Chicago Electric 67561 User's Manual
Contents
1. 8 ConTRols 9 opERATinG insTRuCTions 10 sTARTinG ThE EnGinE 10 ChECKinG AnD fillinG EnGinE oil 10 ChECKinG AnD fillinG fuEl 11 sTART pRoCEDuRE 11 BREAK in pERioD 12 EquipMEnT opERATion 12 ConTRol pAnEl fEATuREs 13 TEChniCAl spECifiCATions 14 sERviCinG 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 16 EvERY 100 opERATion houRs 16 EvERY 300 opERATion houRs 16 sToRAGE 16 EnGinE TRouBlEshooTinG 18 EquipMEnT TRouBlEshooTinG 20 MAin pARTs lisT 21 MAin AssEMBlY DiAGRAM 22 pARTs lisT AnD DiAGRAM A CRAnKCAsE AssEMBlY 23 pARTs lisT AnD DiAGRAM B CYlinDER hEAD AssEMBlY 24 pARTs lisT AnD DiAGRAM C CRAnKshAfT pisTon ConnECTinG RoD CAMshAfT AnD flYWhEE2. 59 Plate washer 5 4 60 Spring washer 5 2 61 Flange Screw M5x16 2 62 Flange Screw M5x16 1 63 Flange Screw M5x12 2 64 Flange Screw M5x16 2 65 Flange Screw M8 8 66 Flange Screw M8 2 67 Spring washer 8 2 68 Plate washer 8 2 69 Nut M6x20 2 70 Spring washer 6 2 71 Flange Screw M8x35 1 72 Flange Screw M8 1 73 Flange Screw M6x12 2 74 Nut M6x14 2 75 Flange Screw M8x20 4 76 Washer 8 4 77 Flange nut M8 4 78 Flange Screw M6x12 6 79 Toothed Washer 5 1 80 Plate washer 5 1 81 Spring washer 5 1 82 Flange Screw M5x16 1 83 Flange nut M6 1 84 Toothed Washer 5 1 85 Plate washer 6 1 86 Spring washer 6 1 87 Flange Screw M6x12 1 88 Flange nut M6 4 89 Flange nut M8 4 90 Flange Screw M8x25 2 91 Flange nut M6 4 92 Nut M6x12 4 Page 22 for technical questions please call 1 800 444 3353 SKU 67561 Main Assembly Diagram Page 23 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram A Crankcase Assembly part Description qty a 1 Drain Plug 2 a 2 Drain Plug Washer 2 a 3 Crankshaft Oil Seal 2 a 4 Crankcase 1 a 5 Regulating Sway Bar 1 a 6 Washer 1 a 7 Split Pin 1 a 8 Regulating Shaft 1 part Description qty a 9 Snap Ring 1 a 10 Driven Gear Assembly 1 a 11 Dipstick with Seal 2 a 12 Crankcase
3. Set up and use only on a flat level 4 well ventilated surface Wear ANSI approved safety goggles 5 heavy duty work gloves and dust mask respirator during set up Use only oil and fuel recommended 6 in the Specifications section of this manual opERATinG pRECAuTions 1 CARBon MonoXiDE hAzARD 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 a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents Keep children away from the equipment 2 especially while it is operating Do not leave the equipment unattended 3 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 4 hearing protection during use People with pacemakers should 5 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 6 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 7 atmospheres such as in th
4. WARninG indicates a hazardous situation which if not avoided could result in death or serious injury CAuTion used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury noTiCE is used to address practices not related to personal injury CAuTion without the safety alert symbol is used to 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 Gasoline fuel and fumes are 1 flammable and potentially explosive Use proper fuel storage and handling procedures Do not store fuel or other flammable materials nearby Have multiple ABC class fire 2 extinguishers nearby Operation of this equipment may 3 create sparks that can start fires around dry vegetation Page 4 for technical questions please call 1 800 444 3353 SKU 67561 A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements
5. 4 Stator assy 1 5 Protection board 1 6 Rear cover 1 7 White grounding wire 1 8 Connection pole 1 9 Carbon Brush 1 10 Rear cover 1 11 3kw Automatic Voltage Regulator 1 12 Shock Absorber 4 13 Muffler guard 1 14 Muffler assy 1 15 Pulsed Valve 1 16 Muffler Gasket 1 17 Exhaust Gasket 1 18 Fuel Tank CARB Standard 278C blue 1 19 Strainer 1 20 Fuel Tank Cap Assembly 1 21 Fuel Marker 1 22 Fuel Tank Connecter 1 23 Washer 10 5 4 24 Shock Absorber for fuel tank 4 25 Clamp 7 1 26 Fuel Pipe 4 5 1 27 Clamp 8 1 28 Fuel Tank Cock Assembly 1 29 Fuel Pipe 7 5 300mm 1 30 Clamp 13 4 31 Fuel Pipe 7 5 380mm 1 32 Carbon Box 1 33 Frame assy 1 34 Control panel assy 1 35 Shock Absorber 4 36 Bracket 2 37 Grounding Wire 12cm 6 6 1 38 Muffler guard 1 1 39 Muffler guard 2 1 40 Flange Screw M8x25 4 41 Flange Screw M8 4 42 Flange Screw M6x45 2 43 Spring washer 6 2 44 Plate washer 6 2 45 Plate washer 8 4 46 Spring washer 8 4 part Description qty 47 Flange Screw M8x25 4 48 Washer 8 1 49 Spring washer 8 1 50 Flange Screw 5 16 210 24UNC 1 51 Flange Screw M6x130 4 52 Spring washer 6 4 53 Toothed Washer 5 1 54 Plate washer 5 1 55 Spring washer 5 1 56 Flange Screw M5x16 1 57 Full screw bolt M5x20 2 58 Flange nut M5 4
6. Check clearances replace as 7 needed Engine speed is self regulating Be 8 sure choke if fully open Reduce electrical load on generator Check for wear Replace as needed 9 Page 20 for technical questions please call 1 800 444 3353 SKU 67561 Equipment Troubleshooting problem possible Causes probable solutions Engine Will Not Start No fuel in tank 1 Engine Switch in OFF position 2 Fuel Valve turned OFF 3 Engine Oil level low 4 No spark at spark plug 5 No fuel reaching carburetor 6 Refill the fuel tank 1 Move the Switch to the ON 2 position Turn the fuel valve ON 3 Top off oil level 4 Check that the spark plug wire is 5 not loose or disconnected Clean and re gap spark plug Replace if necessary Clean fuel filter cup Check fuel line 6 for leaks or obstructions Engine misses is hard to start or runs poorly Fuel filter dirty 1 Air cleaner dirty 2 Spark plug dirty or wrong gap 3 Check and clean the fuel filter 1 Check and clean the air filter 2 Check clean and re gap spark 3 plug Power Light does not come on Engine is running poorly 1 Ground wire is not connected 2 Generator is not functioning 3 Improve engine performance 1 Connect ground wire 2 Take generator to qualified service 3 technician No or not enough power at the AC outlets AC Breaker switch in the OFF 1
7. Cover before use spark plug Maintenance Disconnect spark plug wire from 1 end of plug Clean out debris from around spark plug Using a spark plug wrench remove 2 the spark plug Inspect the spark plug 3 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 4 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 5 cleaned spark plug into the engine 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 6 protector sold separately to the end of the spark plug and reattach the wire securely Page 16 for technical questions please call 1 800 444 3353 SKU 67561 Cleaning Maintenance and lubrication 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
8. 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 Change engine oil a Every 25 operation hours Thereafter Clean replace air filter element a Inspect clean spark plug b Every 50 operation hours Change engine oil a Replace fuel filter if equipped b Check spark plug Clean and re gap c as needed Every 100 operation hours Replace spark plug a Replace air filter element b Clean fuel tank and fuel strainer c note All maintenance procedures scheduled for 25 50 and 100 operation hours should be performed at least yearly Every 300 operation hours Clean fuel tank and carburetor a Clean carbon build up from b combustion chamber Check oil tube condition and replace c as needed storage Wait for engine to cool then clean 1 engine with clean cloth When the equipment is to remain idle 2 for longer than 20 days prepare the engine for storage as follows Change engine oil and empty fuel a tank Either leave fuel tank empty or b 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 t
9. 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 1 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 2 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 3 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 4 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 for 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
10. leaks in the engine s fuel system This product contains or when used 17 produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq When spills of fuel or oil occur they must 18 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 bottom ventilated covered metal container Keep hands and feet away from moving 19 parts Do not reach over or across equipment while operating Before use check for misalignment 20 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 21 application Do not modify the equipment and do not use the equipment for a purpose for which it is not intended CAuTion 22 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
11. 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 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 Manu
12. possible tool damage see Table A The smaller the gauge number of the 3 wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord see Table A When using more than one extension 4 cord to make up the total length make sure each cord contains at least the minimum wire size required see Table A If you are using one extension cord 5 for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size see Table A If you are using an extension cord 6 outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use Make sure the extension cord is 7 properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it Protect the extension cords from 8 sharp objects excessive heat and damp or wet areas RECoMMEnDED MiniMuM WiRE GAuGE foR EXTEnsion CoRDs 120 240 volT nAMEplATE AMpEREs at full load EXTEnsion CoRD lEnGTh 25 feet 50 feet 75 feet 100 feet 150 feet 0 2 0 18 18 18 18 16 2 1 3 4 18 18 18 16 14 3 5 5 0 18 18 16 14 12 5 1 7 0 18 16 14 12 12 7 1 12 0 18 14 12 10 12 1 16 0 14 12 10 16 1 20 0 12 10 TABlE A Based on limiting the
13. 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 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 6 for technical questions please call 1 800 444 3353 SKU 67561 AC AppliCATions Before connecting an appliance or 1 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 If an appliance begins to operate 2 abnormally becomes slug
14. to failure to follow the maintenance and operating instructions set forth in the Owner s Manual including but not limited to Use of parts which are not authorized by HFT a Improper installation adjustment or repair of the engine b or of any warranted part unless performed by an authorized warranty center Failure to follow recommendations on fuel use contained c in the Owner s Manual Improper or inadequate maintenance of any warranted d parts Repairs performed outside of the authorized warranty e service dealers Alterations by changing adding to or removing parts f from the engine service and Maintenance 5 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 a qualified technician mechanic to perform all required maintenance as outlined in the Inspection Cleaning and Maintenance section in this manual Warranted parts 6 Fuel Metering System 1 Carburetor and its internal parts i Fue
15. 3050 RATED WATTs 3500 MAX WATTs GAsolinE GEnERAToR CERTifiED in CAlifoRniA Model 67561 sET up opERATinG AnD sERviCinG insTRuCTions 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 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 a home or garage EvEn if doors and windows are open only use ouTsiDE and far away from windows doors and vents Page 2 for technical questions please call 1 800 444 3353 SKU 67561 ConTEnTs iMpoRTAnT sAfETY infoRMATion 3 AC AppliCATions 6 EXTEnsion CoRDs 7 BAsiC spECifiCATions 8 funCTions 8 unpACKinG
16. 7 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 Disconnect all loads from the 8 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 features Engine Power Switch must be in ON 1 position for engine to start and run Move to OFF position to stop engine Power Indicator Light when lit 2 shows that the generator is producing electrical energy AC Circuit Breaker Switch protects 3 circuits when using AC power 120 V duplex outlet provides two 4 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 twi
17. Belt Sander 1200 2400 Refrigerator Freezer 700 2200 1 2 HP Sump Pump 1050 2150 1 2 HP Well Pump 1000 2100 Miter Saw 1650 3000 1 1 2 HP Capacitor Start amp Run Motor 1400 3100 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 9 for technical questions please call 1 800 444 3353 SKU 67561 ConTRols note Be sure to use the proper plug for the amps needed Plug for up to 20A figure 1 Plug for up to 15A 120V Duplex Receptacle for 15A or 20A plugs Engine Power Switch Power Indicator Light AC Circuit Breaker Switch 120 V Duplex Receptacle 120 V Twist Lock Receptacle AC Reset Switch DC Circuit Breaker Switch 10 Amps Ground Wire Connection 12 VDC Outlet MAin BREAKER 20A REsET 120v AC ouTlETs onlY Page 10 for technical questions please call 1 800 444 3353 SKU 67561 opERATinG insTRuCTions Read the EnTiRE iMpoRTAnT sAfETY infoRMATion section at the beginning of this manual including all text under subhead
18. Cover 1 a 13 Crankcase Gasket 1 a 14 Bearing 6205 2 a 15 Set Pin m 8 x 14 2 a 16 Bolt m8 x 33 5 6 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 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 Page 24 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram B Cylinder head Assembly part Description qty b 1 Bolt m 6 x 12 6 b 2 Cylinder Head Cover 1 b 3 Cylinder Head Cover Gasket 1 b 4 Valve Rocker Assembly 1 b 5 Push Guide 1 b 6 Cap 1 b 7 Exhaust Spring Seat 1 b 8 Intake Spring Seat 1 b 9 Valve Spring 2 b 10 Bolt m 8 x 60 4 b 11 Stud AM 8 x 34 2 b 12 Cylinder Head Assembly 1 part Description qty b 13 Cylinder Head Gasket 1 b 14 Set Pin 2 b 15 Exhaust Valve 1 b 16 Intake Valve 1 b 17 Tappet 2 b 18 Pusher 2 b 19 Stud AM 6 x 112 2 b 20 Lead Wind Cover 1 b 21 Oil Pipe Seal 1 b 22 Clip 2 Page 25 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram C Crankshaft piston Con
19. an for safety if you have any doubts about your ability to safely service the equipment or engine have a qualified technician service the equipment instead note Warranty is void if proper maintenance and servicing procedures are not followed Engine oil Change CAuTion Oil is very hot during operation and can cause burns Wait for engine to cool before changing oil Place a drain pan not included 1 underneath the crankcase s drain plug Remove the Drain Plug 1a and if 2 possible tilt the crankcase slightly to help drain the oil out Recycle used oil If the Drain Plug Washer 2a is 3 damaged replace with a new Washer Re install the Drain Plug and tighten 4 it in place Refill the oil to the proper level 5 following the instructions under the Starting the Engine section Air filter Element Maintenance Wipe off the air cleaner cover 1 Page 15 for technical questions please call 1 800 444 3353 SKU 67561 The air cleaner cover is held in place 2 by clamps Remove the clamps and the cover Remove the air filter element 3 Cleaning 4 There are two foam filter elements a Wash them in warm water and mild liquid soap several times Rinse Squeeze out excess water and allow it to dry completely Soak the filter in lightweight oil b briefly then squeeze out the excess oil Install the new filter or the cleaned 5 filter Secure the Air Cleaner
20. e presence of flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes Stay alert watch what you are doing 8 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 9 and balance at all times This enables better control of the equipment in unexpected situations Use this equipment with both hands only 10 Using equipment with only one hand can easily result in loss of control Dress properly Do not wear loose 11 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 5 for technical questions please call 1 800 444 3353 SKU 67561 Parts especially exhaust system 12 components get very hot during use Stay clear of hot parts Do not cover the engine or equipment 13 during operation Keep the equipment engine and 14 surrounding area clean at all times Use the equipment accessories etc in 15 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 16 known
21. elow Engine system possible Cause possible solution Ignition System Incorrect Ignition Timing Adjust Engine Advance Angle Fuel Supply System Air in fuel line or fuel line clogged 1 Main Jet not adjusted properly 2 Metering Jet or Main Jet clogged 3 Fuel Cock clogged 4 Carbon Fouling in Combustion 5 Chamber Clogged Air Filter 6 Intake Manifold leaking 7 Purge air or clear obstruction 1 Readjust Main Jet 2 Clean and Readjust 3 Clean as needed 4 Clean out Combustion Chamber 5 Clean or replace Air Filter 6 Repair or replace as needed 7 Poor Compression Worn Piston Piston Ring or 1 Cylinder Wall Leaking Cylinder Head Gasket 2 Worn Valves Valve Seats Stems 3 or Valve Guides Check compression and wear 1 tolerances repair or replace as needed Check compression replace as 2 needed Check wear tolerances repair or 3 replace as needed Problem Engine does not start or does not run smoothly See chart below Symptom Possible Cause Possible Solution Engine is Pinging Excess wear of Piston Cylinder Wall or Rings Piston Pin or Piston Pin Hole Connecting Rod Wrist Pin Crankshaft Roller Bearing Check wear replace as needed Abnormal Com bustion or engine running hot or excess smoking Combustion chamber carbon 1 fouling Dirty or old gasoline or oil in gas 2 Clean out Combu
22. ew 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 3 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 Engine Oil SAE 10W 30 above 32 F SAE 5W 30 at 32 F or below Replace the Oil Dipstick 4 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 Page 11 for technical questions please call 1 800 444 3353 SKU 67561 bottom edge of the oil fill hole before each start up CAuTion Do noT run the engine with low oil or no oil the engine will be permanently damaged Checking and filling fuel Check the fuel level If the fuel level is 1 more than 1 below the fill neck of the fuel tank add more fuel note Do not overfill the fuel tank WARninG To pREvEnT sERious injuRY fRoM fiRE Fill the fuel tank in a well ventilated area away from ignition sources Do not smoke To fill the Fuel Tank first wipe off the 2 Fuel Tank Cap and the surrounding area Unscrew and remove the Fuel Tank 3 Cap Mix fuel stabilizer no
23. facturer 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 31 for technical questions please call 1 800 444 3353 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 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
24. fouled Spark Plug Wire is disconnected 3 Spark Plug wire is shorting against 4 engine body or frame Ignition Coil is shorted or 5 damaged Move Switch to ON position 1 Clean or replace spark plug Reset 2 gap to 0 024 0 031 Check connections at both ends 3 Check condition of spark plug wire 4 replace as needed Check coil continuity and output 5 Mechanical problem Engine Piston Piston Rod Valve 1 or Crankshaft may be damaged Generator Shaft may be seized 2 Have serviced by a qualified 1 technician Disconnect engine and attempt to 2 rotate generator shaft by hand Repair or replace as needed Problem Engine runs excessively hot See chart below Problem Possible Cause Possible Solution Engine runs excessively hot Improper Ignition Timing 1 Exhaust manifold muffler or exhaust 2 pipe damaged or clogged Intake Manifold leaking 3 Dirty or clogged Cylinder Cooling Fins 4 Cooling Fan loose or damaged 5 Bent Piston Rod 6 Worn Piston Piston Ring or Cylinder 7 Wall Improper engine speed 8 Worn Crankshaft Main Bearing 9 Check and reset Ignition Timing 1 Check condition of exhaust system 2 repair as needed Check condition of intake manifold 3 and gasket Repair as needed Clean Cylinder Wall Cooling Fins 4 Check condition of cooling fan 5 Repair or replace as needed Replace Piston Rod 6
25. gish or stops suddenly turn it off immediately Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded Make sure that the electrical rating of 3 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 Substantial overloading will open the 4 circuit breaker Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF but will shorten the service life of the generator sERviCE pRECAuTions Before service maintenance or 1 cleaning Turn the engine switch to its off a position Allow the engine to completely cool b Then remove the spark plug wire s c from the spark plug s Keep all safety guards in place and in 2 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 3 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 4 heavy duty work gloves and dust mask respirator during service Mai
26. ground such as a copper stake in the ground Don t overload the generator The 2 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 3 specified for any one receptacle Move the AC Circuit Breaker Switch 4 to the ON position Plug in your extension cord or 5 appliance Be sure that all appliances are in 6 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 13 for technical questions please call 1 800 444 3353 SKU 67561 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 The DC terminal may be used
27. he carburetor Wait for engine to cool before proceeding Clean out area around spark plug c Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole Reinstall spark plug but leave spark d plug wire disconnected Pull recoil starter to distribute oil e in cylinder Stop after one or two revolutions when you feel the piston start the compression stroke when you start to feel resistance Disconnect battery cables if f equipped Apply a thin coat of rust preventive oil 3 to all uncoated metal parts Page 17 for technical questions please call 1 800 444 3353 SKU 67561 Cover and store in a dry well 4 ventilated area out of reach of children Before starting the engine after 5 storage keep in mind that untreated gasoline will deteriorate quickly Place a container below the carbure a tor bowl and drain the fuel from the fuel tank and carburetor bowl Discard the drained fuel properly as b per local ordinance Change to fresh fuel if untreated c 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 Page 18 for technical questions please call 1 800 444 3353 SKU 67561 Engine Troubleshooting Problem Low power output Engine bogs down or dies under load Excess exhaust or unburned fuel in exhaust See chart b
28. ings therein before set up or use of this product To pREvEnT 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 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 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 1 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 2 filler neck but do not scr
29. l AssEMBliEs 25 pARTs lisT AnD DiAGRAM D RECoil sTARTER AnD iGniTion Coil AssEMBlY 26 pARTs lisT AnD DiAGRAM E AiR ClEAnER AnD MufflER AssEMBlY 27 pARTs lisT AnD DiAGRAM f fuEl supplY sYsTEM 27 pARTs lisT AnD DiAGRAM G sTARTER AnD GEnERAToR AssEMBlY 28 WiRinG DiAGRAM 29 liMiTED 1 YEAR 90 DAY WARRAnTY 30 EMission ConTRol sYsTEM WARRAnTY 30 Page 3 for technical questions please call 1 800 444 3353 SKU 67561 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 a hazardous situation which if not avoided will result in death or serious injury
30. l pump if so equipped ii Cold start enrichment system iii Air Induction System 2 Intake pipe manifold i Air cleaner ii Ignition System 3 Spark plug i Magneto ignition system ii Catalyst System if so equipped 4 Exhaust pipe stud i Muffler ii Catalytic converter if so equipped iii Miscellaneous Items Used in Above Systems 5 Vacuum temperature and time sensitive valves i and switches Hoses belts connectors and assemblies ii
31. line voltage drop to five volts at 150 of the rated amperes Page 8 for technical questions please call 1 800 444 3353 SKU 67561 BAsiC spECifiCATions Fuel Type 91 octane premium unleaded gasoline Capacity 4 Gallons Engine Oil Type SAE 10W 30 above 32 F SAE 5W 30 at 32 F or below Capacity 2 3 Quart with Low Oil Shutdown Sensor Spark Plug Gap 0 024 0 031 Run Time 50 Load 9 Hours with full tank Engine Type 7 HP Four stroke Overhead Valve Design Ignition Recoil Start with Electronic Ignition Electrical Outlets One 20A duplex NEMA 120V receptacle One 25A NEMA 120V 3 prong twist lock receptacle One T Type 12V outlet 10A DC Breaker note Additional specifications found in the TECHNICAL ENGINE SPECIFICATIONS chart in this manual The emission control system 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 functions This unit can power items such as the following iTEM RunninG WATTs sTART up WATTs
32. necting Rod Camshaft and flywheel Assemblies part Description qty c 1 Piston Ring Set 1 c 2 Piston Ring Circlip 2 c 3 Piston 1 c 4 Piston Pin 1 c 5 Connecting Rod Assembly 1 c 6 Crankshaft Assembly 1 part Description qty c 7 Camshaft Assembly 1 c 8 Flywheel 1 c 9 Flywheel Fan 1 c 10 Starting Flange 1 c 11 Nut m 14 x 1 5 1 Page 26 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram D Recoil starter and ignition Coil Assembly part Description qty d 1 Engine Switch 1 d 2 Fan Hood 2 d 3 Bolt m 6 x 12 5 d 4 Bolt m 6 x 8 4 d 5 Recoil Starter Assembly 1 d 6 Complete Shroud 1 part Description qty d 7 Diode 1 d 8 Oil Sensor 1 d 9 Bolt m 6 x 14 2 d 10 Bolt m 6 x 22 2 d 11 Ignition Coil Assembly 1 d 12 Spark Plug F6TC 1 Page 27 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram E Air Cleaner and Muffler Assembly part Description qty e 1 Air Cleaner Assembly 1 e 2 Nut m6 2 e 3 Air Duct 1 parts list and Diagram f fuel supply system part Description qty f 1 Pipe Clamp 2 f 2 Fuel Pipe m 4 5 x 170 1 f 3 Intake Gasket 1 f 4 Connecting Block 1 f 5 Carburetor Gasket 1 f 6 Carburetor Assembly 1 f 7 Air Cleaner Gasket 1 part Description qty f 8 Reg
33. ntain labels and nameplates on 5 the equipment These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Have the equipment serviced by a 6 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 equipment out of the reach of 7 children Follow scheduled engine and equipment 8 maintenance Refueling Precautions 9 Do not smoke or allow sparks flames a or other sources of ignition around the equipment especially when refuelling Do not refill the fuel tank while the b engine is running or hot Do not fill fuel tank to the top Leave c a little room for the fuel to expand as needed Refuel in a well ventilated area only d sAvE ThEsE insTRuCTions Page 7 for technical questions please call 1 800 444 3353 SKU 67561 Extension Cords Grounded 1 tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord As the distance from the supply 2 outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and
34. 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 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
35. position AC circuits overloaded 2 Reset the Breaker Switch to the ON 1 position Disconnect some appliances to 2 reduce the load No power at the 12 VDC outlet DC Breaker Switch open Disconnect the 12 Volt appliance then 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 repairs 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 Page 21 for technical questions please call 1 800 444 3353 SKU 67561 Main parts list part Description qty 1 Gasoline Engine UP170 7 0HP 1 2 Front Cover 1 3 Rotor assy 1
36. rm 1 5 minutes to stabilize Move the AC Circuit Breaker Switch 7 to its ON or RUN position Page 12 for technical questions please call 1 800 444 3353 SKU 67561 Break in period Breaking in the engine will help 1 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 2 Do not apply a heavy load to the equipment After the first 20 hours of use 3 Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section Equipment operation To pREvEnT sERious injuRY AnD DEATh Do noT ConnECT GEnERAToR DiRECTlY To housEholD WiRinG A portable electric generator that 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 Make sure your generator is properly 1 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
37. st lock receptacle provides 5 a grounded outlet for one 120 Volt appliance such as a water heater 12 VDC outlet provides a power 6 source for 12 volt DC items such as automotive accessories 12 VDC Circuit Breaker Switch provides circuit protection for 12 VDC accessories Page 14 for technical questions please call 1 800 444 3353 SKU 67561 TEChniCAl spECifiCATions Engine Type 4 Stroke OHV Bore x Stroke 70 x 54mm Compression Ratio 8 5 1 Displacement 208cc Fuel Type 91 octane premium unleaded gasoline Capacity 4 Gallons Engine Oil Type SAE 10W 30 above 32 F SAE 5W 30 at 32 F or below Capacity 2 3 Quarts Spark Plug Compatible Types NGK BP61S Bosch W6DC Champion N11YC Gap 0 024 0 031 Valve Clearance Intake 0 1mm Exhaust 0 15mm Speed 3600 RPM sERviCinG To pREvEnT sERious injuRY fRoM ACCiDEnTAl sTARTinG Turn the power switch of the equipment to its off position wait for the engine to cool and disconnect the spark plug wire s before performing any inspection maintenance or cleaning procedures To pREvEnT sERious injuRY fRoM EquipMEnT fAiluRE Do not use damaged equipment if abnormal noise vibration or excess smoking occurs have the problem corrected before further use Maintenance procedures Many maintenance procedures including those not detailed in this manual will need to be performed by a qualified technici
38. stion chamber and 1 spark plug Drain gas clean out fuel filter and 2 replace with fresh gas minimum 91 octane premium unleaded gasoline Engine does not start Engine Switch in OFF position 1 Water in Carburetor Bowl 2 Spark Plug gap not correct 3 Incorrect Ignition Timing 4 Damaged coil or ignition wires 5 Low Oil level 6 Move Switch to ON position 1 Drain carburetor Bowl clean Fuel 2 Filter Clean and re gap plug to 0 024 3 0 031 Replace plug if needed Check timing and adjust 4 Check for damaged wires test output 5 Check oil level top off as needed 6 Page 19 for technical questions please call 1 800 444 3353 SKU 67561 Engine not run ning Smoothly Poor Fuel quality 1 Incorrect choke setting 2 Incorrect Timing 3 Replace fuel with 91 octane premium 1 unleaded gasoline Adjust the choke 2 Have the timing checked by a qualified 3 technician Problem Engine stops suddenly while running See chart below Engine system possible Cause possible solution Fuel Supply System Fuel is used up 1 Fuel Filter is clogged 2 Carburetor Float is leaking 3 Needle Valve sticks 4 Check fuel level and refill as needed 1 Clean Fuel Filter 2 Replace if needed 3 Clean and readjust 4 Ignition System Engine Switch is in OFF position 1 Spark Plug tip is burned through 2 or carbon
39. t included 4 with 91 octane or better premium unleaded gasoline according to fuel stabilizer directions note Use only premium octane unleaded gasoline Fill the Fuel Tank to about 1 inch 5 under the fill neck of the gasoline tank with the stabilized unleaded gasoline mixture Then replace the Fuel Tank Cap 6 start procedure Before starting the engine inspect the equipment and a engine fill the engine with the b proper amount and type of fuel and oil Read the Equipment c operation section that follows Unplug loads from the Generator and 1 make sure the AC Circuit Breaker Switch is in the OFF position before starting to prevent permanent generator damage Turn the engine fuel valve to its ON 2 or OPEN position Turn the Engine Power Switch to its 3 ON or RUN position Then turn the engine choke lever to 4 its CHOKE position Set the choke lever in the RUN position when starting a warm engine Grasp the starter handle and pull 5 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 After the engine starts and warms 6 up slowly move the choke lever to its RUN position iMpoRTAnT Allow the engine to run at no load until wa
40. ulator Assembly 1 f 9 Back Spring 1 f 10 Regulating Spring 1 f 11 Pulling Rod 1 f 12 Lock Bolt 1 f 13 Regulating Spring 1 f 14 Nut M6 1 Page 28 for technical questions please call 1 800 444 3353 SKU 67561 parts list and Diagram G starter and Generator Assembly part Description qty g 1 Starting Motor Assembly 1 g 2 Bolt m6 x 28 1 g 3 Bolt m6 x 32 1 g 4 Crankcase 1 g 5 Charge Coil 1 part Description qty g 6 Bolt m6 x 35 2 g 7 Clamp Cord 1 g 8 Bolt m6 x 12 2 g 9 Flywheel 1 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 Page 29 for technical questions please call 1 800 444 3353 SKU 67561 Wiring Diagram Page 30 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 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
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