Craftsman 580325601 User Manual AC GENERATOR Manuals And Guides L0522234

CRAFTSMAN Generator Manual L0522234 CRAFTSMAN Generator Owner's Manual, CRAFTSMAN Generator installation guides

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Owner's

Manual
®

CAUTtON

PRECAUCI6N

Before using this product, read this

Antes de utilizar el producto, lea este

manual and follow all Safety Rules
and Operating Instructions.

manual y siga todas las Reglas de

Sears,

Roebuck

Visit our Craftsman
Part No. 197127GS

and Co., Hoffman
website:

Seguridad e Instrucciones de Uso.

Estates,

_L 60179

o
o
o
o
o

Safety
Assembly
Operation
Maintenance
Parts

o Espa_oN

U.S.A.

www.craftsman.com

Draft 1 (07/29/2005)

WARRANTY

....................................

SAFETY RULES

FEATURES AND CONTROLS
ASSEMBLY
OPERATION

...............................

3-4

......................

...................................

6-7

.................................

8-1 1

SPECIFICATIONS
MAINTENANCE

...............................
..............................

STORAGE .....................................

SCHEMATIC
WIRING

NOTES

EMISSION
ESPAI_OL

DIAGRAM

..........................

..............................
PARTS

.......................

20-28

.......................................
CONTROL

WARRANTY

..............

30-31

...................................

HOW TO ORDER

FOR DELUXE

............................

DIAGRAM

REPLACEMENT

13-15
16

LIMtTED WARRANTY

TROUBLESHOOTING

PARTS

PORTABLE

32-51

................

BACK

PAGE

GENERATORS

SEARS warrants to the original purchaser that the alternator and engine for its portable generator will be free
from defects in materials or workmanship for the items and period set forth below from the date of original
purchase. This warranty is not transferable and applies only to portable generators driven by the Sears
warranted engine.
Alternator
Engine

CONSUMER*
2 years (2nd year parts only)
2 years (2nd year parts only)

COMMERCIAL*
1 year
1 year

* NOTE: For the purpose of this warranty "Consumer Use" means personal residential household and
emergency use by original purchaser, not to be used as a primary source of power. "Commercial Use" means all
other uses, including rental, construction, commercial, and income producing purposes. Once a generator has
experienced commercial use, it shall thereafter be considered a commercial use generator for the purpose of
this warranty.
During said warranty period, SEARS will, at its option, repair or replace any part which, upon examination by
SEARS, is found to be defective under normal use and service**. Starting batteries are not warranted by
SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by
the purchaser and prepaid by him. This warranty does not cover normal maintenance and service and does not
apply to a generator set, alternator or engine, or parts which have been subjected to improper or unauthorized
installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair
or storage so as, in SEARS's judgment, to adversely affect its performance and reliability.
** NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to
perform well. This warranty will not cover repair when normal use has exhausted the life of a part or engine.
THERE IS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE
DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO
THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR
CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES
IS EXCLUDED.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest SEARS authorized warranty service facility. Warranty service can be performed
only by a SEARS authorized service facility. This warranty will not apply to service at any other facility. At the
time of requesting warranty service, evidence of original purchase date must be presented.

Sears,

Roebuck

@ Sears Brands, LLC

and Co., Dept.

DI817 WA, Hoffman

Estates,

IL 60179 U.S.A

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.
,¢'_ I_ Read 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

Operate

generator

ONLY

outdoors.

Keep exhaust gas from entering a confined
windows,
doors, ventilation
intakes or other

area through
openings.

DO NOT operate generator
inside any building
enclosure,
including the generator
compartment
recreational
vehicle (RV).

or
of a

WARNING

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=183and should not be used on
marine applications.
Failure to use the appropriate
U. S. Coast Guard
approved
generator
could result in death, serious injury
and/or

Hazard

property

damage.

Symbols

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
worn, frayed, bare or otherwise
damaged.
DO NOT

operate

generator

which

are

in the rain.

DO NOT handle generator
or electrical
cords while
standing
in water, while barefoot, or while hands or feet
are wet.

and Meanings

DO NOT allow unqualified
or service generator.

persons

or children

to operate

WARNING
Electrocution

Electrical Shock

Explosion

Fire

Toxic Fumes

Hot Surface

When starting engine, pull cord slowly until resistance
felt and then pul! rapidly to avoid kickback.

Kickback

NEVER

start

plugged

in and turned

or stop engine
on.

with electrical

devices

WARNING

WHEN

ADDING

OR DRAINmNG

Turn generator
before

FUEL

OFF and let it cool

removing

pressure

WARNING

fuel cap. Loosen

at least

WHEN ADJUSTING
GENERATOR

2 minutes

cap slowly

to relieve

+ Disconnect

in tank.

place

Fill or drain fuel tank outdoors.
DO NOT

overfill

tank. Allow

Keep fuel away from
heat, and other
DO NOT
WHEN

spark

open

the spark

the wire where
TESTING

for fuel expansion.

Use approved

flames,

DO NOT

pilot lights,

FOR

REPAIRS

plug wire

TO YOUR

from the spark

it cannot

contact

ENGINE

SPARK

spark

plug and

plug.

spark plug tester.

check

for spark

with spark

plug removed.

sources.

light a cigarette

STARTING

Ensure

sparks,

ignition

WHEN

space

OR MAKING

or smoke.

CAUTION

EQUIPMENT

plug, muffler,

fuel cap and air cleaner

are

in place.
DO NOT

crank

If fuel spills,
engine.
WHEN

engine

wait until it evaporates

OPERATING

marine
WHEN

or equipment

choke

This generator

carburetor

before

DO NOT tamper
supplies correct

starting

running
at angle

which

modify

speed. Generator
and voltage when

speed.

generator

in any way.

CAUTION

to stop engine.

is not for use in mobile

TRANSPORTING

Disconnect

equipment

with fuel tank EMPTY

spark

STORING

OR REPAIRING

EQUIPMENT
or with fuel shutoff

plug wire.
FUEL

See "Don't

Overload

Generator".

Start generator
and let engine
electrical loads.

OR EQUIPMENT

WiTH

FUEL

TANK
Store

at governed

DO NOT

causes

with governed
rated frequency

applications.

Transport/repair
valve OFF.

WHEN

plug removed.

EQUIPPv_ENT

Do not tip engine
fue! to spill.
DO NOT

with spark

Connect

electrical

loads

stabilize

in OFF

before

position,

connecting

then turn ON

for operation.
away

from furnaces,

dryers

or other

ignition

source

stoves,

appliances
because

that
they

,water heaters,

have pilot

can ignite

clothes

light or other

Turn electrical
loads OFF
before stopping
generator.

and disconnect

from

generator

fuel vapors.

CAUTION
WARNING
Use generator

only for intended

If you have questions
contact Sears.
Operate
DO NOT
DO NOT
Allow

touch

equipment

hot surfaces.
to cool

before

generator
expose

dirt, or corrosive
touching.

DO NOT

Keep at least 3 feet of clearance
on all sides of generator
for adequate
cooling, maintenance
and servicing.

Shut off generator

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.

use, ask dealer

devices
them

to excessive

moisture,

-unit vibrates

through

overheat,

cooling

turn them

slots.

off and

from generator.
if:

output

-equipment

only on level surfaces.
generator

insert any objects

If connected

-electrical

intended

vapors.

The generator must be at least 5 feet from structures having
combustible
walls and/or other combustible
materials.

disconnect

about

uses.

is lost;

sparks,

smokes,

excessively.

or emits

flames;

dust,

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.

Choke Lever
.J

Air Cleaner

Circuit
Breakers (AC)
FuelTank
120/240 VAC,
30A Receptacle
Fuel Valve
(2) 120 VAC, 20A
Duplex Receptacles

Recoil Starter
Rocker Switch
(on engine shroud)

Grounding Fastener
120 Vomt AC, 20 Amp, Duplex Receptacles -- May
be used to supply electrical power for the operation of
120 Volt AC, 20 Amp, single phase, 60 Hz electrical,
lighting, appliance, tool and motor loads.
120/240 Volt AC, 30 Amp LocHng Receptacle -May be used to supply electrical power for the
operation of 120 and/or 240 Volt AC, 30 Amp, single
phase, 60 Hz electrical, lighting, appliance, tool and
motor loads.
Air Cleaner -- Protects engine by filtering dust and
debris out of intake air.
Choke Lever -- Used when starting a cold engine.
Circuit Breakers (AC) -- Push to reset circuit
breakers are provided to protect the generator against
electrical overload.

Spark Arrester

Muffler

Fuel Tank -- Capacity of five (5) U.S. gallons.
Fuel Valve -- Used to turn fuel on and off to engine.
Grounding Fastener -- If required, please consult a
qualified electrician, electrical inspector, or local
agency having jurisdiction.
Oil Fill -- Add engine oil here.
Recoil Starter -- Used to start the engine.
Rocker Sw{tch -- Set this switch to "On" before using
recoil starter. Set switch to "Off" to switch off engine.
Spark Attester MufflerExhaust muffler lowers
engine noise and is equipped with a spark arrester
screen.

YourCraftsman
generatorrequiressomeassembly
andis readyfor useonlyafterit hasbeenproperly
servicedwiththerecommended
oilandfuel.
If you haveany problemswith the assemMyof
your generator,pleasecallthe generatorhelpline
at 1-800-222-3136.
IMPORTANT:
Anyattemptto runtheenginebeforeit
hasbeenservicedwiththerecommended
oilwillresult
inan enginefailure.

•
•

Socket wrench with a 1/2" or 13mm socket
Pliers

Refer to imlustrationshown below and install the wheel
kit as fol!ows:
1.

Tip generator so that engine end is up.

Slide axle through both mounting brackets.

Place a wheel on each side with air valve facing
out.

REMOVE GENERATOR FROM
CARTON

Place a washer on axle and then place an e-ring
in axle groove.

Set the carton on a rigid flat surface.

Remove everything from carton except generator.

Install e-dng with pliers, squeezing from top of ering to bottom of axle.

Open carton completely by cutting each corner
from top to bottom.

Repeat step 3 through 5 to secure second wheel.

Tip generator so that engine side is down.

Leave generator on carton to install wheel kit.

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

Attach support leg using two short (M8 x 16mm)
cap screws and two locking hex nuts. Tighten with
a 1/2" or 13mm socket and wrench.

CARTON

CONTENTS

Check all contents. If any parts are missing or damaged,
call the generator helpline at 1-800-222-3136.
• The main unit
• Owner's manual
• Engine oil
• 120/240 Volt, 30 Amp locking plug
• Wheel Kit

ASSEMBLING

THE WHEEL

KIT

NOTE: Wheel kit is not intended for over=the=road use.
You will need the following tools to install these
components:
• 1/2" or 13mm wrench

10. On support leg end of generator, slide handle onto
center of top of frame.
11. Attach handle using two long (M8 x 45mm) cap
screws and two locking hex nuts. Tighten with a
1/2" or 13mm socket and wrench.
12. Return generator to normal operating position
(resting on wheels and support leg).
13. Check that tires are inflated to value marked on
tire or within 15 and 40 psi.

Whee_ Kit Assembly

View

Cap Screw
\
\,

Handle Assembly,

Hex

Flat Washer

Axle

Support Leg

Cap Screw
Wheel

Hex Nut _

/
E=Ring

BEFORE STARTING
GENERATOR

THE

Add

Fue_

WARNING

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

Add Engine

Oim

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:

WHEN
Turn

ADDING
generator

FUEL
OFF

and let it coo! at least 2 minutes

before removing fue! cap. Loosen
pressure
in tank.

cap slowly

to relieve

Fill fuel tank outdoors.
DO NOT

overfill

tank. Allow

Keep fuel away from sparks,
heat, and other
DO NOT

STARTING

TEMPERATURE

RANGE

ANTICIPATED

BEFORE

OIL CHANGE

* 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 multiviscosity 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.

Clean area around yellow oil fill cap. Remove oil
fill cap.

Slowly fill engine with oil through oil fill opening
until oil level is to the point of overflowing.

Install yellow oil fill cap and finger tighten securely.

Check engine oil level before starting each time
thereafter. If oil level is below the point of
overflowing, fill to proper level.

NOTE: Check oil often during engine break-in.

light a cigarette

for fuel expansion.

open flames,

pilot lights,

sources.
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.

Slowly add regular unleaded fuel to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank

NOTE: Synthetic oil meeting ILSAC GF-2, API
certification mark and API service symbol with "SJ/CF
ENERGY CONSERVING" or higher, is an acceptable
o11at all temperatures. Use of synthetic oil does not
alter required oil change intervals.
2. Place generator on a level surface.
3.

ignition

space

space for fuel expansion, as shown here.
Tank

\\\\\\\

Install fuel cap and wipe up any spilled fuel.

CAUTmON! 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 16 for additional information.
NEVER use engine or carburetor cleaner products in
the fuel tank as permanent damage may occur.

HOW TO USE YOUR GENERATOR

Generator

if you have any problems operating your generator,
please call the generator helpline at 1o800o222o3136.

Generator Clearance

System

Location

WARNING

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).

Operate

Spec{amRequirements

Keep exhaust gas from entering a confined
windows,
doors, ventilation
intakes or other

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
System

to a BuHding's

E_ectrica_

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
appJicable laws and electrical codes.

generator

ONLY

outdoors.
area through
openings.

DO NOT operate generator
inside any building
enclosure,
including the generator
compartment
recreational
vehicle (RV).

or
of a

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.

WARNING

When using generator
for backup power, notify utility
company.
Use approved
transfer equipment
to isolate
generator
from electric utility.
Use a ground circuit
or highly conductive
work.
DO NOT

touch

bare wires

operate

DO NOT

handle

standing
are wet.

in water,

Shown

or receptacles.

DO NOT use generator
with electrical
cords which
worn, frayed, bare or otherwise
damaged.
DO NOT

Typical Generator

fault interrupter
(GFCI) in any damp
area, such as metal decking or steel

generator
generator
while

DO NOT allow unqualified
or service generator.

are

Exhaust Port

in the rain.
or electrical

barefoot,
persons

cords while

or while

hands

or children

or feet

to operate

TO START THE ENGINE

WARNING

Disconnect alJ electrical loads from the generator. Use
the foiJowing start instruction steps by numerical order:
1. Make sure unit is on a level surface.
iMPORTANT: FaiJure to start and operate unit on a
leveJ surface wilJ cause the unit not to start or shut
down during operation.
2. Turn the fueJ vaJve to the "On" position.

DO NOT touch
Allow

hot surfaces.

equipment

to cool before

touching.

The generator must be at least 5 feet from structures having
combustible
wails and/or other combustible
materials.
+t/t_-

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.

Place the choke Jever in the "Choke" position.

To Stop the Engine
1.
+

Set the rocker switch to "On" position.

UnpJug aJJeJectricaJ loads from generator paneJ
receptacles. NEVER start or stop engine with
electrical devices plugged in and turned on+

-, Rocker Switch
is shown in the
On position

2+ Let engine run at no-load for several minutes to
stabilize internal temperatures of engine and
generator.

5+ Grasp the recoil handJe and puJJsJowJy untiJ slight
resistance is felt. Then puJJrapidly to start engine.

WARNING

DO NOT stop engine
position.

Backfire,

3+ Move rocker switch to "Off' position.
4+ Move fuel vaJve to "Off' position.

Connecting
•

When starting engine, pull cord slowly until resistance
felt and then pull rapidly to avoid kickback.
NEVER start or stop engine with electrical devices
plugged

in and turned

•
•

Move choke Jever to "Run" position a short
distance at a time over several seconds in warm
weather or minutes in coJd weather. Let engine
run smoothly before each change. Operate with
choke in "Run" position.

NOTE: Jf engine starts after 3 puJJsbut fails to run, or
if unit shuts down during operation, make sure unit is
on a leveJ surface and check for proper oil JeveJin
crankcase. This unit may be equipped with a low oiJ
protection device.

Electrica_

Loads

DO NOT connect 240 Volt loads to 120 Volt
receptacles.
DO NOT connect 3-phase Joads to generator.
DO NOT connect 50 Hz loads to generator.

•

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

•

PJug in and turn on desired 120 and/or 240 Volt
AC, singJe phase, 60 Hz eJectricaJ loads.
DO NOT OVERLOAD THE GENERATOR. See
"Don't OverJoad Generator".

on.

iMPORTANT: If engine floods, place choke Jever in
"Run" position and crank untiJ engine starts.

by moving choke lever to "Choke"
CAUTION
damage could occur.

fire or engine

•

CAUTION

See "Don't

Overload

Generator".

Start generator
and let engine
electrical loads.
Connect electrical
for operation.

loads

Turn electrical
loads OFF
before stopping
generator.

in OFF

stabilize
position,

and disconnect

before

connecting

then turn ON
from

generator

CORD SETS AND RECEPTACLES

CAUTION

• NEVER
amperage

attempt

to power

than generator

• DO NOT overload
Generator".

a device

requiring

or receptacle

the generator,

1201240 Volt AC, 30 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 20 Amp push-to-reset
circuit breakers.
4-Wire

Cord

Set

can supply.

See "Don't

Overload

Use only high quality, well-insulated, 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.

_j_
NEMA L14-30

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

Y (Hot)

X (Hot)
/_

Ground (Green)

A NEMA L14-30 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 30 Amps (or greater).

Receptacle

Each receptacle is protected against overload by a
single 20 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.

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.

Plug in and turn on the next load.

Again, permit the generator to stabilize.

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.
Rated*
Too! or Appliance

Total the rated (running) watts of these items. This
is the amount of power your generator must
produce to keep your items running. See the table
on the right.

Essentials
Light Bulb - 75 watt
Deep

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.

Sump Pump
Refrigerator/Freezer-

Rated
Window Air
Conditioner
Refrigerator
Dee£ Freezer
Television
Light (75 Watts)

_Runnin _ VVatts
1200

8OO
5OO
5OO
75
3075 Total
Running Watts

Additional

AC - 10,000
Fan

Furnace
Kitchen

Fan Blower-

= 1800

Total Generator Output Required

= 4875

Stereo

Permit the generator output to stabilize (engine
runs smoothly and attached device operates
properly.

- 27"

Computer

w/17"

75
500
800
800
1000

500
1200
1600
2000

1200
300
800

1800
600
1300

1000
1500
1500
2500
100
100
45O
5OO
8OO

Other
Security System
AM/FM C!ock Radio
Garage
Electric

Door Opener - 1/2 HP
Water Heater - 40

Gallon
D_Y/Job
Quartz
Airless

Circular

Saw - 7 1/4"

Miter Saw - 10"
Table
Table

180
3OO
480
4000

520

Site
Haloqen Work Light
Sprayer - 1/3 HP

Reci rocatin
Saw
Electric Drill - 1/2 HP

Planer - 6"
Saw/Radial
Arm

Saw -

1000
600
960
1000
1500
1800
1800
2000

1200
960
1000
1500
1800
1800
2000

2500

10"

With nothing connected to the generator, start the
engine as described in this manual.

Element

Receiver

Personal
monitor

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:

Plug in and turn on the first load, preferably the
largest load you have.

- 1000 Watt

- Single

Color Television

Management

1/2 HP

Family Room
DVD/CD Player
VCR

1800 Highest
Surge Watts

Highest Additional Surge Watts

Oven

BTU

Maker

Electric Stove
Hot Plate

Surge

1600
5OO

= 3075

Window
Window

Microwave

1800

Total Rated (Running) Watts

18 Cu. Ft.

Water Well Pump - 1/3 HP
Heating/Cooling

Example:

Power

Freezer

Coffee

Tool or Appliance

(Running)
Watts

Additional
Surge
(Starting)
Watts

Air Compressor

*Wattages
appliance

listed

- 1-1/2
are

for actual

approximate
wattage.

only. Check tool or

ENGINE TECHNICAL

INFORMATION

PRODUCT

This is a single cylinder, overhead valve(OHV), air
cooled engine, it is a low emissions engine.

Generator

SPECIFICATIONS
Specifications

in the State of California, Model Series 200000
engines are certified by the California Air Resources
Board to meet emissions standards for 250 hours.
Such certification does not grant the purchaser, owner
or operator of this engine any additional warranties
with respect to the performance or operational life of
this engine. The engine is warranted solely according
to the product and emmisions warranties stated
elsewhere in this manual.

Starting Wattage ..............
Wattage .....................
AC Voltage ........................
AC Current
at 240 Volts ........................
at 120 Volts ........................
Frequency .....................
Phase .............................
Unit Weight .............................

Power

Engine

Ratings

8600 Watts (8.6 kW)
5600 Watts (5.6 kW)
120/240 Volts
23,3 Amps
46,6 Amps
60 Hz at 3600 rpm
Single Phase
170 Ibs,

Specifications

Horsepower ......................
10 at 3600 rpm
Bore ............................
3,12 in. (79mm)
Stroke ..........................
2.44 in. (62mm)
Displacement ...................
18.64 in. (305 cc)
Spark Plug
Type: ..........
Champion RC12YC or Equivalent
Set Gap To: ................
0.030inch (0.76mm)
Armature Air Gap: ..................
0,008-0,0!2 in.
(0,20-0,30ram)
Valve clearance with valve springs installed and piston I/4 in.
(6 mm) past top dead center (check when engine is cold).
Intake ...........................
0,004-0,006 in.
(0,10-0,15 mm)
Exhaust ..........................
0,004-0,006 in.
(0,10-0,15 mm)
Fuel Capacity ......................
5 U.S. gallons

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 200205). 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 peice 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
utilizedin similar applications, and will thereforenot
necessarily match the values derived using the
foregoing codes.

Oil Capacity ................
Oil Type:
Above 40 ° F ........................
Below 40 ° F ............

28 Ounces (.8 Liters)
SAE 30
SAE 5W-30 or 10W-30

OWNER'S

RESPONSIBILITIES

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

SCHEDULE

FILL tN DATES AS YOU
COMPLETE

REGULAR

MAINTENANCE

SERVICI= DATES

SERVICE

TASK

SERVICE DATES
Before
Each Use

Check oil level

Clean debris

Every 25 Hours
or Year y

Every 50 Hours
or Year y

Change engine oil

Every 100
Hours or Yearly

Service air cleaner

Service spark plug

Service spark arrester

Clean cooting system

Prepare for storage

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

Change oit 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

Clean or reptace more often under dirty or dusty conditions.

GENERAL

RECOMMENDATIONS

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.

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.

Generator

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

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.

All service and adjustments should be made at least
once each season. Follow the requirements in the
"Maintenance Schedule" chart above.

Generator parts should be kept clean to reduce the
risk of overheating and ignition of accumulated debris.

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

Cleaning

•

Use a damp cloth to wipe exterior surfaces clean.

CAUTION

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

DO NOT expose generator to excessive moisture, dust,
dirt, or corrosive vapors.
DO NOT insert any objects through cooling slots.

MAINTENANCE

Use a soft bristle
etc.

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.

Use a vacuum

brush to loosen

caked

on dirt, oil,

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.

Check the cleanliness of the generator frequently and
clean when dust, dirt, oil, moisture or other foreign
substances are visible on its exterior surface.
13

ENGINE MAINTENANCE

CJean/Rep_ace

Spark

P_ug

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.

VVARNJNG

Remove and inspect spark plug.

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

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

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

Changing

NOTE: You can purchase a new spark plug by calling
1-800-366-PART.

WHEN ADJUSTING
GENERATOR
Disconnect
place
WHEN

OR MAKING

the spark plug wire from

the wire where
TESTING

Use approved
DO NOT

Checking

REPAIRS

check

FOR
spark

it cannot

contact

ENGINE

SPARK

TO YOUR

the spark

plug and

spark plug.

plug tester.

for spark with spark

plug removed,

Oi_ Leve_

Engine

Change the oil after the first 5 hours of operation.
Change oH 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.

Service

Air Cleaner

Your engine will not run properly and may be
damaged if you run it using a dirty air cleaner. Clean
or replace the air cleaner paper filter once every
25 hours of operation or once a year, whichever
comes first. Clean or replace more often if operating
under dusty or dirty conditions.
Service Air FHter
1. Loosen screws and remove air cleaner cover.
Remove paper filter.

• 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.

Cartridge
Cover

Change the oil while the engine is still warm from
running, as follows:
1. Clean area around oil drain plug. The oil drain
plug is located at base of engine, opposite
carburetor.
2.

Remove oil drain plug and oil fiJJcap and drain oil
completely into a suitable container.

Base
S crew

Install oil drain plug and tighten securely.

FiJJoil sump with recommended oil to the point of
overflowing. See page 7 for oil recommendations.

Install clean (or new) air cleaner assembly inside
cover. Dispose of old filter properly.

Install oil cap. Tighten cap securely.

Wipe up any spilled elk

Assemble air cleaner cover onto base and tighten
screws.

NOTE: You can purchase new air cleaner elements by
calling 1-800-366-PART.

Carburetor

Clean and inspect the spark attester as follows:

if you think your carburetor needs adjusting, see your
nearest Sears service center. Engine performance
may be affected at altitudes above 3000 feet. For
operation at higher elevations, contact your nearest
Sears service center.

CJean Spark Arrester

Screen

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

_._park

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

ea t Shield
.

DO NOT
Allow

touch

equipment

to cool

before

touching.

Keep at least 3 feet of clearance
cooling,

lands.

Reattach screen and muffler guard.

may have similar

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 13). Equally
important is to keep top of engine free from debris.
See "Generator Cleaning".

and servicing.

a spark arrester

4442 of the California

Other states
federal

inspect screen and replace if torn, perforated or
othepMse damaged. DO NOT use a defective
screen. If screen is not damaged, clean it with
commercial solvent.

Air Cooming System

having

on all sides of generator

maintenance

In the State of California
(Section

hot surfaces.

The generator must be at least 5 feet from structures
combustible
walls and/or other combustible
materials.

for adequate

Remove four screws that attach spark attester
screen.

Public
laws.

is required

Resources
Federal

by law

Code).

laws apply

If you equip the muffler with a spark arrester,

it must be maintained

in effective

working

order.

NOTE: You can purchase a new spark arrester screen
by calling 1-800-366-PART.
if you use your generator on any forest-covered, brushcovered, or grass-covered unimproved land, it must
have a spark arrester. The spark arrester must be
maintained in good condition by the ownerloperator.

Change OH

Thegeneratorshouldbestartedatleastonceevery
sevendaysandallowedtorunat least30minutes.If
thiscannotbedoneandyoumuststoretheunitfor
morethan30days,usethefollowinginformation
as a
guideto prepareitforstorage.

While engine is still warm, drain oil from crankcase.
Refill with recommended grade.

•

Remove spark plug and pour about 1 ounce (30ml)
of clean engine oil into the cylinder.

Long Term Storage

•

Install spark plug and crank slowly to distribute oil.

OHCylinder Bore

_nstructions

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

NEVER

To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. Follow
these instructions:

with

spark

plug removed,

Clean generator as outlined in "Generator Cleaning".

Check that cooling air slots and openings on
generator are open and unobstructed.

Other

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 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.
Drain fuel tank outdoors.
fuel away from sparks, open flames,
and other ignition sources,
DO NOT light a cigarette or smoke.

enqine

Generator

WARNING

Keep

crank

Storage

Tips

DO NOT store fuel from one season to another.

Replace fuel can if it starts to rust. Contaminated
fuel will cause engine problems.

If possible, store unit indoors and cover it to give
protection from dust and dirt. BE SURE TO
EMPTY FUEL TANK.

Cover unit with a suitable protective cover that
does not retain moisture.

WARNING

pilot lights,

heat,

DO NOT place a storage cover over a hot generator.
Let equipment coo! for a sufficient time before placing
the cover on the equipment.

Protect Fuet System
1.

Remove all gasoline from fuel tank to prevent gum
deposits from forming on these parts and causing
possible malfunction of engine.

Run engine until engine stops from lack of fuel.

Store generator

in clean,

dry area.

Problem

Correction

Cause
One of the circuit breakers is

Reset circuit breaker.

open.
Engine Bsrunning, but no AC
output is availab{e.

Poor connection or defective
cord set.
3.

Connected device is bad.

Check and repair.
3.

Connect another device that is
in good condition.

EngBne runs good at no-load but
"bogs down" when loads are
connected.

Engine shuts down during
operation.

or falters.

Contact Sears service facility.

Short circuit in a connected
load.

Disconnect shorted electrical
load.

Generator is overloaded.

See "Don't Overload
Generator".

Engine speed is too slow.

Contact Sears service facility.

Shorted generator circuit.

Contact Sears service facility.

Fuel valve in the "Off" position.

Set fuel valve to the "On"
position.

Rocker Switch set to "Off".

Set switch to "On".

Dirty air cleaner.

Clean or replace air.

Out of gasoline.

Fill fuel tank.

Stale gasoline.

Drain fuel tank; fill with fresh
fuel.

Spark plug wire not connected
to spark plug.

Connect wire to spark plug.

Bad spark plug.

Replace spark plug.

Water in gasoline.

Drain fuel tank; fill with flesh
fuel.

Overchoking.

Open choke fully and crank
engine.

10. Low oil level.

0. Fill crankcase to proper level.

11. Excessively rich fuel mixture.

1. Contact Sears service facility.

12. Intake valve stuck open or
closed.

2. Contact Sears service facility.

13. Engine has lost compression.

3. Contact Sears service facility.

Out of gasoline.

Fill fuel tank.

Load is too high.

See "Don't Overload
Generator".

Dirty air filter.

Replace air filter.

Choke is opened too soon.

Move choke to halfway position
until engine runs smoothly.

Carburetor is running too rich or
too lean.

Contact Sears service facility.

Engine lacks power.

Engine "hunts"

EngBne will not start; or starts
and runs rough.

Fault in generator.

CRAFTSMAN

5600 Watt AC Generator

580.325601
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GRAY
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B_ACK
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GRAY
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Craftsman 580325601 User Manual AC GENERATOR Manuals And Guides L0522234

CRAFTSMAN Generator Manual L0522234 CRAFTSMAN Generator Owner's Manual, CRAFTSMAN Generator installation guides

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