poRTAblE GENERAToR - Harbor Freight Tools
Contents
1. LEVEL DO NOT REMOVE 4 Tofill the Fuel Tank 31 unscrew and remove the Fuel Tank Cap 34 Fill the Fuel Tank with mid to high octane unleaded gasoline Then replace the Fuel Tank Cap When necessary refill the Fuel Tank See Figure E 5 Periodically check the Fuel Filter 32 for excessive dirt and debris If necessary remove the Fuel Filter and clean with compressed air See Figure E FUEL VALVE 41 CHOKE LEVER 21A FIGURE F SKU 66603 For technical questions please call 1 800 444 3353 Page 13 THIS UNIT CAN POWER THE FOLLOWING ITEMS WATTS WATTS 1 2 HP Sump Pump 1050 2150 1 2 HP Well Pump 1000 2100 1 1 2 HP Capacitor Start amp Run 1400 3100 Motor Central AC 32 000 BTU 5000 6500 10 Table Saw 1800 4500 Note Wattages listed above are estimates Check nameplate wattages on all loads before connecting to Generator OPERATING INSTRUCTIONS Check to make sure the Engine Switch 2 is in its OFF position See Figure A IMPORTANT Make sure to unplug any load from the Generator before starting to prevent permanent damage to any appliances tools or equipment Turn the Engine Fuel Valve 41 to its OPEN position Then turn the Engine Choke Lever 21A to its CHOKE position No choke is required if the Engine is warm Make sure the Choke Lever is in the RUN position when starting a warm Engine See Figure F To start the Engine using the Battery 45 for cranking power ins2. 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 Asthe 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 Youare 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 reason able 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 Cus tomer Service Department at 1 800 444 3353 Harbor Freight Tools Emission Control Defects Warranty Provisions 1 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 2 NoCharge 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 a
3. 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 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 SKU 66603 For technical questions please call 1 800 444 3353 Page 4 If an appliance begins to operate abnormally becomes sluggish 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 the tool or appliance does not ex
4. 50 of the rated Co co oo Oo A Co Oo P N N Co P N o P N eo N x e SKU 66603 For technical questions please call 1 800 444 3353 Page 8 Symbology Volts Alternating Current No Load Revolutions per Minute UNPACKING When unpacking check to make sure all of the parts shown on the Parts List in this manual are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover and at the bottom of each page of this manu al as soon as possible CONTROL PANEL FEATURES 7 7B FIGURE A 108 5 8 1 Engine Switch 2 Used to start and stop the Engine To start insert the Engine Switch Key and turn to the right to its START position Then immediately release the Key To turn off the Engine turn the Key all the way to the left to its OFF position Always remove the Key from the Engine Switch when the unit is not in use See Figure A above 2 Outlet Sockets 8 10 10B The Generator features three Outlet Sockets with which to power tools and equipment The type and voltage of the Outlet Sockets are as follows SKU 66603 For technical questions please call 1 800 444 3353 Page 9 a 3 Prong duplex NEMA 120 volt Outlet Socket 8 Qty 2 b 3 Prong NEMA Twistlock 120 volt Outlet Socket 10 c 4 Prong NEMA Twistlock 240 120 volt Outlet Socket 10B AWARNING Connect tools and equipmen
5. 8A prior to performing any inspection maintenance or cleaning procedures 2 Before each use Inspect the general condition of the Generator and its Engine Check for loose screws misalignment or binding of moving parts cracked or broken parts loose hose connections and any other condition that may affect the safe operation of the unit If abnormal noise or vibration occurs have the problem corrected before further use GENERATOR MAINTENANCE 1 Keep the Generator clean and dry at all times 2 The Generator should not be operated or stored in locations that include excessive moisture dust flammable or corrosive vapors If these substances are on the Generator clean with a soft cloth or brush 3 Donot use a garden hose or anything with liquid to clean the Generator Liquid may enter the cooling air slots and could damage the interior workings of the Generator ENGINE MAINTENANCE 1 After the first 5 to 8 hours of use Change the oil Then change the oil every 50 hours of use Change the oil every 25 hours of use when operating the Engine under a heavy load or in high temperatures PLUG 59A L Witwe 2 Tochange the oil remove the Plug 59A and allow the old oil to drain in a proper container Once drained replace the Plug See Figure G SKU 66603 For technical questions please call 1 800 444 3353 Page 16 REV 10e 3 NOTE If the Engine will be run in temperatures above 32 degrees Fahrenheit use SAE 30
6. CHICAGO Electric 6500 RATED WATTS 7000 MAXIMUM WATTS PORTABLE GENERATOR VEX 66603 SET UP OPERATING AND SERVICING INSTRUCTIONS ADANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home Only use OUTSIDE and or garage EVEN IF doors far away from windows and windows are open doors and 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 2007 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 Manual Revised 10e SPECIFICATIONS 6500 Rated Watts Rated 7000 Maximum Watts Maximum 60 Hz 3600 RPM Output Receptacles 2 NEMA 120V Household Receptacles with a 20 A Circuit Breaker 1 NEMA 120V 3 Prong Twist Lock Receptacles with a 30 A Circuit Breaker 1 NEMA 120V 240V 4 Prong Twist Lock Receptacles with two 30 A Ci
7. NUAL 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 66603 For technical questions please call 1 800 444 3353 Page 18 TROUBLESHOOTING 1 Low on fuel or oil 1 Add fuel or oil Problem Engine will not siart 2 Tum engine power switch to the ON position 2 Engine power switch is in the OFF position 3 Faulty spark plug Replace spark plug 4 Choke in wrong position Properly adjust choke Tum fuel valve lever to OPEN position Fuel valve lever in CLOSED position Generator loaded during start up Remove load from Generator Spark plug wire loose Attach wire to spark plug Fuel line clogged Clean fuel line and fuel filter No electrical output Repeated circuit breaker tripping Generaior overheating SKU 66603 Faulty ignition system Faulty outlet Circuit breaker tripped Defec
8. Spark Plug 28A See Figure l 0 028 0 031 SPARK PLUG 28A FIGURE I 10 Todo so use a 13 16 spark plug wrench not included to remove the Spark Plug SKU 66603 For technical questions please call 1 800 444 3353 Page 17 11 Use a fine grade sandpaper to clean off carbon build up from the electrodes of the Spark Plug 28A Clean with compressed air to remove residue See Figure l 12 Measure the electrode gap with a suitable gauge The gap should be 0 028 to 0 031 If necessary correct the gap by carefully bending the side of the electrode See Figure I 13 Reinstall the Spark Plug 28A carefully to avoid cross threading See Figure I 14 Daily Inspect the Fuel Filter 32 15 Todo so remove the Fuel Tank Cap 34 from the Fuel Tank 31 See Figure J 16 If necessary use compressed air to remove any dirt and debris from the Fuel Filter 32 Then replace the Fuel Filter and Fuel Tank Cap 34 See Figure J When storing the Generator for extended periods Before storing drain all fuel out of the Engine s Fuel Tank 31 If this is not followed old fuel in the Fuel Tank may clog the Carburetor of the Engine and prevent it from starting until cleaned out Then make sure to store the unit in a clean dry safe location out of reach of children and other unauthorized people PLEASE READ THE FOLLOWING THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MA
9. art Description aiy 70A Compression Ring 1 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead SKU 66603 For technical questions please call 1 800 444 3353 Page 23 ASSEMBLY DIAGRAM ENGINE SKU 66603 For technical questions please call 1 800 444 3353 Page 24 WIRING DIAGRAM Page 25 For technical questions please call 1 800 444 3353 SKU 66603 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 Har bor 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
10. ceed 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 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 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing a tool use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury SPECIFIC SAFETY RULES IMPORTANT Your Warranty is voided if You do not put engine oil in the Engine s crankcase prior to its first use Before each use check the oil level Never run the Engine with low or no engine oil Running the Engine with low or no Engine oil will permanently damage the Engine Maintain labels and nameplates on the Generator These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Maintain a safe working environment Make sure there is adequate surrounding workspace Avoid unintentional starting Make sure you are prepared to begi
11. e performing any inspection maintenance or cleaning procedures 4 Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users 5 Maintain tools with care Keep the Generator clean Properly maintained tools are less likely to malfunction and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired 6 Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools 7 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool 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
12. ert the Engine Switch Key into the Engine Switch 2 Then turn the Key to the START position NOTE To prolong Starter life use short starting cycles 5 seconds maximum Then wait one minute before attempting to start again See Figure A To start the Engine manually using the Starter Handle 41A insert the Engine Switch Key and turn the Key to its RUN position Grasp the Starter Handle and pull slowly until resistance is felt Allow the Starter Rope to rewind slowly Then pull the Starter Handle with a rapid full arm stroke Allow the Rope to rewind slowly If necessary repeat this procedure until the Engine starts When the Engine starts slowly move the Choke Lever 21A to its RUN position See Figure F IMPORTANT Allow the Generator to run at no load for five minutes after each start up so that the Engine and Generator can stabilize SKU 66603 For technical questions please call 1 800 444 3353 Page 14 TO CONNECT ELECTRICAL LOADS 1 Start the Engine and allow the Engine and Generator to run and warm up for five minutes after starting with no electrical load 2 A WARNING Connect 120 VAC appliances tools and equipment only to the two 120 VAC Outlet Sockets 8 10 Connect 240 VAC appliances tools and equipment only to the one 240 VAC Outlet Socket 10B See Figure A 3 AXCAUTION Never exceed the rated capacity for this Generator as serious damage to the Generator and or appliances tools and equi
13. event be liable for death injuries to persons or property or for incidental contingent special or con sequential 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 com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther 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 re paired 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 SKU 66603 For technical questions please call 1 800 444 3353 Page 26 EMISSION CONTROL SYSTEM WARRANTY The United States Environmental Protection Agency herein EPA and Harbor Frei
14. f the Generator 7 Make sure the Engine Switch is in its OFF position before moving the Generator and before performing any service maintenance or cleaning procedures on the unit 8 Keep all electrical equipment clean and dry Replace any wiring where the insulation is cracked cut abraded or otherwise degraded Replace terminals that are worn discolored or corroded Keep terminals clean and tight 9 Insulate all connections and disconnected wires 10 Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerators 11 Use only Class BC or Class ABC fire extinguishers on electrical fires MISC PRECAUTION AWARNING 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 RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT NAMEPLATE AMPERES EXTENSION CORD LENGTH t full load T 1 es Sea 3E 190 21 34 18 18 838 50 18 18 16 1 J 1d 51 70 18 16 o mao 18 14 NEM 121 160 14 12 pue 161 200 12 0 p Co Co O 2 1 3 4 3 5 5 0 5 1 7 0 7 1 12 0 12 1 16 0 16 1 20 0 TABLE A Based on limiting the line rer dd five volts at 1
15. ght Tools herein HFT are pleased to explain the emission control system warranty on your 1997 and later Small Off Road Engine herein engine Within the United States new off road spark ignition engines certified for model year 1997 and later must be designed built and equipped to meet the stringent anti smog 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 Manufacturer s Warranty Coverage The 1997 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 Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the
16. l injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations safety shoes hard hat or hearing protection must be used for appropriate Use safety equipment Always wear eye protection Dust mask nonskid conditions Tool Use And Care Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed Do not force the tool and do not use the tool for a purpose for which it is not intended SKU 66603 For technical questions please call 1 800 444 3353 Page 3 2 Do not use the power tool if the Engine Switch does not turn it on or off Any tool that cannot be controlled with the Engine Switch is dangerous and must be replaced 3 Disconnect the Spark Plug Wire from the Engine before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally Always disconnect the Spark Plug Wire befor
17. lide the Axle 49 through the two Axle Brackets 53 See Assy Diagram 4 Insert one Wheel 50 onto each end of the Axle 49 See Assy Diagram 5 Secure the Axle 49 and Wheels 50 in place using four Pins 51 See Assy Diagram INSTALLATION INSTRUCTIONS 1 IMPORTANT Electrical and other permits may be required for the installation of emergency or portable power systems Make sure to investigate the local building and electrical codes before installing this unit 2 Locate the Generator outdoors only where cooling air is readily available Locate the Generator so that the air inlets and outlets are not blocked by obstructions such as bushes trees walls snow drifts etc Locating the Generator in the path SKU 66603 For technical questions please call 1 800 444 3353 Page 11 of heavy winds may require the placement of a barrier for protection The air inlet in normal weather conditions should face the prevailing wind direction 3 Locate the Generator on a concrete slab or other area where rain drainage or flood waters can not reach it 4 Generator placement should allow four feet of access to all sides for maintenance and proper air cooling 5 Place the Generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords 6 To ground the Generator connect a 6 AWG grounding wire not included from the Grounding Terminal 9 on the Control Panel to a gr
18. list and assembly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Write the product s serial number in the back of the manual near the assembly diagram or write month and year of purchase if product has no number Keep this manual and invoice in a safe and dry place for future reference REV 09l SKU 66603 For technical questions please call 1 800 444 3353 Page 2 GENERAL SAFETY RULES A WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA Keep your work area clean and well lit Cluttered and dark areas invite accidents Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed Children should never be allowed in the work area PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when operating a power tool Do not use a power tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious persona
19. n work before turning on the Generator 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 SKU 66603 For technical questions please call 1 800 444 3353 Page 5 Never leave the Generator unattended when it is running Turn off the Engine of the Generator before leaving the work area Always use the Generator on a flat level surface Make sure to keep hands fingers and feet away from all moving parts of the Generator Keep all safety guards of the Generator in place and in proper working order TOXIC FUMES FIRE AND EXPLOSION PRECAUTIONS This Generator is designed for outdoor use only Do not operate the Generator in a closed area or in a poorly ventilated area When running the Engine of this unit produces carbon monoxide a colorless odorless toxic fume that when inhaled can cause serious personal injury or death Whenever possible use a carbon monoxide detector not included to detect excessive carbon monoxide fumes in the work area and in the surrounding area Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Always have multiple ABC class fire extinguishers nearby Keep the Generator its Engine and surrounding areas clean at all times When s
20. ntenance 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 6 Warranted Parts 1 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 SKU 66603 Fuel Metering System i Carburetor and its internal parts ii Fuel pump if so equipped iii Cold start enrichment system For technical questions please call 1 800 444 3353 Page 28
21. ounding rod not included that has been driven at least 24 inches deep into the earth The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the Generator See Figure C 7 SOGI aag ENGINE FIGURE C GROUNDING TERMINAL 9 6 AWG GROUNDING WIRE NOT INCLUDED GROUNDING ROD NOT INCLUDED PRE START INSTRUCTIONS 1 IMPORTANT Your Warranty is voided if you do not put engine oil in the Engine s crankcase prior to its first use Before each use check the oil level Never run the Engine with low or no engine oil Running the Engine with no or low engine oil WILL permanently damage the Engine 2 The Engine MUST be filled with a high quality engine oil If the Engine will be run in temperatures above 32 degrees Fahrenheit use SAE 30 weight oil If the Engine will be run in temperatures below 32 degrees Fahrenheit use SAE 5W 30 weight oil SKU 66603 For technical questions please call 1 800 444 3353 Page 12 3 To add engine oil unscrew and remove the Oil Dipstick 65A 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 Then make sure to screw the Oil Dipstick back into its Dipstick Hole See Figure D THIS GENERATOR HAS AN AUTO SHUTDOWN OIL SENSOR IF ENGINE STOPS OR WILL NOT START CHECK OIL LEVEL OIL
22. pe and size Battery required is 12 volt DC 7 1 4 long by 3 wide See Figure B next page 3 Locate the factory pre installed Battery Guard Plate 44 and Battery Tray 48 beneath the Control Panel of the Generator See Figure B 4 Slide the Battery into the Battery Guard Plate 44 with the Battery s terminals facing outward and with the Battery s negative terminal facing left See Figure B 5 Align the two mounting holes in the Battery Bracket 47 with the two threaded mounting holes in the Battery Guard Plate 44 Then secure the Battery Bracket REV 09I SKU 66603 For technical questions please call 1 800 444 3353 Page 10 to the Battery Guard Plate using two Bolts with Lock Washers 46 See Figure B FIGURE B 12 VDC BATTER NOT INCLUDED POSITIVE BATTERY CABLE BATTERY GUARD PLATE 44 BATTERY BRACKET 47 BATTERY TRAY 48 BOLT WITH LOCK WASHER 46 6 Connect the Engine s Positive Battery Cable RED to the Battery s positive terminal Then connect the Engine s Negative Battery Cable BLACK to the Battery s negative terminal See Figure B TO ATTACH THE WHEEL ASSEMBLY 1 With additional assistance and a proper lifting device raise the left side of the Generator about 6 to 8 inches off the floor surface 2 Attach the two Axle Brackets 53 to the lower Frame 42 using two Bolts 52 and two Lock Washer Nuts 13 for each Axle Bracket See Assy Diagram 3 S
23. pills 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 covered metal container Never store fuel or other flammable materials near the Generator Do not smoke or allow sparks flames or other sources of ignition around the Generator Keep grounded conductive objects such as tools away from exposed live electrical parts and connections to avoid sparking or arcing These events could ignite fumes or vapors Do not refill the Fuel Tank while the Engine is running or hot Do not operate the Generator with known leaks in the Engine s fuel system Use only oil and fuel recommended in the Product Specifications section of this manual SKU 66603 For technical questions please call 1 800 444 3353 Page 6 MECHANICAL PRECAUTIONS 1 Prior to performing service maintenance or cleaning procedures always make sure the Engine Switch is in its OFF position Allow the Engine to completely cool Then remove the Spark Plug Wire from the Spark Plug 2 Do notalter or adjust any part of the Generator or its Engine that is assembled and supplied by the manufacturer or distributor 3 Always follow and complete scheduled Engine maintenance CHEMICAL PRECAUTIONS 1 Avoid contact with hot fuel oil exhaust fumes and solid surfaces 2 Avoid body contact with fuels oils and lubricants used in the Engine If
24. pment could result from an overload Starting and running wattage requirements should always be calculated when matching this Generator s wattage capacity to the appliance tool or equipment 4 Most appliances tools and equipment will list on the motor nameplate the starting and running voltage and amperage requirements Use the following formula to convert voltage and amperage to wattage a Volts x Amps Watts example 120 Volts x 3 Amps 360 Watts b To determine the approximate wattage requirement for most appliances tools and equipment with inductive type motors multiply the wattage that was calculated by 2 times to assure adequate Generator capacity c The starting and running wattage for resistant loads are the same Example a 100 watt light bulb requires only 100 watts to turn on Most resistant loads will be listed in wattage 5 Always power the largest electric motor first The plug in other appliances tools and equipment a Connect inductive load appliances tools and equipment first Inductive loads consist of small hand tools and some small appliances Connect the items that require the most wattage first b Connect any lights next c Voltage sensitive appliances tools and equipment should be the last to be connected to the Generator Plug voltage sensitive items such as T V s VCR s microwaves and cordless telephones into a UL Listed voltage surge protector not included Then connect the
25. rcuit Breakers Input Power 12 VDC Battery 7 1 4 Long x 3 Wide not included with an In Line Circuit Breaker Voltmeters 0 150 Volts 50 Volt Marked Increments 0 300 Volts 100 Volt Marked Increments w 50 Volt Hash Marks 16 HP 4 Cycle Air Cooled Electric amp Recoil Start 3600 RPM 420cc Displacement 6 6 Gallon Fuel Tank Powered with Mid to High Octane Unleaded Gasoline Engine Family 5CSG 41925C Recommended Oil 37 Fluid Ounces SAE 30W Above 32 Fahrenheit SAE 5W 30 Below 32 Fahrenheit Recommended Spark Plug Gap 0 028 0 031 Estimated Run Time 8 Hours 50 Load Automatic Low Oil Shutdown Additional Features Locking ON OFF with 2 Keys Overall Dimensions 24 1 8 Long x 20 1 2 Wide x 24 1 2 High Net Weight 205 Pounds IMPORTANT This product requires oil and fuel to be added before starting Attempting to start the Engine without oil WILL ruin the Engine and void the warranty Electrical Requirements Engine Specifications NOTE The Engine s carburetor may need to be adjusted by a qualified mechanic for efficient high altitude use The emission control system for this Generator s Engine is warranted for standards set by the U S Environmental Protection Agency For warranty information refer to the last pages of this manual SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts
26. surge protector into the Generator 6 IMPORTANT Failure to connect and operate appliances tools and equipment in this sequence can cause damage to the Generator appliances tools and equipment and will void the Warranty of this Generator 7 Once the Engine is running simply connect the 120 VAC appliances tools and equipment into the 120 VAC Outlet Sockets 8 10 Also connect a 240 VAC appliance tool or equipment into the 240 VAC Outlet Socket 10B See Figure A 8 NOTE If Engine speed or voltage fluctuates with a load below 250 watts move the En gine Choke Lever 21A to the HALF CHOKE position See Figure F REV 09I SKU 66603 For technical questions please call 1 800 444 3353 Page 15 NOTE Do not allow the generator to completely run out of fuel with devices attached A generator s output may sharply spike as it runs out of fuel causing damage to attached devices 9 When finished using the Generator disconnect all electrical loads Turn the Engine Switch 2 to its OFF position to stop the Engine Then close the Engine Fuel Valve 41 See Figures A and F 10 Allow the Generator and its Engine to completely cool Then store the unit in a clean dry safe location out of reach of children and other unauthorized people INSPECTION MAINTENANCE AND CLEANING 1 AWARNING Always make sure the Engine Switch 2 is in its OFF position and the Spark Plug Wire is removed from the Spark Plug 2
27. swallowed seek immediate medical treatment Do not induce vomiting if fuel is swallowed For skin contact immediately wash with soap and water For eye contact immediately flush eyes with clean water NOISE PRECAUTION Prolonged exposure to high noise levels is hazardous to hearing Always wear ANSI approved hearing protection when operating or working around the Generator when it is running ELECTRICAL PRECAUTIONS 1 All connections and conduits from the Generator to the load must only be installed by trained and licensed electricians and in compliance with all relevant local state and federal electrical codes and standards and other regulations where applicable 2 The Generator must be earth grounded in accordance with all relevant electrical codes and standards before operation SKU 66603 For technical questions please call 1 800 444 3353 Page 7 3 Ifan extension cord not included is used make sure to use only UL listed cords having the correct gauge and length See Table A 4 Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground 5 Do not touch electrically energized parts of the Generator and interconnecting cables or conductors with any part of the body or with any non insulated conductive object 6 Connect the Generator only to a load or electrical system 120 volt or 240 volt that is compatible with the electrical characteristics and rated capacities o
28. t only to the Outlet Socket 120 volt or 240 volt that is compatible with the electrical characteristics and rated capacities of the tools and equipment being used See Figure A 3 Circuit Breakers 3 5 The Generator features five Circuit Breakers to protect the unit from overloading a One 20 Amp Circuit Breaker controls the 3 Prong 120 volt Outlet Socket 8 b One 30 Amp Circuit Breaker controls the 3 Prong Twistlock 120 volt Outlet Socket 10 c Two 30 Amp Circuit Breakers control the 4 Prong Twistlock 240 120 volt Outlet Socket 10B d One In Line Circuit Breaker to protect the Engine s Starter 83A Should any of the four Circuit Breakers trip the Engine will automatically shut down In this event unplug all loads from the Generator Allow the Generator to cool down Then press the tripped Circuit Breaker and restart the Engine See Figure A 4 Voltmeters 7 The Generator features two Voltmeters which provide readings of voltage output depending on which of the three Outlet Sockets 8 10 10B are being used See Figure A 5 Grounding Terminal 9 Prior to each use always connect a ground wire not included to the Grounding Terminal to properly ground the Generator See Figure C page 11 BATTERY INSTALLATION 1 The Engine of the Generator may be started manually or electrically 2 To use the Engine s electric start capability a Battery 45 not included must first be installed The ty
29. tive capacitor Faulty cords or equipment Generator overloaded Insufficient ventilation For technical questions please call 1 800 444 3353 Have a qualified technician check ignition system Have a qualified technician check outlets Depress circuit breaker and reset Have a qualified technician check capacitor Repair or replace cord Reduce load Check for damaged bare or frayed wires on equipment Repair or replace Reduce load Move to adequate supply of fresh al Page 19 PAR NERATOR 5 Circuit Breaker 20 Ame 1 6 eeu fe 7 vemeerg sv 1 78 Votmeter 0 300v 1 e ea 8 OutetSocet 20V 2 9 Grounding Terminal a 52 Bolt mex2o 8 60_ BoltwiLock Washer M6x12 8 22 Bolt M10x1 25x265 63 Pin 8x45 66 Washer MO 4 68 nume fa 69 Num 2 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 66603 For technical questions please call 1 800 444 3353 Page 20 ASSEMBLY DIAGRAM GENERATOR Battery 45 is not included SKU 66603 For technical questions please call 1 800 444 3353 Page 21 PARTS LIST ENGINE Par Description aty GA Gear Case Packing 6 SKU 66603 For technical questions please call 1 800 444 3353 Page 22 PARTS LIST ENGINE CONT P
30. uthorized by HFT For emissions warranty service contact the HFT Customer Service Department at 1 800 444 3353 3 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 4 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 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 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 war ranty center c Failure to follow recommendations on fuel use contained in the Owner s Manual d Improper or inadequate maintenance of any warranted parts e Repairs performed outside of the authorized warranty service dealers f Alterations by changing adding to or removing parts from the engine SKU 66603 For technical questions please call 1 800 444 3353 Page 27 EMISSION CONTROL SYSTEM WARRANTY CONT 5 Service and Mai
31. weight oil If the Engine will be run in temperatures below 32 degrees Fahrenheit use SAE 5W 30 weight oil 4 To add engine oil unscrew and remove the Oil Dipstick 65A 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 can not see the oil through the oil fill hole then the oil is too low and more oil must be added Then make sure to screw the Oil Dipstick back into its Dipstick Hole See Figure G 5 After every 25 hours of use Service the Air Cleaner Element 19A and Air Cleaner Separator 20A See Figure H AIR CLEANER SEPARATOR 20A FIGURE H AIR CLEANER COVER 18A AIR CLEANER ELEMENT 19A 6 Todo so remove the Air Cleaner Cover 18A Remove the Air Cleaner Element 19A Immerse the Air Cleaner Element in a mild solvent and squeeze the Element several times to clean Remove the Element from the solvent and squeeze thoroughly to dry Then squirt several drops of a light weight oil into the Element and squeeze the Element so oil reaches all parts of the Element See Figure H 7 Use compressed air to clean the Air Element Separator 20A Then replace the Air Element Separator Air Cleaner Element and Air Cleaner Cover 184A See Figure H 8 Clean more often under dusty conditions or when airborne debris is present Replace Air Cleaner parts if necessary See Figure H 9 After every 100 hours of use Clean and re gap the
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