Craftsman 580.32727 Portable Generator User Manual
Contents
1. Drawing No 99373 12 CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 PART NO 99369 95902 85652 143 53621 86292 75475 85651 22129 38150 91824 66365 F 91820 65791 24420 66825B 86308D 22264 66849 68759 77247 72092 91825 67451 51715 74908 86494 84242 DESCRIPTION ENGINE 5HP TECUMSEH 1 REQ BASE MOUNTING 1 REQ VIBRATION MOUNT ALT 2 REQ GROUND WIRE 1 REQ RE SELF DRILLER 10 SCREW PAN HD MACH M407 X 10 2 REQ MOUNT VIBRATION E NGINE LOCK WASHER M8 6 REG WASHER FLAT 8 2 REQ STATOR ASSEMBLY 1 REQ HOUSING ENGINE ADAPTOR 1 REQ ROTOR ASSEMBLY 1 REQ BEARING BALL 1 REQ BOLT ROTOR 5 16 24 x 6 25 1 REQ CARRIER REAR BEARING 1 REQ BOLT STATOR M6 1 00 x 85MM 4 RED LOCK WASHER NO 8 2 REQ SCREW TAP TITE M5 0 80 x 16mm 2 REO RECEPTACLE 120VOLTS AC 20A 1 REQ BREAKER CIRCUIT 20A 1 REQ PANEL RECEPTACLE 1 REQ BRUSH amp BRIDGE RECTIFIER 1 REQ FLAT WASHER ISPECIAL 1 REG NUT HEX M4 0 7 2 REQ SCREWITAPTITE M5 0 80 x 10mm 4 REQ SCREW M6 1 0 x 15 WING 1 REQ GROMMET RBC 2 REQ 13 iTEM 33 34 35 36 37 38 45 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 PART NO 86307 67022 45771 26850 22145 22769 93639 93728 99377 98247 97082 81895 97178 97912 989568 98956A 98955 87841 392532. LENGTH OF COVERAGE Sears warrants to the initial owner and each subsequent purchaser that the engine is free from defects in materials A and workmanship which cause the failure of a warranted per fora ponpe of two years 18
3. ha pere FERNEN 50 Hours or Every A eta et ATIO ee REN EEE vts p Pull 4 Kesi LE NUM M IUS EA I te Me a e tu ey A A ALPES D ervvevevrc re ro LIADA cet OS AMT FA EN te S NA Y Arbrit ker ROC nn EEE Qe eie QN MS bea oA Str A OA eA ate NEN A Sa SR AN heh N iie al fes mt A a E ee n C Eh QUK PN NEIN de CA PIER A BERN un n S OC ene TR A Rd Mte o N 55 RO EAE ARS HW vH TE n m A OR C d o Season 25 Hours or Every Prepare unit for storage if itis to rema x PIKE er dmi RR EEE VE EEE ae v 4 K r PN p EEE STERNE BEREITETE ED DERE an TIER a Na a RO EAE b ie BES e v e treat wie Every k gap Fig 9 to 0 030 inch 0 76mm Clean air filter by tapping it gently on s solid surface if the filter is too dirty replace it with a new one Dispose of the oil filter properly spar REDE Quem CANC VEG RI CPV MAINTENANCE OPERATION DN WP TER N aer iut ee x WESEN TE ET TINTEN m BERN AH sarta aot pp fy ir a al WA Ya N D E i NST ER N er SNNT ER n EUER Aa AS in Ae etd A ee ee ten tb nta et NEE ER RE veuve SAO ve OEIL nd Et NEN C he m oye why MRA Pata O
4. 1 4 20 x 1 1 4 Screw 7 req Fiywheei Key 1 req Fiywheel 1 req Belleville Washer 1req Fiywheel Nut 1 req Solid State Ignition 1 req Spark Plug Cover 1req Solid State Mounting Stud 2 req No 10 24 x 1 Torx Screw 2 req Ground Wire 1 req Low Oil Sensor 1 req Low Oil Indicator Light 1 reg Low Oil Sensor Gasket 1 req Torx T 25 10 24 x 5 8 Screw 4 req Cylinder Head Gasket 1 req a Cylinder Head 1 req Exhaust Valve Std inet 1511 1 req Exhaust Valve 1 32 OS incl 151 1 req 1 15 ITEM 126 130 130A 136 150 161 163 194 155 157 158 159 160 161 181A 173 178 182 184 185 203 204 207 215 223 261A 262 277 287 292 301 311 313 341 370A 3708 370C 370K 390 400 416 417 PART NO 29314B 29315C 650912 660999 34645 31872 31673 36649 650913 36624A 650914 36629 306026 36630A 651008 651012 650652 650451 26756 36631 36747 31342 650549 610973 36632 650821 36638 650451 36581 28820 27272A 36633 36046 36635 650886 650821 36701 36702 36812 651008 650821 651008 36641 651009 369858 30705 36812 36246 27625 36261 33107 36260 640017 590736 36716 650760 651013 REPAIR PARTS DESCRIPTION Std intake Valve 1 req 0 8 Intake Valve 1 req 5 16 18 x 1 1 2 Screw 7 req 5 16 18 x 2 41 64 Screw 1 req Spark Plug IRJ T7LM 1 req Valve Sprin
5. 2 SERVICE AND ADJUSTMENTS ENGINE SPEED CAUTION ENGINE SPEED WAS PROPERLY AD JUSTED AT THE FACTORY AND SHOULD RE QUIRE NO ADDITIONAL ADJUSTMENT DO NOT ATTEMPT TO CHANGE ENGINE SPEED IF YOU BELIEVE THE ENGINE iS RUNNING TOO FAST OR TOO SLOW TAKE YOUR GENERATOR TO AUTHORIZED SERVICE CENTER FOR REPAIR AND ADJUSTMENT CHANGING ENGINE GOV ERNED SPEED WILL VOID ENGINE WARRANTY Your generator 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 followng reasons e High engine speeds are dangerous and increase the risk of personal injury or damage to equipment e Lowengine speeds impose a heavy load on the engine when sufficient engine power is not available and may shorten engine life e The generator will supply correct rated AC frequency and voltage only atthe proper speed Some connected electrical devices could be damaged by incorrect fre quency and or voltage ADJUSTING THE CARBURETOR The carburetor of your generator setis presetat the factory DO NOT TAMPER WITH THE CARBURETOR as this wil void the warranty for the emission contol system If your generator is to be used at an altitude above 5 000 feet consult wth a Sears Authorized Service Facility regarding high altitude jetting changes STORAGE The generator should be started atleast once every seven days and
6. 52858 22246 25391 49808 91094 75402 99368 96049 99541 REPAIR PARTS DESCRIPTION CAPSCREW HEX HD 4 REQ 5 16 24 x 3 4 S GROMMET BEARING CARRIER 1 REQ M8 1 25 HEX NUT 6 REQ WASHER SHAKE PROOF M6 1 4 2 REQ FLAT WASHER M8 4 REQ WASHER SHAKE PROOF 10 1 REQ DECAL DANGER ENGLISH 1 REQ AXLE WHEEL 2 REQ DECAL LOGO 1 REQ DECAL CONTROL PANEL 1 REQ POSITIONER HANDLE 2 REG CAP PLUG 3 4 SQUARE 4 REQ KNOB HANDLE 2 REQ BOLT CARRIAGE 1 4 20 x 2 1 4 2REO LEG amp FOOT SUPPORT ASSEM LEFT SIDE 1 REQ LEG amp FOOT SUPPORT ASSEM RIGHT SIDE 1 REQ HANDLE 1 REQ VIBRATION en Ms 2 REQ SCREW HEX HD CAPSC M8 1 25 x 20 LONG 6 REQ NUT FLANGE M8 1 25 6 REQ LOCKWASHE R 5 8 2 REO NUT JAM 5 8 18 2 REQ WASHER FLAT M12 2 REQ WHEEL 8 DIA 2 REQ PUSH NUT 1 2 DIA 2 REQ PLATE ANTI SCRATCH AND WEAR 2 REQ DECAL 1 300 NUMBER 1 REG DECA PE INSTRUCTIONS Drawing No 99373 CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 REPAIR PARTS CRAFTSMAN 4 CYCLE ENGINE 143 965011 Drawing No 99625 KM CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 CRAFTSMAN 4 CYCLE ENGINE 143 965015 ITEM BR M S 2EBRSEBESSSERSEJUJOSOSZB5858A8 111A 112 113 119 120 125 SBURHEBENB PART NO 36768 26727 28277 30589 36618 36700 650548 36750 32600 36621 35541 35542 35543 3554 7A 35548A 35549 203
7. De LR S 5 IN ewe RI RER M Ed i pM IRSE RE a a DONE REO NND o TEE A teu to a Aa NM Reb KAAN E em PIA Qu ar ER ei th 39 C ER AES URN CEA mi a iw grs a ay SAP ANG NA A Ka A us Led MUEVE nea dit 5 a Sehnert de Oy VALE aM AM P 5 bn EEE Wi ee A AY dde dic he ANI eh ah aw NON AY NI kawahe E OR 0 n KAI ER tum NGA KAYAK n ao f3 Sut ANNAM P a a a Da in 2 0 SRO Nt i H EEE TEN fs CH KH Rene WY FS Be RR ROR RK u fi BANG KN EENE ta San OR Re ee a B LORS RN e PPS AP M CRGA We Na s Ta T oru Fr a Ve LA atta e RE RET REY SA KERN eM EA SE EEE NEE i E RE e d run better Replace with Cham lent type ieran iva il Air Filter to start eas RC J8 or equ Clean air cleaner cover then insert new paper filter into ervice cover and assemble to the base of the air cleaner REPLACE SPARK PLUG hange the spark plug every 100 hours of op engine once each year whichever comes first This wili heip your pion Replace or Clean Spark Plug Check Oil Level Change O Prepare Unit for Storage NOTE 1 To clean or replace air cleaner S C tor in high ambient temperature Clean more often when operating the unit under dirty or dusty conditions Change oil and oil filter after first 2 hours of operation and then every 50 hours thereafter Change sooner when operating under heavy load or in dusty or dirty environmen E NOTE
8. Welch Plug 1 req 632164 Fuel Fitting 1 req 48 631027 Weich Plug Atmospheric Vent 1 req 650417 Throttle Crack Adie Speed Screw 28 632019 Float 1req pris ido Re so 1 ewi n 29 631028 0 Ring Float Bow to body 1 req e Restrictor Screw rea 631867 Float Bow 1 req b ee gt inei No all ea SPIER 631024 Shaft Float 1 req Drawing No 99625 FOR CALIFORNIA RESIDENTS ONLY WHEN SEEKING SERVICE IN CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The Califomia Air Resources Board and Sears Roebuck and Co USA Sears are pleased to explain the emissions control system warranty on your 1995 and later lawn and garden equipment engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the State s stringent anti smog standards Sears must warrant the emission control system on your lawn and garden equipment engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your lawn and garden equipment engine Your emission control system includes parts such as the carburetor and the ignition system Where a warrantable condition exists Sears will repair your lawn and garden equipment engine at no cost to you Expenses covered under warranty include diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 1995 and later utility and lawn and garden equipment
9. for starting than for running This surge of power lasts only a fewseconds 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 sa x figure the running watts of all other connected oads e The GUIDE below is provided to assist vou in deter mining how many items your generator can operate at one time WATTAGE REFERENCE GUIDE RUNNING WATTS Air Conditioner 12 000 Btu 1700 Battery Charger 20 amp sese harana ERN Belt Sander O Tarraa tet d deus 1000 Chain Saw wee 1200 Circular Saw 6 1 2 sanieren COO tO T000 Coffee Maker s 1000 Compressor 1 HP kasan OO Compressor 3 4 HP A NEE IE 52 9 8 Compressor 1 2 HP aaa anae nanana rennes SAWO Curling iron EE NON end eddie AU Deep Freeze jaraan ia aan E eripe dons O Disce Sander ae 1200 Edge Timmer ccs naeh Electric Nail Gun esses 1200 _ Electric Range one element sanan tana anggana MODE Electric Skillet 0 eaaa san anaa teuer 1250 Furnace Fan 1 3 HP aaesaeeermasanenenasasannnanenenanenanena 1200 Hair Den NA PN a TA LADO Hand Drill 1 TEMPE uec EPIO Hand Drill 1127 Sob ATE REHASH REA EAE ZZ ANG ANNA AKA NABA b Bh TET E HE HEEEH AEE ZZ I Zu EE weke ean RES REKP PR AHAREESP PEERED
10. incl No 184 1 iod Rewind Starter 1 req Gasket Set 1 req Spark Arresting Screen and Cover foptionail 1req 86 32 x 3 8 Screw optional n req Washer 1 feq Drawing No 99625 CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 REPAIR PARTS CRAFTSMAN 4 CYCLE ENGINE 143 965015 Rewind Starter No 590736 ITEM PARTNO DESCRIPTION 5 1 590599A PIN SPRING included No 4 1 REQ 2 590600 WASHER 1 REQ 3 590696 RETAINER 1 REQ 4 590601 WASHER 1 REQ 5 590697 SPRING BRAKE 1 REQ 6 590698 DOG STARTER 2 REQ 7 590699 SPRING DOG 2 REQ B 8 590700 PULLEY AND REWIND SPRING ASSEMBLY 1 REQ 11 590687 HOUSING ASSEMBLY STARTER 1REQ 12 590535 ROPE STARTER 1 REQ u 13 590701 HANDLE ASSEMBLY STARTER 1 REQ Drawing No 99625 16 CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 CRAFTSMAN 4 CYCLE ENGINE 143 965015 REPAIR PARTS Carburetor No 640017 17 PARTNO DESCRIPTION ITEM PART NO DESCRIPTION 631615 Throttle Shaft and Lever Assembly 31 631022 Spring Clip 1 req 7 req u 35 36045 Primer Bulb retainer Ring 1 req 631767 Throttle Return Spring 1 req 368 5400719 Main Nozzle Tube 1 req 631184 Dust Seal Washer 1 req 37 632547 0 Ring Main Nozzle Tube 2 req 631183 Dust Seal throttle 1 req 40 640015 High Speed Bow Nut 1 req 631036 Throttle Shutter 1 req 44 27110 Bow Nut Washer 1 req 650506 Shutter Screw 1 req 47 630748 idie Mixture Well
11. unit Please read and retain this manual The instructions will enable you to assemble and maintain your generator prop erly Always observe the SAFETY RULES MODEL NUMBER 580 327270 SERIAL NUMBER DATE OF PURCHASE THE MODEL AND SERIAL NUMBERS WILL BE FOUND ON A DECAL ATTACHED 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 Agreementis available on this prod uct Contact your nearest Sears store for details CUSTOMER RESPONSIBILITIES Read and observe the safety rules Followregular schedule in maintaining caring for and using your generator Followthe instructions under Maintenance and Stor age sections of this Owner s Manual PRODUCT SPECIFICATIONS Generator Specifications RATED MAXIMUM POWER 2500 Watts 2 5 kW RATED VOLTAGE 120 Volts a c RATED MAXIMUM LOAD CURRENT RATED FREQUE NCY PHASE 20 8 a c amperes 50 Hz at 3600 Single Phase Engine Specifications RATED HORESPOWER 5 at 3600 rpm i DISPLACEMENT 10 49 cu in 172cc SPARK PLUG Type Champion RJ 8C or or equivalent 0 030 inch 0 76mm 3 U S quarts SAE 30 oil Set Gap to GASOLINE CAPACITY OIL 1 1 4 U S pints In the State of California a spark arrestor is required by law Section 4442 of the California Public Resources Code Other states
12. 0 MAINTENANCE ONE TROP 7 8 EMISSIONS WARRANTY sasada gedang enue 02 SERVICE AND ADJUSTME NTS ass 9 10 PARTS ORDERING nennen BACK COVER G m Air Cleaner 7 8 Gasoline eese 5 Safety Rules inside cover Assembly x 4 3 du 4 l Grounding Wing Screw eed 4 Service and Adjustments Carbureibr ios ase Ex xs 9 B m e Engine Speed uuuu 9 Service Recommendations 9 Before Starting 4 Lubrication 5 7 Specifications 1 Starting Engine 5 M Stopping Engine 6 Sorge nee 9 zx us Maintenance Agreement llle 1 T Carburetor ee oa eee a CE die 9 Cleaning generator nn RR 7 P Circuit Breakers 5 6 Engine maintenance 7 Troubleshooting 10 Cord Sets esses 9 General Recommendations 7 Customer Responsibilites 1 Generator Maintenance 7 We EN ee O Warranty l PAWS E sake EE ET 1 Engine Oil Level lt 5 7 Emission Control 18 19 Carburetor adjustment aset t n 9 Operation iron acd aah ciet qe 3 6 Wattage Reference Guide 8 Gi lgual ur rer 7 x Overloading Deu LER 2 68 Wiring Diagram 11 SUBBU oie sak eee 9 Electrical Loads 5 ER eT Parts repair 6 05 12 20 OPERATION KNOW YOUR GENERATOR READ THIS OWNER S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR GE
13. 81 32875A 32610A 35616 36611 36620 36623 650378 30200 36624 36761 27642 28460 30574A 30590A 30591 36057 650488 610961 611205 650815 650816 34443A 610118 651007 650814 36767 611207 611212 35967 650950 36738 36739 36471 36472 DESCRIPTION Cylinder includes 2 20 72 amp 125 1 reg Dowel Pin 2 req Washer 1 req Governor Rod Governor Lever 7 req Governor Lever Clamp 1 req No 8 32 x 5 16 Hex Screw 1 req Extension Spring 1 req Oil Seal 1 req Air Baffler 1 req Air Baffle 1 req 510 24 x 9 16 Screw 2 req Crankshaft 1 req Screw 10 32 x 3 4 1 req Lock Washer 1 req Lock Nut 410 32 Treq Retaining Ring 1 req Piston Pin amp Ring Set iStd Piston Pin amp Ring Set 0 01 O S Piston Pin amp Ring Set 0 02 O S Piston amp Pin Assy ISTD Piston amp Pin Asay 0 01 0 5 Piston amp Pin Assy 0 02 05 Piston Ring Set STD Piston Ring Set 0 01 0 5 Piston Ring Set 0 02 0 8 Piston Pin Retaining Ring 1 req Connecting Rod Assy 1 req Connecting Rod Bolt 1 req Valve Lifter 4 req Oil Dipper 1 req Camshaft BCR 1 req Blower Housing Ext 1 req Screw 1 4 20 x 5 8 1 req No 10 24 x 9 16 Screw 1 rag Cylinder Cover Gasket 1 req Gyliner Cover Assy 7 req Oil Drain Plug 2 req Oil Seal f req Governor Shaft 1 req Flat Washer 1req Governor Gear 1 req incl No 8 Governor Spool 11 reg
14. AE Wd M EEE EAEE SERIE EEE hahah baita SHADER ZZ SALE ZU ZZ ZZ ZU ZZ a Hand Drill 1 EEE 4 DZ Inn B3 S dk HE EUR E HN N b 9 29499644x R 49 537t amp 250 i ledge Frimmer BE ET RI A A KN EOE ED PORE HRD SHER HAE OE 750 to 1000 Hand Drill 3 8 bb kih Foae ee TELESERIES Stee ae aeeeze a En eh es 500 I elevision tek EEO EERE bh babak bh b bah t HD 450 RUNNING WATTS Jet Pump me 8 Laut MOWBP 4 eo une Le Light BID nous Vase FOO Microwave Oven ae FOO Milk Cooler 1100 Oil Burner on Furnace uesssemssssnosnsasssunsnsensonnneensnsunennn TOG Cil Fired Space Heater 140 000 Btu sss 400 Oil Fired Space Heater 85 000 Btu s 225 Cil Fired Space Heater 30 000 Btu areeresernsssnennannnneen DO Paint Sprayer Airless 1 3 HP 600 Paint Sprayer Airless handheld 150 Nager keine BONO 200 EETEREEFTTREEEBEFSEREFTEAR REES TED AK EK RE HR T A AN BA b d EAE EZ U EZ etkhtittht ktkk5 7 5 efrigerator FE TECH RS EE TE 4 b A EERE AVES WE 6 AE DEE ER ER EE CHEER RO TR IE RN 600 Slow COOK eb ce nen ee DON Submersible Pump 1 1 2 HP 2800 Submersible Pump 1 HP 2000 Submersible Pump 1 2 HP 1500 Table Sawi 109 271750 to 2000 cumsan 200 to 500 Weed 500 eecettr REt Pt QeO REP NABDA TANGEN GA Allow 2 1 21 times the ised watts for sta
15. NERATOR Compare the illustrations with your generator to familiarize yourself with the locations of various controls and adjustments Save this manual for future reference GUIDE HANDLE CIRCUIT BREAKER DUPLEX RECEPTACLES 120 VOLTS DUPLEX RECEPTACLES May be used to supply electrical power for the operation of 120 volts at 20 amps a c single phase 60 Hz a c electrical lighting applicance tool and motor loads RECOIL STARTER Used for starting the engine manu ally FUEL TANK Tank holds three U S quarts of unleaded gasoline FUEL TANK 5 H P ENGINE MUFFLER AIR CLEANER PRIMER SWITCH CARBURETOR 20 AMP A C CIRCUIT BREAKER Protects the gener ator against electrical overload Breaker is push to reset type AIR CLEANER Filters intake air as itis drawn through the engine 5 H P NGINE Provides the power needed to generate 2400 watts of AC output EE bo OPERATION Your a c generator was completely assembied at the fac tory Itis ready for use after it has been prop tly serviced with the recommended ash oil and fuel EI eh Nm nd OF YOUR GENERATOR PLEASE CALL THE GENER ATOR HELPLINE AT 1 800 222 3136 IMPORTANT ANY ATTEMPT 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 Setthe carton on a flat rigid surface with T ne SIDE UP arrows poi
16. RATOR AND MAY ALSO RESULT IN INJURY OR DEATH TO ELECTRIC UTILITY WORKERS DUE TO BACKFEED OF ELECTRI CAL ENERGY This generator supplies dangerously high electrical voltages Use care to preventextremely 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 while hands or feetare wet Dangerous electrical shock will result The spark arrestor muffler can become extremely hot DO NOT operate this equipmentin areas where combustible material such as grass leaves or paper products can come in contact wth the muffler Maintain all wring extension cords etc in good condition Worn bare frayed or otherwise dam aged wring 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 gen erator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the unit See ASSEMBLY sec tion for more grounding information _ Wire gauge sizes of wring and cord sets must be large enough to handle the maximum electrical load to which they will be subjected Most devices re _ quire cord sets rated 125 AC volts at 20 to 30 amperes or 250 AC volts at 20 amps or greater Some devices may require a higher or lower rating Refer to the Ow
17. SEARS OWNER S MANUAL MODEL NO 580 327270 PORTABLE GENERATOR 7 my CUSTOMER m duo X 3 G M anc 2 A tr 120 VOLT 2500 WATT A C GENERATOR 1 800 222 3136 HOURS e Assembly Mon i E to 5 p m Operation Customer Responsibilities CAUTION un Read and Follow i e Service and Adjustment and instructions Before Operating This Equipment Repair Parts SEARS ROEBUCK and CO Hoffman Estates IL 60179 USA Part No 99372 Revision 1 4 2 96 SAFETY RULES CAUTION ALWAYS DISCONNECT SPARK PLUG WIRE AND PLACE WIRE WHERE IT CANNOT CON TACT SPARK PLUG TO PREVENT ACCIDENTAL STARTING WHEN SETTING UP TRANSPOREING 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 AND OR COOLING VENTILATION WILL ELIMINATE THE DANGER If this unit is used for backup power in the event of a utility power failure take the following steps BE FORE CONNECTING THE GENERATOR TO AN ELECTRICAL SYSTEM OPEN THE MAIN CIR CUIT BREAKER OR MAIN SWITCH SERVING THE SYSTEM TO ISOLATE THE GENERATOR SYSTEM FROM THE ELECTRIC UTILITY FAIL ff URE TO ISOLATE THE GENERATOR AND UTIL ITY SYSTEMS MAY RESULT IN DAMAGE TO THE GENE
18. allowed to run atleast 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 prepare it for storage STORAGE INSTRUCTIONS WARNING NEVER STORE ENGINE WITH FUEL IN THE TANK INDOORS OR IN ENCLOSED POORLY VENTILATED AREAS WHERE FUMES CAN REACH AN OPEN FLAME SPARK OR PILOT LIGHT AS ON A FURNACE WATER HEATER CLOTHES DRYER OR OTHER GAS FURNACE ENGINE Run engine for about five minutes to warm it NOTE If you did use gasohol drain fuel tank then run engine until engine stops from lack of fuel WARNING DRAIN FUEL INTO APPROVED CON TAINER OUTDOORS AWAY FROM OPEN FLAME BE SURE ENGINE IS COOL NOTE Using a fuel additive such as Sears Craftsman Fuel Stabilizer or an equivalent will prevent gum deposits from forming in the generator s fuel system e While engine is still warm drain oil from crankcase Refill wth fresh oil See BEFORE STARTING EN GINE on Page 5 for oil recommendations e Remove spark plug and pour about 1 ounce 30mi of engine oil into cylinder Crank slowly to distribute oil CAUTION AVOID SPRAY FROM SPARK PLUG HOLE WHEN CRANKING ENGINE SLOWLY e Install spark plug Do not connect spark plug wre Clean dirt oil and grease from cylinder cylinder head fins blower housing rotating screen and muffler area GENERATOR e Clean the generator as outlined on Page 7 To Clean the Generator e C
19. elp 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 IF YOU HAVE ANY PROBLEMS OPERATING YOUR GENERATOR PLEASE CALL THE GENERATOR HELPLINE AT 1 800 222 3136 BEFORE STARTING ENGINE Add Oil Place generator on a level surface and remove oil fill plug Fill wth SAE 30 detergent oil to point of overflowing for oil fill plug Fig 3 POUR SLOWLY DO NOT OVERFILL Oil capacity of engine is 21 ounces 62 Liters or 1 1 4 U S N FiG 3 Whenoilsumpis full install and tighten oil fill plug Use no special additives with recommended oils OIL FILL PLUG OPERATION NOTE Use of muiti viscosity oils above 40F 4T will resultin high oil consumption and possible engine damage Use 5W 30 nen Operating aio generator in weather below 32T NOTE When adding oil to the engine crankcase in the future use only high quality detergent oil rated with API service classification SF SG or SH rated SAE 30 weight Select the oil s viscosity grade according to your expected operating temperature Although multi viscosity oils 5W30 improve starting in cold weather these mult viscosity oils will result in in colder creased oil consumption when used above 32 F Check your engine oil level more frequently to avoid possible dama
20. engines are warranted for two years If any emission related part on your engine as listed below is defective the part will be repaired or replaced by Sears OWNER S WARRANTY RESPONSIBILITIES As the lawn and garden equipment engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual Sears recommends that you retain all receipts covering maintenance on your lawn and garden equipment engine but Sears cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the lawn and garden equipment engine owner you should be aware that Sears may deny you warranty coverage if your lawn and garden equipment engine or a part of it has failed due to abuse neglect improper maintenance unapproved modifications or the use of parts not made or approved by the original equipment manufacturer You are responsible for presenting your lawn and garden equipment engine to a Sears authorized repair center as soon as a problem exists Warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you shouid contact your nearest authorized service center or call Sears at 1 800 473 7247 WARRANTY COMMENCEMENT DATE The warranty period begins on the date the lawn and garden equipment engine is delivered to the original end use purchaser
21. evel Install and tighten oil fill plug SERVICE AIR CLEANER Your engine wil not run properly and may be damaged if you run it using a dirty air cleaner Clean or replace the air cleaner paper filter Fig 8 once every 100 hours of operation or once a year whichever comes first Clean or replace more often if operating under dusty or dirty conditions FIG 8 CAUTION NEVER RUN THIS UNIT WITHOUT THE COMPLETE AIR CLEANER SYSTEM INSTALLED ON THE ENGINE THIS COULD RESULT IN PRE MATURE WEAR TO THE ENGINE MAINTENANCE gt CETERI Y ch AN AN ony Des TS a 5 j PA e S v Si e a y E ie P E s 7 e e 5 x 20 te y 2 ta n Zur eK Yah ate b 21 MA gt Ns Maura va e XE Hi 4 S o vae 5 3 255 us 62 ee o gt n r t o 2 E AN s 9 Arty ons MR Caen ae tah state Jj C2 e o S a atu d NG x e EN Fe X ety win WA n Er 9 R x RAY EAIN a y Ta e Season 5 n KR rx z AG ys e X REN Een ya ys jan CL d LAE ad Rag grata nA n O6 EIS es a yes BR OR tae DO x5 taf P ta t e n 5 es r re M X n a e o i
22. g 2 req Lower Valve Spring Cap i2 req Push Rod Guide 1 req Hocker Arm Stud 2 req Rocker Arm i2 req 1 4 28 Nutt2Z reg Push Rod 2 req Rocker Arm Cover Gasket 1 reg Rocker Arm Cover i rad 147 20 x 31 64 Screw 2 req Stud f2 req i Breather Tube t reg 1 47 20 Nut 2 req 1 4 20 x 1 Screw 2 req Carburetor Gasket 1req Intake Pipe 1req Control Bracket Assembly 1 req Compression Spring 1 reg 5 40 x 7 16 Screw 1 req Terminal Assembly 1 req Throttle Link 1 req 10 32 x 1 2 Screw 2 req Control Knob 1 req 5 16 18 x 1 Screw 2 req intake Pipe Gasket 1re4 10 32 x 1 2 Screw I2 req Air Cleaner Gasket 1re4 Air Cleaner Body incl 239 1 raa Air Cleaner Filter 1 req Air Cleaner Cover 1 req Wing Nut 1 req 10 32 x 1 2 Screw 1 req Compression Release 1 rag Compression Release Spring 1 req Fuel Tank amp Blower Housing 1 req 144 20 x 31 61 Screw 1 req 810 32 x 1 2 Screw 1 req 1 4 20 x 31 64 Screw 2 req Muffler 1 req 1 4 20 x 2 9 32 Screw 2 req Starter Cup 1 raa Rivet can be purchased focally Fuel Line 1 req Fuel Line Ciamp 1 req Fuel Tank amp Blower Housing 1 req Fuel Cap 1 req Oil Fill Plug 1 req Spacer T req Wire Clip 1 req Fuel Tank Bracket 1 req Lubrication Decal 1 req Control Decal 1 rag Primer Decal 1 req Starter Decal 1 req Carburetor
23. ge from runnign low on oil Oil sump capacity is 21 ounces 62 Liters or 1 1 4 U S pin s Add Gasoline e Fill fuel tank with clean fresh UNLEADED gasoline Leaded regular grade gasoline may also be used DO NOT USE PREMIUM GASOLINE DO NOT MIX OIL WTH GASOLINE BE CAREFUL NOT TO OVERFILL FUEL TANK Allow about 1 4 inch of tank space for expansion IMPORTANT EXPERIENCE INDICATES THAT ALCO HOL BLENDED FUELS CALLED GASOHOL CAN AT TRACT 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 WHEN USING GASOHOL EMPTY THE FUEL SYSTEM BEFORE STORAGE PERIODS OF 30 DAYS OR LONGER DRAIN THE GAS TANK START THE ENGINE AND LET IT RUN UNTIL THE FUEL LINES AND CARBURETOR ARE EMPTY USE FRESH FUEL NEXT SEASON SEE STORAGE INSTRUCTIONS FOR ADDITIONAL INFORMATION NEVER USE ENGINE OR CARBURETOR CLEANER PRODUCTS IN THE FUEL TANK OR PERMANENT DAMAGE MAY OCCUR NOTE DO NOTUSE GASOLINE CONTAINING METHA NOL WOOD ALCOHOL You can use gasolines contain ing 1096 ethanol or grain alcohol See STORAGE IN STRUCTIONS for more information i TO START THE ENGINE Unpiug ail electrical loads from generator receptacles be fore starting the engine Never start or stop engine with electrical devices plugged into panel DEREN and turned on e Move engine control lever to START position Fig 4 e Press the primer bulb
24. generator s rated watt age capacity or b circuit breaker rating of the recep tacle supplying power See Don t Overload the Gen erator on Page 6 OPERATION STOPPING THE ENGINE Unplug all electrical loads from generator panel recep tacles Never start or stop engine with electrical de vices plugged i in and turned on e Letengine run at no load for several minutes to stabi lize the internal temperatures of engine and generator Move Stop lever to OFF position DON T OVERLOAD THE GENERATOR This generator is equipped with one 20 amp circuit breaker The duplex receptacle is protected against elec trical overload with the 20 amp breaker Overloading a generator in excess ofits rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the following to prevent overioading the unit e Add up the wal wattage of all electrical devices to be connected at one time This total should NOT be greater than the generator s wattage capacity e 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 e ifthe appliance tool or motor does not give wattage multiply 120 volts times ampere rating to dete e watts volts x amps watts e Some electric motors such as induction types re fe about two and a half times more watts of power
25. heck that cooling air slots and openings on generator are open and unobstructed OTHER STORAGE TIPS e Do not store gasoline from one season to another e Replace your gasoline can if it starts to rust Rust and or dirt in your gasoline can cause probiems when you use tt with this unit e Store in clean and dry area DANGER STORAGE COVER IS FLAMMABLE DO NOT PLACE THE STORAGE COVER OVER A HOT GENERATOR LET THE UNIT COOL FOR A SUFFI CIENT TIME BEFORE PLACING THE COVER ON THE UNIT iF YOU PLACE THE COVER ON THE UNIT BEFORE GENERATOR IS COOL THE COVER COULD START ON FIRE TROUBLESHOOTING POINTS PROBLEM Engine is running butno CAUSE One of the circuit breakers is open _CORRECTION Reset circuit breaker AC outputis available Faultin generator 2 Contact Sears Service Department Poor connection or defective 3 Check and repair cord set Connected device is bad 4 Connect anather device that is z in good condition Engine runs good at no load but bogs Short circuit in a connected load 1 Disconnect shorted electrical load down when loads are connected Engine speed is too slow 2 Contact Sears Service Department Run Stop Switch setto STOP intake valve stuck open or closed Engine compression lost Failed battery Generator is overloaded 3 See Don t Overload the Generator on Page 10 Shorted generator circuit 4 Contact Sears Service Department Engine wil no
26. may have similar laws Federal laws apply on federal lands NOTE If you equip your generator with a spark arrestor muffler the spark arrestor must be maintained in effective working order by the owner operator You can order a spark arrestor muffler through your Sears Service Center FULL TWO YEAR WARRANTY For two years from the date of purchase Sears will repair any defect in material or workmanship in this generator atno 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 the generator to the nearest SEARS SERVICE CENTER DEPART MENT 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 Department 817 WA Hoffman Estates IL 60179 TABLE OF CONTENTS SAFETY RULES nen secugeeeaconeneess INSIDE COVER SERVICE RECOMMENDATIONS sessapangoasnnsenansansnnnen 10 MAINTENANGE AGREEMENT BEE E E ka Prayer retest ity TE STORAGE ATTI TTTTTTTT KA ross C eneteconas TP E TII ees uses ee don aa 1 PRODUCT SPECIFICATIONS eese anana aane 1 TROUBLESHOOTING POINTS PNI Tagen RR SDR 12 WARRANTY ccsssonssannenssennnnn sen Bossa 1 WIRING DIAGRAM E OPERATION jaan aranana aaa mn de REPAIR PARTS eeesseeresssnssssunsssesssrsionansensusssunssensusesuns 142
27. ner s manual of the electrical device for the manufacturer s recommendations Cord sets that are too small in diameter or too long will overheat become damaged and may cause prop erty damage and or electrical shock The generator engine consumes oxygen Sn gives Off DEADLY carbon monoxide gas through its ex E haust system This dangerous gas if breathed in sufficient concentrations can cause unconscious ness or even death Operate this equipment out doors only in well ventilated areas where exhaust gases cannot accumulate and endanger people or animals The angin exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 heatin the vicinity while handling gasoline Avoid spilling gasoline 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 fili fuel tank completely full Allowroom at top of tank for fuel expansion or fuel may expand and overflow 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
28. nting upward Carefully open the top flaps of shipping carton Cutdown corners atone end of shipping carton and lay that side of carton down flat e Remove packing material carton fillers etc e Remove generator from shipping carton TO ADJUST GUIDE HANDLE Your generator is equipped with a wheel kit for easy manuevering After you remove the generator from the carton you complete the following tasks to Risa to gener ator for use e Loosen knobs of the guide handle as shown in Fig 1 e Raise the guide handle as also shown in Fig 1 and tighten the knobs to hold the handie in place FIG 1 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 control panel Fig 2 Generally connecting a No 12 AWG American Wire Gauge stranded copper wire to E fa Er WING SCREW the grounding lug and to an earth driven copper or brass grounding rod electrode provides adequate protection against electrical shock Fig 2 may vary widely Consult with a local electrician for grounding requirements in your area However locat ian d 12 AWG STRANDED COPPER WIRE _ ye GROUNDING ROD FIG 2 Proper grounding of generator will h
29. 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 re ceive the unit Excessively high engine speeds may resultin injury or damage equipment DO NOT use the unitifithas been damaged Repair or replace all damaged or defective a before you run the unit DO NOT permit children to ED 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 MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED CONGRATULATIONS on your purchase ofa Sears Crafts man Generator It has been designed engineered and manufactured to give you the best possible dependability and performance Should you experience any problem you cannot easily remedy please contact your nearest Sears Service Cen ter Department or call the 1 800 number listed in this man ual We have competent well trained technicians and the proper tools to service or repair this
30. ow pressure air not to exceed 25 psi may be used to blowaway dirt Inspect cooling air slots and opening on the generator These openings must be dirt clean and unobstructed A CAUTION NEVER INSERT ANY OBJECTOR TOOL THROUGH THE AJR COOLING SLOTS EVEN IF THE ENGINE IS NOT RUNNING DAMAGE TO THE UNIT OR PERSONAL INJURY MAY RESULT ENGINE MAINTENANCE CHECKING OIL LEVEL See OPERATION section on Page 4 for information on checking oil level Oil level should be checked before each use or atleastevery five hours of operation Keep oil level maintained CHANGING OIL Change oil after first 2 hours of operation change oil every 50 hours thereafter if you are using your generator under dirty or dusty conditions or in extremely hot weather change oil more often CAUTION DISCONNECT SPARK PLUG WIRE FROM SPARK PLUG AND KEEP IT AWAY FROM SPARK PLUG DO THIS EVERY TIME YOU PER FORM ANY MAINTENANCE ON THE ENGINE OR THE GENERATOR Change oil while engine is sull warm Dom funning A se follows e Clean area around oil drain Blocs remove ipio Fig 7 and drain oil completely into a suitable container When oil has drained install and tighten oil drain plug FIG 7 e Remove oil fill plug and insert a clean fill funnel into plug opening Fill engine crankcase with recom mended oil until oil level is at point of overflowing About 21 ounces is required POUR SLOWLY e When engine crankcase is filled to proper l
31. rting Br vices MAINTENANCE GENERAL RECOMMENDATIONS The Owner Operator i is responsible for making sure thatall 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 dam aged or defective generator GENERATOR MAINTENANCE Generator maintenance consists of keeping the unit clean and dry Operate and store the unitin a clean dry environ ment where it wil 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 oil moisture or other foreign substances are visible on its exterior surface NOTE We DO NOT recommendid using a garden hose to clean the generator Water can enter the engine fuel System and cause problems In addition if water enters the generator through cooling air slots some of the water will be retained in voids and cracks of the rotor and stator winding insulation Water and dirtbuild up on the generator internal windings will eventually decrease the insulation resistance of these windings TO CLEAN THE GENERATOR e Use a damp cloth to wipe exterior surfaces clean Use a soft bristle brush to loosen caked on dirt oil etc e A vacuum cleaner may be used to pick up loose dirt and debris e L
32. t start or starts 1 Set switch to RUN and runs rough Dirty air cleaner 2 Clean or replace air cleaner Out of gasoline 3 Fill fuel tank Stale gasoline 4 Drain gas tank fill with fresh fuel Spark plug wre not connected 5 Connect wire to spark plug to spark plug Bad spark plug 6 Replace spark plug Water in gasoline 7 Drain gas tank fill with fresh fuel Overchoking 8 Open choke fully and crank engine Excessively rich fuel mixture 9 Contact Sears Service Department Intake valve stuck open or closed 10 Contact Sears Service Departmen Engine has lost compression 11 Contact Sears Service Deparment Contact Sears Service Department Contact Sears Service Department Replace battery Engine shuts down during operation Out of gasoline 1 Fill fuel tank Low oil level 2 Fill crankcase to proper level Engine lacks power Load is too high 1 See Don t Overload the Generator on Page 10 Dirty air filter 2 Replace air filter Carburetor is running too rich Contact Sears Service Department Engine hunts or falters 5 or too lean 10 WIRING DIAGRAM CRAFTSMAN 2500 WATT DELUXE AC GENERATOR 580 327270 034 arid OSNINV3H OL 1839010 HSN 3AlLISOd SION 4 A _ Ho voc T3NYd NO M3HOS Oi c AVEOVIC ONIS m c ce ry 3341939 390188 QJUuvW3HOS Drawing No 93438 11 CRAFTSMAN 2500 WATT A C GENERATOR 580 327270 REPAIR PARTS
33. te i NA lt PL y PN gt gt e 00 Hours or Ever EN x5 P e Y r on one KRJ AN Ex o6 A aha afa m m N ee AUR don a co 4 Y Na hes Y y is d Ex e d e A A e tte a wee Med Vu 5 t M i e ba m Ae teh aia 4 r d 4 a ne A 4 eK PER N AN A m s H oes NDA RS LAN us MN s y fios o O AH has 0 a Ni A a y Ans s S yn eN P A o x ip AS NO Qut wi In NS KAP os eot y AN aeta hee des em Sy on a a n ci i n Cte A PR y ND 5 i WA te wy v 5 Mte Er A t ws ase x eas a 7 5 v s 2 5 rA As t y oo M r Y A e t e A Le mu et Site QUA gt 6 KG ie fus un s a 4 C E C PN Ne Re tet ee 17 e 2 e FEELER GAUGE i a N n o P A Pes aS y I RO NS vt w v rt gt s A oO A N P e i on Ye arene z 22 v i x t ue e PUR rae m F NGA ome UN y HAM A urn A S o 4 os re 2 Vl m ie die for more than 30 da See Note 1 et ed eats YON in i Li 0 030 k
34. three times Wait 2 seconds each time you press the primer NOTE The primer may be heeded to restarta warm engine after a short shutdown e Grasp starter grip and pull slowy until you feel some resistance Let rope return slowly Then pull cord out with rapid fulliarm stroke Letrope return siowy Do not let rope snap back against starter FiG 5 FiG 4 120 VOLT CORD SETS Use oniy high quality well insulated extension cords with the generator s 120 volt duplex type electrical receptacles Fig 6 Check the ratings of all extension cords before you use them Extension cord sets used should be rated 125 volts at 20 a c amps or greater for most electrical devices Some devices however may not require this type of ex tension cord Check the owner s manuais of those devices for the manufacturer s recommendations Keep extension cords as shortas possible preferably less than 15 feet long to prevent voltage drop and possible overheating of wires FIG 6 CONNECTING ELECTRICAL LOADS e Use this generator to operate 120 voit single phase 60 Hz a c lighting appliance tool and motor loads e DO NOT connect 240 volts to 120 volts duplex outlets e de NOT connect any 3 phase loads to pane recepta cles e DO NOT connect any 50 Hz loads to the generator e Add up rated watts of all lights tool appliance and motor loads you are powering at one time This total should NOT be greater than a
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