Chicago Electric 66603, Set Up, Operating, And Servicing Instructions

Page 1: ...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 imp...

Page 2: ... 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 NOTE The Engine s carburetor may need to be adjusted by a qualif...

Page 3: ... 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 personal injury Dress properly Do not wear loose clothing or jewelry Contain long hair Keep 2 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 wrenc...

Page 4: ...n 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...

Page 5: ...sk of injury When servicing a tool use only identical replacement parts Follow 2 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 1 You do not put engine oil in the Engine s crankcase prior to its first use Befo...

Page 6: ... area and in the surrounding area Gasoline fuel and fumes are flammable and potentially explosive 2 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 3 When spills of fuel or oil occur they must be cleaned up immediately 4 Dispose of fluids and cleaning materials as per any...

Page 7: ... lubricants used in the Engine 2 If 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 Gene...

Page 8: ...ng where the 8 insulation is cracked cut abraded or otherwise degraded Replace terminals that are worn discolored or corroded Keep terminals clean and tight Insulate all connections and disconnected wires 9 Guard against electric shock Prevent body contact with grounded surfaces such 10 as pipes radiators ranges and refrigerators Use only Class BC or Class ABC fire extinguishers on electrical fire...

Page 9: ...lts Alternating Current A Amperes n0 xxxx min No Load Revolutions per Minute RPM Engine Switch 2 1 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...

Page 10: ...tor Allow the Generator to cool down Then press the tripped Circuit Breaker and restart the Engine See Figure A Voltmeters 7 4 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 Grounding Terminal 9 5 Prior to each use always connect a ground wire not included to the Grounding Terminal t...

Page 11: ... floor surface Attach the two Axle Brackets 53 to the lower Frame 42 using two Bolts 52 and 2 two Lock Washer Nuts 13 for each Axle Bracket See Assy Diagram Slide the Axle 49 through the two Axle Brackets 53 3 See Assy Diagram Insert one Wheel 50 onto each end of the Axle 49 4 See Assy Diagram Secure the Axle 49 and Wheels 50 in place using four Pins 51 5 See Assy Diagram INSTALLATION INSTRUCTIONS...

Page 12: ...Control Panel to a grounding 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 GROUNDING TERMINAL 9 CONCRETE SLAB 6 AWG GROUNDING WIRE NOT INCLUDED GROUNDING ROD NOT INCLUDED FIGURE C PRE START INSTRUCTIONS IMPORTANT Your Warranty is voided if yo...

Page 13: ... 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 To fill the Fuel Tank 31 unscrew and remove the Fuel Tank Cap 34 Fill the 4 Fuel Tank with mid to high octane unleaded gasoline Then replace the Fuel Tank Cap When necessary refill the Fuel Tank See Figure E Periodically check the Fuel...

Page 14: ... 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 5 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 Handl...

Page 15: ...dequate Generator capacity The starting and running wattage for resistant loads are the same Example a 100 c watt light bulb requires only 100 watts to turn on Most resistant loads will be listed in wattage Always power the largest electric motor first The plug in other appliances tools and 5 equipment Connect inductive load appliances tools and equipment first Inductive loads consist a of small h...

Page 16: ...unit If abnormal noise or vibration occurs have the problem corrected before further use GENERATOR MAINTENANCE Keep the Generator clean and dry at all times 1 The Generator should not be operated or stored in locations that include excessive 2 moisture dust flammable or corrosive vapors If these substances are on the Generator clean with a soft cloth or brush Do not use a garden hose or anything w...

Page 17: ... remove the Air Cleaner Cover 18A Remove the Air Cleaner Element 19A 6 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 Use compressed air to cl...

Page 18: ...ngine 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 manual a...

Page 19: ...Page 19 SKU 66603 For technical questions please call 1 800 444 3353 TROUBLESHOOTING ...

Page 20: ...t M5x20 4 25 Connection Board 1 26 Nut M5 4 27 Stator 1 28 Rotor 1 29 Cooling Fan 1 30 Heat Insulation Board Assy 1 31 Fuel Tank 1 32 Fuel Filter 1 33 Seal Ring 1 34 Fuel Tank Cap 1 35 Overflow Valve Pipe 2 36 Overflow Valve 1 37 Lock Washer Bolt M6x30 4 38 Spacer 4 Part Description Qty 39 Rub Washer 4 40 Bushing 4 41 Fuel Valve 1 42 Frame 2 43 Switch Box Cover 1 44 Battery Guard Plate 1 45 Batter...

Page 21: ...Page 21 SKU 66603 For technical questions please call 1 800 444 3353 ASSEMBLY DIAGRAM GENERATOR ...

Page 22: ... 2 32A Anti Wear Valve Stem Protector 2 33A Cylinder Head Cover Packing 1 34A Governor Spring 1 35A Bolt 1 36A High Tension Line 1 37A Ignition Coil 1 38A Nut Special 14mm 1 Part Description Qty 39A Starter Ratchet Spring 2 40A Starter Rope 1 41A Starter Handle 1 42A Recoil Starter 1 43A Spiral Spring 1 44A Starter Wheel 1 45A Circlip 1 46A Starter Ratchet 2 47A Friction Plate Screw 1 48A Cover 1 ...

Page 23: ...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 Part Description Qty 78A Compression Ring I 1 79A Compression Ring II 1 80A Oil Scraper Ring 1 81A Piston Pin 1 Part Description Qty 82A Piston Pin Circlip 1 83A Starter 1 84A Gear 1 85A Fuel Pipe 1 ...

Page 24: ...Page 24 SKU 66603 For technical questions please call 1 800 444 3353 ASSEMBLY DIAGRAM ENGINE ...

Page 25: ...Page 25 SKU 66603 For technical questions please call 1 800 444 3353 WIRING DIAGRAM ...

Page 26: ... 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 advantag...

Page 27: ...roved 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 reason able amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should con...

Page 28: ... 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 1 Fuel Metering System Carburetor and its internal parts i Fuel pump if so equipped ii Cold start enrichment system iii 2 Air Induction System Intake pipe...