Craftsman 580.327750 User Manual

120 VOLT

2500 WATT

Owner's

anuam

MODEL NO.

580.327750

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CAUTION: Before using this product, read this manual and

follow all Safety Rules and

Operating Instructions.

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

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

Partr',lo.B2418 REV._3/12/98

GENERATOR

CUSTOMER

HELPLINE

1_800-222-3136

SERVICEANDADJUSTMENTS .......... 12-13

SAFETYRULES.............. INSIDECOVER

MAINTENANCEAGREEMENT................. 10

PRODUCTSPECIFICATIONS.............. 10

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

OPERATION......................... 4-9

MAINTENANCE........................ 9-12

LIMITED ONE YEAR WARRANTY CRAFTSMAN GENERATORS

SEARS warrants to the original purchaser that the alternator and engine for its portable generator will be free from

defects inmaterials or'workmanship for the items and period set forth below from the date of original purchase, this warranty is not trasnferable.

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, includ-

ing rental, construction, commercial, primary source of residential household power 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.

SERVICERECOMMENDATIONS........... 12

TROUBLESHOOTINGPOINTS ............. 14

WIRINGDIAGRAM...................... 15

REPAIRPARTS...................... 16-37

EMISSIONSWARRANTY................ 38-39

PARTSORDERING............. BACKCOVER

CONSUMER* COMMERCIAL*

During said warranty period, SEARS wit!, at its option, repair or replace any part which, upon examinations by SEARS, is found to be defective under normal use and service_** Starting batteries and expendable items such as spark plugs and air filters, which become worn during normal use are not warranted by SEARS. All transportation costs under warranty, including return to the factory if necessary, are to be borne by the pruchaser 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, negli- gence, accident, overloading, overspeeding, improper maintenance, repair or storage so as, in SEAR'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 tS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRAN- TIES, 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 limita-

tion of incidental or'consequential damages, so the above limitations or' exclusions may not apply to you_ This war- ranty 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 request- ing warranty service, evidence of original purchase date must be presented.

SEARS, ROEBUCK and CO., Hoffman Estates, IL 60719 U.S.A.

CAUTION:ALWAYSDISCONNECTSPARKPLUGWIREANDPLACEWIREWHEREIT CAN- F_

NOTCONTACTSPARKPLUG,TO PREVENTACCIDENTALSTARTINGWHENSETTINGUP,

TRANSPORTING,ADJUSTING,ORMAKING REPAIRSTOYOURGENERATOR

IMPORTANT

THISGENERATORIS DESIGNEDFOROUTDOORUSEONLY.USINGTHIS GENERATORINSIDEANY BUILDINGORENCLOSURE,

INCLUDINGTHEGENERATORCOMPARTMENTOFA RECREATIONALVEHICLE(RV), IS DANGEROUS,FIREORANEXPLOSIONMAY

RESULT.NOUSERPERFORMEDMODIFICATIONS,INCLUDINGVENTINGOFEXHAUSTAND!ORCOOLINGVENTILATION,WILL ELiM-

INATETHE DANGER°

• If this unit isusedfor backup power in the event of a utility powerfailure, takethefollowing steps: BEFORECONNECT- INGTHEGENERATORTOAN ELECTRICALSYSTEM,OPEN

THEMAINCIRCUITBREAKERORMAIN SWITCHSERVIC-

INGTHESYSTEMTOISOLATETHEGENERATORFROM

THEELECTRICUTILITY.FAILURETOISOLATETHE GENER- ATORANDUTILITYSYSTEMSMAY RESULTINDAMAGE TOTHEGENERATORANDMAYALSO RESULTIN INJURY

ORDEATHTOELECTRICUTILITYWORKERSDUETO BACKFEEDOFELECTRICALENERGY.

• This generator produces dangerously highvoltage that can causeextremelyhazardouselectrical shock.. Avoid contact

with barewires,terminals, etc. Neverpermit any unqualified

personto operateor service the generator.

- DONOToperatethis equipmentin the rain, while standing

in water,while barefoot, or while hands or feet are wet..Dan-

gerous electricalshock will result.

, TheNational ElectricCode requires the frame and external

electrically conductive parts of the generator be properly

connectedto an approvedearth ground° Localelectrical codesmay also requireproper grounding of the generator° Consultwith a localelectricianfor grounding requirements in your area.

Theengineexhaustfromthisproductcontainschemicals

knowntotheStateofCaliforniato causecancer,bidhdefects H

Gasolineis highly FLAMMABLEand its vaporsare EXPLO- SIVE.Donot permit smoking, open flames, sparksor heat in the vicinity while handling gasoline..Avoid spilling gaso- line ona hot engine..Complywith alt lawsregulating storage and handlingor gasoline_.

• Never addfuel whileunit is running ° Do not overfill thefuel tank.Always allow room for fuel

expansion. If tank is overfilled, fuel can overflow onto a hot engine and cause FIREor an EXPLOSION..

• Drainall gasoline from tank before transporting yourgener- ator insideyour car or other vehicle.

, Neverstore generator with fuel in tank where gasoline

vapors might reach an open flame orspark or pilot light (as on afurnace, water heateror clothes dryer). FIREor AN

EXPLOSIONmight resulL

• Allow at least2 feet of clearanceon all sides of generator, evenwhile operating unit outdoors, or you could damage

the unit..

• Generatorexhaustgases contain DEADLYcarbonmonoxide gas_This dangerousgas, if breathed in sufficient concentra-

tions, can causeunconsciousness or evendeath_Operate this equipment outdoors only in the open air whereade-

quate ventilation is available.

• Donot insert any object through cooling slots ofthe engine- generator°You coulddamagethe unit or injure yourself.

• DONOTattempt to change the engine governed speed.Fac- tory settings are correct when you receivethe unit..Exces- sively high engine speeds may result ininjury or damageto

equipment.

o DONOT usethe unit if it has beendamaged..Repairor

replaceall damaged or defective components before you run the unit.

• Do not permit childrento operate or servicethe unit..

= Readyour Owner'sManual carefully..Only personswho are

familiar with these safety rulesand havebeen properly

instructed inthe use of this product should be permittedto usethe product.,

Note:Inthe Stateof Californiaasparkarrestorisrequiredbylaw(Sec-

tion4442oftheCaliforniaPublicResourcesCode).,Otherstatesmay

havesimilartaws_Federallawsapplyonfedera!lands,

,t_ LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS.IT MEANS "ATTENTION!!! BECOME ALERT!!! YOUR SAFETY IS INVOLVED!!!"

Your AC generator was completely assernsble at the fac- tory. It is ready for use after it has been properly serviced

with the recommended lubricating oil and fuel.,

IF YOU HAVE ANY PROBLEMS WITH THE ASSEMBLY OF YOUR GENERATOR, PLEASE CALL THE GENERA-

TOR HELPLINE AT 1-800_222-3136.

IMPORTANT: ANY ATTEMPT TO RUN THE ENGINE BEFORE tT HAS BEEN SERVICED WITH THE RECOM- MENDED OIL WILL RESULT IN AN ENGINE FAILURE..

CORD SETS AND CONNECTOR PLUGS

TOQREMOVE GENERATOR FROM CARTON

Set the carton on a flat rigidsurface with "THIS SIDE

UP" arrows pointing upward.

° Carefully open the top flaps of shipping carton_ ° Cut down corners at one end of shipping carton and

lay that side of carton down flat.

- Remove packing material, carton fillers, etc_. ° Remove the generator from the shipping carton°

TO ADJUST HANDLE GUIDE

Yourgenerator is equipped with a wheel kit for easy man-

ueveringo After' you remove the generator from the carton

Lifthandle into upright position and push the black slides

down to hold the handle in position. The handle may be

lowered for easier' storage.

120 VOLT CORD SETS use only high quality, wefl-insutated, extension cords with

the generator's 120-volt type electrical receptacle&

Each receptacle of this pair 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, A C electrical loads requiring up to 2400 watts (2.4 kW) at 20 amps of current_

Figure-1

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 manual of those devices for the manufacturer's recommendations.

CAUTION:Althougheachreceptacleis ratedfor120 voltsat 20 amps(2400 wattsor2A KW), the generator

israted for a totalof 2500 watts.Poweringloadsthat

exceedthewattagecapacityofthe generatorcandam- age itor causeseriousinjuries.Thetotal loadswith

120 voltspoweredthoughthese receptaclesshouldnot exceed20 amps.

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

12 VOLTS DC 10 AMP BATTERY CHARGE OUTLET

Figure-2

The 12 VOLT DC outlet has a unique configuration that will only allow the 12 volt wire harness to be inserted, When the 12 volt harness is properly inserted the red wire wil! be positive 12 volts and the blackwire will be negative_

DO NOT modify any plug to make it fit this outlet or dam- age to the generator may result.

KNOW YOUR GENERATOR

Read the owner's manual and safety rules before operating your generator. Compare the illustrations with your Genera- tor to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference_

GUIDE HANDLE

HEATSHIELD AND MUFFLER

AIR CLEANER

GAS CAP

CHOKE

ON/OFFLEVEL

5 HP ENGINE

OIL FILL

OIL DRAIN

120 VOLT RECEPTACLES. May be used to supply elec-

trical power for the operation of 120 volts at 20 amps AC, single phase, 60 Hz,.This may be used for AC electrical

lighting, appliance, tool and motor loads. BATTERY CHARGE RECEPTACLE. May be used to

supply electrical power to charge 12 volt batteries. CIRCUIT BREAKERS (AC and DC), Each receptacle is

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

type AIR CLEANER. Filters intake air as it is drawn into the

engine

5.0 H.P. HONDA ENGINE. Provides the power needed to generate 2500 watts of AC output,

RECOIL STARTER. Used for starting the engine,

ON/OFF LEVER. Set this lever to "ON" before using

recoil starter Set lever to "OFF" to switch engine off. Located on the engine block.

CIRCUIT BREAKERS, BATTERY CHARGE

RECEPTACLE, AND DUPLEX RECEPTACLE

FUEL TANK. Tank holds 18 quarts of unleaded gasoline. SPARK ARRESTOR MUFFLER. Exhaust muffler lowers

engine noise and is equipped with a spark arrestor screen°

CHOKE SWITCH. Used when starting a cold 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 by properly connected to an approved earth ground. Local

electrical codes may also require proper grounding of the unit. For that purpose, a GROUND LUG is provided (Fig-

ure-3).,

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, tocaf codes may very widely. Consult with a local electrician for grounding requirements in your area.

Proper grounding of generator will help prevent electricat shock in the event of a ground fault condition in the gener-

ator or in connected electrical devices. Proper grounding

also helps dissipate static electricity, which often builds up in ungrounded devices.,

IF YOU HAVE ANY PROBLEMS OPERATING YOUR GENERATOR, PLEASE CALL THE GENERATOR

HELPLINE AT 1-800-222-3136.,

• Pour oilinto the oil fill opening until oil reaches FULL mark on the dipstick. DO NOT OVERFILL. Oii capac-

ity of engine is 0.61 US quarts.

o Install oil dipstick, hand tighten securely

Figure-4

CAUTION:ANYATTEMPTTOCRANKORSTARTTHE ENGINEBEFOREIT HASBEENPROPERLYSER- VICEDWITHTHERECOMMENDEDOILRESULTSIN ANENGINEFAILURE.

t_12 AWG STRANDEO

GROUNDING ROD

FLgure-3

BEFORE STARTING THE GENERATOR Tooperatethe engtne youwill need todothe following:

ENGINE OIL, Important: To avoid engine damage never run engine

unless:

• Oil level is between =Full" and "Add" marks on the dip- stick,.

• Oil fillplug is tightened securely intooi! fill tube or hole.

ADD OIL

• Place generator on a level surface.

• Clean area around oil fill and remove oildipstick.

• Wipe dipstick clean,.

Note: When adding oil to the engine crankcase in the

future, use only high quality detergent oit rated with API

service classification SF, SG, or SH rated SAE 30 weighL Use no special additives. Although multi-viscosity oils (5W30) improve starting in cold weather, multi-viscosity oilswill result in increased oil consumption when used

above 32° E It will be necessary to check "yourengine oil level more frequently to avoid possible damage from run- ning low on oil Oil sump capacity is 0.61 US quarts. DO

NOT use 10W-40.

colder ._ 32° _LI=.- warmer

5W30 SAE30

ADD GASOLINE

• Use 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 1/4-inch of tank space for expansion.

• tnstaflfuel cap and wipe up any spilted gasoline. Important: It is important to prevent gum deposits from

forming in essential fuel system parts such as the carbu- retor, fuel filter, fuei hose or tank during storage. Also, experience indicates that alcohol-blended fuels (catled

gasohol,ethanolormethanol)canattractmoisturewhich

leadstoseparationandformationofacidsduringstorage.. Acidicgascandamagethefuelsystemofanengine whileinstorage.Toavoidengineproblemswhenusing

gasohoI,emptythefuelsystembeforestorageof 30 days

or longer., See "Storage" on Page 13. Never use engine or carburetor cleaner products in the fuel tank or permanent

damage may occur.

NOTE: DO NOT USE GASOLINE CONTAINING METHA-

NOL (WOOD ALCOHOL). You can use gasolines contain-

ing 10% ethanol or grain alcohol See "Storage" for more

information°

CAUTION:DO NOTOVERFILLTHEFUELTANK.

ALWAYSALLOWROOMFORFUELEXPANSION.

WARNING:NEVERFILLFUELTANKINDOORS.

NEVERFILLFUELTANKWHENENGINEIS RUN- NINGOR HOT,DONOTLIGHTA CIGARETOR SMOKEWHENFILLINGFUELTANK.

o Pul! engine CHOKE LEVER (Figure-6) to "Full

Choke Position",.

o Grasp start 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 the starter grip.

. When engine starts, move choke lever to "1/2 Choke

Position until the engine runs smoothly and then to "No Choke Position". if engine falters, move choke lever to' "112 Choke Position" until the engine runs smoothly and then to "No Choke Position"..

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

Note: If engine fires, but does not continue to run, move choke lever to "Full Choke Position" and repeat starting

instructions..

TO START THE ENGINE

WARNING:NEVERSTART,ORSTOP,THE ENGINE-GENERATORWITHELECTRICALLOADS

CONNECTEDTOTHE RECEPTACLESWITHTHE CONNECTEDDEVICESTURNEDON.

Figure-5

• 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.

° Set ON/OFF LEVER to ON (Figure-5).

Figure-6

CONNECTING ELECTRICAL LOADS o Let engine stabilize and warm up for a few minutes

after starting..

• Use this generator to operate 120 volt, single phase, 60 Hz, AC lighting, appliance, tool and motor loads,.

° DO NOT connect 240 volts to 120 voIts duplex recep-

tacles.

• DO NOT connect 3-phase loads to panel receptacles.

° DO NOT connect any 50 Hz loads to the generator. o Plug in and turn on the desired 120 volts single

phase, 60 HZ, AC electrical loads. DO NOT OVER-

LOAD 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 "Do Not Overload the Generator" on Page 8.

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 stabi- lize the internal temperatures of engine and genera-

tort

• Move On/Off Switch to Off position.

CHARGING A BATTERY

Your generator has the capability of recharging a dis- charged, 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 bat- tery 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 posts or terminals° ° Connect battery charge cable connector' plug to panel

receptacle (Figure-2, Page 4) identified by the words

"12-VOLT DoC."

• Connect battery charge cable clamp with red handle to battery post or terminal indicated by a POSITIVE,

POS,or (+).

° Connect battery charge cable clamp with black han-

" die to battery post or terminal indicated by a NEGA-

TIVE, NEG, or (-).

• Start engine (see "Starting the Engine" on Page 7).

Let the engine run while battery recharges.

, When battery has charged, shut down engine (see

"Stopping the Engine" above).

Note: Use an automotive hydrometer to test battery state of charge and condition_ Follow the hydrometer manufac- turer's instructions carefully. Generally, a battery is con* sidered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1o260.

LOW OIL PRESSURE SHUTDOWN SYSTEM

itsetf and the fuel tank has enough gasoline, check engine oil level.

INITIAL STARTUP

A delay in the shutdown system allows oil pressure to

build during starting., The delay allows the engine to run

for about 10 seconds before sensing oil pressure.

RESTARTING

If you try to restart the engine within 5 second after it shuts dowrY,the engine may not start_ The system needs 5 to 10 seconds to reseL

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.

DON'T OVERLOAD THE GENERATOR

Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to

connected electrical devices. Observe the following, to prevent overloading the unit: = Add up the total 'wattage of afl electrical devices 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 motor does not give wattage,

multiply volts times ampere rating to determine watts (volts x amps = watts).

, Some electric motors, such as induction types,

require about two and a half times more watts of power' for starting than for running° This surge of power lasts only a few second when starting such

motors. Make sure you allow for'this high starting wattage when selecting electrical devices to connect

to your generator. First, figure the watts needed to start the largest motor. Add to that figure the running

watts of all other connected loadso

The engine is equipped with a low oil pressure sensor that shuts down the engine autornaticaIly when the oil pressure drops below 6 psL If the engine shuts down by

The Wattage Reference Guide is provided to assist you in determining how many items your generator' can operate

at one time.

WATTAGE REFERENCE GUIDE

ELECTRICALDEVICE

RUNNING ELECTRICALDEVICE RUNNING ELECTRICALDEVICE RUNNING

WATTS WATTS WATTS

L_L ..._..... LLL _ :; :; :;:; :: ...................

*AirConditioner 1700 ElectricSkillet I250 OilFiredSpaceHeater 400

(12,000btu) (85,000Btu) BatteryCharger 500 *FurnaceFan(113HP) 1200 OilFiredSpaceHeater 225

(20amp) (30,000Btu) BeltSander t000 HairDryer 1200 *PaintSprayer, 600

Airless(1/3HP)

== ;,,. ..........

ChainSaw t200 HandDrill (1") 1100 PaintSprayer, 150

Airless(handheld) CircularSaw(6112") 800to 1000 HandDdlf(1/2") 750to 1000 Radio 50to 200 CoffeeMaker 1000 HandDrill(3/8") 500 *Refrigerator 600

J r

*Compressor(I HP) 2000 HandDrill(1/4") 250 SlowCooker 200 *Compressor(3/4 HP) 1800 HedgeTrimmer 450 *SubmersiblePump 2800

(I-1/2 HP)

*Compressor(i/2 HP) 1400 *JetPomp 800 *SubmersiblePump 2000

(1 HP)

CurlingIron 700 LawnMower 1200 *SubmersiblePump t500

(1/2HP) "DeepFreeze 500 LightBu]b 700 SumpPump 600 DiscSander(9") t200 MicrowaveOvern 700 *TableSaw(10") 1750to2000 EdgeTrimmer 500 *Milk Cooler 1100 Television(10") 200to 500

............................................................... , ....... i ............

ElectricNailGun 1200 OilBurneronFurnace 300 WeedTrimmer 500

.... ..... J , ..........,, ,

ElectricRange 1500 OilFiredSpaceHeater 400 (oneelement) (140,000Btu)

"Allow 2-1/2 times the Iisted watts for starting these device&

CUSTOMER RESPONSIBILITIES

GENERAL RECOMMENDATIONS

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on a timely

basis; that all discrepancies are corrected; and that the unit is kept clean and properly stored. Never operate a

damaged or defective generator°

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.

All adjustments in the Service and Adjustments section of

this manual should be made at least once each season..

Follow the recommendations in the "Service Recommen- dation" Table on Page 12..

PRODUCT SPECIFICATIONS

Generator Specifications

Rated Maximum Power

Rated Voltage

Rated Maximum

Load Current

Rate Frequency

2500 (2.5 KW)

12 VDC and 120 Volts AC

20.8 AC amperes

60 Hz at 3600 rpm

Follow the instructions under "Maintenance" and "Stor-

age" sections of this Owner's Manual.

NOTE: Your generator is equipped with a spark arrestor muffler: The spark arrestor must be maintained in effec-

tive working order by the owner/operator_ In the State of California a spark arrestor is required by law (Section

4442 of the California Public Resources Code)_ Other states may have similar' laws. Federal laws apply on fed-

eral lands°

Phase

Engine Specifications

Rated Horsepower 5,0 at 3600 rpm

Spark Plug NGK BPR6ES

Set Gap To: 0.030 inch (0.76mm)

Gasoline Capacity: 1.8 quarts

Oil (Q.61 US quarls capacity): SAE 30 weight

Solid State Ignition 0.0125 inch Air Gap

Should you experience any problem you cannot easily

remedy, please contact your nearest Sears Service Cen- terJDepartment or call the 1-800 number listed on the front of this manuat we have competent, well-trained technicians and the proper toolsto service or repair' this

unit,.

Please read and retain tn_smanual, the instructions will

enable you to assemble and maintain your' generator

properly. Always observe the "SAFETY RULES'L

Once a year you should clean or'replace the spark plug

and replace the air filter A new spark plug and clean air

filter assure proper fuel-air mixture and help your engine

run better and last longer

MAINTENANCE AGREEMENT

A Sears Maintenance Agreement is available on this product,,

Single Phase

or equivalent

CAUTION:DISCONNECTSPARKPLUGWIRE FROMSPARKPLUGANDPLACEWIREWHEREIT CANNOT'COMEIN CONTACIWITHYOURSPARK PLUGBEFOREWORKINGONYOURGENERATOR.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping the unit clean and dry Operate and store the unit in a clean, dry envi- ronment where it wilt not be exposed to excessive dust, dirt, moisture or any corrosive vapors,, Cooling air slots in the generator must not become clogged with snow,

leaves, or any other foreign material.

Check the cleanliness of the generator frequently and clean when dust, dirt, oi!, moisture or other foreign sub- stances are visible on itsexterior surface,.

Note: We DO NOT recommend using a garden hose to clean the generator_ Water can enter-the engine fuel sys-

tem and cause problems,, tn addition, ff water enters the

generator through cooling air slots, some of the water will be retained in void and cracks of the rotor and stator

winding insulation, Water and dirt buildup on the genera- tor internal windings will eventually decrease the insula- tion resistance of these windings°

To clean the Generator:

* Use a damp cloth to wipe exterior surfaces cfean. ° A soft bristle brush may be used to loosen caked on

dirt, oil, etc.

. A vacuum cleaner may be used to pick up loose dirt

and debris.

° Low pressure air (not to exceed 25 psi) may be used

to blow away dirt,, inspect cooling air' slots and open-

ings on the generator,, These openings must be kept

clean and unobstructed.

CUSTOMER RESPONSIBILITIES

Read and observe the safety rules. Follow regular schedule in maintaining, caring for and

using your generator.

CAUTION:NEVERINSERTANY OBJECTORTOOL1

THROUGHTHE AIRCOOLINGSLOTS,EVENIF ! THE ENGINEIS NOTRUNNING. DAMAGETOTHEi

UNITOR PERSONALINJURYMAYRESULT. J

ENGINEMAINTENANCE

CHECKING OIL LEVEL Oii levet should be checked prior to each use or at least

every 5 hours of operation, Keep oil level maintained.

° Replace spark plug if electrodes are pitted, burned or

porcelain is cracked° For replacement use NGK BPR6ES only,

o Check electrode gap with wire feeler gauge and set

spark plug gap to 0.030 inch (0.76 mm) if necessary

(Figure-9).

CHANGING ENGINE OIL

CAUTION:DISCONNECTSPARKPLUGWIRE FROMSPARKPLUGAND KEEPITAWAYFROM

SPARKPLUG.DOTHIS EVERYTIME YOU PER- FORMANYMAINTENANCEONTHEENGINEOR

GENERATOR

Change oil after first 2 hours of operation, Change oil

every 25 hours thereafter., tf you are using your generator

under extremely dirty or dusty conditions, or in extremely

hot weather, change oil more often,

Change oil while engine is still warm from running, as fol- lows:

o Clean area around oil drain plug (Figure-7). o Remove oil drain plug and oil fill plug to drain oil.

o When oil has drained, install oil drain plug and tighten

securely°

° Insert a clean fill funnel and fill oil sump with recom-

mended oil until oil level is at point of overflowing. POUR SLOWLY. (See "Before Starting the Engine"

on Page 6 for oil recommendations).,

• Install the oil fill plug and tighten securely,

• Wipe up any spilled oilo

SERVICE AIR CLEANER

Your engine will not run properly and may be damaged if you run it using a dirty" air cleaner,,

Clean or replace the air cleaner once every 125 hours of operation or once each year, whichever comes first.

Replace more often if operating under dirty or dusty con- ditionso Replacements are available at your local Sears

Authorized Service Center.

To clean or replace the air cleaner, follow these steps: ° Push in on tabs and lift outside edge (Figure-8),

= Remove air cleaner cover carefully° ° Remove the air filter and examine itfor damage,

= Replace air filter if damaged or dirty. ° Reassemble all parts and replace cover_, o Push tabs into slots until they %lick"o

F}gure-7

CLEAN SPARK PLUG Change the spark plug every 100 hours of operation or

once each year, whichever comes first. This will help your engine to start easier and run better. Replace with NGK BPR6ES only,

. Clean area around spark plug, ° Remove and inspect spark plug.

Figure_8

REPLACE SPARK PLUG

Change the spark plug every 100 hours or operation or once each year, whichever comes first. This will help your

engine to start easier and run better° Replace with NGK

BPR6ES or equivalent type spark plug, Set spark plug

gap to 0.030 inch (0,76mm)_

0030" FEELER GAUGE

(O,,76mm)

Figure-9

CLEAN SPARK ARRESTOR SCREEN

WARNING:LETTHEMUFFLERCOOLBEFORE WORKINGON IT+CONTACTWITH AHOTMUF-

FLEROR ENGINECANCAUSESEVEREBURNS+

SERVICE RECOMMENDATIONS

The engine exhaust muffler has a spark arrestor screen+ Inspect and clean the screen every 25 hours of operation

or once each year, whichever' comes first. NOTE: If you use your' generator on any forest-covered,

brush-covered or grass-covered unimproved land, it must have a spark anestor.. The spark arrestor must be main- tained in good condition by the ownedoperator+

• Clean and inspect the spark arrestor as follows:

• To remove the heat shield from the muffler (Figure-3), remove the three bolts that connect the shield to the

muffler.

° Remove the phillips head screw that attaches the

spark arrestor screen.

• Pull screen straight ouL

° Inspect screen and replace if torn, perforated or oth-

erwise damaged+ DO NOT USE a defective screen. If the screen is not damaged, clean it with a commercial

solvent.

° Reattach the screen and the heat shield.

Fillin DatesAsYouCompleteRegular HOURLYOPERATINGINTERVAL

Service

Before Every25 Every50 Every100

MAINTENANCETASK EachUse Hoursor Hoursor Hoursor

Yearly Yearly Yearly

ENGINE X

Check011Level

................................ , ............ : ............. i, ......... L L ....

ChangeEngineOil* X** ServiceAir+Cleaner X***

C{eardReplaceSparkPlug X

PrepareForStorage Prepareunitfor storageif_tistoremainidleforMORE

THAN30 DAYS

"Change oil after first 2 hours of operation, then after every 2 hours,

** Change sooner when operating under heavy Goador high ambient temperature

"*'Clean more often under dirty or dusty conditions

SERVICEDATES

ENGINE SPEED

Your generator engine runs at a constant speed+ This constant operating speed is maintained by a mechanical,

flyweight type, fixed speed governor+ DO NOT try to adjust the governed speed setting for' the following rea-

sons:

• High engine speeds are dangerous and increase the risk of personal injury or damage to equipment+

° Low engine speeds impose a heavy load on the

engine when sufficient engine power' is not available

and may shorten engine f_fe+

• The generator will supply correct rated AC frequency and voltage only at the proper speed+ Some con-

nectedelectricaldevicescouldbedamagedby incor- rectfrequencyand/orvoltage

ADJUSTING THE CARBURETOR

Honda uses lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitro-

gen, and hydrocarbons.

The carburetor of your generator is preset at the factory_ DO NOT TAMPER WITH THE CARBURETOR as this wilt

void the warranty for the emission control system. If you think your carburetor needs adjusting, see your nearest

Sears Service dealer Ifyour generator is to be used at an elevation above 5,000 feet in attitude, consult with a

Sears Authorized Service Facility regarding high altitude jetting changes. To improve engine performance, see

your nearest Sears Service dealer_

EMISSION CONTROL SYSTEM INFORMATION Sources of Emissions. The combustion process pro-

duces carbon monoxide, oxides of nitrogen, and hydro.

carbons Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they

react to form photochemical smog when subjected to

sunlight. Carbon monoxide does not react inthe same way but it is toxic°

The U.S. and California Clean Air Acts. EPA and Cali- fornia regulations require all manufacturers to furnish writ-

ten instructions describing the operation and maintenance of emission control systems,

Tampering and Altering. Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tamper-

ingare:

o Removal or alteration of any part of the intake, fuel, or

exhaust systems

° Altering or defeating the governor linkage or speed

adjusting mechanism to cause to engine to operate outside its design parameters.

Problems that may Affect Emissions. If you are aware ofany of the following symptons, have your engine

inspected and repaired by you servicing dealer.

= Hard starting or stalling after starting * Rough idle.

o Misfiring or backfiring under load o Afterburning (backfidng)

GENERAL

The generator should be started at least once every seven days and allowed to run at least 30 minutes_ If this

cannot be done and you must store the unit for more than 30 days, use the following information as a guide to pre-

pare itfor storage.

WARNING:NEVERSTOREENGINEWITH FUELiN

THETANKINDOORSOR IN ENCLOSED,POORLY

VEHTILATEDAREAS,WHEREFUMESCAN REACHANOPENFLAMESPARKORPILOTLIGHT

ASON A FURNACE,WATERHEATER,CLOTHES DRYEROROTHERGASFURNACE.

LONG TERM STORAGE INSTRUCTIONS

It is important to prevent gum deposffs from forming in essential fuel system parts such as the carburetor, fuel fil- ter, fuel hose or tank during storage 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 or 30 days or longer. Fo]low these instructions

PROTECT FUEL SYSTEM:

Remove all gasoline from the fuel tank to prevent

gum deposits from forming on these parts and caus- ing possible malfunction of engine

Run engine until engine stops from lack of fuel

WARNING:DRAINFUELINTO APPROVEDCON-

TAINEROUTDOORS,AWAYFROMOPENFLAME

BESUREENGINEIS COOL°

CHANGE OIL:

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

OIL CYLINDER BORE:

• Remove spark plug and pour about 1/2 ounce (15 ml) of engine oil into the cylinder Cover spark plug hote with rag Crank slowly to distribute oil

- Install spark plugo Do not connect spark plug wire

CAUTION:AVOIDSPRAYFROMSPARKPLUG

HOLEWHEN CRANKINGENGINESLOWLY,

GENERATOR:

o Clean the generator' as outlined on Page 11 to ("To

Clean the Generator'S,.

• Check that cooling air' slots and openings on genera- tor are open and unobstructed,

OTHER STORAGE TIPS: ° Do not store gasoline from one season to another.

• Replace your gasoline can if it starts to rusL Rust

and/or dirt in you gasoline will cause problems, if pos-

sible, store your unit indoors and cover it to give pro- tection from dust and dirt. BE SURE TO EMPTY THE

FUEL TANK.

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

Store generator' in a clean, dry area..

DANGER:STORAGECOVERIS FLAMMABLE,DO NOT PLACETHE STORAGECOVEROVERA HOT GENERATOR°LE'I"THEUNITCOOLFORASUFFI- CIENTTIME BEFOREPLACINGTHECOVERON THEUNIT. IFYOU PLACETHECOVERONTHE

UNIT BEFORETHE GENERATORIS COOL,THE COVERCOULDSTARTFIRE,

PROBLEM CAUSE

Engineis running,but I11 Oneof ille circuit breakersis open. no AC output is available 2. Fault ingenerator:,

3_ Poorconnectionor defectivecord set_ 4_ Connecteddeviceis bad,

Enginerunsgood at no- load but "bogs down"

whenloads are con- nectedo

Enginewill not start; or starts and runs rough,

Engineshuts down dur- ing operation_

1., Short circuit in a connectedload.

2. Enginespeed is too slow.

3. Generatoris overloaded,,

4. Shorted generatorcircuit,

1. On!OffSwitch set to Off.

2, Dirty air cleaner,

3. Outof gasoline,

4,, Stalegasoline,

5, Sparkplug wire not connectedto spark plug.

6. Badspark plug_ 7, Waterin gasoline,, 8, Overchoking

9o Low oi! level. 10_ Excessivelyrich fuel mixture,

11, intake valvestuck open or closed, 12_ Enginehaslost compression.

1. Outof gasoline_ 1,, Fillfuel tank, 2,, Low oit level 2_ Fill crankcaseto proper level

CORRECTION

1_ Resetcircuitbreaker.

2. contactSearsService Facility.

3. Checkand repair: 4o Connect a device that is in good condition

1. Disconnect shorted electrical load_

2. Contact SearsService Facility,, 3, See"Don't Overloadthe Generator",

4. Contact SearsService Facility_ 1o Setswitch to ON,

2.. Cleanor replaceair-cteaner:o

3. Fillfuel tank_

4. Drain gas tank; fill with fresh fuel.

5. Connectwire to spark plug,.

6. Replacespark plug.

7. Drain gas tank; fill with fresh fuel. 8, Open chokefully and crank engine. 9,. Fill crankcase to proper level !0. Contact Sears ServiceFacility, 11_,Contact Sears ServiceFacility.

12. Contact Sears ServiceFacility,

Enginelacks power_ 1o Load is too high,, 1. See "Don't Overloadthe Generator"

2_ Dirty air filter,_ 2. Replaceair filter:

Engine"hunts" or falters 1,, Chokeis openedtoo soon, 1_, Move choke to halfway position until engine

2,. Carburetoris runningtoo rich or too lean, runs smoothly,,

2. Contact SearsService Facifity_

CRAFTSMAN 2500 WATT DELUXE AC GENERATOR 580.327750

<1:

e,/

=i--k r=-t=_"l-=

Drawing No.,B2420

CRAFTSMAN 2500 WATT DELUXE AC GENERATOR 580.327750 REPAIR PARTS

.,,.o

If)

_J o3

L-- 7

CRAFTSMAN 2500 WATT DELUXE AC GENERATOR 580.327750 REPAIR PARTS

t B2392 2 B2406 3 85652 4 143-5362I

5 B2153 6 75475

7 85651 8 22129

9 (NOTUSED)

10 38150 11 82413J t2 66365

!3 91820J

14 65791 15 24420

16 668258

17 (NOTUSED) 18 (NOTUSED)

19 86308D 20 22264

21 66849 22 (NOTUSED)

23 68759 24 77247

25 B2424 26 91825

27 67451

28 (NOTUSED) 29 51715

30 74908 31 86494

32 84242 33 86307

_ESCRIPTION HONDAGC1605 HP (t RE&)

BASEANDAXLEASM (1 REQ..)

VIBRATIONMOUNT- ALT (2 REQ)

GROUNDW1RE{I REQ.) SELFDRILLER1244 X 7/8 {1 REQ.) SCREW,PANHD. MACH M4-&7 X 10 (2 REQ.)

MOUNT,VIBRATION-ENGINE(2 REQ) LOCKWASHER-MS(6 REQo)

WASHER,FLAT_8 (2 REQ.)

STATORASSEMBLY(1 REQ.) HOUSING,ENGINEADAPTOR(1 REQ) ROTORASSEMBLY(t RE&) BEARING,BALL(1 REQ.,)

BOLT,ROTOR-5116"-24X 6 25 (1 REQ,) CARRIER,REARBEARING(i REQo)

BOLT,STATORM6-1.,00X 85MM(4 REQ,) LOCKWASHER- NO8(2 REQ) SCREW(TAPTITE)M5-&80X16MM(2REQ.,)

RECEPTACLE120-VOLTSAC, 20A (1 REQ.) BREAKER,ClRCUIT-20A(i REQ.)

PANEL,CONTROL2AKW (1 REOo) BRUSH& BRIDGERECTIFIER(1 REQ..)

FLATWASHER-(SPECIAL}(1 REQ)

NUT,HEX-M4-O..7(2 REQ,) SCREW(TAPTITE)-M5-O.80X t0 MM (4 REQ.)

SCREW,M6-I nOX 16WING (1 REQ) GROMMETRBC(2 REQ.) CAPSCR_Ai,HE)(HD (4 REQ.)

ITEM PARTNO..

34 67022

35 45771 36 26850

37 22145 38 22769

39- 44 (NOTUSED)

45 93639 46 (NOT USED)

47 B2517 48 82419

49 B2415 50 B2518

51 46476

52 82347

53 51767 54 82395B 55 B2395A 57 27007

58 39253

59 52858 60 B1T/9

61 B2857

62 49808 63 81760

64 75402

65 B2407 66 96409 67 82437 68 77247a

69 90418 70 65795 7I 66849A

DESCRIPTION

GROMMET,BEARINGCARRIER(1 REQ M8-125 HEX NUT (6 REQ)

WASHER,SHAKEPROOF#10 (1 REO.) FLATWASHER-M8(4 REQ.)

WASHER,SHAKEPROOF#10 (1 REQ)

DECAL,DANGER-ENGLISH(1 REQ)

DECAL,RECOIL(1 REQ)

DECAL,CRAFTSMAN(1 REQ..) DECAL,CONTROLPANEL(1 REQ_) DECAL,ENGINESHROUD(I REQ) CAPLUG1" SQUARE(2 REQ,)

ENDCAP(2 REQ,) HHOS,M6-1,,0X 45 (2 REQ)

FOOTASM, SUPPORT LH (1 REQ,) FOOTASM, SUPPORTR,H,.(t RE&)

VIBRATIONMOUNT,LEG(2 REQ,)

SCREW,HID{HD.CAPSC.M8-1,,25X 20 LONG

(6 REQo)

NUT,FLANGE-MS-125 (6 REQ..) (;OVER,HINGE(2 REQ.)

NUT,LOCKINGM6-1o0 (2 REQ,,) WASHER,FLAT-M12(2 REQ.)

WHEELANDTIRE ASM10" (2 REQ)

PUSH NUT-1t2" DIA. (2 REQ.)

HOLDER,EXTENSIONCORD(1 REQ..) DECAL,1-800 NUMBER(1 REQ)

DECAL,STARTINSTRUCTIONS(1 REQ) BREAKER,CIRCUIT-IOA(1 REQ.)

OUTLET,12VDC SNAP RECTIFIER,BATTERYCHARGE(1 REQ.) TAPTITE,M% - 0,7 x 20 (1 RE&)

Drawing No_[32421

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