Chicago Electric 96617 Installation manual

6300 WATT GASOLINE
GENERATOR
Model 96617
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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.
For technical questions or replacement parts, please call 1-800-444-3353.

Page 2SKU 96617 For technical questions, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY INFORMATION ............................ 4
GENERAL SAFETY RULES ................................................. 5
SPECIFIC SAFETY RULES .................................................. 7
FIRE AND EXPLOSION PRECAUTIONS...................................8
MECHANICAL PRECAUTIONS..................................................8
CHEMICAL PRECAUTIONS.......................................................8
NOISE PRECAUTIONS...............................................................9
GROUNDING ....................................................................9
Grounded Tools: Tools with Three Prong Plugs.....................9
Double Insulated Tools: Tools with Two Prong Plugs...........10
Extension Cords .......................................................................10
Symbology.................................................................................11
UNPACKING .................................................................... 12
SET UP INSTRUCTIONS.................................................12
Assembly...................................................................................13
To Install The Battery: .........................................................13
OPERATING INSTRUCTIONS......................................... 13
INSTALLATION INSTRUCTIONS ..............................................14
Grounding The Generator: .................................................14
Control Panel Features .......................................................15
PRE-START INSTRUCTIONS....................................................16
To Add Engine Oil:...............................................................16
To Fill The Fuel Tank: ..........................................................17
OPERATING INSTRUCTIONS......................................... 17
To Connect Electrical Loads: .............................................18
INSPECTION, MAINTENANCE, AND CLEANING..........19
PLEASE READ THE FOLLOWING CAREFULLY.....................21
TROUBLESHOOTING .....................................................22
PART LISTS AND ASSEMBLY DIAGRAMS ................... 23
Main Unit Parts List ..................................................................23

Page 3SKU 96617 For technical questions, please call 1-800-444-3353.
Main Unit Assembly Diagram ..................................................24
Parts List & Diagram A - Cylinder Head Assembly................25
Parts List & Diagram B - Cylinder Barrel................................26
Parts List & Diagram C - Crankcase Cover ............................27
Parts List & Diagram D - Crankshaft Assembly .....................28
Parts List & Diagram E - Piston & Rod Assembly .................28
Parts List & Diagram F - Camshaft Assembly........................29
Parts List & Diagram G - Recoil Starter Assembly ................30
Parts List & Diagram H - Fan Cover Assembly ......................31
Parts List & Diagram J - Carburetor System..........................31
Parts List & Diagram K - Flywheel System.............................32
Parts List & Diagram L - Ignition System ...............................32
Parts List & Diagram M - Starter Motor System.....................33
Parts List & Diagram N - Control System ...............................33
Parts List & Diagram P - Mufer System ................................34
Parts List & Diagram R - Air Cleaner.......................................35
Parts List & Diagram S - Fuel Tank System............................36
Parts List & Diagram T - Control Box......................................36
LIMITED 1 YEAR / 90 DAY WARRANTY ........................37
EMISSION CONTROL SYSTEM WARRANTY................37

Page 4SKU 96617 For technical questions, please call 1-800-444-3353.
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.
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.
DANGERDANGER
WARNINGWARNING
CAUTIONCAUTION
NOTICENOTICE
CAUTIONCAUTION

Page 5SKU 96617 For technical questions, please call 1-800-444-3353.
CAUTION!
Your Warranty Is Voided If:
You do not put engine oil in the Engine’s crankcase prior
to the rst 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 oil will permanently damage the unit.
GENERAL SAFETY RULES
WARNING! Read all instructions
Failure to follow all instructions listed below may result in electric shock,
re, and/or serious injury. The term “tool” in all of the warnings listed below
refers to your gasoline operated Generator.
SAVE THESE INSTRUCTIONS
Work area safety
Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
Do not operate Gasoline Generators in explosive atmospheres, such as in the
presence of ammable liquids, gases, or dust.
Keep bystanders and children away while operating a Gasoline Generator.
Distractions can cause you to lose control. Provide barriers or shields as
needed.
Electrical Safety
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.
The Generator must be grounded in accordance with all relevant electrical
codes and standards before operation.
If an extension cord (not included) is used, make sure to use only UL listed
cords having the correct gauge and length.
Do not attempt to connect or disconnect load connections while standing in
water, or on wet ground.
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.
Connect the Generator only to a load or electrical system (120 volt, 240 volt,
or 12 volt) that is compatible with the electrical characteristics and rated
capacities of the Generator.
1.
a.
b.
c.
2.
a.
b.
c.
d.
e.
f.

Page 6SKU 96617 For technical questions, please call 1-800-444-3353.
Be sure the Engine’s Ignition (38) is in the “OFF” position before moving
the Generator and before performing any service, maintenance, or cleaning
procedures on the unit.
Keep all electrical equipment clean and dry. Replace any wiring if the
insulation is cracked, cut, abraded, or otherwise degraded. Replace terminals
that are worn, discolored, or corroded.
Guard against electric shock. Prevent body contact with grounded surfaces
such as pipes, radiators, ranges, and refrigerator enclosures.
Use only Class BC or Class ABC re extinguishers on electrical res.
Personal Safety
Stay alert. Watch what you are doing, and use common sense when
operating the Gasoline Generator. Do not use the Gasoline Generator while
tired or under the inuence of drugs, alcohol, or medication. A moment
of inattention while operating Gasoline Generators may result in serious
personal 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 Generator on. A
wrench or a key that is left attached to a rotating part of the machine may
result in personal injury.
Do not reach over or across the Generator. Keep proper footing and balance
at all times.
Use safety equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions will reduce the
chance of personal injuries.
Equipment Use and Care
Do not use the Generator if the Engine’s Ignition (38) does not turn it on or off.
Any power switch that cannot control the generator must be replaced.
When not in use, disconnect the battery terminals, and disconnect the spark
plug wire. Store the Generator out of reach of children and other untrained
persons. It could be dangerous in the hands of untrained users.
Maintain the Generator with care. Properly maintained Generators are
less likely to malfunction and are easier to control. Do not use a damaged
Generator.
Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the Generator’s operation. If damaged,
g.
h.
i.
j.
3.
a.
b.
c.
d.
e.
4.
a.
b.
c.
d.

Page 7SKU 96617 For technical questions, please call 1-800-444-3353.
have the Generator serviced before using. Many accidents are caused by
poorly maintained equipment.
Service
Have your Gasoline Generator serviced by a qualied repair person using
only identical replacement parts. This will ensure that the safety of the
Gasoline Generator is maintained.
SPECIFIC SAFETY RULES
Your Warranty is voided if you do not put engine oil in the Engine’s crankcase
prior to the rst use of the Generator. Before each use, check the oil level.
Never run the Engine with low or no engine oil. Running the Engine with low or
no oil will permanently damage the unit.
Maintain labels and nameplates on the Generator. These carry important
information. If illegible or missing, contact Harbor Freight Tools for a
replacement.
Make sure the Generator is located on a at, level, sturdy surface capable of
supporting the weight of the Generator and any additional tools and equipment.
Industrial applications must follow OSHA guidelines.
Never stand on the Generator. Serious injury could result if the Generator tips.
Never leave the Generator unattended when it is running. Turn off the Engine
before leaving.
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 Generator 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.
Do not force the Generator. This Generator will do the work better and safer
at the speed and capacity for which it was designed. Do not overload the
generator. Know the total running wattage necessary to power the desired items.
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 to or failure of the pacemaker.
WARNING: This product contains or, when used, produces a chemical
known to the State of California to cause cancer and birth defects or other
reproductive harm. (California Health & Safety Code § 25249.5, et seq.)
5.
a.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Page 8SKU 96617 For technical questions, please call 1-800-444-3353.
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.
FIRE AND EXPLOSION PRECAUTIONS
Gasoline fuel and fumes are ammable, and potentially explosive. Use proper
fuel storage and handling procedures. Always have multiple ABC class re
extinguishers nearby.
Keep the Generator, Engine, and the surrounding area clean at all times.
Clean up fuel or oil spills immediately. Dispose of uids and cleaning materials
as per any local, state, or federal codes and regulations. Store oil rags in a
bottom-ventilated, covered metal container.
Never store fuel or other ammable materials near the Generator.
Do not smoke, or allow sparks, ames, 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 rell the Fuel Tank while the Engine is running or while the Engine is still
hot. Do not operate the Generator with known leaks in the fuel system.
Use only recommended fuel and oil.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always make
sure the Engine’s Ignition (38) is in the “OFF” position. Allow the Engine and
Generator to completely cool. Then, remove the spark plug from the Engine.
Do not alter or adjust any part of the Generator or Engine that is assembled and
supplied by the manufacturer.
Always follow and complete scheduled Generator and Engine maintenance.
CHEMICAL PRECAUTIONS
Avoid contact with fuel, oil, exhaust fumes, and hot surfaces. If fuel or oil are
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 ush eyes with clean water.
11.
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
1.

Page 9SKU 96617 For technical questions, please call 1-800-444-3353.
NOISE PRECAUTIONS
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.
SAVE THESE INSTRUCTIONS.
GROUNDING
Improperly connecting the grounding wire can result in
electric shock.
Check with a qualied electrician if you are in doubt as to
whether the outlet is properly grounded. Never remove the
grounding prong from the plug. Do not use the Generator
if a power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not
t the outlet, have a proper outlet installed by a qualied
electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of electric
shock. (See 3-Prong Plug and Outlet.)
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)
The tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
1.
2.
3.
WARNINGWARNING

Page 10SKU 96617 For technical questions, please call 1-800-444-3353.
should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)
3-Prong Plug and Outlet Outlets for 2-Prong Plug
Double Insulated Tools: Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satises OSHA requirements and complies
with the applicable standards of Underwriters Laboratories, Inc., the Canadian
Standard Association, and the National Electrical Code.
(See Outlets for 2-Prong Plug.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for 2-Prong Plug.)
Extension Cords
Grounded 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 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 possible tool damage.
(See Table A.)
The smaller the gauge number of the 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 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 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 outdoors, make sure it is marked with the
sufx “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
1.
2.
1.
2.
3.
4.
5.
6.

Page 11SKU 96617 For technical questions, please call 1-800-444-3353.
Make sure the extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualied
electrician before using it.
Protect the extension cords from 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 line voltage drop to ve volts at 150% of the rated amperes.
Symbology
Double Insulated V~ Volts Alternating Current
Canadian Standards Association AAmperes
Underwriters Laboratories, Inc. n0xxxx/min. No Load Revolutions per Minute
(RPM)
7.
8.

Page 12SKU 96617 For technical questions, please call 1-800-444-3353.
Electrical Specications Alternator Type: 2-Pole, Single Phase
Output Frequency: 60 Hz
Output: 5,500 Continuous Watts / 6,300 Peak Watts
AC Receptacles: Four 120V, 20A 3 Prong Grounded Receptacles
One 240V, 30A, 4 Blade Twist Lock Outlet
DC Receptacle: Two Post Threaded 12VDC Outlet
Main Circuit Breaker: Trigger and setting point: 125/250 VAC, 25A,
(Rated: 120/240VAC, 23A)
Circuit Breaker for DC: Trigger and setting point: 50 VDC 10A
(Rated: 12 VDC, 8.3A)
Overload Protection: Yes
Engine Specications 13 HP / 4-Cycle / Electronic Ignition & Recoil Start
389 cc Displacement
Engine Speed: 3,600 RPM
Spark Plugs: F7RTC (NHSP LD) with gap of 0.028”-0.031”
Required Fuel Type: Unleaded Gasoline
Fuel Capacity: 7 Gallon
Recommended Oil Type: F-SAE 30W (Above 32°)
F-SAE 5W-30W (Below 32°)
Engine Oil Capacity: 1.16 Quarts
Automatic Low Oil Shut-Down: Yes
EPA and CARB Approved
Overall Dimensions 28-3/8” L x 20-1/8” W x 21-7/8” H
Run Time 9 hour continuous run time at 50% load
Weight 196 Pounds
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.
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 the number shown
on the cover of this manual as soon as possible.
SET UP INSTRUCTIONS
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the
beginning of this manual including all text under subheadings therein
before set up or use of this product.
Risk of accidental starting; resulting in serious personal
injury. Turn the Power Switch of the Generator to the “OFF”
position before assembling or making any adjustments to the
Generator.
Note: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagrams near the end of this manual.
WARNINGWARNING

Page 13SKU 96617 For technical questions, please call 1-800-444-3353.
Assembly
CAUTION! Always make sure the Engine’s Ignition (38) is in the “OFF” position
prior to performing any service, maintenance, or cleaning of the Generator or
Engine. Always wear ANSI approved safety impact eye goggles when setting up
and using the Generator.
To Install The Battery:
Positive Battery
Cable
Negative Battery
Cable
Battery Guard Plate
(Factory Pre-installed)
Battery Tray
(Factory Pre-installed)
Battery (Not
included)
Battery Bracket
Bolt with lock
Washer
FIGURE B
Acquire a 12V, 18AH Battery, with dimensions no greater than 7” L x 3” W x 7”
H. Read the instruction manual of the Battery for safety warnings and directions.
Remove the packing from the battery. Then, locate the factory pre-installed
battery guard plate and battery tray beneath the control panel of the generator
unit. (See Figure B)
Slide the battery into the battery guard plate, with the battery’s terminals facing
outward and with the battery’s negative (–) terminal facing left.
Align the two mounting holes in the battery bracket with the two threaded
mounting holes in the battery guard plate. Then secure the battery bracket to the
battery guard plate, using two bolts with lock washers.
Connect the end of the positive battery cable to the battery’s positive (+) terminal.
Then connect the negative battery cable to the battery’s negative (–) terminal.
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the
beginning of this manual including all text under subheadings therein
before set up or use of this product.
1.
2.
3.
4.

Page 14SKU 96617 For technical questions, please call 1-800-444-3353.
INSTALLATION INSTRUCTIONS
Electrical and other permits may be required for the installation of emergency or
portable power systems. Investigate local building and electrical codes before
installing this unit.
Prior to using Generator to power tools and equipment, make sure the
Generator’s rated voltage, wattage, and amperage capacity is adequate to supply
all electrical loads the unit will power. If powering needs exceed the Generator’s
capacity, it may be necessary to group one or more of the tools/equipment for
connection to a separate Generator.
It is recommended that the Generator be located; outdoors only, where fresh air
is readily available. Locate the Generator so that the air inlets and outlets are
not blocked by obstructions 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 (on Air Cleaner Cover 2R), in normal weather conditions,
should face the prevailing wind direction.
Locate the Generator on a concrete slab or other area where rain drainage or
ood waters cannot reach it.
Generator placement should allow four feet of access to all sides for
maintenance and for proper air cooling.
Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.
Grounding The Generator:
Grounding
Terminal
#6 AWG Grounding
Wire (Not Included)
Grounding Rod
(Not Included)
FIGURE C
Note: It is recommended that only a trained and licensed electrician perform this
procedure.
1.
2.
3.
4.
5.
6.

Page 15SKU 96617 For technical questions, please call 1-800-444-3353.
Connect a #6 AWG grounding wire (not included) from the Grounding Terminal on
the Generator 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.)
Control Panel Features
FIGURE D
Ignition
Switch
(38)
120V AC Outlets
(49)
240V AC
Outlet (48)
12V DC Outlet
(41)
Circuit
Breaker
(42)
Voltmeter
(44) lead for
ground wire
Oil Indicator Light
(40)
Ignition Switch (38): Starts and stops the Gasoline Engine.
Fuel Tank Cap (11S): Never run the Engine with the Fuel Tank Cap removed.
120 Volt AC Outlets (49): The Generator is equipped with four 3-hole 120 volt AC
outlets to power 120 volt tools and equipment.
There is a circuit breaker that protects the Generator from overloading. Should
a Circuit Breaker “trip”, unplug all electrical loads from the Generator. Allow the
Circuit Breaker to cool down. Then, push the Circuit Breaker back up.
240 Volt AC Outlet (48): The Generator is equipped with one 4-blade twist lock
240 Volt AC Outlet to power 240 volt tools and equipment.
12V DC Terminal (41): Supplies voltage to 12 volt DC appliances such as
radios, emergency lights, etc. To power a 12 volt DC appliance, connect the
positive (+) lead from the appliance to the positive (Red +) 12V DC Terminal
on the Generator. Then connect the negative (–) lead from the appliance to
the negative (Black –) 12V DC Terminal on the Generator. IMPORTANT: This
1.
2.
3.
4.
5.
6.

Page 16SKU 96617 For technical questions, please call 1-800-444-3353.
Outlet is designed for operating 12 volt DC appliances only. Do not attempt to
charge batteries with this Outlet.
Oil Indicator Light (40): Illuminates to indicate when the oil level is low.
Voltmeter (44): This gauge indicates the power draw of the attached equipment
from the generator.
PRE-START INSTRUCTIONS
To Add Engine Oil:
CAUTION! Your warranty is voided if you do not put engine oil in the Engine’s
crankcase prior to the rst 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 oil will
permanently damage the Engine.
Oil Dipstick
Fuel Tank
(1S)
Fuel Gauge
Fuel Filter
(9S)
Fuel Filler
Cap (11S)
FIGURE E
The Engine MUST be lled with a high quality grade 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. (See Figure E, prior page.)
To do so, unscrew and remove the Oil Dipstick. Pour engine oil into the Dipstick
Hole until the level of oil is even with top edge of the Dipstick Hole.
Make sure to screw the Oil Dipstick rmly back into the hole.
7.
8.
1.
2.
3.
4.
Note:
The engine must be on
a at and level surface
prior to checking the
oil level.

Page 17SKU 96617 For technical questions, please call 1-800-444-3353.
To Fill The Fuel Tank:
Prior to using the Generator, the Fuel Tank (1S) must be lled with high octane
unleaded gasoline.
To do so, remove the Fuel Tank Cap (11S) and ll the Fuel Tank (1S) with
unleaded gasoline. Then, replace the Fuel Tank Cap. Thereafter, check the Fuel
Gauge for the amount of unleaded gasoline. When necessary, rell the Fuel
Tank only when the Engine is off and cool.
OPERATING INSTRUCTIONS
Check to make sure the Ignition Switch (38) is in the “OFF” position.
(See Figure D.)
Unplug any load from the Generator before starting to prevent permanent
damage to any appliances, tools, or equipment.
CAUTION! Engine oil MUST be added to the Engine’s crankcase prior to
starting and running the Engine. Failure to add oil will damage the Engine and
void the warranty.
Before the rst use, the Fuel Tank (1S) must be lled with a high octane,
unleaded gasoline. Never ll the Fuel Tank completely. Fill the Fuel Tank to 1/2”
below the bottom of the ller neck to provide space for fuel expansion. Wipe any
fuel spills from the Engine and Generator before starting the Engine. Never ll
the Fuel Tank when the Engine is running or hot. Do not smoke when lling the
Fuel Tank; never smoke while in the vicinty of the Generator.
Fuel Valve Choke Lever
(In “Choke” Position)
Choke Lever
(In “Run” Position)
FIGURE F
ON
OFF
Turn the Engine Fuel Valve to the “OPEN” position. Turn the Engine Choke
Lever to the “CHOKE” position. NOTE: No choke is required if the Engine
is warm. Make sure the Engine Choke Lever is in the “RUN” position when
starting a warm Engine. (See Figure F.)
1.
2.
1.
2.
3.
4.
5.

Page 18SKU 96617 For technical questions, please call 1-800-444-3353.
To start the Engine, using the Battery for cranking power, insert the Key (39)
and turn the Ignition Switch (38) to the “START” position. To prolong starter
life, use short starting cycles (5 seconds maximum, then wait one minute before
attempting to again start). (See Figure D.)
To start the Engine manually, using the Recoil Starter Rope (10G) and Starter
Grip (11G), insert the Key (39) and turn the Ignition Switch (38) to the “RUN”
position. Grasp the Starter Grip and pull slowly until resistance is felt. Allow the
Rope to rewind slowly. Then, pull the 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 to the “RUN” position.
(See Figure F.)
To Connect Electrical Loads:
IMPORTANT: Start the Engine, and allow the Engine and Generator to run for
ve minutes with no electrical load, to warn up and stabilize.
WARNING! Connect 120V AC appliances, tools, and equipment only to the
two 120V AC Outlets. Connect 240 AC appliances, tools, and equipment only to
the 240V AC Outlet. Connect 12V DC appliances, tools, and equipment only to
the 12V DC Terminal. (See Figure D.)
Never exceed the rated capacity for this Generator, as serious damage to the
Generator and/or appliances, tools, and equipment could result from an overload.
Starting and running wattage requirements should always be calculated when
matching this Generator’s rated wattage capacity to the appliance, tool, or
equipment.
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:
Volts x Amps = Watts (example: 120 volts x 3 amps = 360 watts)
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 ensure adequate Generator capacity for motor load
starting current. The starting and running wattage for “resistant” loads are the
same. Example: a 100 Watt light bulb requires only 100 Watts to start. Most
resistant loads will be listed in wattage.
Always power the largest electric motor rst. Then, plug in other appliances,
tools, and equipment one at a time.
6.
7.
8.
1.
2.
3.
4.
5.
6.

Page 19SKU 96617 For technical questions, please call 1-800-444-3353.
Connect “inductive” load appliances, tools, and equipment rst. Inductive
loads consist of small hand tools and some small appliances. Connect the
items that require the most wattage rst.
Connect any lights next.
Voltage sensitive appliances, tools, and equipment should be the last to be
connected to the Generator and the rst to be disconnected. 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, plug the UL
Listed surge protector into the Generator.
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 on this Generator.
If Engine speed or voltage uctuates with a load below 250 Watts, move the
Engine Choke Lever to the “HALF-CHOKE” position.
When nished using the Generator, disconnect all electrical loads. Turn the
Ignition Switch (38) to the “OFF” position to stop the Engine. Then, close the
Engine Fuel Valve.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Always make sure the Engine Ignition is in the “OFF” position,
the Key is removed from the Ignition, and the Spark Plug wire is disconnected
prior to performing any service, maintenance, or cleaning of the Generator or
Engine.
Before each use, inspect the general condition of the Generator and 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 Generator and Engine. If abnormal noise or vibration
occurs, have the problem corrected before further use.
Do not use damaged equipment.
Generator maintenance:
Keep the Generator clean and dry at all times.
The Generator should not be operated or stored in locations that include
excessive moisture, dust, ammable or corrosive vapors. If these substances
are on the Generator, clean with a cloth or soft brush.
Do not use a garden hose or anything with liquid to clean the Generator.
a.
b.
c.
d.
8.
9.
1.
2.
3.
a.
b.
c.

Page 20SKU 96617 For technical questions, please call 1-800-444-3353.
FIGURE G
Oil Dipstick
Drain Plug
Engine maintenance:
After rst 5 to 8 hours of use: Change oil. Then, change oil every 50 hours
of use. Change oil every 25 hours of use when operating the Engine under a
heavy load or in high temperatures. To change the oil, remove the Drain Plug
and allow the old oil to drain in a proper container. Once drained, replace
the Plug. If the Engine will be run in temperatures above 32° Fahrenheit,
use SAE 30 weight oil. If the Engine will be run in temperatures below 32°
Fahrenheit, use SAE 5W-30 weight oil. To ll the Engine crankcase with new
oil, unscrew and remove the Oil Dipstick. Pour engine oil into the Dipstick
Hole until the level of oil is even with the top edge of the Dipstick Hole. Make
sure to screw the Oil Dipstick rmly back into the Dipstick Hole. Wipe off all
spilled oil. Also, make sure to dispose of the old oil according to local waste
disposal requirements.
After every 25 hours of use: Service the Air Cleaner Element (4R) and Air
Outer Filter (5R). To do so, remove the Air Cleaner Cover (2R). Remove the
Air Filter Element. Immerse the Air Filter Element in a mild solvent and rinse
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
onto the Element. Use compressed air to clean the Outer Filter. Then return
the Air Filter Separator, Air Filter Element, and Air Filter Cover. Clean more
often under dusty conditions or when airborne debris is present. Replace Air
Filter parts if necessary.
After every 100 hours of use: Replace the Spark Plug. To do so, remove
the Spark Plug Wire. Install a new Spark Plug. Then, replace the Spark Plug
Wire.
Daily: Inspect the Fuel Filter (32): To do so, remove the Fuel Tank Cap.
Remove the Fuel Filter from the Fuel Tank. If necessary, use compressed
air to remove any dirt and debris from the Fuel Filter. Then replace the Fuel
Filter and Fuel Tank Cap.
4.
a.
b.
c.
d.