Chicago Electric 96617 Set Up And Operating Instructions Manual

Brand: Chicago Electric

Model: 96617

Category: Power generators

Type: Set Up And Operating Instructions 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.

2007 by Harbor Freight Tools

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.

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,

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.)

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.

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

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.

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

Volts Alternating Current

Canadian Standards Association

Amperes

Underwriters Laboratories, Inc.

xxxx/min.

No Load Revolutions per Minute

(RPM)

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.

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.

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

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.

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

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.)

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.

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.

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.

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Chicago Electric 96617 Set Up And Operating Instructions Manual

Brand: Chicago Electric

Model: 96617

Category: Power generators

Type: Set Up And Operating Instructions Manual

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Chicago Electric 96617 Set Up And Operating Instructions Manual

Chicago Electric 96617 Set Up And Operating Instructions Manual

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