Sears 580.327060 User Manual
OWNER'S
MANUAL
MODEL NO.
580.327060
CAUTION:
Read and Follow
CRRFTSMRNo
120-240 VOLT/4000 WATT A-C
PORTABLE A-C GENERATOR
with Automatic Idle Control
all Safety Rules
and Instructions
Before Operating
This Equipment
SEARS ROEBUCK AND Co., Chicago, IL 60684 U.S.A.
Assembly
Operation
Maintenance
Service and Adjustment
Repair Parts
o 36 6
PartNo. 80059GS_v3-1./11/90
SAFETY RULES
& CAUTION: ALWAYS DISCONNECT SPARK PLUG WIRE AND PLACE WtRE WHERE IT CANNOT ACONTACT SPARK PLUG, TO PREVENT ACCIDENTAL STARTING WHEN SETTING UP,
TRANSPORTING, ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR.
IMPORTANT
THIS GENERATOR IS DESIGNED FOR OUTDOOR USE ONLY. USING THIS GENERATOR INSIDE ANY
BUILDING OR ENCLOSURE, INCLUDING THE GENERATOR COMPARTMENT OF A RECREATIONAL VEHICLE
(RV), IS DANGEROUS. FIRE OR AN EXPLOSION MAY RESULT. NO USER PERFORMED MODIFICATIONS,
INCLUDING VENTING OF EXHAUST ANDIOR COOLING VENTILATION, WILL ELIMINATE THE DANGER.
If this unit is used for backup power inthe event of a
utitity power failure, take the following steps: BEFORE
CONNECTING THE GENERATOR TO AN ELECTRI-
CAL SYSTEM OPEN THE MAIN CIRCUIT BREAKER
OR MAIN SWITCH SERVING THE SYSTEM TO ISO-
LATE THE GENERATOR SYSTEM FROM THE
ELECTRIC UTILITY. FAILURE TO ISOLATE THE
GENERATOR AND UTILITY SYSTEMS MAY
RESULT IN DAMAGE TO THE GENERATOR AND
MAY ALSO RESULT IN INJURY OR DEATH TO
ELECTRIC UTILITY WORKERS DUE TO BACK-
FEED OF ELECTRICAL ENERGY.
This generator supplies dangerously high electrica!
voltages. Use care to prevent extremely hazardous
and possibly lethal electrical shock. Never permit any
unqualified person(s) to operate or service the unit.
DO NOT operate this equipment in the rain, while
standing in water, while barefoot, or white hands or
feet are wet. Dangerous electrical shock will result.
Maintain all wiring, extension cords, etc., in good
condition. Worn, bare, frayed, or otherwise damaged
wiring and cord sets may cause dangerous electrical
shock and may also result in damage to equipment
and!or property.
The National Electrical Code requires that the gener-
ator be properly connected to an approved earth
ground. Local electrical codes may also require
proper grounding of the unit. See ASSEMBLY section
for more grounding information.
Wire gauge sizes of wiring and cord sets must be large
enough to handle the maximum electrical load to
which they will be subjected. Cord sets must be rated
125 a-c volts at 20 amperes or (or greater). Some
electrical devices, however, do not require that cord
rating. Refer to the Owner's manual of the electrciat
device for the manufacturer's recommendations.
The generator engine consumes oxygen and gives off
DEADLY carbon monoxide gas through its exhaust
system. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even
death. Operate this equipment outdoors only, in well
ventilated areas where exhaust gases cannot ac-
cumulate and endanger people or animals.
° Gasoline is extremely FLAMMABLE and its vapors are
EXPLOSIVE. Comply with all laws regulating the
storage and handling of gasoline. DO NOT permit
smoking, open flames, sparks or heat in the vicinity
while handling gasoline. Avoid spilling gasoJine on a
hot engine. DO NOT fill fuel tank while engine is
running or hot. Clean off any spilled gasoline before
starting engine.
• DO NOT fill fuel tank completely full. Allow room at
top of tank for fue! expansion or fuel may expand and
over/low onto a hot engine.
• Drain all gasoline from tank before transporting your
generator inside your car or other vehicle.
• DO NOT store the generator with fuel in tank where
gasoline vapors might reach an open flame, spark, or
pilot light, as on a furnace, water heater, dryer, etc.
FIRE or an EXPLOSION might result.
• DO NOT insert any object or tool through cooling air
slots or openings of the engine or generator, even if
the engine is not running. Damage to the unit or
personal injury may result.
• DO NOT attempt to change the engine governed
speed. Factory settings are correct when you receive
the unit. Excessively high engine speeds may result
in injury or damage to equipment.
" DO NOT use the unit if it has been damaged. Repair
or replace all damaged or defective components
before you run the unit.
• DO NOT permit children to operate or service the
generator.
Read your Owner's Manual carefully. Only persons
who are familiar with these safety rules and have been
properly instructed in the use of this product should be
permitted to use the product.
,_ LOOK FOR THIS SYMBOL TO POINT OUT IMPORTANT
SAFETY PRECAUTIONS. IT MEANS "ATTENTION!!I.
BECOME ALERT!H YOUR SAFETY IS INVOLVED."
CONGRATULATIONS on your purchase of a Sears
Craftsman Generator. tt has been designed, engineered
and manufactured to give you the best possible depend-
ability and performance.
Shoul_you experience any problem you cannot easily
remedy, please contact your nearest Sears Service Cen-
ter/Department. We have competent, well-trained tech-
nicians and the proper tools to service or repair this unit.
Please read and retain this manual. The instructions will
enable you-to assemble and maintain your generator
prepedy. Always observe the 'SAFETY RULES."
MODEL
NUMBER 580.327060
PRODUCT SPECIFICATIONS
Generator Specifications
RATED MAXIMUM
POWER
RATED VOLTAGE
RATED MAXIMUM
LOAD CURRENT
RATED FREQUENCY
PHASE
Engine Specifications
4000 Watts (2.4 kW)
120/240 Volts a-c
33.3/16.7 a-c amperes
60 Hz at 3600 rpm
Single Phase
SERIAL
NUMBER
DATE OF
PURCHASE
THE MODEL AND SERIAL NUMBERS WILL BE
FOUND ON A DECAL AI-I-ACHED TO THE GENER-
ATOR STATOR CAN.
YOU SHOULD RECORD BOTH SERIAL NUMBER
AND DATE OF PURCHASE AND KEEP IN A SAFE
PLACE FOR FUTURE REFERENCE.
MAINTENANCE AGREEMENT
A Sears Maintenance Agreement is available on this
product. Contact your nearest Sears store for details.
CUSTOMER RESPONSIBILITIES
• Read and observe the safety rules.
RATED HORSEPOWER
DISPLACEMENT
SPARK PLUG: Type:
_ Set Gap to:
MAXIMUM (full tank)
OPERATING TIME (hrs)
GASOL1NE CAPACITY
OIL (1.5 U.S. pint capacity)
NOTE: This generator is equipped with a spark arrestor
muffler. The spark arrestor must be maintained ineffective
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 have similar laws. Federal laws apply on
federal lands.
8 at 3600 rpm
19.3 cubic inches
Champion RJ171Mor
equivalent
0.030 inch (0.76mm)
full load 3/4 1/2 1t4
1,0 1.25 t.5 t.5
1.0 U.S. gallon
SAE 30 Oil
(SAE 10W-30)
• Followregular schedule in maintaining, caring for and.
using your generator.
Follow the instructions under "Maintenance" and
"Storage" sections of this Owner's Manual.
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 va,'y from state to state.
SEARS, ROEBUCK AND CO., Department 731CR-W, Sears Tower, Chicago, IL 60684
TABLE OF CONTENTS
SAFETY RULES .............................. INSIDE COVER
MAINTENANCE AGREEMENT ............................... 1
CUSTOMER RESPONSIBILITIES ........................... 1
PRODUCT SPECIFICATIONS ................................ 1
WARRANTY ............................................................. 1
ASSEMBLY
To Remove Generator from Carton ...................... 3
Paris Shipped Loose with Unit ............................. 3
Cord Sets and Connector Plugs ........................... 3
Grounding the Generator ..................................... 3
OPERATION
Know Your Generator ........................................... 4
Before Starting Engine ......................................... 5
To Start Engine .................................................... 5
Connecting Electrical Loads ................................. 6
Stopping the Engine ............................................. 6
Don't Overload the Generator .............................. 7
Wattage Reference Guide .................................... 7
MAINTENANCE
General Recommendations ................................. 8
Generator Maintenance ....................................... 8
Engine Maintenance ............................................ 8-9
SERVICE AND ADJUSTMENTS
Engine Speed ...................................................... 10
Carburetor ............................................................ t 0
Check Compression ............................................. I0
Check Ignition ...................................................... 11
Check Carburetion ............................................... t 1
STORAGE
General ................................................................ 11
Storage Instructions .............................................. 11
TROUBLESHOOTING POINTS .............................. 12
WIRING DIAGRAM .................................................. 14
REPAIR PARTS ....................................................... 15-23
PARTS ORDERING ............................. BACK COVER
INDEX
-A-
Air Filter ................. 8
Assembly ................ 3
-B-
Battery
Charging ................... 6
Safety ..................... 6
Before Starting ............ 5
-C-
Carburetor ................ 11
Check Carburetion ......... 12
Check Compression ........ 11
Check lgnitition ............ 11
Circuit Breaker ............ 7
Connecting Electrical Load... 6
Cord Sets, 120 volts ........ 3
Customer Responsibilities ... 1
-E-
Engine
Maintenance ................ 8
Oil Level ................... 5
Speed ..................... 11
-G-
Generator Maintenance ..... 8
Grounding ................ 3
Gasoline ................. 5
-L-
Lubrication ............... 5, 8
-M-
Maintenance
Agreement .................. 1
Engine ..................... 8
Generator .................. 8
Recommendations ........... 8
Spark Arrestor ............... 9
Spark Plug .................. 9
-O-
Operation ................ 4-7
Overloads ................ 7
=p=
Parts, loose in carton ....... 3
Parts, repair .............. 15-23
-R-
Replace Foam Filter ........ 8
Replace Paper Element ..... 9
-S-
Safety Rules ........... inside cover
Service and Adjustments
Carburetor .................. 11
Carbutetion ................. 12
CheckingCompression........ 12
CheckingIgnition............. 11
EngineSpeed ............... 11
Service Recommendations .. 10
Specifications ............. 1
Starting Engine ............ 5
Stopping Engine ........... 6
Storage .................. 12
-T-
Troubleshooting ........... 13
-W-
Warranty ................. 1
Wattage Reference Guide ... 7
Wiring Diagram ............ 14
2
ASSEMBLY
Your a-c generator was completely assembled at the fac-
tory. It is ready for use after it has been properly serviced
with the recommended lubricating oil and fuel.
IMPORTANT: ANY A]-I-EMPT TO RUN THE ENGINE
BEFORE IT HAS BEEN SERVICED WITH THE RECOM-
MENDED OIL WILL RESULT IN AN ENGINE FAILURE.
TO REMOVE GENERATOR FROM CARTON
• Set the carton on a flat rigid surface with "THIS SIDE
UP" arrows pointing upward.
• Carefully open the top flaps of shipping carton.
• Remove any loose parts shipped with the unit. These
are shipped in a brown manilla or plastic envelope.
° Cut down comers at one end of shipping carton and lay
that side of carton down flat.
Remove packing material, carton tillers, etc.
Remove generator from shipping carton.
Check carton carefully for any additional loose parts.
CORD SETS AND CONNECTOR PLUGS
120 VOLTS DUPLEX RECEPTACLE
Use only high quality, well-insulated, 3-wire grounded ex-
tension cords with the generator's 120-volt "duplex" type
electrical receptacles (Fig. t ). All cord sets used should be
rated 125 volts at 20 a-c amps or greater for most electrical
devices. Keep extension cords as short as possible,
preferably less than t 5 feet long to prevent voltage drop
and possible overheating of wires.
@
120 V. A.C.
.@
120/240 VOLTS RECEPTACLE:
A 240 volts, 20 amp, twistlock type mating connector plug
(Fig. 2) is required when using this receptacle. A 4-wire
cord set, rate 20 a-c amperes at 250 volts (or greater), is
required and must be connected to the plug and to the
desired load(s). To order additional connector plugs, see
REPAIR PARTS section of this manual. You may also
purchase plugs at a local electrical supply store, ordering
NEMA type L14-20P.
4-Wtre Cord Se!
O AMP
N E tvIA L14-2 OH
FIG. 2
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 LUG is provided on
the base of the cradle (Fig. 3). Generally, connecting a No.
t 2 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 re-
quirements in your area.
Proper grounding of generator will help prevent electrical
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.
]FIG. !
NOTE: To obtain suitable mating 120 volts, 20 amp con-
nector plugs, refer to REPAIR PARTS section of this
manual. Suitable connector plugs may also be purchased
at a local electrical supply store by specifying National
Electrical Manufacturer's Association (NEMA) 5-20P.
]FIG. 3
3
OPERATION
KNOW YOUR GENERATOR
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR GENERATOR. Compare the
illustrationswith your generator, to familiarize yourseff with the locations of various controls and adjustments. Save this
manual for future reference.
120/240 VO LTS
RECEPTACLE
120 VOLTS
RECEPTACLES
120 VOLTS "DUPLEX" RECEPTACLES - May be used to
supply electrical powerfor the operationof 120 volts at 20
amps a-c, single phase, 60 Hz, a-c electrical lighting,
applicance, tool and motor loads.
120/240 VOLTS RECEPTACLE - May be used to supply
electrical power for the operation of up to 240 volts at 20
amps a-c, single phase, 60 Hz, a-c electrical lighting,
applicance, tool and motor loads. Twistlock connectors are
required when using this receptacle.
SPARK ARRESTOR MUFFLER - Exhaust muffler has a
spark arrestor screen.
IDLE CONTROL SWITCH (not shown) - Provides automat-
iccontrol of governed speed, which only runs at high speed
when loads are connected. Otherwise it runs at a slower
idlespeed.
FUEL TANK
SPARK PLUG
i STOP SWITCH
.t AIR
CLEANER
SPARK ARRESTOR
MUFFLER
AIR CLEANER - Uses a dry type filter element to limit the
amount of dirt and dust that gets in the engine. Some units
may be equipped with an optional, dry type pre-cleaner.
FUEL TANK- Can hold one (1) U.S. gallon of gasoline.
Unleaded gasoline is recommended, but regular leaded
gasoline is acceptable.
amount of fuel in tank.
SPARK PLUG STOP SWITCH - Contact this switch with
spark plug to shut down engine.
RECOIL STARTER - (Not shown) Used for starting the
engine.
CHOKE (not shown) - Used when starting a cold engine.
OIL FILL (not shown) - Check and maintain correct oit level
here.
4
OPERATION
BEFORE STARTING ENGINE
ADD OIL:
• Place generator on a level surface and remove oil fill
plug (Fig. 4). Fill with Sears SAE 30 detergent oil to
point indicated on oil dipstick. SAE 10W-30 oil may
also beused. DO NOTUSESAE 10W-40OIL. POUR
SLOWLY. Oil capacity of engine is 1.5 U.S. pints.
When oil pan is full, install and tighten oil fill plug.
ADD GASOLINE:
Fill fuel tank with clean, fresh, UNLEADED gasoline.
Leaded REGULAR grade gasoline may also be used.
DO NOT USE PREMIUM GASOLINE. BE CAREFUL
NOT TO OVERFILL FUEL TANK.
WARNING: Experience indicates that alcohol-blended
fuels (called gasohol or using ethanol or methanol) can
attract moisture which leadsto separation and formation of
acids during storage. Acidic gas can damage the fuel
system of an engine while in storage. To avoid engine
problems when using gasohol,the fuel system should be
emptied before storage periodsof 30 days or longer. Drain
the gas tank, start theengineand letitrun untilthe fuel lines
and carburetor are empty. Use fresh fuelnextseason. See
STORAGE INSTRUCTIONS for additional information.
Never useengine or carburetorcleaner products in thefuel
tank or permanent damage may occur.
FIG. 4
FULt CHOKE POSITION
_, j-"_===CHOKE LEVER=_
,,'_"_. _%= _'_// NO Cf(C'KEPOSITION
]FIG, 5
TO START THE ENGINE
Unplug all electrical loads from generator receptacles
before starting the engine. Never start or stop the engine
with electrical devices plugged into panel receptacles and
turned on.
Start, store and fuel the unit in a level position.
Apply the choke (Fig. 5). Rotate choke lever to its FULL
CHOKE POSITION. If engine iswarm, close the choke
only part way or leave it fully open. A warm engine
needs less choking than a cold engine.
Check that the spark plug wire is connected to engine
spark plug. Also check that the Stop Switch next to
spark plug (if so equipped) isnot contacting the spark
plug (Fig 6).
Crank engine. Grasp the starter grip (Fig. 7) and pull
slowly until you feel some resistance. Let rope return
slowly. Then pull cord out with rapid full arm stroke. Let
rope return slowly. Do not let rope "snap back" against
starter. Repeat until engine starts.
When engine starts, move the choke to "1/2 CHOKE"
until engine runs smoothly, then to "NO CHOKE" posi-
tion as engine Warms up.
][_[G.6
FiG. 7
Letthe engine stabilize and warm upfor a few minutes.
Then plug in and turn on the desired electrical loads.
NOTE: Ifengine "hunts" or falters after starting, apply the
choke until the engine begins running smoothly. If engine
continues to hunt, you may need to adjust the carburetor.
See SERVICE AND ADJUSTMENTS on Page 10.
5
OPERATION
CONNECTING ELECTRICAL LOADS
• Use this generator to operate 120_240 volts, single
phase, 60 Hz, a-c lighting, appliance, tool and motor
loads.
DO NOT connect 240 volts to the 120 volts duplex
receptacles.
DO NOT connect any 3-phase loads to panel recep-
tacles.
DO NOT connect any 50 Hz loads to the generator.
Add up the rated watts of all lights, tool, appliance and
motor loads you are powering at one time. This total
should NOT be greater than (a) the generator's rated
wattage capacity, or (b) the circuitbreaker rating of the
receptacle supplying power. See "Don't Ovedoad the
Generator" on Page 7.
STOPPING THE ENGINE
ZDLE
CONTROL
SYSTEM
HG. 8
Unplug all electrical loads from the generator panel
receptacles. Never start or stop the engine with electri-
cal devices pluggedin and turned on.
Let the engine run at no-load for several minutes to
stabilize the internal temperatures of engine and gen-
erator.
Push Stop Switch (Fig. 7) against spark plug and hold
until engine has come to complete stop.
AUTOMATIC IDLE CONTROL
An Automatic Idle Control system provides greatly im-
provedluel economy by operating the unit at its normal high
governed speed only when electrical loads are plugged in
and turned on. The system consists of (a) an Idle Control
Circuit Board, (b) a Sensing Transformer, (c) an
Electromagnet, and (d) an Idle Control Switch (Fig. 8).
Idle Control Switch ON: Engine-generator runs at high
governed speed only when an electrical toad is connected
to the generator and turned on. When the electrical load is
disconnected, an Electromagnet is energized to pull the
engine throttle control against its idle stop. Engine then
runs at reduced (idle) speed.
Idle Control Switch OFF: The Electromagnet cannot be
energized, since its power circuit is open. Engine runs at
highgoverned speed (about 3600 rpm) whether load (s) are
connected or not.
The Idle Control System may be briefly described as fol-
tows:
Power voltage for Electromagnet operation is available
to the Idle Control Circuit Board, via Wires 11D and 22.
When an electrical load is not plugged in to panel
receptacles, no current flows through the Sensing
Transformer primary winding and no current flow is
present in the Transformer secondary winding. The
Idle Control Circuit Board then completes the circuitto
the Electromagnet, which energizes to pull the engine
throttle back against its idle stop. The .engine-gener-
ator runs at idle speed.
When an electrical load is plugged in, current flows
through the primary windings of the Sensing Trans-
former, to induce a current flow into the Transformer's
secondary windings..This current flow to the load is
"sensed" by the Idle Control Circuit Board, via Wires
155 and 156. Circuit board action then opens the
power circuit to the Electromagnet, which de-ener-
gizes. The engine governor then maintains engine
speed at about 3600 rpm.
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