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Craftsman 580.328301 User manual

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Owner's Manual
CRAFTSMAN+
120/240 Volt
Electric Start
10,000 Watt
AC GENERATOR
Model No 580.328301
CusGemn:/aHt°lpline_"
HOURS: Mon.- Fri. 8 a.m. to 5 p.m. (CT)
CAUTION:
Before using this product, read this
manual and follow all its Safety Rules
and Operating Instructions
Sears, Roebuck and Co, Hoffman Estates, IL 60179
Visit our Craftsman website: www.sears.com/craftsman
Part No. 186942 Draft 3 (09/19/2002) Printed in the U.S.A.
• Safety
• Assembly
• Operation
• Maintenance
• Parts
•Espahol
Warranty .................................. 2
Safety Rules ............................... 3
Assembly ............................... 4-5
Operation .............................. 6-12
Maintenance ........................... 13-15
Product Specifications ....................... 14
Storage .................................. 16
Troubleshooting ............................ 17
Schematic ................................ 18
Wiring Diagram ............................ 19
Replacement Parts ...................... 20-37
Emissions Warranty ......................... 38
Notes ................................... 39
EspaSol ............................... 40-59
How to Order Parts .................. Back Cover
LIMITED WARRANTY FOR DELUXE PORTABLE GENERATORS
SEARS warrants to the original purchaser that the alternator and engine for its portable generator will be free
from defects in materials or workmanship for the items and period set forth below from the date of original
purchase. This warranty is not transferable and applies only to portable generators driven by the Sears
warranted engine. CONSUMER* COMMERCIAL*
Alternator 2 years (2nd year parts only) 1 year
Engine 2 years (2nd year parts only) 1 year
*NOTE: For the purpose of this warranty "Consumer Use" means personal residential household and
emergency use by original purchaser, not to be used as a primary source of power. "Commercial Use" means all
other uses, including rental, construction, commercial, and income producing purposes. Once a generator has
experienced commercial use, it shall thereafter be considered a commercial use generator for the purpose of
this warranty.
During said warranty period, SEARS will, at its option, repair or replace any part which, upon examination by
SEARS, is found to be defective under normal use and service**. Starting batteries are not warranted by
SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by
the purchaser and prepaid by him. This warranty does not cover normal maintenance and service and does not
apply to a generator set, alternator or engine, or parts which have been subjected to improper or unauthorized
installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair
or storage so as, in SEARS's judgment, to adversely affect its performance and reliability.
** NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to
perform well. This warranty will not cover repair when normal use has exhausted the life of a part or engine.
THERE IS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE
DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO
THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR
CONSEQUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES
IS EXCLUDED.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty
gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest SEARS authorized warranty service facility. Warranty service can be performed
only by a SEARS authorized service facility. This warranty will not apply to service at any other facility. At the
time of requesting warranty service, evidence of original purchase date must be presented.
SEARS, ROEBUCK AND CO., D/817 WA, Hoffman Estates, IL 60179 U.S.A
CAUTION! Before using this product, read this
manual and follow all Safety Rules and
Operating Instructions.
WARNING! You must isolate the generator
from the electric utility by opening the electrical
system's main circuit breaker or main switch if
this unit is used for backup power. Failure to
isolate the generator from the power utility
may result in injury or death to electric utility
workers and damage to the generator due to
a backfeed of electrical energy. When used as
backup power, the local power utilitymust be
notified.
DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. Carbon
monoxide, if breathed in sufficient
concentrations, will cause unconsciousness
or death. Operate this equipment outdoors
where adequate ventilation is available.
CAUTION! To prevent accidental starting when
setting up, transporting, adjusting or making
repairs to your generator, always disconnect
spark plug wire and place the wire where it
cannot contact the spark plug.
• The unit requires an adequate flow of cooling air
for its continued proper operation. Never operate
the unit inside any room or enclosure where the
free flow of cooling air into and out of the unit might
be obstructed. Allow at least 3 feet of clearance on
all sides of generator or you could damage the unit.
• The generator produces dangerously high voltage
that can cause extremely hazardous electrical
shock. Avoid contact with bare wires, terminals,
etc. Never permit any untrained person to operate
or service the generator.
•Do Not overfill the fuel tank. Always allow room for
fuel expansion. If tank is overfilled, fuel can
overflow onto a hot engine and cause FIRE or an
EXPLOSION.
• Never operate the generator:
in rain; in any enclosed compartment; when
connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if flame
or smoke is observed while unit is running; if unit
vibrates excessively.
• Never handle any kind of electrical cord or device
while standing in water, while barefoot or while
hands or feet are wet. Dangerous electrical shock
will result.
• Use a ground fault circuit interrupter in any damp
or highly conductive area (such as metal decking or
steel work).
• Do Not use worn, bare, frayed or otherwise
damaged electrical cord sets with the generator.
Using any defective cord set may result in electrical
shock or damage to property.
• Operate generator only on level surfaces and
where it will not be exposed to excessive moisture,
dirt, dust or corrosive vapors.
• Gasoline is highly FLAMMABLE and its vapors are
EXPLOSIVE. Do Not permit smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine.
Comply with all laws regulating storage and
handling of gasoline.
• Never store generator with fuel in tank where
gasoline vapors might reach an open flame or
spark or pilot light (as on a furnace, water heater or
clothes dryer). FIRE or EXPLOSION may result.
• Never add fuel while unit is running.
• Never start or stop the unit with electrical loads
connected to receptacles AND with connected
devices turned ON. Start the engine and let it
stabilize before connecting electrical loads.
Disconnect all electrical loads before shutting down
the generator.
• Do Not insert any object through cooling slots of
the engine-generator.
NOTE: Your generator is equipped with a spark
arrester muffler. The spark arrester must be
maintained in effective working order by the owner/
operator. In the State of California, a spark arrester is
required by law (Section 4442 of the California Public
Resources Code). Other states may have similar laws.
Federal laws apply on federal lands.
,_ 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.
Your generator requires some assembly and is ready
for use after it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of
your generator, please call the generator helpline
at 1-800-222-3136.
IMPORTANT: Any attempt to run the engine before it
has been serviced with the recommended oil will result
in an engine failure.
TO REMOVE THE GENERATOR
FROM CARTON
• Set the palleted carton on a rigid flat surface.
• Carefully cut bands around the shipping carton.
• Lift carton off the generator.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping pallet.
CARTON CONTENTS
Check all contents. If any parts are missing or
damaged, call the generator helpline at
1-800-222-3136. Contents Include:
• 10,000 Watt generator
• Owner's manual
• 2 Bottles of engine oil (28 oz.)
• 125 Volt, 30 Amp plug
• 125 Volt, 20 Amp plug
• 240 Volt, 30 Amp plug
• Oil fill spout
• Wheel kit
CHECK BATTERY /ATTACH
NEGATIVE BATTERY WIRE
The battery on the generator is fully charged, sealed
and pre-installed except for the negative (black)
battery cable.
To install:
•Place key switch in "Stop" position.
•Remove hardware on the negative battery terminal.
f
Neg_
• Align the negative battery cable with the terminal.
• Reattach hardware and tighten.
• Ensure the connections to the battery and
generator and tight and secure.
4
WHEEL KIT INSTALLATION
To install your wheel kit, you will need the following
tools:
•13mm metric box, open end or socket wrench
• Neddle-nose pliers
Install Wheel Kit as follows:
1. Place the bottom of the generator cradle on a flat,
even surface. Place temporary blocks under the
cradle to ease assembly.
2. Slide axle through both axle mounting brackets on
cradle frame.
3. Slide spacer over each end of axle.
4. Slide a wheel over the axle.
NOTE: Be sure to install both wheels with the air
pressure valve on the outboard side.
5. Place the e-ring onto the groove in the axle. You
may add the flat washer if desired.
6. Place one end of the needle nose pliers on the
bottom of the axle and the other end of the pliers
on top of the e-ring. Seat the e-ring by pressing
the pliers closed.
7. Repeat step 4 through 6 to secure second wheel.
8. Secure the vibration mount on the support leg with
lock nut,and 30mm long capscrew.
9. Fasten the support leg to the bottom of the
generator cradle using two 20 mm capscrews, two
lock washers and two flat washers. Remove
temporary blocks.
10. Position the handle below the muffler bracket on
the frame, as shown. Attach the handle with four
45mm long capscrews and four lock nuts.
11. Recheck all nuts to make sure they are tight and
secure.
Handle
Weld
Nut
Locking
Nut
45mm
Capscrew
Locking
Nut
Support
Leg
Axle Spacer
Wheel
Washer
E-Ring
Vibration
Mount .
30mm
Capscrew
Flat Washer
Washer
_ 20mm
Capscrew
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.
FuelTank
Circuit Breakers
(AC)
120 Volt AC,
20 Amp
Duplex
Receptacle
120 Volt AC.
20 Amp
Locking
Receptacle
120 Volt AC,
30 Amp
Locking
Receptacle
120/240 Volt AC,
30 Amp Locking
Receptacle
Fuel Shut Off Valve
120/240 Volt AC,
50 Amp Receptacle
Air Filter
top of engine)
Key Switch
Choke
Oil Filter
120 Volt AC, 20 Amp Duplex Receptacle -- Each
supplies electrical power for the operation of 120 Volt
AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 20 Amp Locking Receptacle --
Supplies electrical power for the operation of 120 Volt
AC, 20 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 30 Amp Locking Receptacle --
Supplies electrical power for the operation of 120 Volt
AC, 30 Amp, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120/240 Volt AC, 30 Amp Locking Receptacle --
Supplies electrical power for the operation of
120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz
electrical lighting, appliance, tool and motor loads.
120/240 Volt AC, 50 Amp Receptacle -- Supplies
electrical power for the operation of 120/240 Volt AC,
single phase, 60 Hz welder or motor loads at
50 Amps.
Air Filter -- Filters intake air as it is drawn into the
engine.
Choke -- Used to start a cold engine.
Circuit Breakers (AC) -- Each receptacle is provided
with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.
Fuel Shut-Off Valve -- Always have the fuel shut-off
valve closed when engine not running.
Fuel Tank -- Tank holds 10 U.S. gallons of unleaded
gasoline.
Key Switch -- Used to start engine. Always have key
switch in the "Stop" position when not in use.
Oil Filter- Filters engine oil to prolong engine life.
BEFORE STARTING THE
GENERATOR
Add Engine Oil
NOTE: A 20 hour break-in period is required. Replace
engine oil and oil filter after the first 20 hours. Do Not
use synthetic oil during the break-in period.
NOTE: When adding oil to the engine crankcase in
the future, use only high quality detergent oil rated
with API service classification SF or higher. Use no
special additives.
Select the oil's viscosity grade according to your
expected operating temperature:
i[tlYivj
PZ*IT_VJ
Single
Grade
Multi • •
Grade • •
-20 -10 0 10 20 30 40°C
-4 14 32 50 68 86 104°F
NOTE: For operating temperatures above 90°F,
synthetic oil is recommended. Synthetic oil will last
longer and protect the engine better in high
temperature conditions.
Although multi-viscosity oils (10W40, 10W30, etc.)
improve starting in cold weather, these multi-viscosity
oils will result in increased oil consumption when used
above 32°F. Check your engine oil level more
frequently to avoid possible damage from running low
on oil.
To add oil:
• Place generator on a level surface.
• Clean area around oil fill cap and dipstick. Remove
oil fill cap and dipstick.
• Wipe dipstick clean.
• Slowly fill engine with oil through the oil fill opening
until it reaches the upper line on the dipstick. An oil
spout is supplied that can be attached to the oil
bottle. Always check the oil level with the dipstick
plugged into position. Stop filling occasionally to
check oil level. Do Not overfill!
• Install dipstick. Install oil fill cap and hand tighten
securely.
• Check engine oil level before starting each time
thereafter. Refill if below the lower line on the
dipstick.
0,,Oau0e
Upper Level
Add Gasoline
A ARNING! Never fill fuel tank indoors. Never
fill fuel tank when engine is running or hot.
Do Not light a cigarette or smoke when filling
the fuel tank.
A ARNING! Do Not overfill the fuel tank.
Always leave room for expansion.
• Use regular UNLEADED gasoline in the
generator. Do Not use premium gasoline. Do Not
mix oil with gasoline.
• Clean area around fuel fill cap; remove cap.
• Fill fuel tank with clean, fresh, unleaded gasoline.
Be careful not to overfill. Allow 1/2" of tank space
for fuel expansion.
Tank
1/2" Air _ _ J Fuel
:___Space _ __ _:_zz_
• Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: If the generator stops because it ran
out of fuel, turn key switch to "Stop" position so that
the battery is not depleted.
IMPORTANT: It is important to prevent gum deposits
from forming in fuel system parts during storage, such
as the carburetor, fuel filter, fuel hose or tank. Also,
alcohol-blended fuels (called gasohol, ethanol or
methanol) can attract moisture, which leads to
formation of acids during storage. Acidic gas can
damage the fuel system while in storage. To avoid
engine problems, the fuel system should be emptied
before storage of 30 days or longer. See "Storage" on
page 16. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may
Occur.
HOW TO USE YOUR GENERATOR
If you have any problems operating your generator,
please call the generator helpline at 1-800-222-3136.
Grounding The Generator
The National Electrical Code requires that the
frame and external electrically conductive parts of
this generator be properly connected to an
approved earth ground. Local electrical codes may
also require proper grounding of the unit. For that
purpose, a grounding lug is provided on the base of
the cradle.
TO START THE ENGINE
CAUTION! Never start or stop engine with electrical
devices plugged into the receptacles AND devices
turned ON.
• Unplug all electrical loads from generator
receptacles before starting the engine.
• Make sure the unit is in a level position.
• Open the fuel shut-off valve.
\FUEL TANK
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding lug and
to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against
electrical shock. However, local codes may vary
widely. Consult with a local electrician for
grounding requirements in your area.
Proper grounding of generator will help prevent
electrical shock in the event of a ground fault
condition in the generator or in connected electrical
devices. Proper grounding also helps dissipate static
electricity, which often builds up in ungrounded
devices.
Connecting Electrical Loads
• Let engine stabilize and warm up for a few minutes
after starting.
• Plug in and turn on the desired 120 Volt or
240 Volt, single phase, 60 Hz electrical loads.
• Do Not connect 240 Volt loads to 120 Volt
receptacles.
• Do Not connect 3-phase loads to the generator.
• Do Not connect 50 Hz loads to the generator.
• Add up the rated watts (or amps) of all loads to be
connected at one time. This total should not be
greater than (a) the rated wattage/amperage
capacity of the generator or (b) circuit breaker
rating of the receptacle supplying the power. See
"Don't Overload the Generator" on page 12.
J
Fuel Valve is shown
in the On position
Pull the choke knob to close. If the engine is warm,
or the ambient temperature is high, pull the choke
knob half-way, or keep it fully open.
Close /
/
\
Turn the key switch to the "Start" position.
IMPORTANT: Do Not operate the electric starter
continuously for more than 5 seconds, even if the
engine does not start. Extended cranking can damage
the starter motor.
NOTE: If engine fails to start, set the key to the "Run"
position and wait for about 10 seconds before retrying.
IMPORTANT: Never turn the key switch to the "Start"
position while the engine is running. You could
damage the starter motor.
• When the engine starts, gradually open choke by
pushing the choke knob and keep it fully opened
while running.
IMPORTANT:DoNotoverloadthegenerator.Also,
DoNotoverloadindividualpanelreceptacles.These
outletsareprotectedagainstoverloadwithpush-to-
reset-typecircuitbreakers.Ifamperageratingofany
circuitbreakerisexceeded,thatbreakeropensand
electricaloutputtothatreceptacleislost.Read"Don't
OverloadtheGenerator"onpage12carefully.
STOPPING THE ENGINE
• Unplug (or turn OFF) all electrical loads connected
to generator panel receptacles. Never start or
stop engine with devices plugged in and turned
on.
• Let engine run at no-load for 30 seconds to
stabilize the internal temperatures of engine and
generator.
• Turn the key switch to the "Stop" position.
• Close the fuel valve.
STOPPING THE ENGINE WITH THE
FUEL VALVE
This procedure eliminates fuel from the carburetor.
Use this method to stop the generator if you plan to
store the generator over a long period. Fuel will clog
the internal passages of carburetor if allowed to
remain for an extended period.
• Unplug (or turn OFF) all electrical loads connected
to generator panel receptacles. Never start or
stop engine with devices plugged in and turned
on.
• Let engine run at no-load for 30 seconds to
stabilize the internal temperatures of engine and
generator.
• Close the fuel valve while the engine is running
and wait until the engine stops.
Set the key switch to the "Stop" position after
stopping the engine. Failure to put the key
switch into the "Stop" position will deplete the
battery.
If the Engine Will Not Start
Perform the following checks if your engine does not
start:
1. Do you have enough gasoline?
Check to make sure you have fuel in the gas tank.
2. Is the fuel valve open?
Check to make sure the fuel valve is open. If it is
closed, open it.
3. Is there enough compression?
Check to see ifeither spark plug is loose. Ifso,
tighten it.
4. Is there enough oil?
You unit comes equipped with a low oil pressure
shutdown system. If there is not enough oil in your
engine it will not start. Fill the engine with oil to the
proper level.
5. Is the spark plug wet with gasoline?
• Apply full choke and crank the engine for 2 or
3 seconds. Remove the plug and check to see if
the electrode is wet. If the electrode is wet, fuel is
well supplied to your engine.
• If the electrode is dry, check to find where the
fuel is restricted. (Check the fuel intake of the
carburetor and fuel strainer intake.)
• In case the engine does not start with well
supplied fuel, try using fresh fuel.
6. Is there a strong spark across the electrode?
,_ WARNING! Wipe off any spilled gasoline
before checking the spark plug. Place spark
plug as far away from the spark plug hole as
possible. Do Not hold spark plug by hand when
checking.
• Remove the spark plug and connect it to the
plug cap. Ground spark plug against engine
body. Turn key switch to "Start" position.
Observe strength of spark.
• Repeat above step with a new spark plug if
the spark is weak or there is no spark.
• The ignition system is faulty if there is no
spark with a new spark plug. Take your unit to
your nearest Sears service center.
7. Is your battery well charged?
• Check the battery as it may be discharged
and unable to operate the electric starter.
Consult your nearest Sears service center.
RECEPTACLES
120 Volt AC, 20 Amp, Duplex Receptacle
This is a 120 Volt AC outlet, consisting of a pair of
receptacles protected against overload by a 20 Amp
push-to-reset circuit breaker.
120 Volt AC, 30 Amp Receptacle
Use a NEMA L5-30 plug with this receptacle. Connect
a 3-wire cord set rated for 125 Volts AC at 30 Amps
(or greater) to the plug.
Cord Set NEMA L5-30
Use each receptacle to power 120 Volt AC, single
phase, 60 Hz electrical loads requiring up to a
combined 2400 watts (2.4 kW) or 20 Amps of current.
Use only high quality, well-insulated, 3-wire grounded
cord sets rated for 125 Volts at 20 Amps (or greater).
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 Receptacle
Use a NEMA L5-20 plug with this receptacle. Connect
a 3-wire cord set rated for 125 Volts AC at 20 Amps
(or greater) to the plug.
3-Wire Cord Set
__l.,.J NEMA L5-20
Neutral
Hot
Ground (Green)
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 2,400 watts (2.4
kW) of power at 20 Amps. The outlet is protected by a
20 Amp push-to-reset circuit breaker.
©__r_nd eutral
120V
iltreen)
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3,600 watts
(3.6 kW) of power at 30 Amps. The outlet is protected
by a 30 Amp push-to-reset circuit breaker.
120/240 Volt AC, 30 Amp Receptacle
Use a NEMA L14-30 plug with this receptacle.
Connect a suitable 4-wire grounded cord set to the
plug and to the desired load. The cord set should be
rated for 250 Volts AC at 30 Amps (or greater).
4-Wire Cord Set
(Neutral)
NEMA L14-30 /_ Ground (Green)
Use this receptacle to operate 120 Volt AC, 60 Hz,
single phase loads requiring up to 3,600 watts
(3.6 kW) of power at 30 Amps or 240 Volt AC, 60 Hz,
single phase loads requiring up to 7,200 watts
(7.2 kW) of power at 30 Amps. The outlet is protected
by a 30 Amp push-to-reset circuit breaker.
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