Chicago Electric 98839, Set Up, Operating, And Servicing Instructions

Page 1: ... Running the Engine with low or no oil will permanently damage the unit 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 2008 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 expr...

Page 2: ...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 back two pages of this manual SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly oper ating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manu...

Page 3: ...may result in personal injury Do not overreach Keep proper footing and balance at all times 5 Proper footing and balance enables better control of the power tool in unexpected situations 6 Use safety equipment Always wear eye protection Always wear ANSI approved safety impact goggles when using this product ANSI approved hearing protection must also be used TOOL USE AND CARE Do not force the tool ...

Page 4: ...ons to a building electrical system can allow electrical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause fires when utility power is restored Consult the utility company or a qualified electrician Sensitive electronic equipment includ...

Page 5: ...cement Make sure the Generator is located on a flat level sturdy surface capable of 3 supporting the weight of the Generator and any additional tools and equip ment Industrial applications must follow OSHA guidelines 4 Never stand on the Generator 5 Serious injury could result if the Generator is tipped Never leave the Generator unattended when it is running 6 Turn off the Engine before leaving Do...

Page 6: ...till hot Do not operate the Generator with known leaks in the fuel system Use only Engine manufacturer recommended fuel and oil 8 Operation of this equipment may create sparks that can start fires around dry 9 vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements MECHANICAL PRECAUTIONS Prior to p...

Page 7: ...of the Generator and interconnect 5 ing 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 6 or 12 volt that is compatible with the electrical characteristics and rated ca pacities of the Generator Be sure the Engine s Ignition 2 is in its OFF position before moving the 7 Generator a...

Page 8: ...iting the line voltage drop to five volts at 150 of the rated amperes MISC PRECAUTIONS WARNING 1 People with pacemakers should consult their physician s before us ing this product Operation of electrical equipment in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker WARNING 2 The warnings and precautions discussed in this manual cannot cover all possible ...

Page 9: ...install a DC 12V 18 35 Amp hour Battery POSITIVE BATTERY CABLE 63 NEGATIVE BATTERY CABLE 64 BATTERY GUARD PLATE 44 FACTORY PRE INSTALLED BATTERY TRAY 48 FACTORY PRE INSTALLED BATTERY 45 Not included BATTERY BRACKET 47 BOLT W LOCK WASHER 46 FIGURE A 1 Remove the packing from the Battery 45 Then locate the factory pre installed Battery Guard Plate 44 and Battery Tray 48 beneath the Control Panel 4 o...

Page 10: ... be necessary to group one or more of the tools equipment for connection to a separate Generator General Location It is recommended to locate the Generator outdoors only where cooling air is 1 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 ...

Page 11: ...CONTROL PANEL FEATURES Engine Ignition 2 1 Starts and stops the Gasoline Engine To start the Engine using power from the Battery 45 insert the Ignition Key 65 and turn the Engine Ignition to its START position To start the Engine manually using the Starter Rope 40A and Starter Handle 41A insert the Ignition Key and turn the Engine Ignition to its RUN position Then pull briskly on the Starter Handl...

Page 12: ...ircuit Breaker 3 6 The 240 Volt AC Outlet has two Circuit Break ers to protect the Generator from overloading Should the Circuit Breakers trip unplug all electrical loads from the Generator Allow the Circuit Breakers to cool down Then push the 240 volt Circuit Breakers See Figure C 12 VDC Terminal 7 7 Supplies voltage to 12 volt DC appliances such as radios emergency lights etc To power a 12 volt ...

Page 13: ...ht 10 9 Indicates voltage is being provided by the Generator See Figure C PRE START INSTRUCTIONS To Add Engine Oil CAUTION 1 Your warranty is voided if you do not put engine oil in the Engine s crankcase prior to its first 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 perma nently damage the Engine OIL DIPSTICK 65A...

Page 14: ... Figure D To do so remove the Fuel Tank Cap 34 and fill the Fuel Tank 31 with unleaded 2 gasoline Then replace the Fuel Tank Cap Thereafter check the Fuel Gauge 35 for the amount of unleaded gasoline When necessary refill the Fuel Tank See Figure D NOTE Periodically make sure to check the Fuel Filter 32 for excessive dirt and debris If necessary remove the Fuel Filter and clean with compressed air...

Page 15: ...he bottom of the filler neck to provide space for fuel expansion Wipe any fuel spills from the Engine and Generator before starting the Engine WARNING b Never fill the Fuel Tank 31 when the Engine is running or hot Do not smoke when filling the Fuel Tank To Start The Engine Generator FUEL VALVE 41 CHOKE LEVER 21A IN CHOKE POSITION CHOKE LEVER 21A IN RUN POSITION FIGURE E ON OFF 1 Turn the Engine F...

Page 16: ...Figure C 3 CAUTION Never exceed the rated capacity for this Generator as serious dam age 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 wattage capacity to the appliance tool or equip ment Most appliances tools and equipment will list on the motor nameplate the...

Page 17: ... appliances tools and equipment should be the last to be con c nected to the Generator and the first 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 connect the UL Listed surge protector into the Generator 8 CAUTION Failure to connect and operate appliances tools and equipment in this ...

Page 18: ...stick 65A Pour engine oil into the oil fill hole until the level of oil is even with the bottom edge of the oil fill hole if you cannot see the oil through the oil fill hole then the oil is too low and more oil must be added Make sure to screw the Oil Dipstick 65A firmly back into its Dipstick Hole Also make sure to dispose of the old oil according to local waste disposal requirements See Figure F...

Page 19: ...he accessory Spark Plug Wrench Kit 86A to remove the old Spark Plug Install a new Spark Plug Then replace the Spark Plug Wire See Figure G FUEL FILTER 32 FUEL TANK CAP 34 FUEL TANK 31 FIGURE I d Daily Inspect the Fuel Filter 32 To do so remove the Fuel Tank Cap 34 Remove the Fuel Filter from the Fuel Tank 31 If necessary use compressed air to remove any dirt and debris from the Fuel Filter Then re...

Page 20: ... REPRESENTATION OR WARRANTY OFANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR ...

Page 21: ... 21 Carbon Brush 1 22 Bolt M10 1 25 265 1 23 Bolt M6 180 4 24 Bolt M5 20 4 25 Connection Board 1 26 Nut M5 4 27 Stator 1 28 Rotor 1 Part Description Qty 29 Cooling Fan 1 30 Heat Insulation Board Assembly 1 31 Fuel Tank 1 32 Fuel Filter 1 33 Seal Ring 1 34 Fuel Tank Cap 1 35 Fuel Gauge 1 36 Bolt M6 12 2 37 Bolt w Lock Washer M6 30 4 38 Spacer 4 39 Rub Washer 4 40 Bushing 4 41 Fuel Valve 1 42 Frame ...

Page 22: ...hnical questions please call 1 800 444 3353 ASSEMBLY DIAGRAM GENERATOR NOTE Some parts are listed and shown for illus tration purposes only and are not available individually as replacement parts Battery Part 45 is not included ...

Page 23: ...ring 1 35A Bolt 1 36A Spark Plug Wire 1 37A Ignition Coil 1 38A Nut Special 14mm 1 39A Starter Ratchet Spring 2 40A Starter Rope 1 41A Starter Handle 1 42A Starter Case Assembly 1 43A Spiral Spring 1 Part Description Qty 44A Starter Wheel 1 45A Circlip 1 46A Starter Ratchet 2 47A Friction Plate Screw 1 48A Cover 1 49A Starter Pulley 1 50A Cooling Fan 1 51A Flywheel Magneto 1 52A Cylinder Block 1 5...

Page 24: ...64A 63A 62A 61A 60A 59A 58A 43A 44A 45A 46A 47A 48A 49A 50A 51A 84A 52A 42A 41A 40A 39A 38A 37A 36A 18A 19A 20A 17A 16A 15A 83A 54A 53A 55A 56A 57A 34A 35A 74A 75A 76A 77A 81A 82A 80A 79A 78A 1A 14A 85A 21A 13A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A 33A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 86A Spark Plug Wrench Kit Not Shown ...

Page 25: ...r unapproved modifications You are responsible for shipping your engine to a HFT warranty station as soon as a problem exists Contact the HFT Customer Service department at the number below to make shipping arrangements The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you shou...

Page 26: ...anted part unless performed by an authorized warranty center c failure to follow recommendations on fuel use contained in the Owner s Manual d improper or inadequate maintenance of any war ranted parts e repairs performed outside of the authorized war ranty service dealers f alterations by changing adding to or removing parts from the engine 5 Service and Maintenance Component parts which are not ...

Page 27: ...Page 27 SKU 98839 For technical questions please call 1 800 444 3353 Electrical Diagram Please note All electrical work should be performed by a qualified service technician ...