Craftsman 580.327181 User Manual
Operator's Manual
CRAFTSMAN°
7500 Watt
AC Generator
Model No.
580.327181
GENERATOR 7
CUSTOMER
HELPLINE
HOURS: Mon.- Fri. 8 a.m. 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, IL 60179 U.S.A.
Visit our Craftsman website: www.sears.com/craftsman
Part No, B1901 Draft 4 (6/29/1999)
• Safety
• Assembly
• Operation
• Maintenance
• Parts
Safety Rules ........................... 2-3
Assembly .............................. 4-5
Operation ............................. 6-10
Maintenance ......................... 11-13
Storage ................................ 14
Troubleshooting ......................... 15
Replacement Parts .................... 17-27
HOW TO ORDER PARTS .......... BACK PAGE
Specifications ........................... 11
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 GN-Series Sears warranted engine.
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, over-
loading, overspeeding, improper maintenance, repair or storage so as, in SEARS's judgment, to adversely affect its perfor-
mance 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 DIS-
CLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSE-
QUENTIAL, 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 conse-
quential 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 war-
ranty service, evidence of original purchase date must be presented.
CONSUMER* COMMERCIAL*
SEARS, ROEBUCK and CO., D/817WA, Hoffman Estates, IL 60179 U.S.A.
CAUTION:Alwaysdisconnectspark plugwire and placethe wirewhereit cannotcontactthe spark plug.To
preventaccidentalstartingwhen setting up,transporting,adjustingor makingrepairsto yourgenerator.
DANGER:Thisgeneratoris designedfor outdooruse only.Do not usethis generatorinsideanybuildingor
enclosureincludingthe generatorcompartmentof a recreationalvehicle(RV). Fireoran explosionmayresult.No
userperformedmodifications, includingventingof exhaustand/orcoolingventilation,will eliminatethe danger.
Also,allowat least twofeet of clearanceon all sidesof the generatoreven whileoperatingthe unit outdoors.
1,_ CAUTION:Beforeusingthis product,read this
manualandfollowall Safety Rulesand
OperatingInstructions.
• The generator produces dangerously high voltage
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.
• 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.
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.
• 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 equipment and/or
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 add fuel while unit is running.
• 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.
Allow at least 2 feet of clearance on all sides of
generator, even while operating unit outdoors, or
you could damage the unit.
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. This dangerous gas, if breathed in
sufficient concentrations, can cause
unconsciousness or even death. Operate this
equipment only in the open air where adequate
ventilation is available.
• The engine-generator 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. Without
sufficient cooling air flow, the unit quickly
overheats, damaging the generator or nearby
property.
• 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. You could damage the unit
or injure yourself.
• Never operate generator (a) in rain; (b) in any
enclosed compartment; (c) if engine speed
changes; (d) if connected electrical devices
overheat; (e) if electrical output is lost; (f) if engine
or generator sparks; (g) if flames or smoke are
observed while unit is running; (h) if unit vibrates
excessively.
Note: Your generator is equipped with a spark
arrestor muffler, the spark arrestor must be
maintained in effective working order by the
owner/operator.
I,_ LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. IT I
MEANS "ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED."
TO REMOVE GENERATOR FROM
CARTON
• Slice two corners at end of carton from top to
bottom so the panel can be folded down fiat.
• Remove all packing material, carton fillers, etc.
• Remove the generator from the shipping carton.
CARTON CONTENTS
• Generator
• Wheel Kit
• Locking Plugs
• Battery Tray components
• Manual
Check all contents. If any parts are missing or
damaged, call the Generator Helpline at
1-800-222-3136.
INSTALLING TRAY AND BATTERY
You must purchase and install a 12 Volt DC battery
(Sears DieHard Lawn & Garden Battery #28-27145).
The battery should be serviced with electrolyte fluid
and fully charged prior to installation. Install the battery
as follows:
• Find the battery tray and fasteners shipped loose in
the carton. You should have two 7" J bolts, two
lock washers,two flat washers and two hex nuts
• Remove the 4 battery tray screws from cradle
• Position the battery tray and install with supplied
hardware.
• Set battery onto tray
• Retain battery to tray with two J bolts, two lock
washers, two flat washers and two hex nuts.
• Connect the red battery cable from the engine
starter switch to positive (+) terminal on the
battery.
RED bNi_ery'_
• Connect the black battery cable to the negative (-)
terminal on the battery.
• Connect the other end of the black cable to the
engine, not the frame.
I,_ AUTION: Be sure the BLACKcableis
connectedto the enginemountandnotthe frame.
You could damagethegroundwire.
ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the
portability of your generator. You will need a socket
wrench with 1/2" or 13mm sockets to install the wheel
kit.
Refer to illustration shown below and install the wheel
kit as follows:
• Place the generator on a hard flat surface.
• Slide the axle (item 3) through the holes in the
brackets provided on the generator cradle and then
add the two spacers (item 5) on each protruding
end of the axle.
• Stand at the engine end of the generator and gently
tilt the generator forward, high enough to place
blocks beneath the cradle. This will allow you to
add the wheels.
Wheel Kit Exploded View
• Slide on the wheels (item 2) and flat washer
(item10) on each end of the axle and insert
retaining pin (item 4). Remove the blocks.
• Attach the vibration mounts (item 7) to the support
leg (item 6) with two M8 x 30mm capscrews
(item 8), M8 washers (item 12) and M8 Lock Nuts
(item 9).
• With the Wheels on, you can now tilt the generator
end forward and attach the support leg with two
M8 x 20mm cap screws (item 11) and two lock nuts
(item 9).
• Set the generator down so it is level and attach the
handle with four M8x45mm capscrews(item 13) and
four lock nuts (item 9).
Item
1
2
3
4
5
6
7
/
13
Pan # Qty
93393A 1
89742 2
93693A 1
87005 2
89635 2
93696 1
27007 2
/
/
/
9
6
Description
HANDLE
WHEEL
AXLE
PIN, Retaining
SPACER, Wheel
LEG, Support
MOUNT, Vibration
9
!
4
Item
Pan #
8
42909
Qty
2
Description
CAPSCREW, Hex Hd. M8 -
1.25 x 30 Lg.
9
10
11
52858
22247
39253
8
NUT, Lock M8
2
WASHER, Wheel
2
CAPSCREW, Hex Hd. - M8 -
1.25 x 20 Lg.
12
13
22145
39287
2
WASHER, Vibration Mtg.
4
HHCS, M8 - 1.25 x 45 Lg
GR 10.9
CORD SETS AND CONNECTOR PLUGS
120 Volt Cord Sets
Use only high quality, well-insulated, extension cords
with the generator's 120 Volt type electrical
receptacles.
Each receptacle socket is protected against overload
by a single 20-Amp push-to-reset type of circuit
breaker. Use each receptacle to operate 120 Volts,
single phase 60 Hz, AC electrical loads requiring up to
2400 watts (2.4 kW) at 20 Amps of current.
Check the ratings of all extension cords before you
use them. Extension cord sets used should be rated
125 Volts at 20 AC 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.
Keep extension cords as short as possible, preferably
less than 15 feet long, to prevent voltage drop and
possible overheating of wires.
120 Volt, 30 AMP Receptacle
Use a NEMA L5-30P type plug with this receptacle.
Connect a 3-wire cord set rated for 125 Volts at 30 AC
Amps to the plug. Use this receptacle to operate
120 Volt AC, 60 Hz, single phase loads requiring up to
3600 watts (3.6 kW) of power at 30 AC Amps. The
outlet is protected by a 30 Amp circuit breaker.
3-Wira Cord Set
-- Neutral
120V
Hot
NEMA L5-30
240 VOLT, 50 AMP RECEPTACLE
Use a compatible 3 prong plug with this receptacle.
Connect a 3-wire cord set rated for 250 Volts at 50 AC
Amps to the plug. Use this receptacle to operate 240
Volt AC, 60 Hz single phase loads requiring up to
7,500 watts (7.5 kW) of power.
120/240 Volt, 30 AMP Receptacle
This is a full capacity receptacle which means you can
take the full rated generator capacity from this
receptacle. The outlet is protected by a 30 Amp push-
to-reset circuit breaker.
4-Wire Cord Set
240V
_- 120V_- 120V--_
Neutrai)
Y I P_ot)_ X (Hot)
NEMA L14-30 ,/-717 _rrOUenn_
A NEMA L14-30P mating connector plug is required
for use with 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.
Use this receptacle to operate 120/240 Volt AC, 60 Hz
single phase loads requiring up to 7200 watts (7.2 kW)
of power.
CAUTION! Althoughthis outlet states it has a
240 Volt50-Amprating(up to 12,000watts),the
generator is ratedfor 7,500watts. Powering loads
thatexceed thegeneratorcapacitycan damageit
or causeserious injuries.240Volt loadspowered
throughthis outletshould not exceed31.25Amps.
DO NOTconnect120 VoltAC loadstothis
receptacle.
2 Volt DC Receptacle
This receptacle allows you to recharge a 12 Volt
automotive or utilitystyle storage battery with the
battery charge cables provided. This receptacle can
not recharge 6 Volt batteries and can not be used to
crank an engine having a discharged battery. See the
sections "Battery Safety" and "Charging a Battery"
(page 9) before attempting to recharge a battery.
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 "_
Choke Lever
12 Volt DC 10 Amp
Receptacle
Idle Control
Switch
Run/Stop
Switch
Cleaner
120 Volt AC, 30 Amp
Receptacle
120/240 Volt AC, 30 Amp
Receptacle
120 Volt AC, 20 Amp"
Receptacles
120/240 Volt AC, 30 Amp Receptacle -- May be
used to supply electrical power for the operation of
120 and/or 240 Volt at 30 Amp AC, single phase,
60 Hz electrical lighting, appliance, tool and motor
loads.
120 Volt AC, 30 Amp Receptacle -- May be used to
supply electrical power for the operation of 120 Volt at
30 Amp AC, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
120 Volt AC, 20 Amp Receptacles -- May be used
to supply electrical power for the operation of 120 Volt
at 20 Amp AC, single phase, 60 Hz electrical lighting,
appliance, tool and motor loads.
240 Volt AC, 50 Amp Receptacle -- May be used to
supply electrical power for the operation of 240 Volt at
31.25 Amp AC, single phase, 60 Hz electrical loads.
12 Volt DC, 10 Amp Receptacle --This receptacle
allows you to recharge a 12 Volt automotive or utility
style storage battery with the charge cables provided.
Engine
240 Volt AC, 50 Amp
Receptacle
15 H.P. Engine -- Provides the power needed to
generate 7,500 watts of AC output.
Air Cleaner -- Filters intake air as it is drawn into the
engine.
Circuit Breakers (AC) -- Circuit breakers are
provided for most receptacles to protect the generator
against electrical overload. Breakers are "push to
reset" type.
Choke Lever- Used when starting a cold engine.
Fuel Tank -- Tank holds 5 U.S. gallons of automotive
unleaded gasoline.
Idle Control Switch -- The idle control runs the
engine at normal (high) speeds when there is a load
present and runs the engine at idle (low) speeds when
a load is not present. This feature greatly improves
fuel economy, extends the life of the engine, and
reduces engine noise.
Run/Stop Switch -- Must be in "Run" position to start
engine. Set to "Stop" to stop a running engine.
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
wing nut is provided on the base of the cradle.
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.
Do not connect 240 Volts to 120 Volt duplex
receptacles
Do not connect 3-phase loads to receptacles.
Plug in and turn on the desired 120 and/or 240
Volt, single phase, 60 Hertz, AC electrical loads.
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 10.
colder _ 32°F _ warmer
!
I
Place generator on a level surface and remove the
yellow oil fill cap and add engine oil until level is at
point of overflowing. Check engine oil level before
starting each time thereafter.
Add Gasoline
_ AUTION: Donotoverfillthefueltank.Always
• Use regular UNLEADED gasoline with the
generator engine.
IMPORTANT: 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 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. See "Storage" on
page 14. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may
Occur.
TO START THE ENGINE
• Unplug all electrical loads from generator
receptacles before starting the engine. NEVER
start or stop engine with electrical devices plugged
into the panel receptacles and turned on.
• Make sure the idle control switch is "Off".
5W30 SAE 30
WARNINGNEVERfill fuel tank indoors.NEVERfill
fuel tank when engineisrunningor hot.DO NOT
lighta cigaretteor smokewhen filling the fuel tank.
leaveroomfor expansion.
BEFORE STARTING THE GENERATOR
To operate the engine you will need to do the
following:
Add Engine Oil
NOTE: When adding oil to the engine crankcase in
the future, use only high quality detergent oil rated
with API service classification SF or SG rated SAE 30
weight. Use no special additives. Select the oil's
viscosity grade according to your expected operating
temperature.
Although multi-viscosity oils (5W30, 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.
_ AUTION!Never runengineindoorsor in enclosed
poorlyventilatedareas. EngineExhaustcontains
carbonmonoxide,an odorlessanddeadlygas.
,_ WARNING!Temperatureof mufflerand nearby
areasmay exceed 150°F(65°C).Avoidtheseareas.
• Open the fuel valve.
* Place the Run/Stop Switch in the "RUN" position.
• Move engine CHOKE LEVER to "FULL CHOKE
POSITION."
• For manual starting: Grasp starter grip and pull
slowly 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.
• For electric starting: Press start switch on
generator cradle until engine cranks. Keep
pressing until it starts.
Whenenginestarts,movechokeleverto"1/2
ChokePosition"untiltheenginerunssmoothly
andthento"RunPosition."Ifenginefalters,
movechokeleverto"1/2ChokePosition"until
theenginerunssmoothlyandthento"Run
Position."
FULL RUN
HALF
//
Note: If engine fails to start after 3 pulls, move the
choke lever to "Run Position" and pull starter rope
again.
Note: If engine fires, but does not continue to run,
move choke lever to "Full Choke" and repeat starting
instructions.
STOPPING THE ENGINE
• Unplug all electrical loads from generator panel
receptacles. Never start or stop engine with
electrical devices plugged inand turned on.
• Turn "Off" the idle control switch if on.
• Let engine run at no-load for several minutes to
stabilize the internal temperatures of engine and
generator.
• Move Run/Stop switch to "Stop" position.
• Close fuel valve.
Sensing Low Pressure
If the system senses low oil pressure during operation,
the engine shuts down. As the system shuts down, the
low oil light comes ON. However, once the engine has
stopped rotating, this light will go OFF.
Restarting
If you try to restart the engine within 10 seconds after
it shuts down, the engine may NOT start. The system
needs 5 to 10 seconds to reset.
If you do restart the engine after such a shutdown and
have not corrected the low oil pressure, the engine
runs for about 10 seconds as described above and
then stops.
BATTERY SAFETY
DANGER: Storagebatteriesgive offexplosive
hydrogengas while recharging.Anexplosive
mixturewill remainaroundthe batteryfor a long
timeafter it has beencharged.The slightestspark
canignitethe hydrogenand causean explosion.
Suchan explosioncan shatterthe batteryand
causeblindnessor other seriousinjury.
DANGER: Donotpermitsmoking,openflame,
sparksoranyothersourceofheatarounda
battery.Wearprotectivegoggles,rubberapronand
rubbergloveswhenworkingaroundabattery.
Batteryelectrolytefluid isanextremelycaustic
sulfuricacidsolutionthatcancausesevereburns.
Ifspilloccursflushareawithclearwater
immediately.
OPERATING AUTOMATIC IDLE CONTROL
This switch is designed to greatly improve fuel
economy. When this switch is turned "On", the engine
will only run at its normal high governed engine speed
when an electrical load is connected. When an
electrical load is removed, the engine will run at a
reduced speed. With the switch "Off", the engine will
run at the normal high engine speed. Always have the
switch off when starting and stopping the engine.
LOW OIL PRESSURE SHUTDOWN
SYSTEM
The engine is equipped with a low oil pressure sensor
that shuts down the engine automatically when the oil
pressure drops below 6 psi. If the engine shuts down
by itself and the fuel tank has enough gasoline, check
engine oil level.
Initial Start-up
A delay built in the low oil shutdown system allows oil
pressure to build during starting. The delay allows the
engine to run for about 10 seconds before sensing oil
pressure.
CHARGING A BATTERY
Your generator has the capability of recharging a
discharged 12 Volt automotive or utility style storage
battery. Do not use the unit to charge any 6 Volt
batteries. Do not use the unit to crank an engine
having a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
• Check fluid level in all battery cells. If necessary,
add ONLY distilled water to cover separators in
battery cells. Do not use tap water.
• If the battery is equipped with vent caps, make
sure they are installed and are tight.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to
panel receptacle identified by the words "12 VOLT
D.C."
• Connect battery charge cable clamp with red
handle to the positive (+) battery terminal
• Connect battery charge cable clamp with black
handle to the negative (-) battery terminal.
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