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Sears 580.32601 manual

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Table of contents for the manual

  • Page 1

    Sears owners manual MODEL NO. 580.326010 CAUTION: READ INSTRUCTIONS AND RULES FOR SAFE OPERATIONS CAR E FULLY TO PREVENT ACCIDENTS, GENERAL INFORMATION INSTALLATION OPERATING INSTRUCTIONS MAINTENANCE REPAIR PARTS 4500 WATT HEAVY DUTY PORTABLE ALTERNATOR ALTERNATOR Record in space provided below the Model No. and Serial No. of the alternator, Model [...]

  • Page 2

    FULL ONE YEAR WARRANTY For one year from the date of purchase, Sears will repair any defect in material or workmanship in this alternator at no charge° If the alternator is used for commercial or rental purposes, this warranty applies for only thirty days from the date of purchase. Warranty service is available by contacting the nearest Sears Stor[...]

  • Page 3

    TABI.E OF CONTENTS WARRANTY ....................... inside Front Cover RULES FOR SAFE OPERATION inside Front Cover SPECIFICATIONS ............................... 1 NOMENCLATURE ........................................... 2 WIRING DIAGRAM ............................................... 3 INSTALLATION OF STAND-BY POWER SYSTEMS .......................[...]

  • Page 4

    NOMENCLATURE CENTRIFUGAL BLOWER SHROUD CRADLE WHEELS (SHIPPED WITH WHEEL KIT) MUFFLER ENGINE AIR CLEANER OIL FILLER & DIPSTICK 120 VOLT, 15 AMP OUTLETS HANDLES (SHIPPED WITH WHEEL KIT) STARTER MOTOR STARTER SOLENOID INDICATOR LIGHT FUSE - 15 AMP 5 GALLON FUEL TANK NAMEPLATE 12 VOLT BATTERY _IIUSTOME R SUPPLI ED RESTING SUPPORT (SHIPPED WITH WHE[...]

  • Page 5

    WIRING DIAGRAM Model No. 580.326010 o !ci _ oooooo V) DO 0 0[...]

  • Page 6

    INSTALLATION OF STAND-BY POWER SYSTEMS _I_DANGER installation of Stand-By Electrical Power Systems should be done by a QUALIFIED electrtctam ALL APPLICABLE ELEC- TRICAL AND BUILDING CODES MUST BE COMPLIED WITH. improper installation methods or procedures are EX- TREMELY DANGEROUS add may damage equipment and personal property° Alternator F! om Uti[...]

  • Page 7

    SECTION 1 PREPARATION FOR USE Alternator Unpacking and Removal from Shipping Skid 1 Cut Straps 2. Lift Cardboard Shtpplng Carton Straight Up and Off Shipping Pallet Cardboard Insert Alternator Localed Here Kit Located Here Shipping Pallet ¢ "4 | Alternator Cradle Wood Sh,pping PatIet " !.j ] ? Washer ! _b Bolt 1o The alternator is bolted[...]

  • Page 8

    Wheel Kit parts are shown below, See WHEEL KIT INSTALLATIONin this section for installation instructions. Make sure the Kit has the following parts: _" Item [] 1 [] 2 [] 3 [] 4 [] 5 [] 6 [] 7 [] 8 [] 9 []10 Description [_ltem Axle Shaft (1 Req'd) [] 11 U-Bolt (2 Req'd) [] 12 Lock Nut - 5/16-18 (4 Req'd) [] 13 Axle Spacer (2 Req&[...]

  • Page 9

    Strap Bracket Fuel Tanl< / ,i, Rubber Strap Check that both the 5 gallon fuel tank and its rubber strap have been received. The rubber strap has an "S" -Hook at each end that in- serts into strap brackets on the alternator cradle° 120 Volt, 30 Amp, 4-Prong Connector Plug 240 Volt, 20 Amp, 4-Prong Connector Plug ! Check that both the 1[...]

  • Page 10

    LUBRICATION CAUTION Engines are shipped without oil. Any attempt to start the engine before the recommended oil has been properly added may result in an engine failure. Service the engine crankcase with a high quality detergent oil having a classification which in- cludes"For Service MS, SC, SD or SE", and as recommended in the following [...]

  • Page 11

    BATTERY INSTALLATION A 12 Volt automotive type storage battery is required, and must be purchased separately. Battery should have a 32 amplhour (or higher) capacity° Install the battery as follows: _ CAUTION install the battery and connect battery cables EXACTLY as outlined in this Manual. Incorrect battery cable connec- tions will damage the engi[...]

  • Page 12

    FILL FUEL TANK 1_ Pull back on knurled fitting and remove fuel line from tank filler cap. 2. Remove Fuel Tank filler cap° Fill tank with CLEAN, FRESH, NON-LEADED gasoline. (Leaded, REGULAR grade gasoline is an ac- ceptable substitute.) Reinstall cover. _ DANGER Gasoline vapors are highly flammable and explosive. Avoid spillage. Do not permit smoki[...]

  • Page 13

    Optional Wiring Connections - 240 Volt Connector Plug _1_ DANGER All wiring connections should be done by a QUALIFIED electrician. Improper or unauthor- ized wiring connections are not only dangerous, but may damage equipment. Wire gauge sizes must be large enough to handle the maximum amperage load. All applicable elec- trical codes must be compli[...]

  • Page 14

    GROUNDING THE ALTERNATOR An earth grounding lug is provided on the alternator blower shroud. Connect a groun- ding wire to this lug that is no smaller than a No, 8 AWG. When using the alternator, the free end of the grounding wire must be con- nected to earth ground, or to a pipe or struc- ture that is attached to earth ground° DANGER DO NOT, unde[...]

  • Page 15

    Section 2 OPERATING INSTRUCTIONS DO AND DON'T CHART DO DON'T 1. DO read all instructions in this Manual before operating your alternator° 2o DO unplug all power cords from alternator outlets before starting or stopping the unit. 3_ DO add up wattages of all equipment to be powered by the alternator at one time. This total must not exceed[...]

  • Page 16

    BEFORE STARTING THE ENGINE CAUTION Do not operate engine wtth oll levet below "add 1 pint" mark_ FULL ADD 1 PINT 1, Disconnect Fuel Line 2, Remove Filler Cap t. Make sure engine crankcase has been pro- perly filled with the recommended oil. See LUBRICATION on Page 8. 2. Fill gas tank with clean, fresh, NON- LEADED gasoline. (Leaded, REGUL[...]

  • Page 17

    5. Unplug, disconnect or turn OFF all elec- trical equipment. _ CAUTION Never start the, alternator with electrical equipment plugged in and turned ON. Cor- rect voltage and frequency can only be ob- tained with engine running at governed speed of 1800 rpm. Some electrical equip- ment can be damaged by incorrect voltage and/or frequency. STARTING T[...]

  • Page 18

    STOPPING THE ENGINE 1. Unplug, disconnect, or turn OFF all electrical loads. Let the engine run for a few minutes to cool. 2. Set the StartlStop switch to STOP position. Do not leave unit until engine has come to a com- plete stop. WATTAGE AND POWER Watts is a measure of electrical POWER. In most cases, approximate watts can be found by multiplying[...]

  • Page 19

    USING THE 240 VOLT, 20 AMP OUTLET The outlet has a 20 amp capacity and can han- dle the full 4500 watt capacity of the alter- nator. To plug the connector plug into the outlet, align the 4 prongs and insert plug. Then twist the plug clockwise to lock. A 4-prong, 20 amp connector plug for this outlet is shipped with the alternator (see PARTS SHIP- P[...]

  • Page 20

    CHARGING A BATTERY The alternator battery receives a trickle charge of 0 - 8 amps as long as the engine is running. This battery charging circuit can be used to recharge an external 12 volt battery, as well. CAUTION The battery charging circuit is designed for 12 volt, automotive type storage batteries only. Do not attempt to recharge any 6 volt ba[...]

  • Page 21

    Section 3 PREVENTIVE MAINTENANCE MAINTENANCE CHART Maintenance Task General Inspection Change Oil Service Air Cleaner Inspect 30 Amp Fuse Replace Spark Plugs Clean Gas Tank Inspect Cooling Fins De-Carbonize Muffler Replace Fuel Filter De-Carbonize Cylinder Head Prepare Unit for Storage After First 5 Hours X X Each 25 Hours X X X X Each 100 Hours Ea[...]

  • Page 22

    CHANGE OIL Drain and refill engine crankcase with oil after the first 5 hours of operation, every 25 operating hours thereafter. Always drain oil wMle engine is warm from running. Always check oil level with unit level° Change oil as follows: J 1. With engine still warm from running, remove Oil Drain Plug at base of engine° Drain oil completely i[...]

  • Page 23

    SERVICE AIR CLEANER Clean and re-oil Air Cleaner foam pre-cleaner at 3 month intervals or every 25 operating hours, whichever comes first. Service more often if operating under dirty or dusty conditions. Service foam pre-cleaner as follows: 1o Remove cover nut and cover. 2. Remove foam pre-cleaner by sliding it up and off the paper cartridge. 3oA-W[...]

  • Page 24

    SPARK PLUGS Replace both spark plugs every 100 operating hours, as follows: 1. Remove wires from spark plugs. 2. Use 13/16 inch spark plug wrench (or deep socket) to remove both spark plugs. Turn plugs counterclockwise to remove. 3. Use Champion RJ-8, Auto-Lite A-71, or' AC plug GC-46 replacement spark plugs. Set gap on plug to 0°030 inch, us[...]

  • Page 25

    DE-CARBONIZE MUFFLER Clean carbon and condensation from spark arrest muffler every 100 hours of operation. Remove pipe plug from muffler, Start engine and let run for about 5 - 10 minutes. Shut engine down. When muffler has cooled, reinstall pipe plug. Spark Arrest Muff Jet REPLACE FUEL FILTER Replace In-Line Fuel Filter every 300 hours of operatio[...]

  • Page 26

    Troubles - Causes And Remedies POSSIBLE CAUSE A. ENGINE WILL NOT START OR STARTS WITH DIFFICULTY ! il. Out of gas 2. Fuel tank not vented 3. Clogged in-line fuel filter 4. Clogged fuel tank screen filter 5_ Engine over-choked 6o Defective spark plug 7_ Engine air cleaner dirty 8, Gummy deposits from old gasoline 1, Fill fuel tank 2oTurn fuel tank f[...]

  • Page 27

    Repair Parts Exploded View Of Fuel Tank Model No. 580.326010 _L_ o_cr _ E ._q (_ m_ o 0a o.u m __-_ 25[...]

  • Page 28

    Repair Parts Exploded View Of Alternator Model No. 580.326010 24 25 36 42 26[...]

  • Page 29

    Repair Parts Parts List Exploded View Of Alternator Model No. 580.326010 item 3 4 5 6 7 8 9 !0 11 12 13 14 t5 !6 17 18 !9 20 21 22 23 24 25 26 27 28 29 3O 31 32 33 34 35 36 37 38 39 4O 41 42 43 44 45 46 Part No. 42764 22104 42775 22129 49463 24489 42776 50378 42782 42876 30332 22145 42770A 42770B 42770C 31545 24655 50396 49462 42780 42774 42875 492[...]

  • Page 30

    Repair Parts Exploded View Of Sheet Metal And Accessories Model No. 580.326010 / o _O p.. CO p,. LO c'q v- 03 c_q 0 co o3 _0o o CN o3 28[...]

  • Page 31

    Repair Parts Parts List Exploded View Of Sheet Metal And Accessories Model No. 580.3260'10 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3O 31 32 33 34 35 36 37 38 39 4O 41 42 43 44 45 46 47 48 49 5O 51 52 53 Part No. Description 49421 49436 38045 49420 49437 49459 36781 22097 49457 49456 24489 49439 47672 [...]

  • Page 32

    Repair Parts P_ LO 03 LO L_ Exploded View Of Control Panel p,. t-- C-q / c_J Pq CO 03 O3 O C'q_ Model No. 580.326010 c) G) CO p.. O3 03 C3 C'q 30[...]

  • Page 33

    Repair Parts Parts List Exploded View Of Control Panel Model No. 580.326010 item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 ++ ++ ++ ++ Part Non 42356 24409 36918 22264 42786 42440 25034 38045 42353 22693 33868 32300 22676 22158 22152 22694 25388 23484D 43482 36933 37807 48731 49426 49474 36942 23484-C 49208 407t6[...]

  • Page 34

    Repair Parts Exploded View Of Wheel Kit And Accessories 03 04 o L_) s Model No. 580.326010 o3 LO 03 CO L_ O3 _3 w_ o _J I- D- LU t3- fr- O3 EO r_ f_ cc_ u J© _ Co O30 LO O3 04 O 03 t-- _2 p_ LO o ('4 ('4 04 04 c J3 r_ co 03 o3 04 o3 03 04 03[...]

  • Page 35

    Repair Parts Parts List Wheel Kit And Accessories Model No. 580.326010 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3O 31 32 33 34 35 Part Nor Description 42343 42344 28238 28237 42346 22746 26911 47459-B 45193 28124 45900 22268 27028 22142 22145 27007 22250 22128 47466 22458 42361 29268 50543* 30288 48031-C 47[...]

  • Page 36

    Repair Parts 6 Exploded View Of Engine Parts Model No. 580,326010 3 *Special Tool Required For Installation 7 8 3 58 1_ 13 16 21 20 32 34 19 _23 t8 39 ._ 25 26 3_ 40 41 50 51 8' 17 56 34[...]

  • Page 37

    b,.l_ r- .o o o3 o E 35[...]

  • Page 38

    Repair Parts Exploded View Of Engine Parts Model No. 580.326010 4 8 9 39 38 3 37 10 5 3t 33 1t 32 2 33 ! 12 2O 27 1 ' 40 35 34 26 41 5O 47 46 57 6O 36 52 53 52 58 59[...]

  • Page 39

    Repair Parts Parts List Engine Parts "o cr 03 or" Model No. 580.326010 ___0__ __0___ r- 0 °C 0 @3 0 13.., 37[...]

  • Page 40

    Repair Parts Exploded View Of Starter Model No. 580.326010 5 10 15 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No, 49462 42878 42692 42696 42693 42695 42782 22129 42870 42694 42690 42699 42691 42698 50940 Description GEAR, Ring (Includes fasteners (1 req'd) KtT, Pinion Spring (1 Req'd) DRIVE, Starter (1 Req'd) GEAR, Starter (1 Req&[...]

  • Page 41

    owners manual MODEL NO. 580.3260'10 SERVICE HOW TO ORDER REPAIR PARTS 4500 WATT HEAVY DUTY ALTERNATOR Now that you have purchased your Alternator, should a need ever exist for repair parts or service, simply contact any Sears Service Center and most Sears, Roebuck and Co. stores, Be sure to provide all pertinent facts when you call or visit. T[...]