Craftsman 580327150, 580327152 Owner’s Manual

Owner's Manual

COMPANION I

5000 "Watt
AC Generator

Model No. 580.327152

Start

HOURS: Mon.- Fri. 8 aom. to 5 p.m. (CT)

CAUTION:
Before using this product, read this

manual and follow all Safety Rules

and Operating Instructions.

Sears, Roebuck and Co., Hoffman Estates,

Visit our Craftsman website: www.sears.com

Part No, B2473 Draft 2 (6/18/1999) Printed in the U,S.A.

IL 60179

• Safety

• Assembly

• Operation

• Maintenance
° Parts

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

SAFETY INSTRUCTIONS .................... 3

ASSEMBLY ............................... 4

OPERATION ............................. 5-9

PRODUCT SPECIFICATIONS ................ 10

MAINTENANCE ........................ t0-11

LIMITED ONE YEAR WARRANTY FOR COMPANION GENERATORS

SEARS warrants to the original purchaser that the alternator and engine for its portable generator wilt 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 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 witll at its optioni repair or replace any part which, upon examination by

: i SEARS, is found to be defective under norrnal use and service**. Starting batteries are not warranted by

SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by

the purchaser and prepaid by him. This warranty does not cover normal maintenance and service and does not
apply to a generator set, alternator or engine, or parts which have been subjected to improper or unauthorized

installation or alteration, misuse, negligence, accident, overloading, over-speeding, improper maintenance, repair

or storage so as, in SEARS's judgment, to adversely affect its performance and reliability.
** NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to

perform well. This warranty wit! 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 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.

STO RAG E ............................... 12

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

WIRING DIAGRAM ......................... !5

REPLACEMENT PARTS .................. 16-22

EMISSIONS WARRANTY ................. 24-25

HOW TO ORDER PARTS/SERVICE . .BACK PAGE

SEARS, ROEBUCK and CO., D/817WA, Hoffman Estates, IL 60179 U.S.A.

2

contains chemicals known to the State

I The engine exhaust fromthis pr0duCt :

• The generator produces dangerously high voltage

• Never handle any kind of electrical cord or device

• Use a ground fault circuit interrupter in any damp

• Operate generator only on level surfaces and

• Do not use worn, bare, frayed or otherwise

of California to cause cancer, birth

defects, or other reproductive harm_.............................

CAUTION: Always disconnect spark plug
wire and place-the wire where itcannot
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 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.

that can cause extremely hazardous electrical
shock. Avoid contact with bare wires, terminals,
etc. Never permit any unqualified person to
operate or service the generator.

while standing in water, while barefoot or while
hands or feet are wet.

The National Electric Code requires the frame and
external electrically conductive parts of generator
be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the generator. Consult with a
local electrician for grounding requirements in your

area.

or highly conductive area (such as metal decking
or stee! work).

where it will not be exposed to excessive moisture,
dirt, dust or corrosive vapors.

damaged electrical cord sets with the generator.

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 add fuel while unit is running.

@

Do not overfill the fuel tank. Always allow room for
fLielexpansion. If tank is overfilled, fuel can
overflow onto a hot engine and cause FIRE or an

EXPLOSION.
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 an EXPLOSION might

result.

- Generator exhaust gases contain DEADLY carbon
monoxide gas. Operate this equipment only in the

open air where adequate ventilation is available.

° The engine-generator requires an adequate flow of

cooling air for itscontinued 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 2 feet of clearance on all sides of generator,

even while operating unit outdoors, or you could
damage the unit.

= Never start, or stop, the engine-generator with

electrical loads connected to receptacles with the
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.

= Never operate generator

(a) in rain;

(b) in any enclosed compartment;
(c) if connected electrical devices overheat;
(d) if electrica! output is lost;
(e) if engine or generator sparks;
(f) if flames or smoke are observed while unit is

running;
(g) if unit vibrates excessively.

Note; If you equip the engine with a spark arrestor

muffler, the spark arrestor must be maintained in
effective working order by the owner/operator.

In the State of California a spark arrestor isrequired by
law (Section 4442 of the California Public Resources

Code). Other states may have similar laws. Federal laws
apply on federal lands. The spark arrestor part number

for this unit is p/n 34479A.

i

LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. IT MEANS

"ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED."

J

Your generator requires some assembly and is ready •
for use after it has been properly serviced with the ::

recommended oil and fuel. o

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.

REMOVE GENERATOR FROM CARTON

• Set the carton on a rigid flat surface with 'q-HIS

SIDE UP" arrows pointing upward.

• Carefully open the top flaps of the shipping carton.

• Cut down corners at one end of carton from top to
bottom and lay that side of carton down flat.

, Remove all packing material, carton fillers, etc.
o Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents, if any parts are missing or
damaged, call the Generator Helpline at

1-800-222-3136.
o The main unit

° Electric start battery cables
" Owner's manual

• Engine oil

o Battery mounting brackets

Secure battery as shown with bracket, (2) bolts, (2)

flat washers, (2) lock washers and (2) hex nuts.

Connect the black battery cable from the engine
mount bolt to the negative (-) battery post. Tighten

securely.

Red ¢abte

connected to

engl

switch here

\

8lack cabie

connected to

engine mount here

INSTALLING BATTERY

You must purchase and instalfa !2 Volt DC battery,
Series U1 Lawn & Garden Tractor battery (Sears
p/n 96135). The battery should be properly serviced
with electrolyte fluid and fully charged pnor to

installation.
Install the battery as follows:

° Set the battery on the generator's battery tray.

_ CAUTION: Be sure the black cable isconnected to the engine mount and not the

frame. You could damage the ground wire.

• Connect the red battery cable from the engine
starter switch to the positive (+) battery post.

4

KNOW YOUR GENERATOR

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

Compare the illustration shown below with your generator to familiarize yourself with the locations of various
controls and adjustments. Save this owner's manual for future reference.

FuelTank

Muffler

Air Cleaner

1201240 Volt AC, 20 Amp /

Locking Receptacle /

120 Volt AC, 20 Amp /
Duplex Receptacle Grounding Wing Nut

120 Volt 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, 20 Amp Locking Receptacle

May be used to supply electrical power for the
operation of 120 and/or 240 Volt AC, 20 Amp, single
phase, 60 Hz electrical lighting, appliance, tool and

motor loads.
Air Cleaner -- Filters intake air as it is drawn into the

engine.

Battery Tray -- Insta!l battery here.

Choke Lever

Oil Fill
Dipstick

Oil Drain Plug

Battery Tray

Circuit Breakers

Choke Lever- Used when starting a cold engine.

Circuit Breakers (AC) m Each receptacle is provided

with a circuit breaker to protect the generator against
electrical overload. Breakers are "push to reset" type.

Fuel Tank m Tank holds 5 U.S. gallons of unleaded
gasoline.

Grounding Wing Nut - Provides earth grounding point
for generator

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

Oil Fill Dipstick -- Fill engine with oil here.

5

CORD SETS AND CONNECTOR PLUGS ....

120 Volt Duplex Receptacle

Use only high quality, well-insulated, extension cords

with the generator's t20 Volt duplex electrical

receptacles.
Each receptacle is protected against overload by a

push-to-reset circuit breaker. Use each receptacle to
operate 120 Volt AC, single phase, 60 Hz electrical

loads requiring up to 2400 watts (2.4 kW) at 20 Amps
of current.

Keep extension cords as short as possible, preferably
tess than 15 feet long, to prevent voltage drop and
possible overheating of wires.

120t240 Volt, 20 Amp Receptacle

This receptacle is a NEMA L14-20R and is protected
by a push-to-reset circuit breaker. A NEMA L14-20P

mating connector plug is required to use this
receptacle. Connect a suitable 4-wire cord set to the
plug and to the desired load. The cord set should be
rated for 250 Volts at 30 Amps (or greater).

4-Wire Cord Set

i_ 240V
_--120V--> <-- 120V-->

i

W (Neutral)

CAUTION! Although each receptacle is 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 of all extension cords before you use
them. Extension cord sets used should be rated for

t25 Volts AC 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 manufacturer's recommendations.

Y (Hot)

X (Hot)

Ground

NEMA L14-20

for 240 Volts at 20 Amps (4800 watts or 4.8

A AUTION! Although this receptacle is rated

(Green)

kW), 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.

6

HOW TO USE YOUR GENERATOR

If you have any problems operating your Generator,
please call the Generator hetpline 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
wing nut is provided on the base of the cradle.

Grounding Wing Nut

.Generally, connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing
nut 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 wilt 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.

Place generator on a level surface.
= Clean area around oil fill and remove oil dipstick.
o Wipe dipstick clean.

° Pour oil into oil fill opening until oil reaches FULL

mark on the dipstick Do not overfil!!

Add Gasoline

WARNING NEVER fill fuel tank indoors.

NEVER fillfuel tank when engine is running or
hot. DO NOT light a cigarette or smoke when

filling the fuel tank.
CAUTION: Do not overfi!l the fuel tank.

Always leave room for expansion.

regular UNLEADED gasoline with the
Generator engine. Do not use premium gasoline.
Do not mix oil with gasoline.

= Clean area around fuel fill cap, remove cap.

• Add unleaded regular gasoline, slowly to fuel tank.

Be careful not to overfill. Allow about 1/2" of tank

space between bottom of fill opening and top of fuel
for fuel expansion.

- Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: tt is important to prevent gum deposits
from forming in essential fuel system parts such as the
carburetor, fuel filter, fue! 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 gas can damage the fuel
system of an engine while in storage. To avoid engine
problems, the fue! system should be emptied before

storage of 30 days or longer. See "Storage" on

page 12. Never use engine or carburetor cleaner

products in the fuel tank or permanent damage may
occur.

BEFORE STARTING THE GENERATOR

To operate the engine you mustdo the following:

Add Engine Oil

NOTE: When adding oil to the engine crankcase in the

future, use onIy high quality detergent oil rated with
API service classification SF or SG or higher rated
SAE 30 weight. Use no special additives. Select the
oil's viscosity grade according to your expected
operating temperature.

colder _ 32°F,, _ warmer 1

5W30 • SAE 30 i

Although multi-viscosity oils (5W30, 10W30, etc.)
improve starting in cold weather, this type oil 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 START THE ENGINE

A WARNING: Never start or stop engine withelectrical devices plugged into the panel

receptacles and 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

FuelValve--.._ t Turn Clockwise to

"Open" PositionShown _/ "OFF" Position

• Move the choke lever to the "Full Choke

Position,"

FULLCHOKEPOSITION

LEVER

CHOKEPOSITION

• Set the engine control switch to the On (-)

Position.

Engine
Control

Switch

• Manual Start: Grasp starter grip and pull s!owiy
until you feel some resistance. Then pull cord out

with rapid full arm stroke. Let rope return slowly. Do

not let rope "snap back" against starter.

• Electric Start: Hold the engine starter switch on

the cradle down until the engine starts.

NOTE: Use short starting cYCleS(15 seconds per
minute) to avoid overheating starter.

• When engine starts, move choke lever to "1/2
Choke Position" untilthe engine runs smoothly

and then to "No Choke Position." if engine falters,
move choke lever to "1/2 Choke Position" until the

engine runs smoothly and then to "No Choke

Position."

Note: If engine fails to start after 3 pulls, move the
choke lever to "No Choke Position" and pull starter

rope again.
Note: If the engine fails to start after three (3) pulls,

check for proper oil level in crankcase. Unit is

equipped with a low oil shutdown system.

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

move choke lever to "Full Choke" and repeat starting
instructions.

CAUTION! Never run engine indoors or in

enclosed poorly ventilated areas. Engine
exhaust contains carbon monoxide, an

odorless and deadly gas.
WARNING! temperature of muffler and nearby

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

STOPPING THE ENGINE

• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with
electrical devices plugged in and turned on.

• Let engine run at no-load for several minutes to
stabilize the internal temperatures of engine and

generator.

• Move engine control switch to Off (o) Position.

• Close the fuel shut-off valve

CONNECTING ELECTRICAL LOADS

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

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

AC, single phase, 60 Hz electrical loads.

° Do not connect 240 Volt loads to the 120 Volt

duplex receptacles

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

° Do not connect 50 Hz 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 should not be

greater than the rated wattage/amperage capacity
of the generator. See "Don't Overload the

Generator" on Page 9.

LOW OIL LEVEL SHUTDOWN SYSTEM

Sensing Low Oil Level
tf the system senses a low oil level during operation,

the engine shuts down. If the engine shutsdown by

itself and ithas enough gasoline in the fuel tank, check
oil level.

Restarting

If you attempt to restart the engine after such a

shutdown and have not corrected the engine oil level,
the engine will not start. Check the oil and refill

according to the instructions on page 7.

8