Chicago Electric 54206 User manual

GENERATOR – MANUAL START
11 HP – 6,000 W
Model 54206
OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright 2002 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.
For technical questions, please call 1-800-444-3353.
Generators

PRODUCT SPECIFICATIONS
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, operating, in-
spection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the
front cover. Keep this manual and invoice in a safe and dry place for future refer-
ence.
SKU 54206 PAGE 2 REV 12/02 REV 12/03
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page 15
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
GENERAL SAFETY WARNINGS AND PRECAUTIONS
1. KEEP WORK AREA CLEAN AND DRY. Cluttered, damp, or wet work areas
invite injuries.
2. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle
thisproduct.
3. STORE IDLE EQUIPMENT. When not in use, tools and equipment should be
stored in a dry location to inhibit rust. Always lock up tools and equipment, and
keep out of reach of children.
Item Description
Generator
Electrical Output
Capacities
Surge Output = 7200 Watts
Maximum Output = 6000 Watts*
Rated Output = 4800 Watts**
Output Current = 20 Amps @ 120 Volts
20 Amps @240 Volts
Output Frequency = 60 Hz
Electrical Receptacles Two 120 VAC/20 Amp Outlets
One 120/240 VAC/20 Amp Twist Lock Outlet***
Alternator Type Brushless/Two-Pole/Single Phase
Engine Horsepower 11 HP Briggs & Stratton®Engine
Engine Speed 3600 RPM
Engine Starter Type Manual (Pull Type Recoil)
Engine Shut Off Feature Low Oil Automatic Shut Off
Fuel Tank Capacity 6.5 Gallons
Fuel Requirement Unleaded Gasoline
Run Time 10-1/2 Hours @ 50% Load
Roll Cage Type Full
Overall Dimensions 29-3/4” x 25-1/2” x 20-5/8”
Weight 154 Pounds
* Under ideal lab test conditions. ** Under practical conditions.Output is further
limited by the circuit breaker for each outlet. *** With Circuit Breaker Protection
Notice !
THIS GENERATOR MAY COME EQUIPPED
WITH A 30 AMP, 240 VOLT RECEPTACLE. THE
CIRCUIT BREAKER IS RATED AT 20 AMPS
AND WILL NOT SUPPORT A 30 AMP LOAD.
THIS
GENERATOR IS NOT INTENDEDTO
POWER SENSITIVE ELECTRONIC
EQUIPMENTWITHOUTTHE ADDITION
OF AN APPROPRIATE LINE
CONDITIONER (SOLD SEPARATELY).

5. USE EYE, FACE, HEARING and HAND PROTECTION. Wear ANSI approved
safety impact eye goggles, full face shield, hearing protection and safety gloves
when using this product. ANSI approved safety impact eye goggles, hearing
protection, and safety gloves are available from Harbor FreightTools.
6. DRESS SAFELY. Do not wear loose clothing or jewelry, as they can become
caught in moving parts. Wear a protective hair covering to prevent long hair from
becoming caught in moving parts.
7. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etcetera.
8. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.
9. STAY ALERT. Watch what you are doing at all times. Use common sense. Do
not use this product when you are tired or distracted from the job at hand.
10. CHECK FOR DAMAGED PARTS. Before using this product, carefully check that
it will operate properly and perform its intended function. Check for damaged
parts and any other conditions that may affect the operation of this product.
Replace or repair damaged or worn parts immediately.
11. REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only
identical replacement parts. Only use accessories intended for use with this
product. Approved accessories are available from Harbor Freight Tools.
12. MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for
better and safer performance. For your safety, service and maintenance should
be performed regularly by a qualified technician.
13. USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or
attachment to do the work of a larger industrial tool. There are certain
applications for which this tool was designed. It will do the job better and more
safely at the rate for which it was intended. Do not modify this tool, and do not
use this tool for a purpose for which it was not intended.
14. WARNING: The warnings, precautions, and instructions discussed in this manual
cannot cover all possible conditions and situations that may occur. The operator
must understand that common sense and caution are factors, which cannot be
built into this product, but must be supplied by the operator.
SKU 54206 PAGE 3
4. DO NOT USETHIS PRODUCT IF UNDERTHE INFLUENCE OF ALCOHOL OR
DRUGS. Read warning labels on prescriptions to determine if your judgement or
reflexes are impaired while taking drugs. If there is any doubt, do not attempt to
use this product.

ADDITIONAL PRODUCT WARNINGS AND PRECAUTIONS
1. WARNING: Before using the Generator, read and understand the Engine
manufacturer’s Operation, Maintenance,and Parts manual. Also read the
safety precautions in this manual which should always be followed to reduce
the risk of personal injury and damage to equipment.
Installation Precautions:
1. Ensure installation meets all applicable safety, and local and national electrical
codes. Have installation performed by a qualified, licensed electrician and
building contractor.
2. All electrical work, including the earth-ground connection, should be completed
by a licensed electrician.
3. Any separate fuel storage Generator supply facility must be built or installed in
full compliance with relevant local, state, and federal regulations.
4. If the generator is installed indoors, exhaust fumes must be piped out of the
building using leak-free, heat-resistant piping. Secure the generator in place
before piping exhaust. Pipes and silencer should not use any flammable materi-
als, nor should they be installed near the same. Generator exhaust fumes should
be within legal limits. All applicable building codes must be followed. The gen-
erator must be located in a well ventilated work area. See section on Generator
Support and Mounting on page 9.
5. If the generator is permanently installed outdoors, it must be weatherproofed and
can be soundproofed. It should not be run outdoors without protection to the
Generator and wiring connections (plug in connections, not hard wired).
6. Never lift the Generator using the engine or alternator for lifting. Use only lifting
devices capable of safely supporting the weight of this generator. This generator
weighs 154 lbs. Never attempt to lift or move this generator without assistance.
7. Before lifting the Generator, ensure the lift rigging and supporting structure, if
required, are in good condition, and are rated to lift such a load.
8. Keep all personnel away from the suspended generator during relocating.
9. The supporting floor/ground surface should be level, and strong enough to safely
hold the weight of the Generator. If the floor/ground surface is not level, strong
cross members should be placed under the full length of the Generator Frame
(part #21) at its low side.
SKU 54206 PAGE 4

10. For trailer installation, the Generator should be mounted on the center point of the
trailer, over the wheels and properly secured in place.
11. Install sound and weather proofing only when it is not raining or snowing to avoid
trapping moisture within the Generator.
Fire And Explosion Precautions:
1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel
storage and handling procedures. Always have multiple ABC class fire
extinguishers nearby.
2. Keep the Generator and surrounding area clean at all times.
3. When spills of fuel, oil occur, they must be cleaned up immediately. Dispose of
fluids and cleaning materials as per any local, state, or federal codes and regula-
tions.Store oil rags in a covered metal container.
4. CAUTION:Never store fuel or other flammable materials near the generator.
5. Do not smoke, or allow sparks, flames or other sources of ignition around the En-
gine and Fuel Tank (part #32). Fuel vapors are explosive.
6. Keep grounded conductive objects, such as tools, away from exposed, live electri-
cal parts and connections to avoid sparking or arcing. These events could ignite
fumes or vapors.
7. CAUTION: Do not refill the FuelTank (part #32) while the Engine is running.
8. Do not operate the Generator with known leaks in the fuel system.
9. Excessive buildup of unburned fuel gases in the exhaust system can create a
potentially explosive condition. This buildup can occur after repeated failed start
attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust system
drain plugs, if equipped, and allow the gases to dissipate before attempting to
restarttheGenerator.
10. Use only engine manufacturer recommended unleaded fuel and oil.
Mechanical Precautions:
1. ALWAYS turn off the Engine when not in use or when performing maintenance.
Allow the Engine to completely cool, and disconnect the Engine’s Spark Plug Cable
from the Spark Plug before carrying out maintenance.
SKU 54206 PAGE 5

2. Check for damaged parts. Before using the Generator, any part that appears
damaged should be carefully checked to determine that it will operate properly
and perform its intended function. Check for alignment and binding of moving
parts, any broken parts or mounting fixtures, and any other condition that may
affect proper operation. Any part that is damaged should be properly repaired or
replaced by a qualified technician.
3. The Generator is designed with guards for protection from moving parts. In any
case, care must still be taken to protect personnel and equipment from other
mechanical hazards when working around the generator.
4. Do not operate the Generator with safety guards removed. While the Generator
is running, do not attempt to reach around the safety guards for maintenance or
any other reason.
5. Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts.
Be aware that when Engine parts are moving fast they cannot be seen clearly.
6. Keep access doors on enclosures closed and locked when access is not re-
quired.
7. When working in and around the Generator always wear protective clothing
including ANSI approved safety gloves, safety eye glasses, full face shield and
safetyhat.
8. Do not alter or adjust any part of the Generator assembled and supplied by the
manufacturer.
9. Always follow and complete scheduled Engine and Generator maintenance.
10. For detailed information regarding the engine, refer to the Engine Manufacturer’s
Operation, Maintenance and Parts Manual included with the generator.
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 Generator. If
swallowed, seek medical treatment immediately. 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 Precautions:
1. Prolonged exposure to noise levels above 85 dBA is hazardous to hearing.
Always wear ANSI approved ear protection when operating or working around
the Generator when it is running.
SKU 54206 PAGE 6

Electrical Precautions:
1. All connections and conduit 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. If the Generator is hard wired it must be earth-grounded in accordance with all
relevant electrical codes and standards before operation. Refer to Article 250 of
the National Electrical Code for requirements.
3. If an extension cord (not included) is used, make sure to use only UL®approved
cords having the correct gauge and length. (See Figures A, and B.)
FIGURE A
REQUIRED MINIMUM EXTENSION CORD GAUGE – 240 VOLT
NAMEPLATE
AMPERES EXTENSION CORD LENGTH
_______________________________________________
(At Full Load) 0-25 Feet 25-50 Feet 50-100 Feet 100-150 Feet
6181614 12
8181612 10
10 18 14 12 10
12 16 14 10 8
14 16 12 10 8
16 16 12 10 8
18 14 12 8 8
20 14 12 8 6
22 14 10 8 6
24 14 10 8 6
26 12 10 8 6
28 12 10 6 4
30 12 10 6 4
FIGURE B
SKU 54206 PAGE 7
REQUIRED MINIMUM EXTENSION CORD GAUGE – 120 VOLT
NAMEPLAT
E
AMPERES
(
At Full Load
)
EXTENSION CORD LENGTH
0 - 25
Feet 25 - 50 Feet 50 -100 Feet 100 – 15
0
Feet 150– 200 Feet
0 - 5 16 16 16 12 12
5.1 - 8 16 16 14 10 -
8.1 - 12 14 14 12 - -
12.1 - 15 12 12 10 - -
15.1 - 20 10 10 10 - -

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 and 240 volt)
that is compatible with the electrical characteristics and rated capacities of the
Generator.
7. Before servicing equipment powered by the Generator, disconnect the equipment
from its power input.
8. Keep all electrical equipment clean and dry. Replace any wiring where the insu-
lation 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 refrigerator enclosures.
11. Use only Class BC or Class ABC fire extinguishers on electrical fires.
12. WARNING: People with pacemakers should consult their physician(s) before
using this product. Operation of electrical equipment in close proximity to a heart
pacemaker could cause interference or failure of the pacemaker.
INSTALLATION
1. NOTE: Prior to powering tools and equipment, make sure the Generator’s rated
voltage, wattage, and amperage capacity (120V/20Amp and 240V/20 Amp, 4,800
rated Watts) is adequate to supply all electrical loads that the unit will power. If
powering exceeds the Generator’s capacity, it may be necessary to group one or
more tools and equipment for connection to a separate Generator.
SKU 54206 PAGE 8 REV 12/02
2. Electrical and other permits may be required for the installation of emergency
power systems. Investigate the local building and electrical codes before install-
ing this unit. Installation must be completed by licensed contractors.
3. Warning:The Generator weighs 154 pounds. Never attempt to lift or move this
generator without assistance. Use care and the proper lifting or hoisting equip-
ment, if required, when moving it to the installation location. Always connect hoist
lines to the Frame (part #21) of the Generator.

GENERAL LOCATION
1. It is recommended to locate and install the Generator outdoors where cooling air
is readily available.
2. Install the Generator so that the air inlets and outlets are not blocked by obstruc-
tions such as bushes, trees, or snow drifts. Locating it in the path of heavy winds
or snowdrifts may require the placement of a barrier for protection. The air inlet,
in normal weather conditions, should face the prevailing wind direction.
3. Install 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 mainte-
nance.
5. Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.
6. If the Generator in located indoors, or in a Generator house, the Engine exhaust
must be ventilated to the outdoors using leak-proof, heat resistant, metal, flex
tubing.
GENERATOR SUPPORT AND MOUNTING
1. Mount the Generator on a concrete slab capable of supporting the weight of the
Generator. The slab must extend on all sides beyond the Frame (part #21) by at
least one foot. Contact a cement contractor for slab specifications if necessary.
Attach the Frame to the concrete slab using 3/8” diameter masonry type anchor
bolts (not supplied).
GROUNDING THE GENERATOR
1. NOTE: It is recommended that only a trained and licensed electrician perform
this procedure.
SKU 54206 PAGE 9
2. For permanent hardware applications, connect a #6 AWG grounding wire (not
included) from the Wing Nut (part #43) to a grounding rod (not included) that has
been driven to the proper depth into the earth. The grounding rod must be an
earth-driven copper or brass rod (electrode) which can adequately ground the
Generator. Refer to Article 250 of the National Electrical Code.
(See Figure C, next page.)

6 AWG GROUND WIRE
(NOT INCLUDED)
GROUND ROD
(NOT INCLUDED)
EARTH CONCRETE SLAB
WING NUT (#43)
FIGURE C
OPERATING INSTRUCTIONS
NOTE: For additional references to the parts listed below, refer to the Assembly
Diagram on page 15.
Pre-Start Checks:
1. NOTE: During operation, it may be necessary to refer to the Engine
manufacturer’s Operation, Maintenance, and Parts manual (included) for detailed
information regarding the Engine.
2. Check to make sure the Engine’s “ON/OFF” Switch is in its “OFF” position.
(See Figure D, next page.)
3. Unscrew and remove the Engine’s Oil Fill Cap located at the bottom of the En-
gine Crankcase. Check to make sure the oil level is even with the top of the Oil
Fill Hole. If necessary, add oil until its level is even with the Oil Fill Hole. Then,
screw the Oil Fill Cap back onto the Oil Fill Hole. NOTE: Check with the Engine
manufacturer’s manual for the proper type of engine oil required for use.
(See Figure E, next page.)
4. Check the Fuel Gauge (part #34) for the amount of unleaded gasoline in the Fuel
Tank (part #32). If necessary, remove the Fuel Tank Cap (part #37) and refill the
Fuel Tank with unleaded gasoline. Then, replace the Fuel Tank Cap. (See
Figure F, page 12.)
SKU 54206 PAGE 10

FUEL VALVE
(#31)
FRAME
(#21)
FUEL
CHOKE
STARTER
PULLEY
“ON/OFF”
SWITCH
FIGURE D
OIL FILL CAP
ENGINE CRANKCASE
FIGURE E
SKU 54206 PAGE 11
FUEL TANK (#32)

FUEL TANK CAP (#37)
FUEL GAUGE (#34)
FUEL TANK (#32) FIGURE F
To Start The Generator:
1. Turn the Fuel Valve (part #31) to its vertical “OPEN” position. (See Figures D
and G.)
2. Move the Engine’s Fuel Choke all the way to the right to its “START” position.
(See Figures D and G.)
FUEL VALVE
(#31)
FUEL CHOKE
RUN START
FIGURE G
SKU 54206 PAGE 12

3. Turn the Engine’s “ON/OFF” Switch to its “ON” position. (See Figure D.)
4. Grasp the Handle of the Engine’s Starter Pulley and rapidly pull the Starter Pulley
to start the Engine. NOTE: It may take one or more pulls on the Starter Pulley to
start the Engine. (See Figure D.)
5. Allow the Engine to run for several seconds, then move the Engine’s Fuel Choke
all the way to the left to its “RUN” position. (See Figures D and G.)
Powering Tools And Equipment:
1. Prior to powering tools and equipment, make sure the Generator’s rated voltage,
wattage, and amperage capacity (120V/20 Amp and 240V/20 Amp, 4,800 rated
Watts) is adequate to supply all electrical loads that the unit will power. If power-
ing exceeds the Generator’s capacity, it may be necessary to group one or more
tools and equipment for connection to a separate Generator.
2. Once the Generator is running, simply connect the Power Cords of 120 volt
powered tools and equipment into the 120 VAC Outlets (part #41). If a 120/240
volt tool or equipment is used, connect its power cord into the 120/240 VAC Twist
Lock Outlet (part #42). (See Figure H.)
3. NOTE: The Generator features two AC Non-Fuse Overload Breakers (part #40)
to protect the AC circuit in case of an overload. Should an overload occur one or
both of the Breakers will “trip”, causing the Generator to automatically shut off
power output. In this case, refer to Step #1 in this section. Then, reset the circuitry
system by depressing the Breaker(s). Restart the Generator, if necessary, and
continue powering the remaining tools and equipment. (See Figure H.)
AC CIRCUIT OVERLOAD BREAKER (#40)
120 VAC OUTLET (#41)
240 VAC
TWIST LOCK
OUTLET
(#42)
FIGURE H
SKU 54206 PAGE 13 REV 12/02

INSPECTION, MAINTENANCE, AND CLEANING
1. NOTE: Preventative maintenance procedures and frequency will vary depending
on the amount of Generator use. Refer to the Engine manufacturer’s Operation,
Maintenance, and Parts manual (included) for detailed information regarding
maintenance of the Engine.
2. CAUTION: Always turn off the Engine.Allow sufficient time for the Engine and
Generator to completely cool. Then, disconnect the Engine’s Spark Plug Wire
from the Spark Plug before performing any inspection, maintenance, or cleaning.
3. BEFORE EACH USE, inspect the general condition of the Generator. Check for
loose screws, misalignment or binding of moving parts, cracked or broken parts,
damaged electrical wiring, and any other condition that may affect its safe opera-
tion. If abnormal noise or vibration occurs, have the problem corrected before
further use. Do not use damaged equipment.
4. BEFORE EACH USE, check to make sure the Engine’s oil level is adequate.
Refer to the Engine manufacturer’s Operation, Maintenance, and Parts Manual
(included) for specific information.
5. DAILY: With a soft brush, cloth, or vacuum, remove all debris from the Generator.
Then, use a premium quality, lightweight machine oil to lubricate all moving parts.
SKU 54206 PAGE 14
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
DISTRIBUTORMAKESANYREPRESENTATION ORWARRANTYOFANYKINDTOTHE BUYERTHAT
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 MANUFACTUER AND/OR
DISTRIBUTOREXPRESSLY STATESTHATALL REPAIRSAND PARTSREPLACEMENTSSHOULDBE
UNDERTAKENBYCERTIFIEDANDLICENSEDTECHNICIANS,ANDNOTBYTHEBUYER. THEBUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL
PRODUCTOR REPLACEMENTPARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OFREPLACEMENTPARTSTHERETO.

PARTS LIST
ASSEMBLY DIAGRAM
SKU 54206 PAGE 15
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
Part # Description Qt
y
. Part # Description Qt
y
.
1 Bolt (M5 x 12) 2 23 Bolt (M12 x 30) 4
2 Connection Board 1 24 Lock Washer (M10) 4
3 Bolt (M5 x 20) 4 25 Shock Absorber 4
4 Bolt (M5 x 12) 2 26 Rail 2
5 Cable Sheath 1 27 Lock Washer (M5) 4
6 Rear Cover 1 28 Bolt (M8 x 55) 4
7 Bolt (M6 x 16) 2 29 Lock Washer (M8) 4
8 Bolt (M6 x 155) 4 30 Rail Protection 4
9 Capacitor 1 31 Fuel Valve 1
10 Motor Back Cover 1 32 Fuel Tank 1
11 Bolt (5/16 x 205) 1 33 Bolt (M6 x 25) 4
12 Stator 1 34 Fuel Gauge 1
13 Bridge Combination 2 35 Bolt (M5 x 12) 2
14 Voltage Dependent Resistor 2 36 Filter 1
15 Rotor 1 37 Fuel Tank Cap 1
16 Hex Bolt (3/8 x 30) 4 38 Seal Ring 1
17 Fan Blade 1 39 Switch Box Cover 1
18 Motor Front Cover 1 40 AC Overload Breaker 2
19 Bolt (M5 x 12) 4 41 Outlet (120 V/15A) 1
20 Panel 1 42 Outlet (240V/20A) 1
21 Frame 1 43 Wing Nut 1
22 Shock Absorber Support 4