Home

Chicago Electric 67561 User's Manual

1. 120 V Duplex Reset Ground Wire 12 VDC Outlet Receptacle Switch Connection 120 V Twist Lock Receptacle Plug for up to 15A DC Circuit Breaker Switch 10 Amps Loy cas Plug for up 120V Duplex to 20A Receptacle for 15A or 20A plugs Note Be sure to use the proper plug for the amps needed Figure 1 SKU 67561 For technical questions please call 1 800 444 3353 Page 9 OPERATING INSTRUCTIONS Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT AWARNING SERIOUS INJURY Operate only with proper spark arrestor installed Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements Starting the Engine Inspect engine and equipment A looking for damaged loose and missing parts before set up and starting If any problems are found do not use equipment until fixed properly Before starting first familiarize yourself with proper shut down and emergency shut down procedures Checking and Filling Engine Oil CAUTION Your Warranty is VOID if the engine s crankcase is not properly filled with oil before each use Before each use check the oil level Do not
2. BASIC SPECIFICATIONS 8 MAIN PARTS LIST FUNCTIONS erre 8 MAIN ASSEMBLY DIAGRAM PARTS LIST AND DIAGRAM A 8 CRANKCASE ASSEMBLY CONTROLS enne 9 PARTS LIST AND DIAGRAM B OPERATING INSTRUCTIONS 10 ________ PARTS LIST AND DIAGRAM STARTING THE ENGINE 10 C CRANKSHAFT PISTON CHECKING AND FILLING CONNECTING ROD ENGINE 10 CAMSHAFT AND FLYWHEEL CHECKING AND FILLING FUEL 11 ASSEMBLIES en START PROCEDURE 11 PARTS LIST AND DIAGRAM BREAK IN PERIOD 12 D RECOIL STARTER AND EQUIPMENT OPERATION 12 IGNITION COIL ASSEMBLY CONTROL PANEL FEATURES 13 SERVICING soos scent 14 MAINTENANCE PROCEDURES 14 ENGINE OIL CHANGE 14 AIR FILTER ELEMENT MAINTENANCE 14 SPARK PLUG MAINTENANCE 15 CLEANING MAINTENANCE AND LUBRICATION SCHEDULE 16 AFTER INITIAL 20 OPERATION HOUR PERIOD 16 EVERY 25 OPERATION HOURS THEREAFTER 16 EVERY 50 OPERATION HOURS T ee eee 16 EVERY 100 OPERATION HOURS 16 SKU 67561 For technical questions please call 1 800 444 3353 PARTS LIST AND DIAGRAM E AIR CLEANER AND MUFFLER ASSEMBLY cran anis PARTS LIST AND DIAGRAM F FUEL SUPPLY SYSTEM PARTS LIST AND D
3. Intake Manifold leaking Dirty or clogged Cylinder Cooling Fins Cooling Fan loose or damaged Bent Piston Rod Worn Piston Piston Ring or Cylinder Wall Improper engine speed Worn Crankshaft Main Bearing For technical questions please call 1 800 444 3353 Replace fuel with 91 octane premium unleaded gasoline Adjust the choke Have the timing checked by a qualified technician Check fuel level and refill as needed Clean Fuel Filter Replace if needed Clean and readjust Move Switch to ON position Clean or replace spark plug Reset gap to 0 024 0 031 Check connections at both ends Check condition of spark plug wire replace as needed Check coil continuity and output Have serviced by a qualified technician Disconnect engine and attempt to rotate generator shaft by hand Repair or replace as needed Check and reset Ignition Timing Check condition of exhaust system repair as needed Check condition of intake manifold and gasket Repair as needed Clean Cylinder Wall Cooling Fins Check condition of cooling fan Repair or replace as needed Replace Piston Rod Check clearances replace as needed Engine speed is self regulating Be sure choke if fully open Reduce electrical load on generator Check for wear Replace as needed Page 19 Equipment Troubleshooting Possible Causes Probable Sol
4. 72 FlangeScrewM8 1 73 Flange Screw M6X12 2 74 NutM6x14 2 75 Flange Screw M8X20 4 Washer 8 4 77 J 4 78 FlangeScrew MOX12 6 79 Toothed Washer5 1 80 Platewasherb 1 81 Springwasherb J 1 82 Flange Screw 5 16 1 83 FlangenutM6 1 84 ToothedWasher5 1 85 PPlatewasher 86 Springwasher6 1 87 Flange Screw MOX12 1 88 FlangenutM6 4 89 Flangent M8 4 90 Flange Screw M8X25 2 91 Flange nutM6 4 4 4 1 1 1 4 1 1 1 1 2 4 4 2 2 1 2 2 2 2 2 2 2 1 1 2 2 4 4 4 1 1 1 1 1 1 1 1 1 4 4 2 4 4 21 69 SKU 67561 For technical questions please call 1 800 444 3353 Parts List and Diagram A Crankcase Assembly NOTE All part numbers listed on the following pages have a letter suffix For example the Crankcase Cover shown in the above diagram is part 12a Whenever refer ring to engine sub assembly parts be sure to include the complete part number including the letter suffix Description Part Description Drain Plug ___________ 9a _ Drain Plug Drain Plug Washer Crankshaft Oil Seal Regulating Sway Bar Split Pin Part 8 Regulating Shaft Crankcase Gasket Dipstick with Seal Bearing 6205 15a SetPin
5. run the engine with low or no engine oil Running the engine with no or low engine oil WILL permanently damage the engine Check the oil level with the engine stopped and in a level position Wipe dipstick exterior with a clean cloth Remove the dipstick and wipe it off with a clean rag Pour engine oil into the oil fill hole until the level of oil is even with the bottom edge of the oil fill hole if you cannot see the oil through the oil fill hole then the oil is too low and more oil must be added Reinsert the dipstick into the oil filler neck but do not screw in then remove it to check the oil level The oil level should reach the upper limit H mark on the dipstick bottom edge of the oil fill hole If the oil level is not to the upper limit mark bottom edge of the oil fill hole add the appropriate type of oil until the oil level reaches the upper limit mark THIS GENERATOR HAS AN AUTO SHUTDOWN OIL SENSOR IF ENGINE STOPS OR WILL NOT START CHECK OIL LEVEL OIL LEVEL DO NOT REMOVE Enaine Oil SAE 10W 30 above 32 F 9 SAE 5W 30 at 32 F or below Replace the Oil Dipstick The Oil Sensor will automatically shut down the engine before the oil level falls below the safe low limit To avoid nuisance tripping of the Oil Sensor and damage to property check that the oil level is at the SKU 67561 For technical questions please call 1 800 444 3353 Page 10 bottom edge of the oil fill hole before each st
6. warranty station as soon as a problem exists Contact the HFT Customer Service department at the number below to make shipping arrangements The 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 should contact the Harbor Freight Tools Customer Service Department at 1 800 444 3353 Harbor Freight Tools Emission Control Defects Warranty Provisions Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two 2 years after the date of delivery to the first retail purchaser No Charge Repair or Replacement Repair or replacement of any warranted part will be performed at no charge to the owner if the work is performed through a warranty station authorized by HFT For emissions warranty service contact the HFT Customer Service Department at 1 800 444 3353 Consequential Damages Coverage Coverage under this warranty shall also extend to the failure of any engine components caused by the failure of any warranted part while it is still covered under this warranty Coverage Exclusions Warranty claims shall be filed in accordance with the provisions of the HFT warranty policy explained in the box at the top of the previous page HFT shall not be liable f
7. a period of ninety days from date of purchase that the engine motor the belts if so equipped and the blades if so equipped are free of defects in materials and workmanship Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that all other parts and components of the product are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace SKU 67561 For technical questions
8. a qualified technician mechanic to perform all required maintenance as outlined in the Inspection Cleaning and Maintenance section in this manual Warranted Parts 1 Fuel Metering System i Carburetor and its internal parts ii Fuel pump if so equipped iii Cold start enrichment system 2 Air Induction System i Intake pipe manifold ii Air cleaner 3 Ignition System i Spark plug ii Magneto ignition system 4 Catalyst System if so equipped i Exhaust pipe stud ii Muffler iii Catalytic converter if so equipped 5 Miscellaneous Items Used in Above Systems i Vacuum temperature and time sensitive valves and switches ii Hoses belts connectors and assemblies Page 31
9. for this engine is warranted for standards set by the U S Environmental Protection Agency and by the California Air Resources Board also known as CARB For warranty information refer to the last pages of this manual At high altitudes the engine s carburetor governor if so equipped and any other parts that control the fuel air ratio will need to be adjusted by a qualified technician to allow efficient high altitude use and to prevent damage to the engine and any other devices used with this product SKU 67561 For technical questions please call 1 800 444 3353 Functions This unit can power items such as the following WATTS WATTS 1 2 HP Sump Pump 1050 2150 1 2 HP Well Pump 1000 2100 1650 3000 1 1 2 HP Capacitor Start 1400 3100 amp Run Motor Note The above wattages are estimates Check nameplate wattages on all loads before connecting to generator UNPACKING When unpacking check to make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at 1 800 444 3353 as soon as possible REMOVE THESE BOLTS AND BRACKETS BEFORE USE There are two metal brackets that hold the generator in place during shipment to prevent damage They must be removed before use See the photo above Page 8 CONTROLS Power Indicator Light AC Circuit Engine Power Switch Breaker Switch e ENGINISWITCH 00 MAIN BREAKER ON
10. good working order before connecting them to the generator If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn off the AC Circuit Breaker and the generator Engine Power Switch immediately Then disconnect the appliance and examine it for signs of malfunction Page 12 Note If an overloaded circuit causes the AC Circuit Breaker to switch off reduce the electrical load on the circuit and wait a few minutes before resetting the circuit breaker 7 DC terminal may be used to operate 12 Volt DC portable appliances only CAUTION Do not use this generator to charge 12VDC batteries Directly charging a 12 Volt battery may cause the battery to overheat and possibly explode CAUTION Do not attempt to start an automobile engine with this generator Voltage back feed from the alternator may damage the generator Note The DC terminal may be used while the AC power is in use An overloaded DC circuit will trip the DC circuit protector push button comes out If this happens wait a few minutes before pushing in the circuit protector to resume operation 8 Disconnect all loads from the generator before shutting off To prevent accidents turn off the engine and disconnect its spark plug wire after use Wait for the engine to cool clean external parts with clean cloth then store the equipment out of children s reach according to the Storage instructions in this manual Control Panel F
11. may include parts such as the carburetor or fuel injection system and the ignition system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists HFT will repair your engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 1995 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by HFT Harbor Freight Tools Emission Control Defects Warranty Coverage Engines are warranted for a period of two 2 years relative to emission control parts defects subject to the provisions set forth below If any emission related part on your engine is defective the part will be repaired or replaced by HFT Page 30 SKU 67561 Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual HFT recommends that you retain all receipts covering maintenance on your engine but HFT cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that HFT may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for shipping your engine to a HFT
12. please call 1 800 444 3353 the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 EMISSION CONTROL SYSTEM WARRANTY California and United States Emission Control Defects Warranty Statement The California Air Resources Board herein CARB the United States Environmental Protection Agency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 1995 and later Small Off Road Engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti smog standards Elsewhere within the United States new off road spark ignition engines certified for model year 1997 and later must meet similar standards set forth by the EPA HFT must warrant the emission control system on your engine for the periods of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system
13. 8 1 28 Fuel Tank Cock Assembly 1 29 Fuel Pipe 97 5 300mm_ 1 30 Clamp 913 4 31 Fuel Pipe 97 5 380mm_ 1 32 CatbonBox 1 33 Frameassy 1 34 Control panel assy 1 35 ShockAbsorber 4 37 Grounding Wire 12cm p6 96 1 38 Mufflerguard1 1 39 Mufflerguard2 1 40 Flange Screw M8X25 4 41 FlangeScrewvM8 4 42 Flange Screw M6X45 2 43 Springwasher 2 44 Platewashero 2 45 Platewasher8 4 46 Springwasher8 4 1 1 EN 1 1 1 1 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 2 2 2 4 4 SKU 67561 For technical questions please call 1 800 444 3353 Flange Screw 5 16 210 240 1 Spring washer 6 Description Flange Screw M8X25 ___ 4 EM i _1 4 1 1 1 2 58 FlangenutMS 44 59 PlatewasherS 4 60 Springwasherhb 2 61 Flange Screw M5X16 2 62 Flange Screw M5X16 _ _ 1 63 FlangeScrewM5X12 2 64 Flange Screw 5 16 2 65 FlangeScrewM8 8 66 Flange Screw M8 J 2 67 Springwasher8 2 68 Platewasher8 2 69 4 6 0 J2 70 Springwasher6 2 71 Flange Screw MSX35 1
14. CHICAGO lite 3050 RATED WATTS 3500 WATTS GASOLINE GENERATOR CERTIFIED IN CALIFORNIA SET UP OPERATING AND SERVICING INSTRUCTIONS A DANGER Using an engine indoors CAN KILL YOU IN MINUTES Engine exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside Only use OUTSIDE a home or garage and far away from EVEN IF doors and windows doors and windows are open vents Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2009 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included For technical questions or replacement parts please call 1 800 444 3353 CONTENTS EVERY 300 OPERATION HOURS IMPORTANT SAFETY STORAGE osito INFORMATION 3 TROUBLESHOOTING AC 6 EQUIPMENT EXTENSION 0 7 TROUBLESHOOTING
15. IAGRAM G STARTER AND GENERATOR ASSEMBLY rint WIRING DIAGRAM LIMITED 1 YEAR 90 DAY WARRANTY EMISSION CONTROL SYSTEM WARRANTY 16 Page 2 SAVE THIS MANUAL Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates DANGER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury SKU 67561 For technical questions please call 1 800 444 3353 CAUTION used ACAUTION with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to personal injury CAUTION CAUTION without the safety alert symbol is used t
16. SKU 67561 For technical questions please call 1 800 444 3353 Page 17 Ignition System Fuel Supply System Engine System Poor Compression Engine is Pinging Excess wear of Piston Cylinder Wall or Rings Piston Pin or Piston Pin Hole Connecting Rod Wrist Pin Crankshaft Roller Bearing Abnormal Com bustion or engine running hot or excess smoking Engine does not start SKU 67561 Combustion chamber carbon Dirty or old gasoline or oil in gas Engine Switch in OFF position Water in Carburetor Bowl Spark Plug gap not correct Incorrect Ignition Timing Damaged coil or ignition wires Low Oil level Engine Troubleshooting Problem Low power output Engine bogs down or dies under load Excess exhaust or unburned fuel in exhaust See chart below Air in fuel line or fuel line clogged Main Jet not adjusted properly Metering Jet or Main Jet clogged Fuel Cock clogged Carbon Fouling in Combustion Chamber Clogged Air Filter Intake Manifold leaking Worn Piston Piston Ring or Cylinder Wall Leaking Cylinder Head Gasket Worn Valves Valve Seats Stems or Valve Guides fouling For technical questions please call 1 800 444 3353 Possible Cause Possible Solution Incorrect Ignition Timing Adjust Engine Advance Angle Purge air or clear obstruction Readjust Main Jet Clean and Readjust Clean as needed Clean out Combustion Chamb
17. U 67561 NEVER use inside a home or garage EVEN IF doors and windows are open PD Gr Only use OUTSIDE and far away from windows doors and vents Keep children away from the equipment especially while it is operating N 10 For technical questions please call 1 800 444 3353 Do not leave the equipment unattended when it is running Turn off the equipment and remove safety keys if available before leaving the work area Wear ANSI approved safety goggles and hearing protection during use People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure Caution is necessary when near the engine s magneto or recoil starter Use only accessories that are recommended by Harbor Freight Tools for your model Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment Do not operate in explosive atmospheres such as in the presence of flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes Stay alert watch what you are doing and use common sense when operating this piece of equipment Do not use this piece of equipment while tired or under the influence of drugs alcohol or medication Do not overreach Keep proper footing and balance at all times This enables better control of the
18. airs beyond your training or ability PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 67561 For technical questions please call 1 800 444 3353 Page 20 Main Parts List Description 0 Rear cover 8 Connectionpole Cid 9 CarbonBrush 11 3kw Automatic Voltage Regulator 1 13 Muflergurd 1 14 Muflerassy ___ 1 15 PulsedValve J 1 16 Muffler Gasket 11 17 ExhaustGasket 1 Fuel Tank EI CARB Standard 278C blue 19 Straimr 1 Fuel Tank Cap Assembl 21 FuelMarker 11 22 Fuel Tank Connecter 1 23 Washerg10 5 4 24 ShockAbsorberforfueltank 4 25 Clampog7 11 26 FuelPipeg45 11 27 Clampg
19. and Muffler Assembl Part Description Parts List and Diagram F Fuel Supply System Back Spring Regulator Assembl SKU 67561 For technical questions please call 1 800 444 3353 Page 27 Parts List and Diagram G Starter and Generator Assembl Qty Part Description Part Description 6g jBotm6x35 8 12 2 9g Flywheel d l i Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 67561 For technical questions please call 1 800 444 3353 Page 28 Wiring Diagram Asse 109 1105095 UOT 1181 8114 ids 9119 i 100 4 9pdand Cd 48591 21 10 6 10 81 __ 3 2 00 ren 8 MOT 94 AGL OV 101819098 4061 OV 4061 OV 49 29 For technical questions please call 1 800 444 3353 SKU 67561 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for
20. art up CAUTION DO NOT run the engine with low oil or no oil the engine will be permanently damaged Checking and Filling Fuel 1 Check the fuel level If the fuel level is more than 1 below the fill neck of the fuel tank add more fuel Note Do not overfill the fuel tank A WARNING TO PREVENT 55 SERIOUS INJURY FROM FIRE Fill the fuel tank in a well ventilated area away from ignition sources Do not smoke 2 Tofill the Fuel Tank first wipe off the Fuel Tank Cap and the surrounding area 3 Unscrew and remove the Fuel Tank Cap 4 Mix fuel stabilizer not included with 91 octane or better premium unleaded gasoline according to fuel stabilizer directions Note Use only premium octane unleaded gasoline 5 Fill the Fuel Tank to about 1 inch under the fill neck of the gasoline tank with the stabilized unleaded gasoline mixture 6 Then replace the Fuel Tank Cap Start Procedure SKU 67561 Before starting the engine a Inspect the equipment and engine For technical questions please call 1 800 444 3353 b Fill the engine with the proper amount and type of fuel and oil c Read the Equipment Operation section that follows 1 Unplug loads from the Generator and make sure the AC Circuit Breaker Switch is in the OFF position before starting to prevent permanent generator damage 2 Turn the engine fuel valve to its ON or OPEN position 3 Turn the Engine Power Swit
21. ch to its ON or RUN position 4 Then turn the engine choke lever to its CHOKE position Set the choke lever in the RUN position when starting a warm engine 5 Grasp the starter handle and pull slowly until resistance is felt While holding the handle allow the starter rope to rewind Then pull the starter handle with a rapid full arm stroke Once again while holding the handle allow the rope to rewind Repeat as necessary until the engine starts 6 After the engine starts and warms up slowly move the choke lever to its RUN position IMPORTANT Allow the engine to run at no load until warm 1 5 minutes to stabilize T Move the AC Circuit Breaker Switch to its ON or RUN position Page 11 Break in Period 1 Breaking in the engine will help to ensure proper equipment and engine operation and will extend the engine s lifespan The warranty is void if the engine is not broken in properly The first 20 hours of operation is the break in period During the first 3 hours of use Do not apply a heavy load to the equipment After the first 20 hours of use Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section Equipment Operation TO PREVENT AWARNING SERIOUS INJURY SKU 67561 AND DEATH DO NOT CONNECT GENERATOR DIRECTLY TO HOUSEHOLD WIRING A portable electric generator that
22. e the greater the capacity of the a qualified electrician before using it cord For example a 14 gauge cord gauge cord sharp objects excessive heat and See Table A damp or wet areas 4 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Table A RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES at full load 25Feet 75 Feet 100 Feet 0 20 128 a 18 18 241 34 18 _ 6 389 58 3 e 2 S e cms _ e 4 e 0 Lace o 2 0 SKU 67561 For technical questions please call 1 800 444 3353 Page 7 BASIC SPECIFICATIONS 91 octane premium Fuel yp unleaded gasoline Capacity 4 Gallons Type SAE 10W 30 above 32 F Engine SAE 5W 30 at 32 or below Capacit 2 3 Quart with Low Oil Shutdown Sensor Spark Plug 0 024 0 031 Run Time 9 Hours with full tank 50 Load 7 HP Four stroke Overhead Valve Design Recoil Start with Electronic One 20A duplex NEMA 120V receptacle One 25A NEMA 120V 3 prong twist lock receptacle One T Type 12V outlet 10A DC Breaker Electrical Outlets Note Additional specifications found in the TECHNICAL ENGINE SPECIFICATIONS chart in this manual The emission control system
23. eatures 1 Engine Power Switch must be in ON position for engine to start and run Move to OFF position to stop engine 2 Power Indicator Light when lit shows that the generator is producing electrical energy SKU 67561 AC Circuit Breaker Switch protects circuits when using AC power 120 V duplex outlet provides two grounded outlets for standard 110 120 V household appliances The outlets are configured for both standard 15A plugs or 20A plugs See Figure 1 Controls 120 V twist lock receptacle provides a grounded outlet for one 120 Volt appliance such as a water heater 12 VDC outlet provides a power source for 12 volt DC items such as automotive accessories 12 VDC Circuit Breaker Switch provides circuit protection for 12 VDC accessories For technical questions please call 1 800 444 3353 Page 13 TECHNICAL Maintenance Procedures SPECIFICATIONS Many maintenance procedures including those not detailed Engine Type 4 Stroke OHV 9 in this manual will need to Bore x Stroke 70 x 54mm A be performed by a qualified Compression Ratio e technician for safety If you isplacemen 8cc have any doubts about your 91 octane premium ability to safely service the Capacity allons equipment or engine have a qualified technician service the SAE 10W 30 above 32 F 22 4 Type SAE 5W 30 at 32 F or equipment instead Engine Oil below Note Warranty is void if pr
24. electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes WARNING Improper connections to a building electrical system can allow electrical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause fires when utility power is restored Consult the utility company or a qualified electrician Sensitive electronic equipment includes but is not limited to audio video equipment some television sets computers and printers Page 5 AC APPLICATIONS 1 Before connecting an appliance or power cord to the generator Make sure that it is in good working order Faulty appliances or power cords can create a potential for electrical shock 4 2 Ifan appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately 5 Disconnect appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded 3 Make sure that the electrical rating of the tool or appliance does not exceed that of the generator Never exceed the maximum power rating of the generator Power levels between rated and maximum may be used for no more than 30 minutes 4 Substantial overloading will open the circ
25. equipment in unexpected situations Use this equipment with both hands only Using equipment with only one hand can easily result in loss of control Dress properly Do not wear loose clothing or jewelry Keep hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Page 4 125 13 14 19 16 17 18 19 20 41 SKU 67561 Parts especially exhaust system components get very hot during use Stay clear of hot parts 22 Do not cover the engine or equipment during operation Keep the equipment engine and surrounding area clean at all times Use the equipment accessories etc in accordance with these instructions and in the manner intended for the particular type of equipment taking into account the working conditions and the work to be performed Use of the equipment for operations different from those intended could result in a hazardous situation Do not operate the equipment with known leaks in the engine s fuel system This product contains or when used produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 8 25249 5 et seq When spills of fuel or oil occur they must be cleaned up immediately Dispose of fluids and cleaning materials as per any local state or federal codes and regulations Store oil rags in a bott
26. er Clean or replace Air Filter Repair or replace as needed Check compression and wear tolerances repair or replace as needed Check compression replace as needed Check wear tolerances repair or replace as needed Check wear replace as needed Clean out Combustion chamber and spark plug Drain gas clean out fuel filter and replace with fresh gas minimum 91 octane premium unleaded gasoline Move Switch to ON position Drain carburetor Bowl clean Fuel Filter Clean and re gap plug to 0 024 0 031 Replace plug if needed Check timing and adjust Check for damaged wires test output Check oil level top off as needed Page 18 Engine not run ning Smoothly Fuel Supply System Ignition System Mechanical problem Engine runs excessively hot SKU 67561 1 Poor Fuel quality 2 Incorrect choke setting 3 Incorrect Timing Fuelis used up Fuel Filter is clogged Carburetor Float is leaking Needle Valve sticks Engine Switch is in OFF position Spark Plug tip is burned through or carbon fouled Spark Plug Wire is disconnected Spark Plug wire is shorting against engine body or frame Ignition Coil is shorted or damaged Engine Piston Piston Rod Valve or Crankshaft may be damaged Generator Shaft may be seized Improper Ignition Timing Exhaust manifold muffler or exhaust pipe damaged or clogged
27. ere are two foam filter elements Wash them in warm water and mild liquid soap several times Rinse Squeeze out excess water and allow it to dry completely b Soak the filter in lightweight oil briefly then squeeze out the excess oil Install the new filter or the cleaned filter Secure the Air Cleaner Cover before use Spark Plug Maintenance 1 SKU 67561 Disconnect spark plug wire from end of plug Clean out debris from around spark plug Using a spark plug wrench remove the spark plug Inspect the spark plug If the electrode is oily clean it using a clean dry rag If the electrode has deposits on it polish it using emery paper If the white insulator is cracked or chipped the spark plug needs to be replaced When installing a new spark plug adjust the plug s gap to the specification on the Technical specification chart Do not pry against the electrode or the insulator the spark plug can be damaged Install the new spark plug or the cleaned spark plug into the engine For technical questions please call 1 800 444 3353 Gasket style Finger tighten until the gasket contacts the cylinder head then about 1 2 2 3 turn more Non gasket style Finger tighten until the plug contacts the head then about 1 16 turn more Apply dielectric spark plug boot protector sold separately to the end of the spark plug and reattach the wire securely Page 15 Cleaning Maintenance and Lubricatio
28. is connected to your household wiring without a proper cut off switch can back feed into the power lines connected to your home Power created by your generator can injure or even kill a utility lineman making outage repairs many miles away Only a certified electrician can safely connect the generator to your home s wiring For technical questions please call 1 800 444 3353 Make sure your generator is properly grounded to avoid electrical shocks Connect a 10 gauge or larger insulated copper wire to the Ground Wire Connection on the Control Panel Connect this wire to a suitable external ground such as a copper stake in the ground Don t overload the generator The total wattage used by the appliances should be less than the output rating of the generator If you put too many appliances on the generator it could seriously damage the appliances and electronics Overloading the generator could also cause fires in the power cord This generator is rated at 3050 3500 Watts NOTE At start up appliances draw more power in a surge than they do during continuous operation When figur ing total wattage of all appliances connected to this generator use the higher start up amperage rating of each appliance Do not exceed the current limit specified for any one receptacle Move the AC Circuit Breaker Switch to the ON position Plug in your extension cord or appliance Be sure that all appliances are in
29. m8 x 14 Bolt m8 x 33 5 NOTE Not all engine sub assembly components shown on the following pages are available as separate replacement parts They may be shown for informational purposes only SKU 67561 For technical questions please call 1 800 444 3353 Page 23 Parts List and Diagram B Cylinder Head Assembly Part Description ___ Qty 15 j Botm6x12 6 i 22 22 2 n E 8b Intake SpringSeat 1 9b Valve Spring 2 SKU 67561 For technical questions please call 1 800 444 3353 Partt Description Qty Lead Wind Cover Page 24 Parts List and Diagram C Crankshaft Piston Connecting Rod Camshaft and Flywheel Assemblies Qty Description Qty Piston 1 1 Flywheel Fan 11 PistonPin 1 Connecting Rod Assembly 1 Piston Ring Set SKU 67561 For technical questions please call 1 800 444 3353 Page 25 Parts List and Diagram D Recoil Starter and Ignition Coil Assembly 1 Diode 1 2d FanHood 2 8d 1 2 5 9d Botm6x14 2 Description Qty Part amp ___ Description 1 Diode 1 Bolt m 6 x 8 4 10d Boltm 6 x 22 2 Recoil Starter Assembl 1 Ignition Coil Assembl Shroud Spark Plug SKU 67561 For technical questions please call 1 800 444 3353 Page 26 Parts List and Diagram E Air Cleaner
30. n Schedule Note This maintenance schedule is intended solely as a general guide If performance decreases or if equipment operates unusually check systems immediately The maintenance needs of each piece of equipment will differ depending on factors such as duty cycle temperature air quality fuel quality and other factors Note These procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the engine and equipment After Initial 20 Operation Hour Period a Change engine oil Every 25 Operation Hours Thereafter a Clean replace air filter element b Inspect clean spark plug Every 50 Operation Hours a Change engine oil b Replace fuel filter if equipped c Check spark plug Clean and re gap as needed Every 100 Operation Hours a Replace spark plug b Replace air filter element c Clean fuel tank and fuel strainer Note All maintenance procedures scheduled for 25 50 and 100 operation hours should be performed at least yearly SKU 67561 For technical questions please call 1 800 444 3353 Every 300 Operation Hours a Clean fuel tank and carburetor b Clean carbon build up from combustion chamber c Check oil tube condition and replace as needed Storage 1 Wait for engine to cool then clean engine with clean cloth 2 When the equipment is to remain idle for longer than 20 days prepare the engine for storage as follo
31. o address practices not related to personal injury WARNING Read all instructions Failure to follow all instructions listed below may result in fire serious injury and or DEATH The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS SET UP PRECAUTIONS 1 Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Do not store fuel or other flammable materials nearby 2 Have multiple ABC class fire extinguishers nearby 3 Operation of this equipment may create sparks that can start fires around dry vegetation Page 3 A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements Set up and use only on a flat level well ventilated surface Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during set up Use only oil and fuel recommended in the Specifications section of this manual OPERATING PRECAUTIONS CARBON MONOXIDE HAZARD Using an engine indoors CAN KILL YOU IN MINUTES e Engine exhaust contains carbon monoxide This is a poison you cannot see or smell SK
32. om ventilated covered metal container Keep hands and feet away from moving parts Do not reach over or across equipment while operating Before use check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the equipment s operation If damaged have the equipment serviced before using Many accidents are caused by poorly maintained equipment Use the correct equipment for the application Do not modify the For technical questions please call 1 800 444 3353 equipment and do not use the equipment for a purpose for which it is not intended CAUTION This generator is not intended to power sensitive electronic equipment without the addition of an appropriate line conditioner and surge protector both not included Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators If the plugged in product operates abnormally or unusually slow immediately stop using the generator as a power source Always read and adhere to the instruction manual of the product to be powered to make sure that it can be safely and efficiently powered by a portable generator Note When using a generator to provide home standby electricity a transfer switch sold separately is needed to prevent back feeding power into the utility line Connections for standby power to a building electrical system must be made by a qualified
33. oper Capacit Ne maintenance and servicing Bosch W6DC procedures are not followed Plug yp Champion N11YC Engine Oil Change sie amm cautions Oir is very hot during operation and can cause burns Wait for engine to cool before changing oil 1 Place a drain pan not included SERVICING underneath the crankcase s drain TO PREVENT plug AWARNING SF RIOUS INJURY 2 Remove the Drain Plug 1a and if FROM ACCIDENTAL au STARTING possible tilt the crankcase slightly to help drain the oil out Recycle used Turn the Power Switch of the oil equipment to its OFF position wait for the engine to 3 If the Drain Plug Washer 2a is cool and disconnect the damaged replace with a new spark plug wire s before Washer performing any inspection maintenance or cleaning Re install the Drain Plug and tighten procedures it in place TO PREVENT 5 Refill the oil to the proper level AWARNING SERIOUS INJURY following the instructions under the FROM EQUIPMENT FAILURE Starting the Engine section Do not use damaged equipment If abnormal noise vibration or excess smoking 4 wipe off the air cleaner cover occurs have the problem corrected before further use Air Filter Element Maintenance SKU 67561 For technical questions please call 1 800 444 3353 Page 14 5 The air cleaner cover is held in place by clamps Remove the clamps and the cover Remove the air filter element Cleaning a Th
34. or any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconvenience Warranty coverage shall also be excluded for any part which fails malfunctions or is damaged due to failure to follow the maintenance and operating instructions set forth in the Owner s Manual including but not limited to a Use of parts which are not authorized by HFT b Improper installation adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty center Failure to follow recommendations on fuel use contained in the Owner s Manual d Improper or inadequate maintenance of any warranted parts Repairs performed outside of the authorized warranty service dealers f Alterations by changing adding to or removing parts from the engine For technical questions please call 1 800 444 3353 Service and Maintenance Component parts which are not scheduled for replacement as required maintenance or are scheduled only for regular inspection to the effect of repair or replace as necessary are warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part Any replacement part provided it is equivalent in durability and performance may be used in performance of maintenance or repairs The owner is responsible for commissioning
35. pment out of the reach of children Follow scheduled engine and equipment maintenance Refueling Precautions a Do not smoke or allow sparks flames or other sources of ignition around the equipment especially when refuelling b Do not refill the fuel tank while the engine is running or hot c Do not fill fuel tank to the top Leave a little room for the fuel to expand as needed d Refuel in a well ventilated area only SAVE THESE INSTRUCTIONS SKU 67561 For technical questions please call 1 800 444 3353 Page 6 Extension Cords 5 If you are using one extension cord for more than one tool add the 1 Grounded tools require a three wire nameplate amperes and use the sum extension cord Double Insulated to determine the required minimum tools can use either a two or three cord size wire extension cord See Table A 2 Asthe distance from the supply 6 f you using an extension cord outlet increases you must use a outdoors make sure it is marked with heavier gauge extension cord Using the suffix W A in Canada to extension cords with inadequately indicate it is acceptable for outdoor sized wire causes a serious drop in use voltage resulting in loss of power and possible tool damage 7 sure the extension cord is See Table A properly wired and in good electrical condition Always replace a damaged 3 smaller the gauge number of the extension cord or have it repaired by wir
36. uit breaker Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector 8 OFF but will shorten the service life of the generator SERVICE PRECAUTIONS 1 Before service maintenance or cleaning a Turn the engine switch to its OFF position b Allow the engine to completely cool c Then remove the spark plug wire s from the spark plug s 2 Keep all safety guards in place and in proper working order Safety guards include muffler air cleaner mechanical guards and heat shields among other guards Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor Only a qualified service technician may adjust parts that may increase or decrease governed engine speed Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during service Maintain labels and nameplates on the equipment These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Have the equipment serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the equipment is maintained Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly Store equi
37. utions Engine Will Not Start 1 No fuel in tank Refill the fuel tank 2 Engine Switch in OFF position Move the Switch to the ON position 3 Fuel Valve turned OFF Turn the fuel valve ON 4 Engine Oil level low Top off oil level 5 No spark at spark plug Check that the spark plug wire is not loose or disconnected Clean and re gap spark plug Replace if necessary No fuel reaching carburetor Clean fuel filter cup Check fuel line for leaks or obstructions Engine misses is Fuel filter dirty Check and clean the fuel filter hard to start or runs Air cleaner dirty Check and clean the air filter poorly Spark plug dirty or wrong gap Check clean and re gap spark plug Power Light does not Engine is running poorly Improve engine performance come on Ground wire is not connected Connect ground wire Generator is not functioning Take generator to qualified service technician No or not enough AC Breaker switch in the OFF Reset the Breaker Switch to the ON power at the AC position position outlets AC circuits overloaded Disconnect some appliances to reduce the load No power at the 12 DC Breaker Switch open Disconnect the 12 Volt appliance then VDC outlet press the 12 VDC breaker switch IN Reconnect the 12 V accessory Follow all safety precautions whenever diagnosing or servicing the equipment or engine Consult a qualified service technician for any rep
38. ws a Change engine oil and empty fuel tank b Either leave fuel tank empty or refill fuel tank with fresh unleaded gasoline mixed with a fuel stabilizer intended for long term engine storage not included After filling run engine for about 5 10 minutes to circulate the treated gasoline through the carburetor Wait for engine to cool before proceeding c Clean out area around spark plug Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole d Reinstall spark plug but leave spark plug wire disconnected e Pull recoil starter to distribute oil in cylinder Stop after one or two revolutions when you feel the piston start the compression stroke when you start to feel resistance f Disconnect battery cables if equipped 3 Apply a thin coat of rust preventive oil to all uncoated metal parts Page 16 4 Cover and store dry well ventilated area out of reach of children 5 Before starting the engine after storage keep in mind that untreated gasoline will deteriorate quickly a Place a container below the carbure tor bowl and drain the fuel from the fuel tank and carburetor bowl b Discard the drained fuel properly as per local ordinance c Change to fresh fuel if untreated gasoline has been sitting for a month if treated gasoline has been sitting beyond the fuel stabilizer s recommended time period or if the engine does not start properly

Chicago Electric 67561 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents