Craftsman 580.328330 User Manual

Sears

MODEL NUMBER

580.328330

CAUTION: READ INSTRUCTIONS AND RULES FOR SAFE OPERATION CAREFULLY

TO PREVENT ACCIDENTS,,

OPERATING

INSTRUCTIONS REPAIR PARTS

ACCESSORIES

2400WATT

PORTABLE

AC GENERATOR

Record in space provided below the Model No., and Serial No, of the generator. Model No and Serial No are both located on the Nameplate

Model No, Serial No Retain these numbers for future reference.

Sears, Roebuck and Co., Chicago, IL 60684 U.S.A.

FULL ONE YEAR WARRANTY

For one year from the date of purchase, Sears will repair any defect in material or workmanship in this Generator at no charge.

If the Generator is used for commercial or rental purposes, this warranty

applies for only ninety days from the date of purchase Warranty service is available by RETURNING TO THE NEAREST SEARS

SERVICE CENTER/DEPARTMENT THROUGHOUT THE UNITED STATES. This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

Sears, Roebuck and Co.

Dept. 698f731A Chicago, tL 60684

RULES FOR SAFE OPERATION

i. Never permit any unqualified person- especially children- to oper- ate this equipment. Equipment misuse, carelessness, improper procedures, or incorrect application may result in personal injury or damage to equipment and/or property.

2. Never handle any kind of electrical device while standing in water,

while barefoot, or while hands or feet are wet. Dangerous electrical

shock will result.

3. The engine that drives the generator consumes oxygen and gives off

deadly carbon monoxide gas through its exhaust system. This dangerous

gas, when breathed in sufficient concentrations, can cause unconsciou-

sness and even death, this equipment only in well ventilated

areas. Never operate this equipment in any room or enclosed space

where exhaust gases might accumulate and endanger people.

4. This equipment requires an adequate free flow of cooling air for its operation. Without adequate cooling air flow, overheating and resultant damage to equipment and/or property will result. Never

operate the generator inside any room or enclosure that might obstruct

the free flow of cooling air into and out of the unit.

5. Engines, engine exhaust mufflers and surrounding areas on this

equipment become extremely hot during operation and remain hot for several minutes after shutdown. Avoid contact with these areas or

serious burns may result.

6. Gasoline is extremely flammable and its vapors are explosive. Do not permit smoking, open flame, or sparks in the vicinity while

handling gasoline. Avoid spillage of gasoline on a hot engine. Never

fill the gas tank while the engine is running. Comply with all laws regulating the storage and handling of gasoline.

'7. Never store this equipment indoors or in enclosed, poorly

ventilated enclosures with fuel in tank where gasoline fumes might

reach an open flame, spark or pilot light (as on a furnace, water

heater, clothes dryer, etc.).

8. In addition to these RULES FOR SAFE OPERATION, other SAFETY RULES may apply. Practice safety at all times- by staying alert and by

reading the instructions in this Manual carefully.

AC GENERATOR SPECIFICATIONS

Model Number ............................................... 580.328330

Type of Equipment ....................... Revolving Field a-c Generator

Rated Maximum Continuous a-c Power Capacity ...... 2400 watts (2.40 kW)

Rated Maximum Continuous Load Current ................ 20.0 a-c amperes

Generator Circuit Breaker Rating ..................... 20.0 a-c amperes

Rated Voltage ........................................... 120 volts a-c

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

Rated a-c Frequency .............................. 60 hertz at 3600 rpm

NL_ber of Revolving Field Poles ..................................... 2

Driven Speed of Revolving Field ................... 3720 rpm at No-Load

Type of Revolving Field Excitation.. Direct Excited (Bridge Rectifier)

Rated Maximum Battery Charge Output ........ i0 amperes at 12 volts d-c

Battery Charge Circuit Breaker Rating .................. 10 d-c amperes

ENGINE SPECIFICATIONS

Engine Manufacturer .......................................... KAWASAKI

Manufacturer's Model Number .................................... FA-210

Type of Engine .................. Single Cylinder, 4-Stroke, Air Cooled

Rated Horsepower ...................................... 5.0 at 3600 rpm

Fuel Consumption Ratio ................... 0.68 Ib/hp/hr (310 gr/hp/hr)

Displacement .............................. 12.67 Cubic Inches (207 cc)

Compression Ratio ............................................ 6.4 to 1

Cylinder Block Material ......................... High Silicon Aluminum

Ignition System

Type ........................ Flywheel Magneto (with Breaker Points)

Recommended Spark Plug ........................ Resistor Type 14 mm _

NGK ...................................................... BMR-6A

CHAMPION .................................................. RCJ-8

Set Spark Plug Gap to ................ 0.023-0.027 inch (0.6-0.7 mm)

Set Breaker Point Gap to ............... 0.01-0.02 inch (0.3-0.5 mm)

Ignition Timing ........................... Fixed at 23 degrees BTDC

Engine Speed Governor

Type ....................................... Mechanical, Fixed Speed

Governor Setting ............................. 3720 rpm at No-Load _

Air Cleaner ......... Semi-dry Type, washable polyurethane element with

ny!on brush

starter ...................................... Manual, Recoil Rope Type

Engine Crankcase Oil Capacity ................. 1.27 U.S. pint (600 cc)

Recommended Oils ........ Use oil classified "For Service SC, SD or SE"

Primary Recommended Oil ........... SAE 10W-30 Multiple Viscosity _

Acceptable Substitute ................................... SAE 30 Oil

SAE 10W-40 OIL IS NOT RECOMMENDED

Maximum Permissible Inclination for Continuous Operation

without Lubrication Problems ................. 20 degrees any direction

Fuel Tank Capacity ..................... 2.34 U.S. gallons (9.0 liters)

Recommended Fuel

Primary Recommended Fuel .......... UNLEADED Automotive Gasoline _e_

Acceptable Substitute ..... Leaded REGULAR Grade Automotive Gasoline

Canada requires the use of RESISTOR spark plugs, in compliance

with the radio noise limitations (radio frequency interference) order issued by the Ministry of Communications of the Canadian Telecommunications Regulations Branch.

At 3720 rpm the generatorts a-c output will be 62 hertz. This

slightly high engine speed setting at no-load helps ensure that engine speed (and a-c frequency) do not drop excessively when heavier electrical loads are applied.

Use of a multiple viscosity oil will contribute to easier starting in cold weather. Use of UNLEADED gasoline in a 4-cycle engine contributes to in-

creased valve life by reducing lead and and carbon deposits. A high quality REGULAR grade gasoline may be used, however, UN- LEADED gasoline is the primary recommended fuel.

SECTION 1 - GENERAL INFORMATION

1.1- INTRODUCTION

This OWNER'S _ANUAL has been prepared especially for the purpose of

familiarizing personnel with the handling, operation and servicing of the applicable equipment. Study the Manual carefully and comply with

all instructions. This will help prevent possible injury or damage to equipment and!or property, that might be caused by carelessness,

equipment misuse or abuse, improper procedures, or incorrect applica-

tion.

1.2- SAFETY

Prior to handling, operating or servicing this equipment, study the ROLES FOR SAFE OPERATION at the front of this Manual carefully. All ROLES must be complied with fully, to help avoid personal injury or

damage to equipment and/or property.

The following definitions apply to DANGER, CAUTION and NOTE blocks

found throuqhout this Manua!:-

DANGER!

Under this heading will be found handling, operating and servicing in-

structions that, if not complied with fully, may result in persona]

injury.

CAUTION!

Under this heading will be found handling, operating and servicing in-

structions that, if not complied with fully, may result in damage to equipment.

NOTE

that require

Under this heading will

special emphasis.

be found explanatory statements

1.3- EQUIPMENT DESCRIPTION

This equipment is a gasoline engine-driven, revolving field a-c gener- ator set. The generator may be used to operate 120 volts, single

phase, 60 hertz, a-c electrical devices requiring up to 2400 watts

(2.4 kW) of electrica! power or up to 20.0 a-c amperes of current. A

circuit breaker will open the unit's a-c output circuit if the current

requirements of connected electrical loads exceeds 20.0 a-c amperes.

The generator's revolving field (rotor) is directly attached to and

driven by a 4-cycle, air-cooled, gasoline engine. Engine speed with no electrical loads connected to the generator is maintained at approxi-

mately 3720 rpm by a mechanical governor. Engine speed and generator a-c output frequency are directly proportional. Thus, at 3600 rpm a-c

frequency will be 60 hertz; at 3720 rpm a-c frequency is 62 hertz. The slightly high engine speed setting at no-load helps ensure that engine

speed (and a-c frequency) do not drop excessively under heavier elec-

trical loads.

In addition to its a-c power capability, the generator may be used to

recharge a discharged 12 volts, automotive or utility type storage battery. When properly connected to the discharged battery, an

operating generator will supply a maximum charge rate of approximately

i0 d-c amperes at 12 volts. The maximum rate of charge will gradually

decrease as the connected battery approaches a i00 percent state of

charge.

1.4- RECEIVING AND HANDLING

Upon receipt, completely remove the generator from its shipping carton

and from any shipping pallet to which it might be attached. Remove all

packing material from around the generator. Inspect the unit carefully

for any damage that might have occured during shipment.

In addition to this OWNERtS MANUAL a BATTERY CHARGE CABLE is shipped with the generator. To order additional Manuals or Cables, refer to

the REPAIR PARTS section of the Manual.

CAUTION!

DO NOT to crank and start the generator engine until it has been properly prepared for use, as outlined in Section 2 of this

Manual. Any attempt to crank or start the unit before it has been properly serviced with the recommended oil will result in an engine

SECTION 2 - OPERATING INSTRUCTIONS

DO AND DON'T CHART

i. DO comply with all SAFETY RULES.

i. DON'T operate the unit inside any enclosure that might obstruct

the free flow of cooling air.

2. DO check oil level before start-

up or at least every 5 hours of op- eration.

2. DON'T operate the unit inside any room or enclosure where ex- haust fumes might accumulate and result in carbon monoxide poison-

iing.

3. DO disconnect electrical loads from panel before

starting or stopping the engine.

3. DON'T overload the generator. The total of all connected loads

should not exceed 2400 watts (2.4

kW), or 20.0 a-c amperes.

4. DO comply with instructions in this Manual when charging a battery.

4. DON'T touch areas around the engine exhaust muffler. These

areas are HOT.

5. DO operate the generator only on

surfaces that are as level as poss-

ible.

5. DON'T handle electrical

equipment while standing in

water, while barefoot, or while

hands or feet are wet.

2.1- PI_PARATION BEFORE USE (Figure 2-1)

a. Check Enqine Oii Level (Figure 2-1):- Check oil level and (if

necessary) fill to proper level with the recommended oil as follows:-

(I) Place the generator on a level surface. (2) Remove OIL FILL PLUG by turning counterclockwise.

(3) Check oil level. Oil should be at point of overflowing the 0IL

FILL PLUG opening. If necessary, add oil to that level. See

ENGINE SPECIFICATIONS CHART at front of Manual for recommended

oils and crankcase capacity.

(4) When oil is at proper level, install and tighten OIL FILL PLUG.

NOTE

The revolving field rotates on a pre-lubricated, sealed bearing which requires no additional lubrication for the life of the

bearing.

OIL FIL_

PLUG _ _ _ _ .......... :_ ,

""_ OIL DRAIN

PLUG

Figure 2-1. Engine Oil Fill and Oil Drain Locations

b. Fill Fuel Tank:- Remove Fuel Tank FILLER CAP by turning counterclockwise. Fill Fuel Tank with clean, fresh gasoline as

recommended in the ENGINE SPECIFICATIONS CHART at front of Manua!. Install and tighten FILLER CAP.

DANGER! Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE. DO NOT permit smoking€ open flame or sparks in the vicinity while handling

gasoline. Avoid spillage of gasoline on a hot engine. Comply with all laws regulating the storage and handling of gasoline. Never store the generator with fuel in tank where gasoline vapors might reach an open

flame, spark or pilot light (such as on a furnace, water heater,

dryer, etc.)- FIRE or an EXPLOSION might result.

C. 120 Volts Cord Sets:- Use only high quality, well insulated, grounded cord sets with the generator's 120 volts a-c receptacles. Wire gauge of cord sets must be large enough to handle the maximum

anticipated current draw of connected electrical loads. Cord sets that

are excessively long or that are rated at too low an amperage will cause a voltage drop and will overheat. Table 2-1 lists minimum

recommended wire gauges, based on the cord set length and the load

current draw in amperes.

COUNT

(AMPERES}

2-3 4-5

12 14

18 2O

....LENGTH OF,,,..CORD SET IN FEET

0-50

18AWG ..........

16 AWG 16 AWG 16 AWG 16 AWG

14 AWG

14 AWG 12 AWG

12 AWG I0 AWG

51-100 18 AWG

16 AWG 16 AWG 14 AWG 14 AWG 14 AWG

12 AWG 12 AWG 10 AWG

8 AWG

101-150 18 AWG

16 AWG 14 AWG 12 AWG 12 AWG 12 AWG

l0 AWG l0 AWG

8 AWG 8 AWG

Table 2-1. Recommended Wire Gauges of 120 Volts Cord Sets

2.2- OPERATING LOCATION

Comply with the following rules pertaining to operating location of

the generator:-

a. Place the generator on a level surface. Maximum tilt of the engine

in any direction must not exceed 20 degrees, or engine lubricating

problems may result. b. Never operate the generator where it will be exposed to flooding,

excessive moisture, dust, dirt or corrossive vapors. c. Provide adequate ventilation. Never operate the generator inside

any room or enclosure where exhaust fumes might accumulate and endanger people.

d. Never run the generator inside any room or enclosure that might ob- struct the free flow of cooling air. Without adequate cooling air, the

unit will quickly overheat, causing serious operating problems and possible damage to equipment and/or property.

2.3- DON'T OVERLOAD THE GENERATOR (Table 2-2)

DO NOT exceed the generator's rated WATTAGE and/or AMPERAGE capacity for continuous operation. Before connecting electrical loads to panel

receptacles, add up the WATTS (or the AMPERES) required to operate those loads. Rated watts and/or amperage can usually be found on the

nameplate of lights, appliances, motors, etc. The total of all loads being powered at one time should not exceed 2400 watts or 20.0 a-c

amperes.

NOTE

Some electric motors (such as saws, drills, etc.) require more watts of power or amperes of current than is stated on their nameplate, when

the motor is being put to hard use. For example, a saw that is used to cut through extremely difficult material may require 3 to 4 times more

wattage or amperage than is stated on its nameplate.

Some electric motors (such as Universal, Repulsion-Induction, Capacitor, or Split Phase type) require more amperes of current for

starting than for continuous on-speed operation. Approximate starting and running current (in amperes) is listed in Table 2-2. To use the

chart, find the TYPE OF MOTOR and its RATED HORSEPOWER on the motor

nameplate. Then, locate the approximate starting and running amperes in the chart.

APPROXIMATE STARTING AMPERES

MOTOR

HORSEPOWER

RATING

1/6 1/4

1/3

1/2

3/4

i-1/2

2 3

APPROXIMATE

RUNNING

A_PERES

2.3

3.3

3.8

5.0

7.1

8.3

12.3

16.7

25.0

40.0

............ ,IREPULSION ......

UNIVERSAL I INDUCTION CAPACITOR

.........MOTORS I MOTORS ........._MOTORS

3.3

4.2

5_0

6.3

8.3

10.4

5.0

7.1

8.1

10.8

15.8

19.2

26.7

32.5

43.3

62.5

ii. 3

15.0

21.7

25.0

35.0

42.5

56.7

81.7

7.1

8.8

SPLIT

PHASE

MOTORS

I0.0

16.2

16.3

21.7

"_ Motors ot nlgner norsepower in tnls c±assltlcatlon are not generali?

used.

Table Approximate Motor Running and Starting Requirements

2.4- STARTING THE ENGINE (Figure 2-2)

a. Disconnect Electrical Loads:- Disconnect or turn OFF all electrical loads connected to generator receptacles.

CAUTION!

Never start or stop the engine with electrical loads connected and

turned on. The generator will supply its rated voltage and frequency

only at its correct rated operating speed. Some electrical devices may

be damaged by incorrect voltage and/or frequency. In addition, start- ing the engine with electrical loads applied imposes a heavy load at

lower operating speeds where adequate power is not yet available and may shorten engine lifeo

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