PowerTec PT6600ES - User Manual

7000W
PT6600ES PORTABLE GENERATOR
INSTRUCTION MANUAL

Summary

General Safety Instructions

Work Area and Personal Safety

Safe Tool Operation and Care

Electrical and Fire Safety Risks

Electrical Safety and Cord Usage

Safe practices for extension cords, grounding, and generator placement to prevent shock.

Fire Prevention and Fuel Handling

Guidelines on preventing fires from hot surfaces, fuel handling, and ventilation.

Operational and Transport Safety

Fuel Spillage and Transport Safety

Preventing ignition from fuel spills and safe generator transportation methods.

Inhalation and Operation Safety Risks

Warnings about carbon monoxide, careless operation, and generator suspension.

Physical Hazard Safety

Hot Surfaces & Moving Parts Safety

Lifting & General Operation Safety

Safe lifting techniques and rules for hazardous locations, confined spaces, and connections.

Appliance Wattage Guide

Generator Preparation and Checks

Engine Oil Check and Fill

Starting the Generator

Key Start Operation

Detailed steps for starting the generator using the key ignition.

Generator Operation Procedures

Manual Engine Start

Connecting Appliances to Generator

How to safely connect appliances to the generator's AC sockets.

AC Safety Switch and Protection

AC Safety Switch Functionality

Safety Switch Tripping and Reset

Explains causes of tripping and provides steps for resetting the safety switch.

Maintenance and Storage

Engine Component Servicing

Troubleshooting and Cleaning

Troubleshooting Common Issues

Table listing common problems, their causes, and suggested remedies.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The POWERTEC PT6600ES Portable Generator is designed to provide reliable power for various applications, including home use, camping, emergency power, and periodic commercial use. It is capable of operating most power tools, appliances, and lighting, offering a versatile solution for your energy needs.

Function Description

The PT6600ES Portable Generator functions by converting fuel into electrical energy, providing an AC output suitable for a range of devices. It features both key start and manual start options, ensuring flexibility in operation. The generator is equipped with a fuel tank, an engine oil system, and an air filter, all essential for its proper functioning. A low oil sensor is integrated to prevent engine damage by automatically stopping the motor if the oil level is too low or preventing it from starting. The generator also includes an AC safety switch designed to protect users from electric shock by cutting off power in case of overload or fault.

Usage Features

Before starting the generator, it is crucial to perform several preparatory steps. First, ensure the engine has oil, as the unit is shipped without it. The crankcase must be filled with the recommended SAE #30 4-stroke oil to the upper level line. The oil level should be checked each time the generator is used. Next, check the fuel level and add unleaded petrol from an approved container, taking care not to overfill the tank to allow for fuel expansion. The fuel cap should be secured tightly, and the fuel filter screen should be in place.

For key start operation, the battery must be connected. Secure the battery to its tray with the provided clamp and connect the red lead to the positive (+) terminal and the black lead to the negative (-) terminal, ensuring they are firmly tightened. Before starting, confirm that no electrical apparatus is connected to the generator. Turn the fuel valve to the 'on' position and move the choke lever towards the back of the generator (to the left) if the engine is cold. Then, turn the key start ignition clockwise to the 'START' position. Once the motor is operating, release the key to allow it to return to the 'ON' position, and push the choke lever back in to switch the choke 'off'. For manual starting, follow the same initial steps for fuel and choke, then turn the key start ignition to the 'ON' position and pull the recoil starter briskly until the engine engages.

After starting, allow the engine to run for a couple of minutes to warm up before connecting any apparatus. For AC current, ensure the AC safety switch is turned "OFF" before plugging power cords into the AC output sockets. Once connected, switch the AC safety switch to the "ON" position. Always ensure that the total load is within the generator's rated output and that electrical apparatus is turned off before plugging them in. The generator is designed to withstand short operations and loads up to its peak power, but sustained overloading can trip the safety switch and shorten the generator's service life. If the safety switch trips, unplug all electrical apparatus, let the switch cool down, and then reset it. Reduce the load before reconnecting appliances.

To stop the engine, first ensure no electrical apparatus is connected. Turn the key start ignition to the 'OFF' position, and then turn the fuel lever clockwise to the 'off' position.

Maintenance Features

Regular maintenance is vital for the generator's best performance and safe operation. Key maintenance tasks include:

• Spark Plug: Check its condition, adjust the gap, and clean it regularly. Replace if necessary. The standard color for the spark plug should be tan, and the acceptable gap is between 0.7 - 0.8mm.
• Engine Oil: Check the oil level daily and replace it periodically, typically every 50 hours or every 3 months. To replace the oil, warm up the engine, stop it, remove the oil filler cap, and drain the old oil by removing the oil drain cock. Reinstall the drain cock and add new SAE #30 4-stroke oil to the upper level.
• Air Filter: The air filter must be kept clean at all times. Remove the air filter cover, take out the filter, wash it in solvent or kerosene, allow it to dry, lubricate it with motor oil (SAE #30), and squeeze out excess oil before replacing it. Never run the engine without the air filter element in place.
• Fuel Filter: The petrol tank filter, located under the petrol cap, should be removed and washed thoroughly in a solvent. The tap extension fuel filter, located on the inlet side of the fuel valve inside the tank, prevents dirt from entering the fuel system. To clean or replace it, completely empty the fuel tank, turn the fuel valve to OFF, compress the hose clamp on the outlet hose, slide the hose off the fuel valve, loosen the lock nut, and unscrew the tap from the tank. Unscrew the tap extension fuel filter, clean it in petrol, and screw it back into the inlet side of the tap. Reassemble the tap to the tank, ensuring the small seal is fitted and the lock nut is tightened.
• Fuel Line: Check the fuel hose for cracks or damage and replace if necessary.
• Exhaust System: Check for leakage, retighten, or replace gaskets if needed. Clean or replace the muffler screen if necessary.
• Carburetor: Check choke operation.
• Starting System: Check recoil starter operation.
• Decarbonisation: Perform more frequently if necessary.
• Fittings/Fasteners: Check all fittings and fasteners for correctness and tightness.

The generator should be stored in a clean, dry area, away from inflammable liquids. If storing for more than 30 days, drain the fuel tank and fuel system by opening the small drain valve in the carburetor bowl. Never store the generator with fuel in the tank indoors or in poorly ventilated areas where fumes could reach an open flame or spark. Keep the generator clean and dry, avoiding excessive moisture, dust, or corrosive vapors. Clean with a damp soft cloth and mild detergent, but never use water pressure to clean the generator to prevent damage to internal parts. Use a vacuum to clean air inlet and outlet louvres, followed by a compressed air jet for internal cleanliness. Wear eye protection during cleaning.

PowerTec PT6600ES Specifications