Sears 580.32601 Owner'S Manual Download Page 1 | Manualshive

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Summary of Contents for 580.32601

Page 1: ...NG 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 No and Serial No are both located on the Nameplate just below Alternator Control Panel Model Noo Serial No Retain these numbers for future reference Sears Roebuck and Co Ct deago 1 1 60684 U S A ...

Page 2: ...usly high voltages Never permit un qualified people especially children to operate the unit _Never handle electrical equipment while standing in water while barefoot or while hands are wet This carl result in dangerous electrical shock_ Maintain electrical power cords in good condition Worn bare or frayed elec trical cords are dangerous Make sure the wire gauge sizes of electrical power cords are ...

Page 3: ...19 Change Oil 20 Service Air Cleaner 21 Inspect 30 Amp Fuse 21 Spark Plugs 22 Clean Fuel Tank 22 Inspect Cooling Fins 22 De Carbonize Muffler 23 Replace Fuel Filter 23 De Carbonize Engine Cylinder Heads 23 Storage 23 z c3 Z w SPECIFICATIONS Model Noo 58 326010 IWattage Capacity 4500 Watts Continuous 5600 watts m omentary surgei Voltage Output 120f240 Volts Amperes Maximum 37 5 at 120 Voi ts _18175...

Page 4: ... 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 WHEEL KIT 2 ...

Page 5: ...WIRING DIAGRAM Model No 580 326010 o ci _ oooooo V DO 0 0 ...

Page 6: ...on Centers and 4 interconnecting wir ing The CONNECTION BOX and CORD SET is used with the 120 240 volt 4 prong 20 amp outlet The following Stand By Kits are available Model No Connection Box and Cord Set Transfer Switch 580 322280 120 240 Volt 4 wire cord set 100 Amp Manual 580 322290 201240 Volt 4 wire cord set 200 Amp Manual A TRANSFER SWITCH is required to prevent electrical feedback between ut...

Page 7: ... Use two 7 16 inch wrenches to remove bolts and hex nuts Alternator can then be removed from wood pallet The following items are shipped with the alternator and must be installed or assembled To order additional items listed below refer to REPAIR PARTS section of this manual 1_ Battery Hold Down Bracket with retaining hardware 2 Wheel Kit 3 One 5 gallon Fuel Tank with retaining strap 4o One 120 Vo...

Page 8: ...a 4 2 Req d 16 Cotter Pin 3 32 2 Req d 17 Support Leg Cushion 1 Req d 18 Flat Washer 7116 1 Req d 19 Bolt 5 16 18 x 11 4 long 1 Req d Description Nut 5 16 18 1 Req d Support Leg 1 Req d Bolt 5 16 18 x 3 4 tong 2 Req d Washer Flat 5 16 2 Req d Nut 5116 t8 2 Req d Handle 2 Req d Bolt 318 16 x 2s 4 long 4 Req d Locknut 3 8 16 4 Req d Plastic Cap 2 Req d 19 ITEM 17 ITEM 16 ITEM 11 ITEM 13 ITEM 18 ITEM...

Page 9: ...le Spacer with 3 32 Cotter Pin Item 7 4 Repeat Steps 2 and 3 above for other side of Axle Shaft 5 Center Axle Shaft so that no binding is evi dent and both wheels turn freely Then tighten U bolt Lock Nuts Item 3 at both ends of Axle Shaft 6o Slide 7116 Fiat Washer Item 9 over 5116 18 x 1 4 bolt Item t0 o 7_ Insert bolt Item 10 through Support Leg Cushion Item 8 and through hole in Support Leg Item...

Page 10: ...move Oil Dipstick from Oil Filler neck 2 Make sure unit is LEVEL 3 Pour a measured 31 2 pints 56 ounces or 1o65 Liters of the recommended oil into Filler Neck_ DO NOT OVERFILL CAUTION If engine crankcase is overfilled a smoking condition will result as the engine tries to discharge the surplus oil 4 Reinstall Oil Dipstick ALL THE WAY into Oil Filler Neck then remove Oil should be at Dipstick FULL ...

Page 11: ...et with two t 4 20 x 7 long bolts Item 2 Flat Washer Item 3 Lock Washer item 4 and Wing Nuts Item 5 Snug both Wing Nuts down but DO NOT OVER TIGHTEN BATTERY CONNECTIONS 1o The black battery cable is connected to a grounding lug Make sure the cable is TIGHT then connect the other end of black cable to battery post indicated by a NEGATIVE NEG or o Battery Locating Bracket ITEM 5 h t2 Volt Battery fl...

Page 12: ...rds used with the two 120 volt 15 amp outlets must be in good condition Wire gauge sizes of cord sets must be large enough to handle the amperage load of tools and equipment they power The chart at right lists recommended wire sizes for cord sets based on the amperage of equipment being used and the length of the cord in feet 10 2 Remove Filler Cap 1 T_NK FILLER CAP 2 To connect fuel line quick di...

Page 13: ...20 volts a c and 240 volts a c as shown above when a 4 wire cable is connected to the connector plug One method of connecting a 4 wire cable to the connector plug is to terminate the cable at a connection box See illustration above When a Stand By kit is ordered a 4 wire cord set is included see INSTALLATION OF STAND BY POWER SYSTEMS page 4 _ Optional Wiring Connections 120 Volt 30 Amp Connector P...

Page 14: ...ee 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 under any circumstances attach the grounding wire to any structure pipe or container that contains a combustible material This can result in fire or explosion in the event the alternator frame becomes electrically charged Centrifugal BJower Shroud Ground Lug t2 ...

Page 15: ...ne is running or in the dark Gasoline spillage on a hot engine can cause fire or an explosion 2 DON T run the alternator in any enclosed space Gasoline engines consume oxygen and give off DEADLY carbon monoxide 3o DON T install the alternator in any compart ment that will restrict the free flow of cooling air Without this free flow of cooling air serious heat damage to the alternator wilt oc cur 4...

Page 16: ...s an acceptable substitute_ k DANGER Gasoline vapors are highly flammable and explosive Do not permit smoking open flame or sparks in the vicinity while filling gas tank Do not allow gasoline to spill on any hot surface E t TANK FILLER CAP 3o Connect fuel supply hose to gas tank outlet fitting Pull back on the knuded sleeve insert hose fitting over tank outlet fitting and let the sleeve snap into ...

Page 17: ... Hold StoplStart Switch To Start Position 2 Release Switch When Engine Starts 1 Move Choke Lever all the way down to CLOSED position NOTE Lesser amounts of choking may be re quired when engine is warm 2 Hold Start Stop switch at START position to crank engine Release switch when engine starts Then open choke gradually as engine warms up CAUTION Do not crank engine continuously for longer than abou...

Page 18: ...120 VOLT 15 AMP OUTLETS on Page 11 Each of these outlets is rated at a maximum capacity of 15 amps or 1800 watts_ Do not at tempt to run equipment requiring more than 15 amps or 1800 watts of power Do not at tempt to run 240 volt equipment from either outlet USING THE 120 VOLT 30 AMP OUTLET _J 120 VOLT 15 AMPS 1800 WATTS 120 VOLT 15 AMPS 1800 WATTS A 3 prong 30 amp connector plug for this outlet i...

Page 19: ...igh internal temperatures which will cause this device to trip NO A C POWER WILL BE AVAILABLE FROM ALTERNATOR OUTLETS UN TIL INTERNAL TEMPERATURES HAVE RETURNED TO NORMAL If a loss of electrical output occurs immediately unplug turn OFF or disconnect electrical loads Let unit cool for several minutes then reconnect loads NOT TO EXCEED 4500 watts MOTOR STARTING REQUIREMENTS Some electric motors req...

Page 20: ...austic sulfuric acid solution that can cause severe burns Avoid spillage of fluid or contact with skin eyes wiring insulation or painted surfaces If spillage or contact occurs flush immediately with clear water To recharge a discharged battery proceed as follows 1 Remove battery vent caps 2 Connect a battery jumper cable to alter nator battery post indicated by a POSITIVE POS or and to the dischar...

Page 21: ... Hours X X Each 25 Hours X X X X Each 100 Hours Each 300 Hours Other X X X X X X NOTE Prepare unit for storage when it is to remain idle longer than 30 days See NOTE GENERAL INSPECTION Perform a complete overall inspection of the entire unit after the first 5 hours of operation every 25 operating hours thereafter Check for 1 oil leaks 2 fuel leaks 3 missing rusted or damag ed nuts bolts washers et...

Page 22: ...d Oils 2 Remove Oil Dipstick from Oil Filler neck Pour a measured 31 2 Pints 56 Ounces or 1_65 Liters into Oil Filler neck 3 Make sure unit is level Wipe dipstick dry with a clean lint free cloth Install dipstick ALL THE WAY into Oil Filler neck Remove dipstick and check oil level Level should be at dipstick FULL mark Do Not Overfill l Do not run engine with oil level below l this line FULL ADD 1 ...

Page 23: ...d paper cartridge Clean paper cartridge by tapping gently on a flat surfacer If extremely dirty replace cartridge or wash cartridge in liquid detergent and water_ Rinse cartridge until water re mains clear AIR DRY CARTRIDGE THOROUGHLY BEFORE USING INSPECT 30 AMP FUSE The alternator is equipped with a battery charging circuit This circuit provides an automatic trickle charge of 0 8 amps to the unit...

Page 24: ...er Gauge CLEAN FUEL TANK About every 100 hours of operation or every 3 months whichever comes first clean the fuel tank Pour about a quart of clean gasoline into tank shake vigorously then empty tank completely Move hose retainer sideways so it will fit through tank filler oDening and remove filler cap Inspect fuel pickup screen for clogging Clean if necessary FUEL TANK FILLER CAP FUEL PICKUP HOSE...

Page 25: ...e P POINT ARROW ON FILTER AWAY FROM FUEL TANK Fuel Tank DE CARBONIZE ENGINE CYLINDER HEADS Excessive carbon build up in engine combustion area will rob engine power and result in rough engine operation Have carbon deposits removed every 300 operating hours more often if operating under a steady load or whenever cylinder head is removed STORAGE Whenever the alternator is to be idle for longer than ...

Page 26: ...T 1_ Lack of lubrication 2o Engine cooling fins dirty 3 Cooling air flow obstructed 4o Excessive load on engine 5o Defective alternator bearing 1 Check oil level fill to FULL mark on dipstick 2 Clean cooling fins 3 Remove all obstructions from cooling air in let and outlet 4 Check wattage of all equipment total wat tage should not be more than 4500 watts 5 Have bearing replaced D LOW OR NO VOLTAGE...

Page 27: ...Repair Parts Exploded View Of Fuel Tank Model No 580 326010 _L_ o_cr _ E _q _ m_ o 0ao u m __ _ 25 ...

Page 28: ...Repair Parts Exploded View Of Alternator Model No 580 326010 24 25 36 42 26 ...

Page 29: ... 3 4 Long 7 Req d WASHER Fiat 5 16 10 Req d SHIM Starter Bracket 002 Thick As Required SHIM Starter Bracket 005 Thick As Required SHIM Starter Bracket _010 Thick As Required CAPSCREW Hex Head 3 8 t6 x 31 4 Long 4 Required SCREW Taptite _A 20 x 1 Long 1 Req d SPACER 1 Req d RING GEAR with fasteners 1 Req d FAN and MAGNET ASSEMBLY 1 Req d WASHER Belleville 5 16 1 Req d SPIDER Disc Drive 1 Req d ROTO...

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: ...ARRIER Fan Spider 1 Req d BOLl 5 16 x 1o25 Lg HHCS 3 Req d LOCKWASHER 5116 15 Req d BOLT 5 16 18 x _75 Lgo HHCS 6 Req d FAN Centrifugal 12 62 Dia 1 Req d RING Inertia 1 Req d WASHER Fan Retainer 1 Req d LOCKWASHER 3 8 3 Req d BOLT 3 8 24 x 1 50 Grade 5 1 Req d COVER Head No 1 1 Req d COVER Head No 2 1 Req d BAFFLE Engine Air 1 Req d BOLT 1 4 20 x 50 Lg HHCS 2 Req d HOUSING Blower 1 Req d SOLENOID ...

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: ...d PLUG Button 1o06 Dia 1 Req d SCREW Whiz No 10 32 x 3 8 Long 11 Req d SILKSCREEN Panel 1 Req d OUTLET 120 Parrallel Blade 2 Req d SWITCH DPST 1 Req d HOLDER Fuse 1 Req d FUSE 15A 1 Req d NUT Hex No 0 32 8 Req d LOCKWASHER No 10 8 Req d RECEPTACLE 2 Req d RIVET 4 Req d BUSHING Snap 2 Req d OUTLET Twistlock 240V 20Ao 1 Req d SCREW PPHM No 10 32 x 3 8 6 Req d OUTLET Twistlok 120V_ 30Ao 1 Req d DIODE...

Page 34: ...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_ uJ _ 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: ... SPACER Axle 2 Req d WHEEL 2 Req d WASHER 3 4 Flat 2 Req d PIN 3 32 Cotter 2 Req d NUT 5116 18 Lock 9 Req d CAPSCREW 5 16 18 x 75 Hexo Head 2 Req d WASHER 5It6 Flat 2 Req d DAMPNER Vibration 1 Req d WASHER 7 16 Flat I Req d CAPSCREW 5116 18 x 1 25 Lg Hex Head 1 Req d LEG Mounting Support 1 Req d CAPSCREW 3 8 16 x 2 75 Lg Hexo Head 4 Req d HANDLE Cradle 2 Req d CAP Handle 2 Req d ASSEMBLY Fuel Tank...

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: ...scription GEAR Ring Includes fasteners 1 req d KtT Pinion Spring 1 Req d DRIVE Starter 1 Req d GEAR Starter 1 Req d CLUTCH Starter 1 Req d RETAINER and PIN 1 Req d BOLT 5 16 18 x 13 4 Long Grade 5 2 Req d WASHER Lock 5 16 2 Req d CAP Starter Drive End 1 Req d ARMATURE Starter 1 Req d THRU BOLT Starter 2 Req d HOUSING Starter 1 Req d BRUSH SET Starter 1 Req d END CAP Commutator 1 Req d STARTER ASSE...

Page 41: ... visit The model number of your Alternator will be listed on the Alternator data plate WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION o PART NUMBER o PART DESCRIPTION MODEL NUMBER NAME OF ITEM All parts listed may be ordered from any Sears Service Center and most Sears stores If the parts you need are not stocked locally your order will be electronically transmitted to a Sears Re...

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