchase if this generator is used for commercial or
rental purposes. Once a generator has experienced commercial or rental use, it shall thereafter be considered a
commercial or rental generator for the purpose of this warranty.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Sears, Roebuck and Co., D/817WA, Hoffman Estates, IL 60179 U.S.A.
© Sears Brands, LLC

_iL This is the safety alert symbol, it is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
[ =_-!] Read this manual carefully and become
...................familiar with your generator. Know its
applications, its limitations, and any hazards
involved.
The safety alert symbol (,A) is used with a signal
word (DANGER, CAUTION, WARNING), a pictorial
and/or a safety message to alert you to hazards.
DANGER indicates a hazard which, if not avoided, will
result in death or serious injury. WARNING indicates a
hazard which, if not avoided, could result in death or
serious injury. CAUTION indicates a hazard which, if
not avoided, might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in equipment
damage. Follow safety messages to avoid or reduce
the risk of injury or death.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
• This generator does not meet U. S. Coast Guard
Regulation 33CFR-183 and should not be used on
marine applications.
• Failure to use the appropriate U. S. Coast Guard
approved generator could result in bodily injury and/or
property damage.
Hazard Symbols and Meanings
Explosion Fire Electrical Shock
Toxic Fumes 'W, 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 (even if doors or windows are open), including
the generator compartment of a recreational vehicle (RV).
DANGER
Fresh Start TM fuel cap is designed to hold a cartridge
which contains fuel stabilizer.
If SWALLOWED, call physician immediately. DO NOT
induce vomiting. If inhaled, remove to fresh air. In case
of eye or skin contact, flush with water for 15 minutes.
Store unopened cartridges in a cool, dry, well ventilated
area. Keep open cartridge in fuel cap, and fuel cap
closed on fuel tank when not in use.
In the case of an emergency, contact a physician
immediately and call 1-800-424-9300 for material safety
information.
'Fuei stabilizer contains: 2,6-di-tret-butylphenol (128-39-2) and aliphatic
petroleum distillate (64742-47-8)
WARNING
When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
Use a ground circuit fault interrupter (GFCI) in any damp
or highly conductive area, such as metal decking or steel
work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords which are
worn, frayed, bare or otherwise damaged.
DO NOT operate generator in the rain or wet weather.
DO NOT handle generator or electrical cords while
standing in water, while barefoot, or while hands or feet
are wet.
DO NOT allow unqualified persons or children to operate
or service generator.
WARNING
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 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
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Reflective exhaust heat may damage fuel tank causing fire.
Code of Federal Regulation (CFR) Title 36 Parks,
Forests, and Public Property require equipment powered
by an internal combustion engine to have a spark
arrester, maintained in effective working order, complying
to USDA Forest service standard 5100-1C or later
revision. In the State of California a spark arrester is
required under section 4442 of the California Public
resources code. Other states may have similar laws.
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
ReadtheOperator'sManualandsafetyrulesbeforeoperatingyourgenerator,
Compare the illustrations with your generator to familiarize yourself with the locations of various controls
and adjustments, Save this manual for future reference,
Fuel Tank
\,
I
Rocker
Switch
StatStation TM
Cleaner
Oil Fill Data Tag
Cap/Dipstick }J Spark Arrester
120 Volt AC, 20 Amp Muffler
Duplex Receptacles ',,
\
Circuit Breakers
120 Volt AC, 20 Amp, Duplex Receptacles iMay
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.
Air Cleaner iProtects engine by filtering dust and
debris out of intake air.
Choke Lever iUsed when starting a cold engine.
Circuit Breakers (AC) iPush to reset circuit
breakers are provided to protect the generator against
electrical overload.
Data Tag -- Provides model, revision and serial
number of generator. Please have these readily
available when calling for assistance.
Fuel Tank iCapacity of four (4) U.S. gallons (15 I).
Recoil Starter
Choke Lever
Grounding Fastener
Grounding Fastener iConsult your local agency
having jurisdiction for grounding requirements in your
area.
Oil Fill Cap/Dipstick iCheck and fill engine with oil
here. See page 16 for oil recommendations and filling
instructions.
Recoil Starter iUsed to start the engine.
Rocker Switch -- Set this switch to "On" before using
recoil starter. Set switch to "Off" to switch off engine.
Spark Arrester Muffler -- Exhaust muffler lowers
engine noise and is equipped with a spark arrester
screen.
StatStation TM -- Displays the nominal load on
generator based on output frequency. It also has a
built in maintenance reminder.

YourCraftsmangeneratorrequiressomeassembly
andisreadyforuseonlyafterithasbeenproperly
servicedwiththerecommendedoilandfuel.
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:
, 13mmwrench
• Pliers
• Safety glasses
install the Wheel Kit as Follows:
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 below 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.
CAUTION
Always wear eye when
6. Repeat step 4 and 5 to secure second wheel.
7. Tip generator so that engine side is down.
8. Line up holes in support leg with holes in
generator frame.
9. Attach support leg using two short (M8 x 16mm)
cap screws and two locking hex nuts. Tighten with
a 13mm socket and wrench.
10. Return generator to normal operating position
(resting on wheels and support leg).
* Socket wrench with a 13mm socket
Axle
Wheel
Flat Washer
Support Leg /
Screw Axle
/
/
Wheel
Hex Nut
/
/
E-Ring

BEFORE STARTING THE
GENERATOR
Add Engine Oil
CAUTION! Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine failure.
1. Place generator on a level surface.
2. Clean area around oil fill and remove yellow oil fill
cap.
NOTE: See the section "Oil" on page 16 to review oil
recommendations. Verify provided oil bottle is correct
viscosity for current ambient temperature.
3. Using oil funnel (optional), slowly pour entire
contents of provided oil bottle (18 oz.)into oil fill
opening.
4. Replace oil fill cap and fully tighten.
Add Fuel
All fuel is not the same. If a starting or performance
problem is encountered immediately after new fuel has
been used, try another service station or change
brands.
NOTE: This gasoline engine is certified to operate on
gasoline. Exhaust Emissions Control System: EM
(Engine Modifications).
WARNING
WHEN ADDING FUEL
Turn generator OFF and let itcool at least 2 minutes
before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fill fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel expansion.
Wait for spilled fuel to evaporate before starting engine.
Keep fuel away from sparks, open flames, pilot lights,
heat, and other ignition sources.
DO NOT light a cigarette or smoke.
Type of Fuel
1. Always use clean, fresh, UNLEADED gasoline
with a minimum of 87 octane/87 AKI (91 RON).
DO NOT mix oil with fuel. DO NOT modify the
engine fuel system or carburetor to run on
alternative fuels.
NOTE: Fuel with up to 10% ethanol (gasohol) or up to
15% MTBE (methyl tertiary butyl ether), is acceptable.
IMPORTANT: Use of any fuel other than those
approved above will void warranty. Some areas
require that fuel pumps be marked if the fuel contains
alcohols or ethers. If you are not sure if your fuel
contains alcohol or ethers that are different than those
approved above, then check with the service station
operator.
2. Clean area around fuel fill cap, remove cap.
3. Slowly add regular unleaded fuel to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank
space for fuel expansion, as shown here.
Lo Fuel
4. Install fuel cap and let any spilled fuel evaporate
before starting engine.
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 TM fuel stabilizer plus, or FRESH
START TM continuous fuel preserver (concentrated
liquid cartridge), or FRESH START TM preservative &
stabilizer (granular). If fuel preserver is not used, drain
the fuel tank, start the engine and let it run until the
fuel lines and carburetor are empty. Use fresh fuel
next season. See "Storage" on page 19 for additional
information.
NEVER use engine or carburetor cleaner products in
the fuel tank as permanent damage may occur.

FreshStartTM Fuel Cap
Adding fuel preserver helps keep fuel fresh and
carburetors clean for easier starting, all season long.
This new fuel cap automatically drips concentrated
fuel preserver into your fuel tank.
DANGER
If SWALLOWED, call physician immediately.
In case of emergency, contact a physician immediately
and call 1-800-424-9300 for material safety information.
**Fuel stabilizer contains: 2,6-dFtret-butylphenol (128-39-2) and aliphatic
petroleum distillate (64742-47-8).
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.
4. Reinstall fuel cap on fuel tank.
5. Periodically check the cartridge to ensure there is
still fuel preserver inside. If it is empty, remove
cartridge and replace.
High-Altitude Use
Operation at high altitude (over 5,000 feet), may
require a high-altitude carburetor jet kit to improve
performance and decrease fuel consumption. See any
Sears or other qualified dealer for more information.

HOW TO USE YOUR GENERATOR
If you have any problems operating your generator
after reading the manual, please call the generator
helpline at 1-800-222-3136.
System Ground
The generator has a system ground that connects the
generator frame components to the ground terminals
on the AC output receptacles. The system ground is
connected to the AC neutral wire (the neutral is
bonded to the generator frame).
Special Requirements
There may be Federal or State Occupational Safety
and Health Administration (OSHA) regulations, local
codes, or ordinances that apply to the intended use of
the generator. Please consult a qualified electrician,
electrical inspector, or the local agency having
jurisdiction.
• In some areas, generators are required to be
registered with local utility companies.
• If the generator is used at a construction site, there
may be additional regulations which must be
observed.
Connecting to a Building's ElectricaR
System
Connections for standby power to a building's
electrical system must be made by a qualified
electrician. The connection must isolate the generator
power from utility power, and must comply with all
applicable laws and electrical codes.
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.
Generator Location
Generator Clearance
WARNING
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Place generator in a well ventilated area, which will
allow for removal of deadly exhaust gas. DO NOT
place generator where exhaust gas could accumulate
and enter inside or be drawn into a potentially
occupied building. Ensure exhaust gas is kept away
from any windows, doors, ventilation intakes or other
openings that can allow exhaust gas to collect in a
confined area. Prevailing winds and air currents
should be taken into consideration when positioning
generator.
WARNING
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure (even if doors or windows are open), including
the generator compartment of a recreational vehicle (RV).
Typical Generator Shown
Exhaust Po_

To Start The Engine
Disconnect all electrical loads from the generator.
NEVER start or stop engine with electrical devices
plugged in and turned ON. Follow start instruction
steps in numerical order:
1. Make sure unit is on a level surface.
iMPORTANT: Failure to start and operate unit on a
level surface will cause the unit not to start or shut
down during operation.
2. Turn fuel valve to "On" position. Fuel valve handle
should be vertical (pointing toward 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 1
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.
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.
10
WARNING
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
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.
Connecting Electrical Loads
• Let the engine stabilize and warm up for a few
minutes after starting.
• DO NOT connect 240 Volt loadsto 120Volt receptacles.
• DO NOT connect 3-phase loads to the generator.
• DO NOT connect 50 Hz loads to the generator.
• Plug in and turn on the desired 120 Volt AC, single
phase, 60 Hertz electrical loads.
• DO NOT OVERLOAD THE GENERATOR. See
"Don't Overload Generator".
CAUTION
See "Don't Overload Generator".
Start generator and let engine stabilize before connecting
electrical loads.
Connect electrical loads in OFF position, then turn ON
for operation.
Turn electrical loads OFF and disconnect from generator
before stopping generator.
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.
WARNING
DO NOT stop engine by moving choke lever to "Choke"
position.

CORD SETS AND RECEPTACLES
CAUTION
• NEVER attempt to power a device requiring more
amperage than generator or receptacle can supply.
• DO NOT overload the generator. See "Don't Overload
Generator".
Use only high quality, well-insulated, grounded
extension cords with the generator's 120 Volt electrical
receptacles. Inspect extension cords before each use.
Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
for 125 Volt AC loads at 20 Amps or greater for most
electrical devices. Some devices, however, may not
require this type of extension cord. Check the
operator's manuals of those devices for the
manufacturer's recommendations.
Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
120 Volt AC, 20 Amp, Duplex Receptacles
Each duplex receptacle is protected against overload
by a 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. Use cord
sets that are rated for 125 Volt AC loads at 20 Amps
(or greater).
GENERATOR ADAPTER CORD SET
The generator comes with a 25' generator adapter
cord set designed to provide two sets of 120 Volt,
20 Amp outlets from one 120 Volt, 20 Amp duplex
receptacle. The generator adapter cord set provides a
convenient supply of emergency power so that your
generator can be operated safely outside.
The maximum load on each outlet is 20 Amps. The
maximum total load on both black wire outlets or white
stripe wire outlets is 20 Amps.
NOTE: Follow all safety precautions when connecting
any extension cord or device to the generator.
11

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 following:
1. Make sure generator has clean, fresh fuel.
2. Open fuel valve (turn valve to open position).
3. Use SAE 5W-30 oil (synthetic preferred, see
page 16).
4. Check oil level daily or after every eight (8) hours
of operation.
5. Maintain the generator following the "Maintenance
Schedule" on page 15.
6. Shelter unit from elements.
Creating a Temporary Cold Weather
Shelter
1. In an emergency, use the original shipping carton.
2. Cut off top carton flaps and one long side of
carton to expose muffler side of unit. If required,
tape up other sides of carton to fit over generator
as shown below.
Muffler side exposed. Your unit may differ in
appearance from that shown above.
NOTE: If required, remove wheel kit to fit carton over
generator as shown.
3. Cut appropriate slots to access receptacles of unit.
4. Face exposed end away from wind and elements.
5. Locate generator as described in the section
"Generator Location". Keep exhaust gas from
entering a confined area through windows, doors,
ventilation intakes or other openings.
WARNING
.
Operate generator ONLY outdoors.
Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
DO NOT operate generator inside any building or
enclosure (even if doors or windows are open), including
the generator compartment of a recreational vehicle (RV).
Start generator as described in the section
"Starting the Engine", then place carton over
generator. Keep at least 5 ft. (152 cm) clearance
on all sides of generator including overhead with
shelter in place.
WARNING
.
8.
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Remove shelter when temperatures are above 4O°F [4°C].
Remove shelter when temperatures are above
40°F [4°C].
Turn engine OFF and let cool two (2) minutes
before refueling. Wipe up any spilled fuel.
Creating a Permanent Cold Weather
Shelter
1. Build a structure that will enclose three sides and
the top of the generator, making sure muffler side
of generator is exposed.
NOTE: Structure should hold enough heat created by
the generator to prevent icing problem.
2. DO NOT enclose generator any more than shown.
NOTE: If a wheel kit is installed on the generator,
enlarge shelter accordingly.
3. Follow steps 3 through 8 as described previously
in "Creating a Temporary Cold Weather Shelter".
12

DON'T OVERLOAD GENERATOR
Capacity
You must make sure your generator can supply
enough rated (running) and surge (starting) watts for
the items you will power at the same time. Follow
these simple steps:
1. Select the items you will power at the same time.
2. Total the rated (running) watts of these items. This
is the amount of power your generator must
produce to keep your items running.
3. Estimate how many surge (starting) watts you will
need. Surge wattage is the short burst of power
needed to start electric motor-driven tools or
appliances such as a circular saw or refrigerator.
Because not all motors start at the same time,
total surge watts can be estimated by adding only
the item(s) with the highest additional surge watts
to the total rated watts from step 2.
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated
(Running) Watts
1200
800
500
500
75
3075 Total
Running Watts
Total Rated (Running) Watts
Highest Additional Surge Watts
Total Generator Output Required
Additional Surge
(Starting) Watts
1800
1600
5OO
1800 Highest
Surge Watts
= 3075
= 1800
= 4875
NOTE: The rated (running) watts cannot exceed 3600.
Also, given the 3600 watt rated limit, additional surge
(starting) watts cannot exceed 5300.
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.
Tool or Appliance Rated* (Running)
Watts
Essentials
Light Bulb - 75 watt 75
Deep Freezer 500
Sump Pump 800
Refrigerator/Freezer - 18 Cu. Ft. 800
Water Well Pump - 1/3 HP 1000
Heating/Cooling
Window AC - 10,000 BTU 1200
Window Fan 300
Furnace Fan Blower - 1/2 HP 800
Kitchen
Microwave Oven - 1000 Watt 1000
Coffee Maker 1500
Electric Stove - Single Element 1500
Hot Plate 2500
Family Room
DVD/CD Player 100
VCR 100
Stereo Receiver 450
Color Television - 27" 500
Personal Computer w/17" 800
monitor
Other
Security System 180
AM/FM Clock Radio 300
Garage Door Opener- 1/2 HP 480
Electric Water Heater - 40 4000
Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - 1/2 HP
Circular Saw - 7 1/4"
Miter Saw - 10"
Table Planer - 6"
Table Saw/Radial Arm Saw - 10"
Air Compressor - 1-1/2 HP
*Wattages listed are approximate only.
appliance for actual wattage.
1000
6oo
96o
1000
1500
1800
1800
2000
2500
Check
Additional
Surge
(Starting)
Watts
5OO
1200
1600
2000
1800
600
1300
520
1200
96O
1000
1500
1800
1800
2000
2500
tool or
13

ENGINE TECHNICAL INFORMATION
This is a single cylinder, overhead valve(OHV), air
cooled engine. It is a low emissions engine.
In the State of California, Model Series 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
equipment, it may be that the engine you have
purchased will not develop the rated horsepower when
used in a piece of power equipment (actual "on-site"
power). This difference is due to a variety of factors
including, but not limited to, the following: differences
in altitude, temperature, barometric pressure, humidity,
fuel, engine lubrication, maximum governed engine
speed, individual engine to engine variability, design of
the particular piece of power equipment, the manner in
which the engine is operated, engine run-in to reduce
friction and clean out 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
Wattage .................... 3,600 Watts (3.6kW)
Starting Wattage ............. 5,300 Watts (5.3kW)
Rated AC Voltage ............ 120/240 Volts
Rated 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
Gross* Horsepower ........... 7.0 at 3600 rpm
Bore ....................... 2.69 in. (68mm)
Stroke ...................... 2.20 in. (56mm)
Displacement ................ 12.57 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 withvalve 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
NOTE: For practical operation, the generator load
should not exceed 85% of rated wattage. Engine
gross horsepower will decrease 3-1/2% for each
1,000 feet (300 meters) above sea level and 1% for
each 10° F (5.6° C) above 77° F (25 ° C). It should
operate satisfactorily at an angle up to 15°.
14

MAINTENANCE SCHEDULE
Follow the hourly or calendar intervals, whichever occurs first.
More frequent service is recuired when operating in adverse conditions noted below.
MAINTENANCE SCHEDULE
FILL IN DATES AS YOU
COMPLETE REGULAR SERVICE
MAINTENANCE TASK
Check oil level
Clean debris
Change engine oil
Service air cleaner
Service spark plug
Service spark arrester
Clean cooling system
Prepare for storage
SERVICE DATES
Before Every 25 Hours
Each Use or Yearly
X
x
X2
Every 50 Hours
or Year y
X1
Every 100
Hours or Yearly
x
x
x_
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.
2 Replace more often under dirty or dusty conditions.
GENERAL RECOMMENDATIONS
Regular maintenance will improve the performance
and extend the life of the generator. See 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.
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
o
o
o
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.
15

StatStation TM
The StatStation TM displays the nominal load on
generator based on output frequency. It also has a
built in maintenance reminder.
Wattage Monitor
The LED display will indicate 0-95% nominal load.The
display will flash at 90% nominal load and above. If
above 95% nominal load the display will flash "OL"
(meaning 'overload'). When load returns to within
normal range, the display will automatically resume
nominal load indication. See the table below for
Frequency Range
62.5-62.0
61.9-61.5
61.4-61.0
60.9-60.5
60.4-60.0
59.9-59.5
59.4-59.0
58.9-58.5
58.4-58.0
57.9-57.5
57.4-57.0
57.0 and below
operation functions.
Maintenance Reminder
LED Display
0
0
10
20
40
60
70
80
Flash 90
Flash 95
Flash OL
Flash OL
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: Check oil at 8 hour increments"C1"
"C2"
"C3"
"C4"
Change oil at 50 hour increments
Check or replace air filter at 25 hour
increments
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
WARNING
WHEN ADJUSTING OR MAKING REPAIRS TO YOUR
GENERATOR
•Disconnect the spark plug wire from the spark plug and
place the wire where it cannot contact spark plug.
WHEN TESTING FOR ENGINE SPARK
Use approved spark plug tester.
DO NOT check for spark with spark plug removed.
Oil
Oil Recommendations
NOTE: When adding oil to the engine crankcase, use
only high quality detergent oil classified "For Service
SF, SG, SH, SJ" or higher. DO NOT use special
additives.
1. Choose a viscosity according to the following
table:
104 F_
86
68
5O
32
14
4
"_ -22
X_ 40 C
30
20
; 10
0
-10
-20
-30
NOTE: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol with "SJ/CF
ENERGY CONSERVING" or higher, is an acceptable
oil at all temperatures. Use of synthetic oil does not
alter required oil change intervals.
SAE 30:40 °F and higher (5 °C and higher) is good
for all purpose use above 40°F, use below 40°F will
cause hard starting.
10W-30:0 to 100 °F (-18 to 38 °C) is better for
varying temperature conditions. This grade of oil
improves cold weather starting, but may increase oil
consumption at 80°F (27°C) or higher.
*Check oil level frequently at higher temperatures.
Synthetic 5W-30:-20 to 120 °F (-30 to 40 °C)
provides the best protection at all temperatures as well
as improved starting with less oil consumption.
5W-30:40 °F and below (5 °C and below) is
recommended for winter use, and works best in cold
conditions.
16

CheckingOilLevel
Oillevelshouldbecheckedpriortoeachuseorat
leastevery5hoursofoperation,Keepoillevel
maintained,
1. Makesuregeneratorisonalevelsurface,
2. Removeoildipstickandwipedipstickwithclean
cloth,Replaceandtightendipstick,Removeand
andcheckoillevel,
3. Verifyoilisat"Full"markondipstick.Replaceand
tightendipstick.
AddingEngineOil
1. Makesuregeneratorisonalevelsurface.
2. Checkoillevelasdescribedin"CheckingOil
Level".
3. Ifneeded,slowlypouroilintooilfillopeningtothe
"Full"markondipstick.DONOToverfill.
4. Replaceandtightendipstick.
Service Air Cleaner
Your engine will not run properly and may be
damaged if you run it with a dirty air cleaner.
Replace the air cleaner every 25 hours of operation or
once each year, whichever comes first. Replace more
often if operating under dirty or dusty conditions.
To service the air cleaner, follow these steps:
1. Loosen screws and remove air cleaner cover.
Remove paper filter.
Cartridge
Cover kk_
\
Base
2. Install clean (or new) air cleaner assembly inside
cover. Dispose of old filter properly.
3. Assemble air cleaner cover onto base and tighten
screws.
NOTE: You can purchase new air cleaner elements by
calling 1-800-4-MY-HOME (469-4663).
Changing Engine Oil
Change the oil after the first 5 hours of operation.
Change oil every 50 hours thereafter. If you are using
your generator under extremely dirty or dusty
conditions, or in extremely hot weather, change the oil
more often.
CAUTION
Used motor oil has been shown to cause skin cancer in
certain laboratory animals.
Thoroughly wash exposed areas with soap and water.
KEEP OUT OF REACH OF CHILDREN.
DON'T POLLUTE. CONSERVE
RESOURCES. RETURN USED OIL TO
COLLECTION CENTERS.
Change the oil while the engine is still warm from
running, as follows:
1. Make sure unit is on a level surface.
2. Disconnect the spark plug wire from the spark
plug and place the wire where it cannot contact
spark plug.
3. Clean area around oil drain plug. The oil drain plug
is located at base of engine, opposite carburetor.
4. Remove oil drain plug and drain oil completely into
a suitable container.
5. Reinstall oil drain plug and tighten securely.
Remove oil cap/dipstick.
6. Slowly pour recommended oil (about 20 oz.) into
oil fill opening. Pause to permit oil to settle. Fill to
"Full" mark on dipstick.
7. Wipe dipstick clean each time oil level is checked.
DO NOT overfill.
8. Reinstall oil cap/dipstick. Tighten cap securely.
9. Wipe up any spilled oil.
17

Clean/Replace Spark Plug
Change the spark plug every 100 hours of operation
or once each year, whichever comes first. This will
help your engine to start easier and run better.
1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Check electrode gap with wire feeler gauge and
set spark plug gap to 0.030 inch (0.76ram) if
necessary.
_-_ z_ ............
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
1-800-4-MY-HOME (469-4663).
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.
WARNING
DO NOT touch hot surfaces and avoid hot exhaust gases.
Allow equipment to cool before touching.
Keep at least 5 ft. (152 cm) clearance on all sides of
generator including overhead.
Code of Federal Regulation (CFR) Title 36 Parks,
Forests, and Public Property require equipment powered
by an internal combustion engine to have a spark
arrester, maintained in effective working order, complying
to USDA Forest service standard 5100-1C or later
revision. In the State of California a spark arrester is
required under section 4442 of the California Public
resources code. Other states may have similar laws.
NOTE: You can purchase a new spark arrester screen
by calling 1-800-4-MY-HOME (469-4663).
If you use your generator on any forest-covered, brush-
covered, or grass-covered unimproved land, it must
have a spark arrester. The spark arrester must be
maintained in good condition by the owner/operator.
Clean and inspect the spark an'ester as follows:
1. To remove muffler heat shield from muffler, remove
four screws that connect guard to muffler bracket.
Spark Arrester Screen
Muffler .............
\..... Heat Shield
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". CEEAN
Carburetor Adjustment
The carburetor on this engine is low emission. It is
equipped with a non-adjustable idle mixture valve and
governed idle, ifequipped. Governed idle and top
speed have been set at the factory. If adjustment is
required, see any Sears or other qualified dealer.
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.
18

GENERAL
The generator should be started at least once every
seven days and allowed to run at least 30 minutes. If
this cannot be done and you must store the unit for
more than 30 days, use the following information as a
guide to prepare it for storage.
Long Term Storage Instructions
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.
WARNING
WHEN STORING FUEL OR EQUIPMENTWITH FUEL IN
TANK
Store away from furnaces, stoves, water heaters, clothes
dryers or other appliances that havepilot light or other
ignition source because they can ignite fuel vapors.
WHEN DRAiNiNG FUEL
Turn generator OFF and let itcool at least 2minutes
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
Fuel Preserver:
Fill the fuel tank with fresh fuel allowing at least 1.5" of
tank space for fuel expansion as shown on page 7,
when using a fuel preserver cartridge with the fresh
start fuel cap. If only partially filled, air in the tank will
promote fuel deterioration during storage. Engine and
fuel can be stored up to 6 months with fuel preserver.
• Check level of fuel preserver cartridge. Fuel
preserver is dark in color.
• If cartridge is almost empty or empty, replace with
a new fuel preserver cartridge following the
instructions in "Fresh Start TM Fuel Cap" on page 8.
If fuel preserver is not used, remove all fuel from tank
and run engine until it stops from lack of fuel.
Change Oil
While engine is still warm, drain oil from crankcase.
Refill with recommended grade. See "Changing
Engine Oil" on page 17.
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
unless it has been treated as described in "Protect
Fuel System".
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.
4. Cover unit with a suitable protective cover that
does not retain moisture.
WARNING
,
DO NOT place a storage cover over a hot generator.
Let equipment cool for a sufficient time before placing
the cover on the equipment.
Store generator in clean, dry area.
19

Problem Cause
Engine is running, but no AC
output is available.
Engine runs good at no-load but
"bogs down" when loads are
connected.
1. One of the circuit breakers is
open.
2. Fault in generator.
3. Poor connection or defective
cord set.
4. Connected device is bad.
1. Short circuit in a connected
load.
2. Engine speed is too slow.
3. Generator is overloaded,
4. Shorted generator circuit,
1. Rocker Switch set to "Off",
2. Fuel Valve is in "Off" position,
Correction
1. Reset circuit breaker,
2. Contact Sears service facility,
3. Check and repair,
4. Connect another device that is
in good condition.
1. Disconnect shorted electrical
load,
2. Contact Sears service facility,
3. See "Don't Overload
Generator".
4. Contact Sears service facility,
1. Set switch to "On",
2. Turn fuel valve to "Open"
position,
3. Dirty air cleaner.
4. Out of fuel.
5. Stale fuel.
6. Spark plug wire not connected
3. Clean or replace air cleaner,
4. Fill fuel tank,
5. Drain fuel tank and carburetor;
fill with fresh fuel,
6. Connect wire to spark plug,
Engine will not start; or starts
and runs rough. to spark plug,
7. Bad spark plug,
8. Water in fuel,
9. Flooded,
7. Replace spark plug,
8. Drain fuel tank and carburetor;
fill with fresh fuel,
9. Wait 5 minutes and re-crank
engine,
10. Excessively rich fuel mixture,
11. Intake valve stuck open or
closed,
12. Engine has lost compression,
O. Contact Sears service facility.
1. Contact Sears service facility.
2. Contact Sears service facility.
Engine shuts down when Out of fuel. Fill fuel tank.
running.
1. Load is too high. 1. See "Don't Overload
Engine lacks power. Generator",
2. Dirty air filter, 2. Replace air filter,
Carburetor is running too rich or too Contact Sears service facility,
Engine "hunts" or falters. lean,
20