COMPANION 580.327112 Owner's manual

Brand: COMPANION

Model: 580.327112

Category: Power generators

Type: Owner's manual

This manual is also suitable for

580327112

SE/AR_Owner's Manual

C OMPANION I

5000 Watt

A-C Generator

Model No.

580.327112

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.

Part No. B3051 .Draft 0 (7/23/98)

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

SAFETY RULES ............................ 3

TROUBLESHOOTING ....................... 13

WIRING DIAGRAM ......................... 15

ASSEMBLY ................................ 4 REPLACEMENT PARTS .................. 16-22

OPERATION ......................... t.y_3_ _J EMISSIONS WARRANTY ................. 24-25

PRODUCT SPECIFICATIONS .......... {'__i' " ,.10 HOW TO ORDER PARTS ............ BACK PAGE

MAINTENANCE "_.":.":.":',._., ._. ,'T_:',. :_i 'Jl'O.:li

STORAGE -..; .:: .:-::-:-:::-:' ::":":_ .... _!!i:i;.12

'' L'iMi'TED ONE YEAR WARRANTY FOR COMPANION GENERATORS

SEARS warrants tO the Originalpurcl_aser that the alternator and engine for its portable generator will

be free from defects in materials or workmanship for the items and period set forth below from the

date of original purchase. This warranty is not transferable.

CONSUMER* COMMERCIAL*

Alternator 1 year 90 Days

Engine 1 year 90 Days

"NOTE: For the purpose of this warranty "Consumer Use" means personal residential householdand

emergency use by original purchaser, not to be used as a primary source of power. "Commercial Use"

means all other uses, includingrental, construction,commercial, and income producingpurposes. Once

a generator has experienced commercial use, it shall thereafter be considered a commercial use

generator for the purpose of this warranty.

During said warranty period, SEARS will, at its option, repair or replace any part which, upon

examination by SEARS, isfound to be defective under normal use and service**. Starting batteries

are not warranted by SEARS. All transportation costs under warranty, including returnto the factory if

necessary, are to be borne by the purchaser and prepaid by him. This warranty does not cover

normal maintenance and service and does not apply to a generator set, alternator or engine, or parts

which have been subjected to improper or unauthorized installation or alteration, misuse, negligence,

accident, overloading, overspeeding, improper maintenance, repair or storage so as, in SEARS'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 IS NO OTHER EXPRESS WARRANTY. SEARS HEREBY DISCLAIMS ANY AND ALL

IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE

DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE 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 provinces do not allow limitationson how long an implied warranty lasts, or

the exclusion or limitationof incidental or consequential damages, so the abovelimitations or

exclusions may not apply to you. This warranty gives you specific legal rights and you may also have

other rights,which vary from state to state.

For service, see your nearest SEARS authorized warranty service facility. Warranty service can be

performed only by a SEARS authorized service facility. This warranty will not apply to service at any

other facility. At the time of requesting warranty service, evidence of original purchase date must be

)resented.

SEARS, ROEBUCK and CO., DI817WA, Hoffman Estates, IL 60179 U.S.A.

CAUTION: Always disconnect spark plug

wire and place the wire where it cannot

contact the spark plug. To prevent

accidental starting when setting up,

transporting, adjusting or making repairs

to your Generator.

DANGER: This generator is designed for

outdoor use only. Do not use this

generator inside any building or

enclosure including the generator

compartment of a recreational vehicle

(RV). Fire or an explosion may result. No

user performed modifications, including

venting of exhaust and/or cooling

ventilation, will eliminate the danger.

Also, allow at least two feet of clearance

on all sides of the generator even while

operating the unit outdoors.

CAUTION: Before using this product,

read this manual and follow all Safety

Rules and Operating Instructions.

• The generator produces dangerouslyhighvoltage

that can cause extremely hazardous electricalshock.

Avoidcontact with bare wires, terminals,etc. Never

permitany unqualified person to operate or service

the generator.

• Never handle any kindof electrical cordor device

while standingin water, while barefoot or while hands

or feet are wet.

• The National ElectricCode requiresthe frame and

externalelectricallyconductiveparts of generatorbe

properlyconnected to an approved earth ground.

Local electrical codes may also requireproper

groundingof the generator. Consultwith a local

electricianfor groundingrequirements inyour area.

• Use a ground fault circuitinterrupterin any damp or

highlyconductivearea (such as metal deckingor

steel work).

• Do not use any worn, bare, frayed or otherwisedam-

aged electrical cordsets with the generator.

• Operate generator only on level surfaces and where

it willnot be exposed to excessive moisture,dirt, dust

or corrosivevapors.

• Gasoline is highlyFLAMMABLE and itsvapors are

EXPLOSIVE. Do not permit smoking,open flames,

sparks or heat in the vicinitywhilehandlinggasoline.

Avoid spillinggasolineon a hot engine. Complywith

all laws regulatingstorage and handlingof gasoline.

• Never add fuel whileunit is running.

• Do not overfillthe fuel tank. Alwaysallow roomfor

fuel expansion. Iftank isoverfilled,fuel can overflow

ontoa hotengine and cause FIRE or an EXPLO-

SION.

• Never store generatorwith fuel in tank where gaso-

linevapors mightreach an openflame or spark or

pilotlight (as on a furnace, water heater or clothes

dryer). FIRE oran EXPLOSION mightresult.

• Generator exhaust gases contain DEADLY carbon

monoxidegas. Operate this equipmentonlyin the

open air where adequate ventilationisavailable.

• The engine-generatorrequiresan adequate flow of

coolingair for its continuedproperoperation. Never

operatethe unitinsideany roomor enclosurewhere

the free flow of cooling air intoand out of the unit

mightbe obstructed.Allowat least2 feet ofclearance

onall sidesofgenerator,evenwhileoperatingunitout-

doors,oryou coulddamage the unit.

• Never start, or stop,the engine-generatorwith electri-

cal loadsconnected to receptacleswith the connect-

ed devices tumed ON. Start the engine and let itsta-

bilizebefore connectingelectrical loads. Disconnect

all electricalloadsbefore shuttingdownthe genera-

tor.

• Do not insertany objectthrough coolingslots ofthe

engine-generator.

• Never operate generator (a) in rain;(b) in any

enclosed compartment;(c) if connected electrical

devices overheat;(d) ifelectrical outputis lost;(e) if

engine or generatorsparks; (f) if flames or smokeare

observed whileunitis running;(g) if unitvibrates

excessively.

Note: Ifyou equiptheenginewitha sparkarrestormuffler,

thesparkarrestormustbe maintainedineffectiveworking

orderbythe owner/operator.

In theState ofCalifomiaa sparkarrestoris requiredbylaw

(Section4442 oftheCaliforniaPublicResourcesCode).

Otherstatesmay havesimilarlaws. Federallawsapplyon

federal lands.The sparkarrestorpart numberfor thisunitis

pin34479A.

LOOK FOR THIS SYMBOL TO POINT OUT

IMPORTANT SAFETY PRECAUTIONS. IT

MEANS "ATTENTION!!! BECOME

ALERT!!! YOUR SAFETY IS INVOLVED."

Your A(3 generator requiressome assembly and is ready

for useafter it has been properly servicedwiththe rec-

ommended oil and fuel.

If you have any problems with the assembly of your

generator, please call the generator helpline at 1-800-

222-3136

Important: Any attemptto runthe engine beforeit has

been servicedwith the recommendedoilwill resultin an

engine failure.

TO REMOVE THE GENERATOR FROM

CARTON

• Set the cartonon a rigidflat surface with =THISSIDE

UP" arrows pointing upward.

Carefully open the top flapsof the shippingcarton.

• Cut down comers at one end of cartonfrom topto

bottomand lay that side of cartondownfiat.

• Remove all packing material, cartonfillers,etc.

• Remove the generatorfrom the shippingcarton.

CARTON CONTENTS

Check all contents. Ifany partsare missingor damaged,

call the Generator Helplineat 1-800-222-3136.

• The main unit

• Owner's manual

• Engine oil

CORD SETS AND CONNECTOR PLUGS

120 Volt Duplex Receptacle

Use only highquality, well-insulated, extensioncords with

the generator's120-volt duplex electricalreceptacles.

Each receptacle is protected againstoverloadby a push-

to-reset circuitbreaker. Use each receptacleto operate

120 volts,single phase 60 Hz, A C electricalloads requir-

ing upto 2400 watts (2.4 kW) at 20 amps of current.

CAUTION! Although each receptacle is

rated for 120 volts at 20 amps (2400 watts

or 2.4 kW), the generator is rated for a

total of 5000 watts. Powering loads that

exceed the wattage capacity of the

generator can damage it or cause serious

injuries. The total of loads with 120 volts

powered through these receptacles

should not exceed 20 amps.

Check the ratings ofall extension cords before you use

them. Extensioncord sets used shouldbe rated 125 volts

at 20 ac amps or greater for most electricaldevices.

Some devices, however, may not require thistypeof

extension cord. Check the owner's manuals of those

devices for the manufacturer's recommendations.

Keep extensioncordsas shortas possible,preferably

lessthan 15 feet long to prevent voltagedrop and possi-

ble overheating of wires.

120/240 Volt, 20 AMP Receptacle

This receptacle isa NEMA L14-20R and is protected by a

push-to-reset circuitbreaker. A NEMA L14-20P mating

connector plug isrequired to usethis receptaclerecepta-

cle. Connect a suitable4-wire cordset tothe plugand to

the desired load. The cordset shouldbe rated for 250

volts at 30 amps.

Ire Cord Set

(Neutral)

Y(Hot)

X (Hot)

1201240 VOLTS PLUG (Green)

CAUTION! Although this receptacle is

rated for 240 volts at 20 amps (4800 watts

or 4.8 kwh, the generator is rated for a

total of 5000 watts (5.0 kW). Powering

loads that exceed the wattage capacity of

the generator can damage it or cause

serious injuries. Loads with 240 volts

powered through this receptacle should

not exceed 20 amps.

KNOW YOUR GENERATOR

Read the owner's manual and safety rules before operating your generator. Compare the illustrationswithyour

Generatorto familiarize yourselfwith the locationsof vadous controlsand adjustments.

Fuel Tank

120/240-Volt AC, 20 AMP

Locking Receptacle

120-Volt AC, 20 AMP

Duplex Receptacle

Circuit Breakers

Muffler

Air Cleaner

Oil Fill Cap

Oil Drain Plug

120 Volt, 20 AMP, Duplex Receptacles -- May be used

to supplyelectrical power forthe operationof 120 volts at

20 amps ac, single phase, 60 Hz, AC electricallighting,

appliance, tool and motorloads.

120/240 Volt, 20 AMP, Locking Receptacle -- May be

used to supplyelectrical power for the operationof 120

and/or 240 volts at 20 amps AC, single phase, 60 Hz, AC

electrical lighting,appliance, tool and motorloads.

Air Cleaner -- Filtersintake air as it isdrawnthroughthe

engine.

Choke Lever- Used when startinga coldengine.

Circuit Breakers (AC) -- Each receptacleis provided

with a circuitbreakerto protectthe generator against

electrical overload. Breakers are "pushto reset"type.

Fuel Tank -- Tank holds 5 U.S. gallonsofunleaded

gasoline.

Muffler -- Muffler lowersengine noise.

Oil Drain Plug -- Drainengine oilhere.

Oil Fill Cap -- Fill engine with oilhere.

HOW TO USE YOUR GENERATOR

Ifyou have any problemsoperating your Generator,

please call the Generator helplineat 1-800-222o3136.

GROUNDING THE GENERATOR.

The NationalElectricalCode requiresthat the frame and

extemal electricallyconductiveparts of this generator be

properlyconnectedto an approved earth ground. Local

electrical codes may also requireproper groundingof the

unit. For that purpose,a groundinglug is providedon the

base ofthe cradle.

• Place generator on a level surface.

• Clean area aroundoil filland remove oilfillcap

• Wipe cap dean.

• Pouroil intooilfillopening untiloilreaches the point

of overflowing. Do not overfill!

Add Gasoline

WARNING NEVER fill fuel tank indoors.

NEVER fill fuel tank when engine is

running or hot. DO NOT light a cigarette

or smoke when filling the fuel tank.

CAUTION: Do not overfill the fuel tank.

Always leave room for expansion.

Generally, connectinga No. 12 AWG (American Wire

Gauge) stranded copper wire to the groundinglugand to

an earth-drivencopper or brass groundingrod(electrode)

providesadequate protectionagainstelectrical shock.

However, localcodes may varywidely. Consultwith a

• local electricianfor groundingrequirements in yourarea.

Proper groundingof generatorwill help preventelectrical

shock in the event of a groundfault conditioninthe gen-

eratoror in connected electricaldevices. Proper ground-

ingalso helpsdissipatestatic electricity,whichoften

buildsup in ungroundeddevices.

BEFORE STARTING THE GENERATOR

To operatethe engine you willneed to do the following:

• Use regular UNLEADED gasoline withthe Generator

engine. Do not use premiumgasoline.Do not mixoil

with gasoline.

• Clean area aroundfuel fill cap, remove cap.

• Add unleaded regulargasoline,slowlyto fuel tank. Be

careful not to overfill.Allow about 1/4" oftank space

for fuel expansion.

• Installfuel cap and wipe up any spilledgasoline.

IMPORTANT: It isimportantto preventgum deposits

from forming in essentialfuel system partssuch as the

carburetor,fuel filter, fuel hose or tankduringstorage.

Also, experience indicatesthat alcohol-blendedfuels

(called gasohol, ethanolor methanol) can attractmoisture

which leads to separation and formation of acids during

storage.Acidic gas can damage the fuel systemof an

engine while in storage. To avoid engine problems,the

fuel system should be emptied before storageof 30 days

or longer. See "Storage"on page 12. Never useengine

or carburetor cleaner productsin the fuel tank or perma-

nent damage may occur.

TO START THE ENGINE

WARNING: Never start or stop engine I

with electrical devices plugged into the

panel receptacles and turned on.

Add Engine Oil

NOTE: When adding oilto the engine crankcase in the

future, use onlyhigh quality detergent oil rated with API •

service classificationSF or SG or higher rated SAE 30 ,

weight. Use no specialadditives.Select the oil'sviscosity

grade accordingto your expectedoperating temperature.

colder -<----- 32°F _ warmer |

5W30 SAE 30

Although multi-viscosity oils (5W30, 10W30, etc.) improve

startingin coldweather, these multi-viscosity oilswill

resultin increased oil consumptionwhen used above

32°F. Check your engine oil level more frequently to

avoid possibledamage from runninglow on oil.

Unplug all electrical loads from generator receptacles

beforestarting the engine.

Make sure the unitisin a level position.

Open the fuel shut--offvalve.

J..d.._ FuelTank

Turn Clockwise to

"OFF" Position

• Move the choke lever to the "Choke" position.

RUN

t÷t

Set the engine controlswitchto the On position.

• Manual Start: Grasp starter grip and pull slowlyuntil

you feel some resistance.Then pullcord outwith

rapid fullarm stroke. Let rope retum slowly. Do not let

rope "snapback" againststarter.

• When engine starts, move choke lever to "Run"

position.

Note: If engine fails to startafter 3 pulls,move the

choke lever to "RUN" and pull starter ropeagain.

Note: If the engine fails to start afterthree (3) pulls,

check for proper oillevel in crankcase. Unitis equipped

with a lowoil shutdownsystem.

Note: If engine fires, but does not continueto run, move

choke lever to "Choke" and repeat startinginstructions.

,_ CAUTION! Never run engine indoors or

in enclosed poorly ventilated areas.

Engine exhaust contains carbon

monoxide, an odorless and deadly gas.

,_ WARNING! Temperature of muffler and

nearby areas may exceed 150°F (65°C).

Avoid these areas.

STOPPING THE ENGINE

• Unplug all electrical loadsfrom generatorpanel recep-

tacles. Never start or stop engine with electrical

devices plugged inand turned on.

• Let engine run at no-loadfor several minutesto

stabilizethe internaltemperatures of engine and

generator.

° Move engine controlswitchto "Off" Position.

° Closethe fuel shut-off valve

CONNECTING ELECTRICAL LOADS

• Let engine stabilizeand warm up for a few minutes

after starting.

• Plug in and turn on the desired 120 and/or 240 volts,

single phase, 60 Hertz, A C electrical loads.

• Do not connect 240 volts to the 120 volt duplex

receptacles

• Do not connect 3-phase loads to the receptacles.

• Do not connect any 50Hz loads to the receptacles.

• DO NOT OVERLOAD THE GENERATOR. Add up

the rated watts (or amps) of all loads tobe connected

at one time. This total shouldnot be greaterthan the

rated wattage/amperage capacityof the generator.

See Don't Overload the Generator on Page 9.

LOW OIL LEVEL SHUTDOWN SYSTEM

Sensing Low Pressure

If the system sensesa low oil levelduring operation,the

engine shuts down. Ifthe engine shuts downby itselfand

it has enough gasolinein the fuel tank, checkoil level.

Restarting

If you attempt to restartthe engine after such a shutdown

and have not corrected the engine oil level,the engine

will not start. Check the oil and refill accordingto the

instructionson page 7.

DON'T OVERLOAD THE GENERATOR ..

Overloadinga generator in excess of its rated wattage

capacity can resultin damage to the generator and to

connected electricaldevices. Observe the following, to

preventoverloadingthe unit:

, Add up the total wattage of all electricaldevices 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, toolor motordoes not give wattage,

multiply volts times ampere ratingto determinewatts

(voltsx amps = watts).

Some electricmotors,such as inductiontypes,

requireabouttwoand a half times more watts of

powerfor startingthan for running. This surge of

powerlastsonlya few secondswhen startingsuch

motors. Make sure you allowfor this highstarting

wattage when selectingelectricaldevicesto connect

to your generator. First,figurethe watts neededto

start the largestmotor. Add to that figure the running

watts of all other connectedloads.

The Wattage Reference Guide below is provided to

assist you in determininghow many items your generator

can operate at one time.

WATTAGE REFERENCE GUIDE

Electrical Device Running

Watts

*Air Conditioner (12,000 Btu) ....................... 1700

Battery Charger (20 amp) .............................. 500

Belt Sander (3") ........................................... 1000

Chain Saw .................................................... 1200

Circular Saw (6-12/") ........................ 800 to 1000

Coffee Maker ............................................... 1000

*Compressor (1 HP) .................................... 2000

*Compressor (3/4 HP) ................................. 1800

*Compressor (1/2 HP) ................................. 1400

Curling Iron .................................................... 700

*Freezer ......................................................... 500

Disc Sander (9") ........................................... 1200

Edge Trimmer ................................................ 500

Electric Nail Gun .......................................... 1200

Electric Range (one element) ...................... 1500

Electric Skillet ............................................... 1250

*Furnace Fan (1/3 HP) ................................. 1200

Hair Dryer ..................................................... 1200

Hand Drill (1") .............................................. 1100

Hand Drill (1/2") ................................ 750 to 1000

Hand Drill (3/8") ............................................. 500

Hand Drill (1/4") ............................................. 250

Hedge Trimmer .............................................. 450

Electrical Device Running

Watts

Impact Wrench ................................................ 500

*Jet Pump ...................................................... 800

Lawn Mower ................................................. 1200

Light Bulb ....................................................... 100

Microwave Oven ............................................ 700

*Milk Cooler .................................................. 1100

Oil Burner on Furnace ................................... 300

Oil Fired Space Heater (140,000 Btu) ........... 400

Oil Fired Space Heater (85,000 Btu) ............. 225

Oil Fired Space Heater (30,000 Btu) ............. 150

*Paint Sprayer, Airless (1/3 HP) .................... 600

Paint Sprayer, Airless (handheld) .................. 150

Radio .................................................... 50 to 200

*Refrigerator ................................................... 600

Slow Cooker ................................................... 200

*Submersible Pump (1-1/2 HP) .................... 2800

*Submersible Pump (1 HP) .......................... 2000

*Submersible Pump (1/2 HP) ....................... 1500

Sump Pump .................................................. 600

*Table Saw (10") ............................. 1750 to 2000

Television ............................................ 200 to 500

Weed Trimmer ............................................... 500

* Allow 2-1/2 times the listed watts for starting

these devices.

Maintenance Schedule

Follow the hourly or calendar intervals, whichever occurs first.

More frequent service is required when operating in adverse conditions noted below.

Maintenance Operation

Check oil level

Change oil_:

Service air pre-cleaner

Service air cleaner cartridge

Clean coolingsystem

Replace spark plug

Prepare unit for storage

Every5 Hours

or Ually

25 Hours or 50 Hours or 100 Hours or

Every Season Every Season Every Season

Generator Specifications

Rated Maximum Power ......... 5000 Watts (5.0 kW)

Surge Power ......... ....... 6250 Watts (6.25 kW)

Rated Voltage ............... 120/240 Volts AC

Rated MaximumCurrent

at 240 volts ................. 20.8 AC Amperes

Rated MaximumCurrent

at 120 Volts ................ 41.7 AC Amperes

Rated Frequency ............ 60 Hz at 3600 rpm

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

Engine Specifications

Rated Horsepower ........... 10 at 3600 rpm

Spark Plug

Type: ................ Champion RC14YC or

Equivalent

Set Gap To: ........... 0.030inch (0.76mm)

Prepare unitfor storage if its to remain idlefor more than

30 days

Change oil after first 5 hours of operationthen after every 25 hours or every season.

" Change oil sooner when operating under heavy load or in high temperatures.

** Clean more often under dirty or dusty conditions.

PRODUCT SPECIFICATIONS

All adjustments in the Service and Adjustmentssectionof

this manual should bemade at least once each season.

Followthe requirementsinthe "Maintenance Schedule"

chartabove.

Note: Once a year you shouldclean or replace the spark

plugand replace the air filter. A new spark plug and

clean air filter assure properfuel-air mixtureand help

your engine runbetter and last longer.

GENERATOR MAINTENANCE

Generator maintenance consistsof keeping the unit

clean and dry. Operate and store the unitin a clean dry

environmentwhere itwillnot be exposedto excessive

dust,dirt, moistureor any corrosivevapors. Coolingair

slots in the generator mustnot become cloggedwith

snow, leaves, or any otherforeign material.

Check the cleanlinessof the generator frequently and

clean when dust,dirt, oil, moistureor otherforeign sub-

stances are visibleon itsexterior surface.

Gasoline Capacity ............ 5 U.S. gallons

Oil

Summer ............. SAE 30 (10W-30)

Winter .............. SAE 5W-20 or 5W-30

GENERAL RECOMMENDATIONS

The warranty ofthe 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.

Note: We DO NOT recommend using a garden hose to

clean generator. Water can enter the engine fuel system

and cause problems. In addition,ifwater enters the gen-

eratorthroughcoolingair slots, some of the water willbe

retained in voidsand cracksofthe rotorand stator wind-

ing insulation. Water and dirt buildup on the generator

internalwindingswilleventually decrease the insulation

resistanceofthese windings.

A AUTION: Never Insert any object or tool I

through the air cooling slots, even if the

engine is not running.

Toclean.theGenerator- ....

• Use a damp clotht0 Wipeexterior surfacesClean.

• A soft, bristlebrushmay be used to loosen caked on

dirt, oil, etc.

• A vacuum cleaner may be used to pickup loosedirt

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.

ENGINE MAINTENANCE

DANGER: When working on the

generator ALWAYS disconnect spark

plug wire from spark plug and keep it

away from spark plug.

Checking Oil Level

Oil level shouldbe checked priorto each use or at least

every 5 hours of operation. Keep oillevel maintained.

Changing Engine Oil

Change oilafter first 5 hours of operation.Change oil

every25 hoursthereafter. If you are usingyour generator •

under extremely dirtyor dusty conditions,or in extremely

hot weather, change oil more often. •

Change oilwhile engine isstillwarm from running,as fol-

lows:

• Clean area around oil drain plug.

• Remove oildrain plug and oil fill plug and drain 0il

completely intoa suitable container.

• When oil has completely drained, Install oildrain plug

and tightensecurely.

• Fill oil sumpwith recommended oil. (See "Before

Startingthe Engine" on page 7 for oil recommenda-

tions)

• Install the oil fill plug and tighten securely.

• Wipe up any spilled oil.

CLEAN/REPLACE SPARK PLUG

Change the spark plug every 100 hoursof operation or

once each year, whichever comes first. This willhelp

your engine to start easier and run better. See

"Specifications" for proper spark plug.

• Clean area around spark plug.

• Remove and inspectspark plug.

• Replace spark plug if electrodes are pitted, burnedor

porcelain iscracked.

• Check electrode gap with wire feeler gauge and set

spark plug gap to 0.030 inch (0.76ram) if necessary.

" SERVICE AIR.... CLEANER"'_

Your engine willnot run properlyand may be damaged if

you run itusing a dirtyair cleaner.

Clean or replacethe foam pre-cleaner every 25 hours of

operation. Service cartridgeevery 100 hoursof operation

or once a year, whichevercomes first.Clean or replace

more often if operatingunder dustyordirtyconditions.

Replacements are availableat your localSears

Authorized Service Center.

service foam pre-cleaner:

The cover is attachedto the air cleaner housingby

two screws.

Carefullyremove air cleaner assemblyfrom insideof

cover and disassemble.

• Wash in liquiddetergentand water.

• Squeeze (don'ttwist) pre-cleaner in a clean, dry cloth.

• Saturate pre-cleanerin engine oil. Squeeze in a clean

absorbentclothto remove all excess oil.

• Replace pre-cleaner ifvery dirtyor damaged.

• To service cartridge, clean bytappinggentlyon a

flat surface. Replace ifvery dirtyor damaged. Do not

oil cartridge.

Note: Do not use petroleumsolventssuch as kerosene,

or pressurizedair to clean cartridge.

• Reassemble retaineron pre-cleaner and cartridge

(screen side of pre-cleanertoward cartridgepleats).

Install this assembly in cover.

• Insert tabs on cover into slots in base. Tighten cover

screws securely.

KEEP ENGINE AND PARTSCLEAN

With a brushor cloth, remove debris from debrisguard or

rotatingscreen dailyor more often ifneeded to prevent

engine damage caused by overheating.Do not clean with

a forceful spray of water because water couldcontami-

natethe fuel system.

Keep governor linkage, springs, and controlsfree of

debris.Debris or chaff may clogthe air coolingsystem,

especiallyafter prolonged operation.Remove blower

housingand clean area shown to preventoverheating

and engine damage.

CLEAN

OUT

DEBRIS

AND

CHAFF

GENERAL

The generator should be started at leastonce every

seven days and allowed to run at least 30 minutes. If this

cannotbe done and you must store the unitfor more

than 30 days, use the following informationas a guide to

prepare itfor storage.

LONG TERM STORAGE INSTRUCTIONS

WARNING: NEVER store engine with fuel

in tank indoors or in enclosed, poorly

ventilated areas where fumes may reach

an open flame, spark or pilot light as on a

furnace, water heater, clothes dryer or

other gas appliance.

It is importantto prevent gum depositsfrom formingin

essentialfuel system parts such as the carburetor,fuel

filter, fuel hose or tank during storage. Also, experience

indicatesthat alcohol-blendedfuels (calledgasohol,

ethanol or methanol) can attractmoisturewhichleads to

separationand formation ofacids duringstorage. Acidic

gas can damage the fuel system of an engine while in

storage.

To avoid engine problems, the fuel system shouldbe

emptied before storage of 30 days or longer. Follow

these instructions:

PROTECT FUEL SYSTEM

WARNING: Drain fuel into approved

container outdoors, away from open

flame. Be sure engine is cool. Do not

smoke.

• Remove all gasoline from the fuel tank to prevent gum

deposits from forming on these parts and causing

possible malfunction of engine.

• Run engine until engine stops from lackof fuel.

CHANGE OIL

While engine isstill warm, drain oilfrom crankcase. Refill

with recommended grade.

OIL CYLINDER BORE

• Remove spark plug and pour about 1/2 ounce (15ml)

ofengine oilintothe cylinder. Cover spark plug hole

with rag.Crank slowlyto distributeoil.

IA CAUTION' Av°id spray fr°m spark plug I

hole when cranking engine slowly.

• Installspark plug. Do not connectspark piug wire.

GENERATOR:

• Clean the generator as outlined on Page 10 ("To

Clean the Generator").

• Check that cooling air slots and openingson genera-

tor are open and unobstructed.

OTHER STORAGE TIPS:

• Do notstore gasoline from one season to another.

• Replace yourgasoline can if yourcan startsto rust.

Rust and/or dirtin yourgasolinewill cause problems.

• If possible,store yourunitindoors and cover itto give

protectionfrom dust and dirt. BE SURE TO EMPTY

THE FUEL TANK.

Cover your unit with a suitable protective coverthat

does not retain moisture.

• Store generator in clean, dry area.

I A DANGER:NEVERcoveryourGenerator i

while engine and exhaust area are warm.

PROBLEM

Engineisrunning,butno

ACoutputisavailable.

Enginerunsgoodat no-loadbut "bogs

down"whenloadsare connected

Enginewillnotstart;or starts

andrunsrough.

CAUSE

1.Oneofthecircuitbreakersisopen.

2.Faultingenerator.

3.Poorconnectionordefective

cordseL

4.connecteddeviceisbad.

1.Shortcircuitina connectedload.

2.Enginespeedistooslow.

3.Generatorisoverloaded.

4.Shortedgeneratorcircuit.

1.Run/StopSwitchsettoSTOP.

2.Dirtyaircleaner

3.Outofgasoline.

4.Stalegasoline.

5.Sparkplugwirenotconnected

tosparkplug.

6.Badsparkplug.

7.Waterin gasoline.

8.overchoking.

9.Lowoillevel

10.Excessivelyrichfuelmixture.

11.Intakevalvestuckopenor closed.

12.Enginehaslostcompression.

CORRECTION

1. Resetcircuitbreaker.

2. ContactSearsServiceFacility.

3. Checkandrepair.

4. Connectanotherdevicethat

is ingoodcondition.

1. Disconnectshortedelectrical

load.

2. ContactSearsServiceFacility.

3. See=Don_Overloadthe

Generator"

4. ContactSearsServiceFacility.

1. Setswitchto RUN.

2. Cleanor replaceaircleaner.

3. RIIfueltank.

4. Draingastank;fillwithfreshfuel.

5. Connectwiretosparkplug.

6. Replacesparkplug.

7. Draingastank;fillwithfreshfuel.

8. Openchokefully andcrankengine.

9. RIIcrankcasetoproperlevel.

10. ContactSearsServiceFacility.

11. ContactSearsServiceFacility.

12. ContactSearsServiceFacility.

Engineshutsdownduringoperation 1.Outof gasoline. 1. Fillfueltank.

2iow oil level. 2. Fillcrankcaseto properlevel.

Enginelackspower. 1.Loadistoohigh. 1. See=Don'tOverloadtheGenerator"

2.Dirtyairfilter. 2. Replaceairfilter.

Engine=hunts"or falters. 1.

1.Chokeisopenedtoosoon.

2.Carburetorisrunningtoorich

ortoolean.

Movechoketohalfwaypositionuntil

enginerunssmoothly.

ContactSearsServiceFacility.

CRAFTSMAN 5000 Watt AC Generator 580.327112

Wiring Diagram

r_-

_L_ i

_d _/ Ii

I_ n,'o

o _glll II II

_________J

,_ r U L_-_

÷ I

CRAFTSMAN 5000 Watt AC Generator 580,327112

Main Unit -- Exploded View

44 _ 66

• X " (STOP SVITCH TERMINAL)

900

38= tO,,

51 55

-36 TO • A •

CRAFTSMAN 5000 Watt AC Generator 580.327112

Main Unit- Parts List

ITEM PART NO. Q_. DESCRIPTION

900 91011 1 ENGINE, Briggs &

Stratton 10 Hp

2 91020B 1 ASSEMBLY, Cradle

4 143-53621 1 WIRE, Ground

5 86292 1 CAPSCREW, #10 Self

Driller

6 75475 4 SCREW, M4-0.7 x 10ram

7 70642 2 MOUNT, Vibration

8 22129 8 WASHER, M8 Lock

10 38150 4 WASHER, No. 8 Flat

11 93585J 1 ASSEMBLY, Stator

12 66365G 1 HOUSING, Engine

Adapter

13 91844 1 ASSEMBLY, Rotor

14 65791 1 BEARING, Ball

15 47480 1 BOLT, Rotor 5/16"-24 x 7"

16 81917 1 PIN, M4 x 10 Roll

19 86308C 4 BOLT, Stator M6-1.00 x

130ram

20 22264 4 WASHER, No. 8 Lock

21 66849 2 SCREW, M5- .80 x 16ram

Taptite

22 86494 1 SCREW, M6 x 16mm

Wing

23 68759 1 RECEPTACLE, 120Volts

AC, 20AMP

24 94396B 1 BREAKER, Circuit-

20AMP

25 95600 1 PANEL, Control Sheet

Metal

26 91825 1 ASSEM, Brush & Bridge

Rectifier

27 67451 1 WASHER, Flat (Special)

28 23365 4 WASHER, No.8

Shakeproof

29 51715 4 NUT, M4-0.7 Hex

30 74908 4 SCREW, M5- 0.80 x

10ram

31 26850 2 WASHER, Shakeproof -

1/4"

32 84242 2 GROMMET, Rear Bearing

Carrier

33 86307 4 CAPSCREW, Hx Hd.-

5116"x 3/4"

34 67022 1 GROMMET, Bearing

Carrier

35 52858 6 NUT, M8-1.25 Hex

36 22769 1 WASHER, No. 10

Shakeproof

ITEM PAFITNO. QTY. DESCRIPTION

37 22145 2 WASHER, M8 Flat

38 68867 1 OUTLET, 120/240 Volt -

Twistlock

39 76222 2 SCREW, Pan Head-M8 x

40ram

40 48031C 2 CLAMP, 1/4" Hose

41 83465 4 GROMMET, Mounting

Tank

44 78831B 4 CAPSCW., Hx Hd.-M6-

1.0 x 60mm

46 90878 1 CAP, Fuel Tank

47 82857 2 MOUNT, Vibration

48 25244 2 NUT, 5/16" - 18 Hex

49 66825C 1 BEARING, Rear Carder

50 77374 1 TANK, Fuel

51 78299 1 BUSHING, Plastic Tank

52 80270 1 VALVE, Plastic Tank

53 77395 4 NUT, M6 Hex Lock

54 78951 1 SHIELD, Heat

55 56892 2 SCREW, Crimptite #10-24

x 3/8"

56 88977 1 SWITCH, Low Oil Shut-

Down (LOS)

57 91841 1 GASKET

58 91842 1 WIRE, Low Oil Shut-

Down

59 32713 2 SCREW, No. 10-32 x 3/4"

Taptite

60 22471 .... 2 NUT, No. 8-32

61 23365 1 WASHER, No. 8

Shakeproof

62 B3050 1 DECAL, Panel Cradle

63 98247 1 DECAL, Control Panel

64 94396A 1 BREAKER, Circuit 15

AMP

65 92982 1 DECAL, Danger

66 93826 1 DECAL, Operating

Instructions

Parts Not Illusbated

B3051 1 Owner'sManual

B3061 2 2007_EngineOil

Optional Accessories Not Illustrated

09-32684 Wheel I_t

O9-32688 CordWrap I_t

O9-32686 120/240V20A Rug

CRAFTSMAN 5000 Watt AC Generator 580.327112

Briggsand Stratton4 Cycle Engine19G412-1129-E1

3O6

552

I 1058 OWNER'S MANUAL J[ 1019 LABEL KIT I 9r REQUIRESSPECIALTOOLS TOINSTALL.

SEE REPAIR INSTRUCTION MANUAL.

REF. PART

NO. NO. DESCRIPTION

495631 Cylinder Assembly

(Includes OIL GARD®

Cover)

495657 Bushing

*391085 Seal-Oil

214347 Head-Cylinder

_272163 Gasket-Cylinder Hd.

495736 Breather Assembly

(Used After Code Date

95010100).

REF. PART

NO. NO. DESCRIPTION

13 94565 Screw-Cylinder Head

(3-9/16" Long)

13A 94733 Stud-Cylinder Head

Used in Position # 5 &

#6.

14 93723 Screw-Cylinder Head

(3" Long)

15 94239 Plug-Oil Drain

33 390419 Valve-Exhaust

(Indudes Fief. 42)

34 261055 Valve-Intake

35 65906 Spring--Valve

(Intake)

36 26828 Spring-Valve

(Exhaust)

40 221596 Retainer-Valve

41 292260 Retainer-Valve

42 494553 Keeper-Valve

306 496797 Shield--Cylinder

REF. PART

NO. NO. DESCRIPTION

337 496018

354A 94726

383 89838

529 281367

552 491986

635 66538

869 211661

871 261961

1019 491181

1058 272848

307 94386 Screw-Sell' Tapping

308 225055 Cover-Cylinder Head

9 *27803 Gasket-Breather

10 94621 Scfew-Sem

11 280225 Tube-Breather

(Used After Code Date

95010100).

11A 231900 Tube-Breather

(Used Before Code

Date 94111100).

Plug-Spark

Nut-Hex.

Wrench-Spark Plug

Grommet

(Used Before Code

Date 94111100).

Bushing--Gov. Crank

Boot-Spark Plug

Seat-Valve

Bushing-Guide

(Exhaust)

Note

231218 Bushing-

Guide

(Intake)

Label Kit

Owner's Manual

, Included in Gasket Set-Part No. 497070.

• Included in Carburetor Kit-See Rel. No. 121.

4, Included in Carburetor Gasket Set-Part No. 497069.

0432-2

Assemblies include all parts shown in frames.

CRAFTSMAN 5000 Watt AC Generator 580.327112

Briggsand Stratton4 CycleEngine19G412-1129-E1

592

230

219

_:_186

f If'_\\

REF. PART REF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

25 3916733 *391086

12 *271701

16 495832

18 496984

19 295964

21 66768

22 93585

Seal-Oil

Gasket-Crankcase

(.015" Thick)

,27876 Gasket-

Crankcase

(.005" Thick)

,27877 Gasket-

Crankcase

(.009" Thick)

Crankshaft

Note

For "13ruingGear

Retaining Device.

Order Part No.

94388 Key.

495790 Crankshaft

Used on Type No(s).

0068, 0129, 0131,

0169.

Cover-Crankcase

Bushing

Plug-Oil Fill

Screw-Sem

26 393881

27 68546

28 295840

29 390401

Piston Assy.

(Standard)

391674 Piston Assy.

(.010" O.S.)

391675 Piston Assy.

(.02o-o.s.)

391676 Piston Assy.

(.030" O.S.)

Ring Set

(Standard)

299743 Ring Set

(Std.. Chrome)

393882 Ring Set

(.OlO-O.S.)

393883 Ring Set

(.020" O.S.)

393884 Ring Set

(.030"O.S.)

Lock-Piston Pin

Pin-Piston

(Standard)

295841 Pin-Piston

(.005"O.S.)

Rod-Connecting

30 222113

32 94670

45 260933

46 211689

84 9'1488

186 67218

202 263049

219 497037

220 221551

227 496254

23O

232

562

592

614

616

623

624

741

94742

26302O

92613

231082

93306

496818

231520

497207

262479

Note

390773 Rod-Conn.

(.020" Undersize)

Dipper-Connecting

Rod

Screw-Conn. Rod

Tappet-Valve

Gear-Cam

Plug-Pipe

Connector-Fuel Line

Link

Gear--Governor

Washer-Thrust

Lever-Governor

WasHer-Thrust

Spring-Link

Bolt-Carriage

Nut-Hex.

Pin-Cotter

Crank-Governc¢

•Screw-Shoulder

Lever-Linkage

Gear-'13ming

* Included inGasket Set-Part No. 497070.

• Included in Carburetor Kit-See Ref. No. 121.

€ Included in Carburetor Gasket Set-Part No. 497069.

0432-3

Assemblies include all parts shown in frames.

CRAFTSMAN 5000 Watt AC Generator 580.327112

BriggsandStratton4 Cycle Engine 19G412-1129-E1

REQUIRES SPECIAL TOOLS

TO INSTALL. SEE REPAIR

INSTRUCTION MANUAL.

95 987

REF. PART

NO. NO. DESCRIPTION

51 e,,272708 Gasket-Intake

52 ,272707 Gasket-Intake

53 94778 Stud-Carb. Mtg.

93 t281346 Bushing-Shaft

95 e94098 Screw-Round Head

98 495800 Screw-Idle Adjust

104 t231789 Pin-Float Hinge

105 D231935 Valve-Needle

106 e231856 Seat-Inlet

108 224666 Valve-Choke

116 494383 Valve-Needle

123 94616 Screw-Torx®Hex.

125 497844 Carburetor

(Used After Code Date

94083100)o

Note

497164 Carburetor

(Used Before Code

Dale 94090100).

127 • Plug-Welch

(Sold in Kit Only)

130 224539 Valve-Throttle

131 497846 Shaft-Throttle

(Used After Code Date

94083100).

REEF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION

497198 Nozzle-Carb.

(High Altitude)

Include(s):

281164 Washer

(Used Before Code

Date 94062400).

147 o497472 Jet-Pilot

133 494381 Roat-C_,buretor (Used After Code Date

137 o,281165 Gasket-Float Bowl 94072400).

138 e+281164 Washer Note

141 497160 Shaft-Choke e231794 Jet-Pilot

142 e497564 Nozzle-Carburetor

(Used Before Code

(Used Afler Code Date Date 94072500).

94062300). 164 214170 Manifold-Intake

Note

497848 Nozzle-Carb. 186A 493496 Elbow-Fuel Pipe

(High Altitude) 618 e262803 Spring

Include(s): 634 •2.81168 Seal-Choke Shaft

281164 Washer 955 94642 Screw-Bowl Mtg.

(Used After Code Date 965 94010 Nut-Hex.

94062300). 975 494379 Bowl-Float

987 e281166 Seal-Throttle Shaft

e497197 Nozzle-Carb.

(Used Before Code

Date 94062400).

* Included in Gasket Set-Part No. 497070.

• Included in Carburetor Kit-See Ref. No. 121.

. Included in Carburetor Gasket Set-Part No. 497069.

0432-4

Assemblies include all parts shown in frames.

CRAFTSMAN 5000 Watt AC Generator 580.327112

BriggsandStratton4 CycleEngine19G412-1129-E1

REF. PART

NO. NO. DESCRIPTION

55 393576 Housing-Rewind

Starter

56 295871 Pulley-Starter

57 490179 Swing-Rewind Starter

58 65884 Rope-Starter

(63"Long)

59 490653 Insert-Starter Handle

60 490652 Grip-Starter Rope

REF.

NO.

PART

NO. DESCRIPTION

63 260414 Spring-Ratchet

64 230543 Adopter-Ratchet

Spr_j

65 94128 Screw-Sem

66 399671 Clutch-StaRer

67 394897 Housing-Clutch

68 63770 Bali-Starter Clutch

REF. PART

NO. NO. DESCRIPTION

70 298799 Ratchet-Rewind

Starter

71 394506 Washer-Retainer

373 92987 Nut-Hex.

608 390391 Starter-Rewind

655 222598 Anchor-Spring

1018 490617 Spacer

* Included in Gasket Set-Part No. 497070.

• Included in Carburetor Kit-See Ref. No. 121.

• Included in Carburetor Gasket Set-Part No. 497069.

0432-5

Assemblies include all parts shown in frames.

CRAFTSMAN 5000 Watt AC Generator 580.327112

Briggsand Stratton4 CycleEngine19G412-1129-E1

201

° 17sAi

•

209 209A

_271 269_'__ _

268

27O

RER PART REF. PART REF. PART

NO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

75A 495659 Kit-Washer

98A 493280 Swing-Speed Adj.

165 94692 Nut-Wing

201 263051 Link

201A 262970 Link

209 263054 Spring--Governor

209A 260723 Spdng-Govemor

222 497076 Plate-Control

232A 262959 Spring-Link

258 94620 Screw-_elf Tapping

268 65616 Casing-Control Wire

(72" Long)

269 26633

Note

If Longer Casing is

Required, Specify

Length in Inches; if

Shorter Casing is

Needed, Cut to

Required Length.

W'_e-Control

(78" Long)

Note /

If Longer Wire is

Required. Specify

Length in Inches; if

Shorter Wire is

Needed, Cutto

Required Length.

270 63426 Locknut-Casing

271 290568 Lever-Control

333 492341 Armature-Magneto

334 94731 Screw-.Hex.

353 92791 Washer-I.,ock

354 90576 Nut-Hex.

356 491391 Wire--Stop

520 93722 Terminal

851 493880 Terminal-Cable

985 396525 Insulator

. Included in Gasket Set-Part No. 497070.

• Included in Carburetor Kit-See Ref. No. 121.

. Included in Carburetor Gasket Set-Part No. 497069.

0432-6 Assemblies include all parts shown in frames.

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COMPANION 580.327112 Owner's manual

Brand: COMPANION

Model: 580.327112

Category: Power generators

Type: Owner's manual

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580327112

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COMPANION 580.327112 Owner's manual

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