Craftsman 580327112 Owner’s Manual

SE/AR_Owner's Manual

C OMPANION I

5000 Watt
A-C Generator

Model No.

580.327112

CAUTION: Before using this

product, read this manual and
follow all Safety Rules and

Operating Instructions.

SEARS, ROEBUCK and CO., Hoffman Estates, IL 60179 U.S.A.

Part No. B3051 .Draft 0 (7/23/98)

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

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

SAFETY RULES ............................ 3

ASSEMBLY ................................ 4 REPLACEMENT PARTS .................. 16-22

OPERATION ......................... t.y_3_ _J EMISSIONS WARRANTY ................. 24-25

PRODUCT SPECIFICATIONS .......... {'__i' " ,.10 HOW TO ORDER PARTS ............ BACK PAGE

MAINTENANCE "_.":.":.":',._., ._. ,'T_:',. :_i 'Jl'O.:li

STORAGE -..; .:: .:-::-:-:::-:' ::":":_ .... _!!i:i;.12

TROUBLESHOOTING ....................... 13

WIRING DIAGRAM ......................... 15

'' L'iMi'TED ONE YEAR WARRANTY FOR COMPANION GENERATORS

SEARS warrants tO the Originalpurcl_aser that the alternator and engine for its portable generator will

be free from defects in materials or workmanship for the items and period set forth below from the
date of original purchase. This warranty is not transferable.

CONSUMER* COMMERCIAL*

Alternator 1 year 90 Days

Engine 1 year 90 Days

"NOTE: For the purpose of this warranty "Consumer Use" means personal residential householdand
emergency use by original purchaser, not to be used as a primary sourceof power. "Commercial Use"

means all other uses, including rental, construction, commercial, and income producingpurposes. 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, isfound 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 provinces do not allow limitations on how long an implied warranty lasts, or

the exclusion or limitationof incidental or consequential damages, so the abovelimitations 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

)resented.

SEARS, ROEBUCK and CO., DI817WA, Hoffman Estates, IL 60179 U.S.A.

2

CAUTION: Always disconnect spark plug
wire and place the wire where it cannot
contact the spark plug. To prevent
accidental starting when setting up,

transporting, adjusting or making repairs
to your Generator.

DANGER: This generator is designed for
outdoor use only. Do not use this

A

generator inside any building or
enclosure including the generator

compartment of a recreational vehicle
(RV). Fire or an explosion may result. No

user performed modifications, including
venting of exhaust and/or cooling

ventilation, will eliminate the danger.
Also, allow at least two feet of clearance

on all sides of the generator even while
operating the unit outdoors.

CAUTION: Before using this product,
read this manual and follow all Safety
Rules and Operating Instructions.

• The generator produces dangerouslyhighvoltage
that can cause extremely hazardous electricalshock.

Avoidcontact with bare wires, terminals, etc. Never
permitany unqualified person to operate or service

the generator.

• Never handle any kindof electrical cordor device

while standingin water, while barefoot or while hands

or feet are wet.

• The National Electric Code requires the frame and
externalelectrically conductiveparts of generator be

properlyconnected to an approved earth ground.
Local electrical codes may also require proper

groundingof the generator. Consult with a local
electricianfor groundingrequirements inyour area.

• Use a ground fault circuitinterrupterin any damp or
highlyconductivearea (such as metal deckingor

steel work).

• Do not use any worn, bare, frayed or otherwisedam-

aged electrical cordsets with the generator.

• Operate generator only on level surfaces and where

it willnot be exposed to excessive moisture,dirt, dust
or corrosivevapors.

• Gasoline is highlyFLAMMABLE and itsvapors are
EXPLOSIVE. Do not permit smoking,open flames,

sparks or heat in the vicinitywhilehandlinggasoline.
Avoid spillinggasolineon a hot engine. Complywith
all laws regulatingstorage and handlingof gasoline.

• Never add fuel while unit is running.

• Do not overfillthe fuel tank. Alwaysallow roomfor

fuel expansion. If tank is overfilled,fuel can overflow
ontoa hotengine and cause FIRE or an EXPLO-

SION.

• Never store generator with fuel in tank where gaso-

linevapors might reach an openflame or spark or
pilotlight (as on a furnace, water heater or clothes

dryer). FIRE oran EXPLOSION might result.

• Generator exhaust gases contain DEADLY carbon

monoxidegas. Operate this equipment onlyin the
open air where adequate ventilationisavailable.

• The engine-generator requiresan adequate flow of

coolingair for its continuedproper operation. Never
operatethe unitinsideany roomor enclosurewhere

the free flow of cooling air into and out of the unit
mightbe obstructed.Allowat least2 feet of clearance

onall sidesof generator,evenwhile operatingunitout-
doors,oryou coulddamage the unit.

• Never start, or stop,the engine-generatorwith electri-

cal loadsconnected to receptacleswith the connect-
ed devices tumed ON. Start the engine and let itsta-

bilizebefore connectingelectrical loads. Disconnect
all electricalloadsbefore shuttingdown the genera-

tor.

• Do not insert any objectthrough coolingslots of the

engine-generator.

• Never operate generator (a) in rain;(b) in any

enclosed compartment;(c) if connected electrical
devices overheat;(d) if electrical outputis lost;(e) if

engine or generatorsparks; (f) if flames or smoke are
observed whileunitis running;(g) if unitvibrates
excessively.

Note: If you equipthe enginewitha sparkarrestormuffler,
thesparkarrestormustbe maintainedineffectiveworking

orderbythe owner/operator.
In theState ofCalifomiaa sparkarrestoris requiredbylaw

(Section4442 ofthe CaliforniaPublicResourcesCode).
Otherstatesmay have similarlaws. Federallawsapplyon
federal lands.The sparkarrestorpart numberfor thisunitis

pin34479A.

LOOK FOR THIS SYMBOL TO POINT OUT

A

IMPORTANT SAFETY PRECAUTIONS. IT
MEANS "ATTENTION!!! BECOME

ALERT!!! YOUR SAFETY IS INVOLVED."

Your A(3 generator requiressome assembly and is ready
for use after it has been properly serviced withthe rec-

ommended 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 beforeit has

been serviced with the recommendedoil will resultin an
engine failure.

TO REMOVE THE GENERATOR FROM
CARTON

• Set the cartonon a rigidflat surface with =THISSIDE
UP" arrows pointing upward.

Carefully open the top flapsof the shippingcarton.

• Cut down comers at one end of carton from topto
bottomand lay that side of cartondown fiat.

• Remove all packing material, carton fillers,etc.

• Remove the generatorfrom the shippingcarton.

CARTON CONTENTS

Check all contents. Ifany partsare missingor damaged,
call the Generator Helplineat 1-800-222-3136.

• The main unit

• Owner's manual

• Engine oil

CORD SETS AND CONNECTOR PLUGS

120 Volt Duplex Receptacle
Use only highquality, well-insulated, extensioncords with

the generator's120-volt duplex electricalreceptacles.

Each receptacle is protected against overloadby a push-

to-reset circuitbreaker. Use each receptacle to operate

120 volts, single phase 60 Hz, A C electricalloads requir-
ing upto 2400 watts (2.4 kW) at 20 amps of current.

CAUTION! Although each receptacle is

A

rated for 120 volts at 20 amps (2400 watts
or 2.4 kW), the generator is rated for a
total of 5000 watts. Powering loads that
exceed the wattage capacity of the
generator can damage it or cause serious
injuries. The total of loads with 120 volts
powered through these receptacles
should not exceed 20 amps.

Check the ratings ofall extension cords before youuse
them. Extensioncord sets used should be rated 125 volts

at 20 ac amps or greater for most electricaldevices.
Some devices, however, may not require thistype of

extension cord. Check the owner's manuals of those

devices for the manufacturer's recommendations.

Keep extensioncordsas short as possible,preferably

lessthan 15 feet long to prevent voltage drop and possi-
ble overheating of wires.

120/240 Volt, 20 AMP Receptacle

This receptacle isa NEMA L14-20R and is protected by a

push-to-reset circuitbreaker. A NEMA L14-20P mating
connector plug isrequired to use this receptaclerecepta-

cle. Connect a suitable4-wire cord set to the plugand to

the desired load. The cordset should be rated for 250
volts at 30 amps.

Ire Cord Set

(Neutral)

X (Hot)

Y(Hot)

1201240 VOLTS PLUG (Green)

CAUTION! Although this receptacle is

A

rated for 240 volts at 20 amps (4800 watts
or 4.8 kwh, the generator is rated for a

total of 5000 watts (5.0 kW). Powering

loads that exceed the wattage capacity of
the generator can damage it or cause

serious injuries. Loads with 240 volts
powered through this receptacle should

not exceed 20 amps.

KNOW YOUR GENERATOR

Read the owner's manual and safety rules before operating your generator. Compare the illustrationswithyour

Generatorto familiarize yourselfwith the locationsof vadous controls and adjustments.

Fuel Tank

Muffler

Air Cleaner

120/240-Volt AC, 20 AMP
Locking Receptacle

120-Volt AC, 20 AMP
Duplex Receptacle

120 Volt, 20 AMP, Duplex Receptacles -- May be used
to supplyelectrical power forthe operationof 120 volts at

20 amps ac, single phase, 60 Hz, AC electricallighting,
appliance, tool and motorloads.

120/240 Volt, 20 AMP, Locking Receptacle -- May be
used to supplyelectrical power for the operationof 120
and/or 240 volts at 20 amps AC, single phase, 60 Hz, AC

electrical lighting,appliance, tool and motorloads.

Air Cleaner -- Filtersintake air as it is drawnthroughthe

engine.

Choke Lever- Used when startinga coldengine.

/

Oil Fill Cap

Oil Drain Plug

Circuit Breakers

Circuit Breakers (AC) -- Each receptacle is provided
with a circuitbreakerto protectthe generator against
electrical overload. Breakers are "pushto reset"type.

Fuel Tank -- Tank holds 5 U.S. gallonsof unleaded

gasoline.

Muffler -- Muffler lowers engine noise.
Oil Drain Plug -- Drainengine oil here.

Oil Fill Cap -- Fill engine with oilhere.

HOW TO USE YOUR GENERATOR

Ifyou have any problemsoperating your Generator,

please call the Generator helplineat 1-800-222o3136.

GROUNDING THE GENERATOR.

The NationalElectricalCode requiresthat the frame and

extemal electricallyconductiveparts of this generator be
properlyconnected to an approved earth ground. Local
electrical codes may also require proper groundingof the
unit. For that purpose,a groundinglug is providedon the

base of the cradle.

Generally, connectinga No. 12 AWG (American Wire
Gauge) stranded copper wire to the groundinglugand to

an earth-drivencopper or brass groundingrod (electrode)
providesadequate protectionagainstelectrical shock.

However, local codes may vary widely. Consult with a

• local electricianfor groundingrequirements in your area.

Proper groundingof generator will help prevent electrical
shock in the event of a groundfault condition inthe gen-
eratoror in connected electricaldevices. Proper ground-
ingalso helps dissipatestatic electricity,whichoften
buildsup in ungrounded devices.

BEFORE STARTING THE GENERATOR

To operate the engine you willneed to do the following:

• Place generator on a level surface.

• Clean area around oil filland remove oilfillcap

• Wipe cap dean.

• Pour oil into oilfill opening untiloilreaches the point
of overflowing. Do not overfill!

Add Gasoline

A

• Use regular UNLEADED gasoline withthe Generator

• Clean area around fuel fill cap, remove cap.

• Add unleaded regulargasoline,slowlyto fuel tank. Be

• Installfuel cap and wipe up any spilled gasoline.

IMPORTANT: It isimportantto preventgum deposits

from forming in essentialfuel system partssuch as the
carburetor,fuel filter, fuel hose or tankduringstorage.
Also, experience indicatesthat alcohol-blendedfuels

(called gasohol, ethanolor methanol) can attract moisture

which leads to separation and formation of acids during

storage.Acidic gas can damage the fuel systemof an

engine while in storage. To avoid engine problems,the
fuel system should be emptied before storageof 30 days

or longer. See "Storage"on page 12. Never use engine
or carburetor cleaner productsin the fuel tank or perma-
nent damage may occur.

WARNING 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

CAUTION: Do not overfill the fuel tank.
Always leave room for expansion.

engine. Do not use premiumgasoline. Do not mix oil
with gasoline.

careful not to overfill.Allow about 1/4" of tank space
for fuel expansion.

TO START THE ENGINE

WARNING: Never start or stop engine I
with electrical devices plugged into the

panel receptacles and turned on.

I

Add Engine Oil

NOTE: When adding oil to the engine crankcase in the
future, use only high quality detergent oil rated with API •

service classificationSF or SG or higher rated SAE 30 ,
weight. Use no special additives.Select the oil'sviscosity
grade accordingto your expected operating temperature.

colder -<----- 32°F _ warmer |

I

5W30 SAE 30

Although multi-viscosity oils (5W30, 10W30, etc.) improve

startingin cold weather, these multi-viscosity oilswill
resultin increased oil consumptionwhen used above

32°F. Check your engine oil level more frequently to
avoid possibledamage from runninglow on oil.

6

Unplug all electrical loads from generator receptacles
beforestarting the engine.

Make sure the unitis in a level position.
Open the fuel shut--offvalve.

I

J..d.._ Fuel Tank

Turn Clockwise to

"OFF" Position

• Move the choke lever to the "Choke" position.

RUN

I

Set the engine controlswitchto the On position.

t÷t

STOPPING THE ENGINE

• Unplug all electrical loads from generator panel recep-

tacles. Never start or stop engine with electrical

devices plugged inand turned on.

• Let engine run at no-loadfor several minutesto
stabilizethe internal temperatures of engine and
generator.

° Move engine controlswitchto "Off" Position.
° Closethe fuel shut-off valve

CONNECTING ELECTRICAL LOADS

• Let engine stabilizeand warm up for a few minutes

after starting.

• Plug in and turn on the desired 120 and/or 240 volts,

single phase, 60 Hertz, A C electrical loads.

• Do not connect 240 volts to the 120 volt duplex
receptacles

• Do not connect 3-phase loads to the receptacles.

• Do not connect any 50Hz loads to the receptacles.

• DO NOT OVERLOAD THE GENERATOR. Add up

the rated watts (or amps) of all loads to be connected
at one time. This total shouldnot be greater than the

rated wattage/amperage capacityof the generator.

See Don't Overload the Generator on Page 9.

• Manual Start: Grasp starter grip and pull slowlyuntil
you feel some resistance.Then pullcord outwith

rapid fullarm stroke. Let rope retum slowly. Do not let
rope "snapback" against starter.

• When engine starts, move choke lever to "Run"

position.

Note: If engine fails to start after 3 pulls,move the
choke lever to "RUN" and pull starter ropeagain.

Note: If the engine fails to start afterthree (3) pulls,

check for proper oil level in crankcase. Unit is equipped
with a lowoil shutdown system.

Note: If engine fires, but does not continue to run, move

choke lever to "Choke" and repeat startinginstructions.

,_ CAUTION! Never run engine indoors or

,_ WARNING! Temperature of muffler and

in enclosed poorly ventilated areas.
Engine exhaust contains carbon

monoxide, an odorless and deadly gas.

nearby areas may exceed 150°F (65°C).
Avoid these areas.

LOW OIL LEVEL SHUTDOWN SYSTEM

Sensing Low Pressure
If the system sensesa low oil levelduring operation,the

engine shuts down. If the engine shuts down by itselfand
it has enough gasolinein the fuel tank, check oil level.

Restarting
If you attempt to restartthe engine after sucha shutdown

and have not corrected the engine oil level,the engine

will not start. Check the oil and refill accordingto the

instructionson page 7.

7

DON'T OVERLOAD THE GENERATOR ..
Overloadinga generator in excess of its rated wattage

capacity can result in damage to the generator and to
connected electricaldevices. Observe the following, to

preventoverloadingthe unit:

, Add up the total wattage of all electricaldevices to be

connected at one time. This total should NOT be

greater than the generator's wattage capacity.

* The rated wattage of lights can be taken from light

bulbs. The rated wattage of tools, appliances and
motors can usually be found on a data plate or decal

affixed to the device.

• If the appliance, tool or motordoes not give wattage,
multiply volts times ampere ratingto determinewatts

(voltsx amps = watts).

WATTAGE REFERENCE GUIDE

Some electric motors,such as inductiontypes,

requireabout two and a half times more watts of
powerfor startingthan for running. This surge of
powerlasts onlya few seconds when startingsuch
motors. Make sure you allowfor this highstarting

wattage when selectingelectricaldevicesto connect
to your generator. First,figurethe watts neededto

start the largestmotor. Add to that figure the running
watts of all other connectedloads.

The Wattage Reference Guide below is provided to
assist you in determininghow many items your generator

can operate at one time.

Electrical Device Running

Watts

*Air Conditioner (12,000 Btu) ....................... 1700

Battery Charger (20 amp) .............................. 500

Belt Sander (3") ........................................... 1000

Chain Saw .................................................... 1200

Circular Saw (6-12/") ........................ 800 to 1000

Coffee Maker ............................................... 1000

*Compressor (1 HP) .................................... 2000

*Compressor (3/4 HP) ................................. 1800

*Compressor (1/2 HP) ................................. 1400

Curling Iron .................................................... 700

*Freezer ......................................................... 500

Disc Sander (9") ........................................... 1200

Edge Trimmer ................................................ 500

Electric Nail Gun .......................................... 1200

Electrical Device Running

Watts

Impact Wrench ................................................ 500

*Jet Pump ...................................................... 800

Lawn Mower ................................................. 1200

Light Bulb ....................................................... 100

Microwave Oven ............................................ 700

*Milk Cooler .................................................. 1100

Oil Burner on Furnace ................................... 300

Oil Fired Space Heater (140,000 Btu) ........... 400

Oil Fired Space Heater (85,000 Btu) ............. 225

Oil Fired Space Heater (30,000 Btu) ............. 150

*Paint Sprayer, Airless (1/3 HP) .................... 600

Paint Sprayer, Airless (handheld) .................. 150

Radio .................................................... 50 to 200

*Refrigerator ................................................... 600

Electric Range (one element) ...................... 1500

Electric Skillet ............................................... 1250

*Furnace Fan (1/3 HP) ................................. 1200

Hair Dryer ..................................................... 1200

Hand Drill (1") .............................................. 1100

Hand Drill (1/2") ................................ 750 to 1000

Hand Drill (3/8") ............................................. 500

Hand Drill (1/4") ............................................. 250

Hedge Trimmer .............................................. 450

Slow Cooker ................................................... 200

*Submersible Pump (1-1/2 HP) .................... 2800

*Submersible Pump (1 HP) .......................... 2000

*Submersible Pump (1/2 HP) ....................... 1500

Sump Pump .................................................. 600

*Table Saw (10") ............................. 1750 to 2000

Television ............................................ 200 to 500

Weed Trimmer ............................................... 500

* Allow 2-1/2 times the listed watts for starting
these devices.

Maintenance Schedule

Follow the hourly or calendar intervals, whichever occurs first.

More frequent service is required when operating in adverse conditions noted below.

Maintenance Operation

Check oil level
Change oil_:

Service air pre-cleaner

Service air cleaner cartridge

Clean coolingsystem

Replace spark plug
Prepare unit for storage

Change oil after first 5 hours of operationthen after every 25 hours or every season.

" Change oil sooner when operating under heavy load or in high temperatures.
** Clean more often under dirty or dusty conditions.

Every5 Hours

or Ually

X

Prepare unitfor storage if its to remain idlefor more than

30 days

PRODUCT SPECIFICATIONS

Generator Specifications

Rated Maximum Power ......... 5000 Watts (5.0 kW)

Surge Power ......... ....... 6250 Watts (6.25 kW)

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

Rated MaximumCurrent

at 240 volts ................. 20.8 AC Amperes

Rated MaximumCurrent

at 120 Volts ................ 41.7 AC Amperes

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

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

Engine Specifications

Rated Horsepower ........... 10 at 3600 rpm

Spark Plug

Type: ................ Champion RC14YC or

Equivalent

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

Gasoline Capacity ............ 5 U.S. gallons

Oil

Summer ............. SAE 30 (10W-30)

Winter .............. SAE 5W-20 or 5W-30

GENERAL RECOMMENDATIONS
The warranty of the Generator does not cover items that

have been subjected to operator abuse or negligence. To
receive full value from the warranty, operator must main-

tain Generator as instructed in this manual.
Some adjustments will need to be made periodically to

properly maintain your Generator.

25 Hours or 50 Hours or 100 Hours or

Every Season Every Season Every Season

X
X

All adjustments in the Service and Adjustmentssectionof
this manual should be made at least once each season.

Followthe requirementsin the "Maintenance Schedule"
chartabove.

Note: Once a year you should clean or replace the spark
plugand replace the air filter. A new spark plug and
clean air filter assure properfuel-air mixture and help

your engine run better and last longer.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping the unit
clean and dry. Operate and store the unit in a clean dry

environmentwhere itwill not be exposedto excessive
dust,dirt, moistureor any corrosivevapors. Cooling air

slots in the generator must not become clogged with
snow, leaves, or any other foreign material.

Check the cleanlinessof the generator frequently and
clean when dust, dirt, oil, moistureor other foreign sub-

stances are visibleon its exterior surface.

Note: We DO NOT recommend using a garden hose to
clean generator. Water can enter the engine fuel system
and cause problems. In addition,ifwater enters the gen-

eratorthroughcoolingair slots, some of the water willbe
retained in voidsand cracks ofthe rotorand stator wind-

ing insulation. Water and dirt buildup on the generator

internalwindingswill eventually decrease the insulation
resistanceof these windings.

A AUTION: Never Insert any object or tool I

through the air cooling slots, even if the
engine is not running.

!