Chicago Electric 98391 User's Manual
Contents
1. Electric DIESEL GENERATOR 1 5198391 SET UP OPERATING AND SERVICING INSTRUCTIONS A DANGER Using an engine indoors CAN KILL YOU IN MINUTES Engine exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside Only use OUTSIDE a home or garage and far away from EVEN IF doors and windows doors and windows are open vents 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 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 express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein For technical questions or replacement parts please call 1 800 444 3353 CONTENTS IMPORTANT SAFETY 4 BASIC SPECIFICATIONS 8 UNPACKING eiii ea turns 8 SET UP INSTRUCTIONS 8 LOCATION ina pic cicdiam daten 8 CONTROLS 9 10 OPERATING INSTRUCTIONS 10 STARTING THE ENGINE 10 CHECK2. pw Note Wheels and Handles not shown N SKU 98391 For technical questions please call 1 800 444 3353 Page 22 CYLINDER BLOCK CYLINDER BLOCK ASSEMBLY PARTS LIST ASSEMBLY PARTS LIST Part Description Qty Part 14A Nut M6 3 36A Bolt M6x14 1 Air Shroud Air Shroud Collar Shock Absorber Shock Absorber Seat Flat Washer 8mm 42A Spring Washer 8mm Short Cylinder Head Stud Note Use the suffix A when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 23 CYLINDER BLOCK ASSEMBLY DIAGRAM Note Use the suffix A when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 24 CYLINDER HEAD ASSEMBLY PARTS LIST amp DIAGRAM Part __ Description GB JPina8 11 9B Spring Retainer 2 12B RockerArmBolt 1 Exnaust Valve Rocker Arm 1 14B Arm Su SKU 98391 For technical questions please call 1 800 444 3353 CYLINDER HEAD ASSEMBLY PARTS LIST amp DIAGRAM Part Description Note Us
3. SAVE THESE INSTRUCTIONS SET UP PRECAUTIONS 1 Diesel fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling proce dures Do not store fuel or other flammable materials nearby 2 Have multiple ABC class fire extin guishers nearby 3 Operation of this equipment may cre ate sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relat ing to fire prevention requirements 4 Setup and use only on a flat level well ventilated surface Page 4 Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during set up Use only oil and fuel recommended in the Specifications section of this manual OPERATING PRECAUTIONS CARBON MONOXIDE HAZARD Using an engine indoors CAN KILL YOU IN MINUTES e Engine exhaust contains carbon monoxide This is a poison you cannot see or smell SKU 98391 NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents Keep children away from the equip ment especially while it is operating Do not leave the equipment unat tended when it is running Turn off the equipment and remove safety keys if available before leaving the work area Wear ANSI approved safety goggles and hearing protection during use F
4. Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 28 CAMSHAFT ASSEMBLY CAMSHAFT ASSEMBLY PARTS LIST amp DIAGRAM PARTS LIST amp DIAGRAM Ea EE Note Use the suffix G when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 29 AIR CLEANER ASSEMBLY AIR CLEANER ASSEMBLY PARTS LIST amp DIAGRAM PARTS LIST amp DIAGRAM Part Description Part Description 1 1 Note Use the suffix H when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 30 OIL SYSTEM PARTS LIST amp OIL SYSTEM PARTS LIST amp DIAGRAM DIAGRAM Part Description Part Description Note Use the suffix J when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 31 FUEL INJECTION PUMP FUEL INJECTION PUMP PARTS LIST amp DIAG
5. Wash hands with soap and water after handling diesel fuel or lubricat ing oil SERVICE PRECAUTIONS Before service maintenance or cleaning a Turn the engine switch to its OFF position b Allow the engine to completely cool Keep all safety guards in place and in proper working order Safety guards include mechanical guards and heat shields among other guards Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or dis tributor Only a qualified service technician may adjust parts that may increase or decrease gov erned engine speed Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during service All connections from the Generator to the load must be installed by a li censed electrician in compliance with local state and federal laws The generator must be grounded in accordance with applicable electrical codes and standards before opera tion Insulate all connections and discon nected wires Page 6 10 11 12 13 14 15 SKU 98391 Do not connect or disconnect load connections while standing in water or on wet ground Do not overload the generator Over loading can cause fires in the electri cal cords in addition to generator and appliance damage Connect the generator only to a load or electrical system 120 volt or 240 volt that is compatible with the elec trical charact
6. battery Recheck bat tery s positive terminal connection for tightness How to Shut Engine Off A diesel engine is not operated like a gasoline engine When operating a diesel engine one should be aware of various options of how to shut the engine off Page 11 1 the ignition key to the off posi tion 2 Push down on the fuel shut off lever to release the Control Handle 13 3 the fuel valve to its OFF posi tion Start Procedure A Before starting the engine a Follow the Set Up Instruc tions to prepare the equip ment Inspect the equipment and engine c Fill the engine with the prop er amount and type of fuel and oil d Read the Equipment Opera tion section that follows start the engine 1 Unplug all loads from the Generator before starting to prevent permanent damage to any appliances or tools 2 Depress the Decompression Handle 16 all the way Cold starting only Decompression Handle 3 Open the front panel and turn the fuel shut off valve to its OPEN position 4 Rotate the Control Handle 13 to the right until release button on the Right hand side of the Handle Bracket 12 pops up and locks in place SKU 98391 For technical questions please call 1 800 444 3353 Control Handle Release Button nsert the en gine key into the ignition and turn it to START position for up to 10 sec onds Note To prolong s
7. you have any questions regarding your warranty rights and responsibilities you should contact the Harbor Freight Tools Customer Service Department at 1 800 444 3353 SKU 98391 For technical questions please call 1 800 444 3353 Harbor Freight Tools Emission Control Defects Warranty Provisions 1 Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two 2 years after the date of delivery to the first retail purchaser 2 NoCharge Repair or Replacement Repair or replacement of any warranted part will be per formed at no charge to the owner if the work is performed through a warranty station authorized by HFT For emis sions warranty service contact the HFT Customer Service Department at 1 800 444 3353 3 Consequential Damages Coverage Coverage under this warranty shall also extend to the failure of any engine components caused by the failure of any war ranted part while it is still covered under this warranty 4 Coverage Exclusions Warranty claims shall be filed in accordance with the provi sions of the HFT warranty policy explained in the box at the top of the previous page HFT shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconvenience War ranty coverage shall also be exclude
8. 3353 Page 15 TECHNICAL SPECIFICATIONS Four Stroke Single Engine Type Cylinder OHV Diesel 10HP Bore x Stroke 86x72 mm Compression Ratio Valve Clearance 0 10 0 15 mm COLD ses de 100 RM i 3 600 RPM The emission control system for this Generator s Engine is warranted for standards set by the U S Environmental Protection Agency For warranty information refer to the last pages of this manual SERVICING TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL STARTING Turn the Power Switch of the equipment to its OFF position wait for the engine to cool before performing any inspection maintenance or cleaning procedures SKU 98391 For technical questions please call 1 800 444 3353 TO PREVENT AWARNING SERIOUS INJURY FROM EQUIPMENT FAILURE Do not use damaged equipment If abnormal noise vibration or excess smoking occurs have the problem corrected before further use Maintenance Procedures A Many maintenance procedures including those not detailed in this manual will need to be performed by a qualified technician for safety If you have any doubts about your ability to safely service the equipment or engine have a qualified technician service the equipment instead Note Warranty is void if proper mainte nance and servicing procedures are not followed Engine Oil Change A CAUTION Oil is very hot during opera tion and can cause burns Wait for engine to
9. ARTS LIST amp DIAGRAM 23 CYLINDER VALVE COVER PARTS LIST amp DIAGRAM 24 PISTON amp CONNECTING ROD PARTS LIST amp DIAGRAM 25 CRANK SHAFT amp FLYWHEEL PARTS LIST amp DIAGRAM 26 CAMSHAFT ASSEMBLY PARTS LIST amp DIAGRAM 27 AIR CLEANER ASSEMBLY PARTS LIST amp DIAGRAM 28 OIL SYSTEM PARTS LIST amp DIAGRAM 29 FUEL INJECTION PUMP PARTS LIST amp DIAGRAM 30 FUEL NOZZLE PARTS LIST amp DIAGRAM 31 GOVERNOR amp CONTROL SYSTEM PARTS LIST amp 1 32 FUEL TANK AND PIPE PARTS LIST amp DIAGRAM 33 MUFFLER PARTS LIST amp 34 STARTING MOTOR PARTS LIST amp DIAGRAM 34 GENERATOR PARTS LIST amp DIAGRAMS iececc 35 CONTROL PANEL PARTS LIST amp DIAGRAM eee 36 WIRING DIAGRAM 37 LIMITED 1 YEAR 90 DAY WARRANTY 38 SKU 98391 For technical questions please call 1 800 444 3353 Page 3 SAVE THIS MANUAL Keep this manual for the safety warn ings and precautions assembly operat ing 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 numb
10. DED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT 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 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 RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO MAIN ASSEMBLY PARTS LIST Part Description 0 6 MufflerEngine Shield 1 8 EngineMount 1 9 Muffler Pipe Support 1 Engine Front Wind Shield Nuts Record Product s Serial Number Here MAIN ASSEMBLY PARTS LIST Part Description Injector amp Decompressor Access Door Securing Flex Screws M10x25 Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 21 MAIN ASSEMBLY DIAGRAM D 9 F bun 5 4 D 7 ZN LESE RRR R Fw M eis a 29
11. DIAGRAM DIAGRAM Part Description Part Description 17U Waser 8 5 20 Bearing Stator Cover Stator Assembl Rear Cover Note Use the suffix U when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 37 CONTROL PANEL PARTS LIST amp DIAGRAM Part Description i 1 10W CONTROL PANEL PARTS LIST amp DIAGRAM Part Description 8W Screw 5 20 20W Note Use the suffix W when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 38 me BS 2 STATOR i wu YELLOW generator NEN ii co T a TE JEE GREEN REN SKU 98391 WIRING DIAGRAM ACI20V 166 eoe a 7f YELLOW GREEN GROUND BOLT For technical questions please call 1 800 444 3353 REV 09a Page 39 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine motor the belts
12. ING AND FILLING ENGINE OIL iciatis inia udd 10 CHECKING AND FILLING FUEL 11 BLEED THE FUEL LINE 11 CONNECT THE BATTERY 11 START PROCEDURE 11 TO START THE ENGINE 11 BREAK IN PERIOD 12 EQUIPMENT OPERATION 12 TO POWER TOOLS AND 12 TECHNICAL SPECIFICATIONS 13 MOUNTING HOLE PATTERN 13 SHAFT SIZE TYPE isst orn ine 13 SERVICING eerte eere eser tea 13 MAINTENANCE PROCEDURES 14 ENGINE OIL CHANGE 14 AIR FILTER ELEMENT MAINTENANCE 14 FUEL FILTER REPLACEMENT 14 REPLACING THE AC FUSE 15 CLEANING MAINTENANCE AND LUBRICATION SCHEDULE 15 SKU 98391 For technical questions please call 1 800 444 3353 AFTER INITIAL 20 OPERATION HOUR PERIOD 15 EVERY 50 OPERATION 15 EVERY 100 OPERATION lt 15 EVERY 250 OPERATION 65 4 15 EVERY 500 OPERATION HOURS scessssscssssesssessseeesssenees 15 STORAGE ooccssssssssssssssssessssessssessseeses 16 DIESEL FUEL AND MICROBES 16 TROUBLESHOOTING 17 MAIN ASSEMBLY PARTS LIST 19 MAIN ASSEMBLY DIAGRAM 20 CYLINDER BLOCK ASSEMBLY PARTS 21 CYLINDER BLOCK ASSEMBLY DIAGRAM 2 22 CYLINDER HEAD ASSEMBLY P
13. ND PIPE PARTS LIST amp DIAGRAM PARTS LIST amp DIAGRAM Part _ Description 1 Qty Part Description 11P Fuel OilReturnPump 1 12P 2 13 FuelTanRDamper 24 FilterElement_ 1 5P j FuelOilFilter Gasket 1 Fus Oi Pipe 1 Clamp 2 O ring 11 9P _ Fuel Tank Cock 1 Note Use the suffix P when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 35 MUFFLER PARTS LIST amp DIAGRAM Part Description Qty Nut M8 Bolt M8x12 Note Use the suffix R when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts STARTING MOTOR PARTS STARTING MOTOR PARTS LIST amp DIAGRAM LIST amp DIAGRAM Part Description 1 Qty Part Bolt M8x12 Washer 10 POT 1 y Note Use the suffix when ordering parts for this as sembly Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 36 GENERATOR PARTS LIST amp GENERATOR PARTS LIST amp
14. RAM PARTS LIST amp DIAGRAM Part Description Qty Part O ring 11 Pump Bod Shim Set Note Use the suffix K when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 32 FUEL NOZZLE PARTS LIST FUEL NOZZLE PARTS LIST amp DIAGRAM amp DIAGRAM Part Description Part Description 1M jJNozzeHolder 1 5M 1 2M ShimSet 1 2 Nozzle Holder Spring Nozzle Valve 1 Nozzle Case Nut Note Use the suffix M when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 33 GOVERNOR CONTROL SYSTEM PARTS LIST amp DIAGRAM Description GN 111 GOVERNOR CONTROL SYSTEM PARTS LIST amp DIAGRAM Part Description Note Use the suffix N when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 34 FUEL TANK AND PIPE FUEL TANK A
15. ain SKU 98391 For technical questions please call 1 800 444 3353 Page 18 Troubleshooting Possible Causes Probable Solutions Engine will not FUEL RELATED FUEL RELATED start No fuel in tank or fuel valve closed 1 Open fuel valve and fill fuel tank Air trapped in fuel line Filter Bleed fuel line Low quality or deteriorated old Use only fresh 2 diesel fuel diesel Not enough oil in crankcase Add or replace oil Dirty fuel passageways blocking Clean out passageways using fuel flow diesel fuel additive or biocide Heavy deposits may require further cleaning Low oil sensor failure Add oil disconnect low oil sensor start engine and allow to run for several minutes before reconnecting the sensor Generator is not on level surface Move the generator to a level surface to prevent low oil shutdown from triggering Load connected 8 Disconnect load Air filter dirty 9 Change air filter 10 Battery dead 10 Replace batte Black smoke from 1 Generator overloaded 1 Reduce load exhaust Oil in cylinder 2 Check oil level and drain excess from crankcase Contaminated diesel fuel 3 Treat engine with biocide Fuel injection malfunction 4 Have the Generator serviced by a Clogged air filter qualified mechanic Improper setting for specific altitude 9 Replace air filter 6 Have a qualified technician inspect reset the engine fuel system White smoke 1 Water in fuel 1 Empt
16. bolt holding the fuel filter to the frame using a 13 mm wrench Pull the fuel valve filter assembly out of the enclosure Place a bucket un der the assembly to catch the fuel 10 For technical questions please call 1 800 444 3353 Remove the fuel filter cup and the filter element Clean the cup of all sediment using a rag or brush Replace the fuel filter element Reinstall the fuel filter element fill the cup with fresh and clean diesel fuel and assemble per stps 5 and 4 above Open the fuel valve until the filter is filled Remove the hose clamp and slightly remove fuel outlet hose to purge out any trapped air in the line Re attach the hose and clamp Remove four screws and Injector Inspection Cover 49 from top of Sound Shield Panel 41 Place a clean rag under the injector inlet and using two wrenches loosen input line nut by one turn Tap starter to force fuel out of injector line When air bubbles stop re tighten the input line nut REV 09a Page 17 Cleaning Maintenance and Lubrication Schedule Note This maintenance schedule is intended solely as a general guide If performance decreases or if equip ment operates unusually check sys tems immediately The maintenance needs of each piece of equipment will differ depending on factors such as duty cycle temperature air quality fuel quality and other factors Note These procedures are in addition to the regular checks and maintenance ex
17. cool before changing oil 1 Place a drain pan not included un derneath the crankcase s drain plug 2 Remove the drain plug and empty oil Recycle used oil p Inspect drain plug gasket for damage or tears Replace gasket if damaged Replace the drain plug and tighten it 4 Refill the oil to the proper level follow ing the instructions under the Starting the Engine section REV 09a Page 16 Air Filter Element Maintenance 5 1 Routine maintenance to the air cleaner helps maintain proper airflow 6 to the engine Service the air cleaner according to the following steps every 250 or 500 hours or more often when using the generator in a dusty area 8 Wipe off the air cleaner cover Remove the air cleaner maintenance panel by unscrewing the bolts with 10 mm wrench Remove the wing nut from the bolt holding the air cleaner cover Re move the air cleaner cover Take out the used air cleaner ele ment Replace with a new element Reinstall the air cleaner cover tighten the wing nut then screw back the air cleaner maintenance panel Fuel Filter Replacement SKU 98391 AWARNING PREVENT SERIOUS INJURY FROM FIRE Replace the fuel filter in a well ventilated area away from igni tion sources Do not smoke Wait for engine to cool completely before proceeding Wear protective gear including ANSI approved safety goggles Turn the fuel valve to the off posi tion Unscrew the
18. d for any part which fails malfunctions or is damaged due to failure to follow the maintenance and operating instructions set forth in the Owner s Manual including but not limited to Use of parts which not authorized by b Improper installation adjustment or repair of the en gine or of any warranted part unless performed by an authorized warranty center Failure to follow recommendations on fuel use con tained in the Owner s Manual d Improper or inadequate maintenance of war ranted parts Repairs performed outside of the authorized warranty service dealers f Alterations by changing adding to or removing parts from the engine 5 Service and Maintenance Component parts which are not scheduled for replacement as required maintenance or are scheduled only for regular inspection to the effect of repair or replace as necessary are warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part Any replacement part provided it is equivalent in durability and performance may be used in performance of maintenance or repairs The owner is responsible for commissioning a qualified technician mechanic to perform all required maintenance as outlined in the Inspection Cleaning and Maintenance section in this manual 6 Warranted Parts 1 Fuel Meterin
19. e the suffix B when ordering parts for this assembly 25 Some parts listed and shown for illustration purposes only and are not available individually as replacement parts Page 25 CYLINDER HEAD BONNET CYLINDER HEAD BONNET PARTS LIST amp DIAGRAM PARTS LIST amp DIAGRAM Part 1 Qty Part Description 2C Bal o 1 1 Washer 6 Note Use the suffix C when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 26 PISTON amp CONNECTING ROD PARTS LIST amp DIAGRAM Qty 6D jWasher23 1 PISTON amp CONNECTING ROD PARTS LIST amp DIAGRAM Part Description 8D Connecting Rod Body 1 9D RodNut a Note Use the suffix D when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 98391 For technical questions please call 1 800 444 3353 Page 27 CRANK SHAFT amp CRANK SHAFT amp FLYWHEEL PARTS LIST amp FLYWHEEL PARTS LIST amp DIAGRAM DIAGRAM Part Description 1 Qty Part Note Use the suffix E when ordering parts for this assembly
20. enance Place the Generator as close as pos sible to the electrical tools and equip ment being powered to reduce the length of extension cords Grounding Connect a 12 AWG grounding wire not included from the Grounding Point on the Generator to a ground ing rod not included that has been driven at least 24 inches into the ground The grounding rod must be a copper or brass rod which can ad equately ground the Generator Only a trained and licensed electrician should perform this procedure Grounding Point Electrical and other permits may be required for the installation of emer gency power systems Investigate local building and electrical codes before installing this unit Installa tion must be completed by a licensed contractor 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 Starting the Engine Inspect engine and equipment A looking for damaged loose leaking and missing parts before set up and starting If any problems are found do not use equipment until fixed properly Checking and Filling Engine Oil CAUTION Your Warranty is VOID if the engine s crankcase is not properly filled with oil before each use Before each use check the oil level Do not run the engine with low or no engine oil Running the engine with no or low engine oil WILL perma
21. enerator Note Place rags at the bleeding points to capture spilled fuel 2 Turn the fuel valve to the off position Top off fuel tank with fresh diesel fuel Slide the hose clamp away from the fuel pump end Loosen the hose at the pump to allow fuel to bleed SKU 98391 For technical questions please call 1 800 444 3353 out Turn the fuel valve to its open position Depress the decompression lever and while holding it down crank the engine for a few seconds at a time Fuel and trapped air will emerge from the line and as soon as just fuel flows without traces of air push the fuel line back onto the intake of the pump and stop cranking the engine Reattach the hose clamp Note Never crank the engine more than ten seconds at a time Allow at least one minute prior to further cranking 3 Using two wrenches hold the injector with one and back off the steel feed line nut with the other wrench Repeat the above mentioned flushing cycle to bleed the air from the injector Wipe all spilled fuel from the engine and components Note Do not close the fuel valve with the engine running This may only be done for the intention of shutting the engine off should the fuel shut off system fail Connect the Battery 1 The Generator ships with the nega tive battery cable disconnected Before the generator can be started the covering on the battery cable must be removed and the cable must be secured to the negative ground terminal on the
22. er 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 DANGER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury SKU 98391 For technical questions please call 1 800 444 3353 NOTICE is used to NOTICE address practices not related to personal injury CAUTION without CAUTION the safety alert symbol is used to address practices not related to personal injury WARNING Read all instructions Failure to follow all instructions listed below may result in fire serious injury and or DEATH 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
23. eristics and rated capac ities of the generator Set up the generator outdoors in a well ventilated dry area away from building air intakes The genera tor should be protected from direct exposure to rain and snow Do not set up the generator on a conductive surface such as a metal deck Do not connect generator directly into a home s electrical lines Do not plug a generator into an outlet in the home Connecting a generator directly to a utility power supply can back feed along the power lines and kill or injure utility workers working on the lines Do not charge vehicle batteries with this Generator Maintain labels and nameplates on the equipment These carry impor tant information If unreadable or missing contact Harbor Freight Tools for a replacement Have the equipment serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the equip ment is maintained Do not attempt any service or maintenance proce dures not explained in this manual 16 17 18 For technical questions please call 1 800 444 3353 or any procedures that you are un certain about your ability to perform safely or correctly Store equipment out of the reach of children Follow scheduled engine and equip ment maintenance Refueling Precautions a Do not smoke or allow sparks flames or other sources of ignition around the equipment especially when refuell
24. g System i Carburetor and its internal parts ii Fuel pump if so equipped iii Cold start enrichment system REV 09a Page 41 2 Air Induction System i Intake pipe manifold ii Air cleaner 3 Ignition System i Spark plug ii Magneto ignition system 4 Catalyst System if so equipped i Exhaust pipe stud ii Muffler iii Catalytic converter if so equipped 5 Miscellaneous Items Used in Above Systems i Vacuum temperature and time sensitive valves and switches ii Hoses belts connectors and assemblies SKU 98391 For technical questions please call 1 800 444 3353 REV 09a Page 42
25. if so equipped and the blades if so equipped are free of defects in materials and workmanship Har bor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that all other parts and components of the product are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or con sequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replace
26. ing b Do not refill the fuel tank while the engine is running or hot c Do not fill fuel tank to the top Leave a little room for fuel expansion d Refuel in a well ventilated area only SAVE THESE INSTRUCTIONS Page 7 BASIC SPECIFICATIONS AWARNING SERIOUS INJURY FROM ACCIDENTAL MAN Turn the Power Switch of the equipment to its OFF i 1 3 4 qts position wait for the engine to cool before assembling or making any adjustments to the equipment SOPREVENT AWARNING serious INJURY Note Additional specifications found in the TECHNICAL ENGINE SPECIFI operate on y with proper CATIONS chart in this manual Sparicamestor installed At high altitudes the engine s carbu Operation of this equipment retor governor and any other parts that may create sparks that control the fuel air ratio will need to be can start fires around dry adjusted by a qualified mechanic to allow vegetation efficient high altitude use and to prevent A spark arrestor may be damage to the engine and any other de required vices used with this product The operator should contact local fire agencies for laws or regulations relating to fire UNPACKING prevention requirements When unpacking check to make sure Note For additional information regarding that the item is intact and undamaged If the parts listed in the following pages any parts are missing or broken please refer
27. ll times Use the equipment accessories etc in accordance with these instructions and in the manner intended for the particular type of equipment taking into account the working conditions and the work to be performed Use of the equipment for operations differ ent from those intended could result in a hazardous situation Do not operate the equipment with known leaks in the engine s fuel sys tem This product contains or when used produces a chemical known to the State of California to cause cancer and birth defects or other reproduc tive harm California Health amp Safety Code 25249 5 et seq When spills of fuel or oil occur they must be cleaned up immediately Dispose of fluids and cleaning materi als as per any local state or federal codes and regulations Store oil rags in a bottom ventilated covered metal container Keep hands and feet away from moving parts Do not reach over or across equipment while operating Before use check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the equipment s operation If damaged have the equipment serviced before using Many ac cidents are caused by poorly main tained equipment Use the correct equipment for the application Do not modify the equip ment and do not use the equipment 21 For technical questions please call 1 800 444 3353 for a purpose for which it is not in tended
28. ment We will return re paired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo 93011 800 444 3353 SKU 98391 For technical questions please call 1 800 444 3353 Page 40 EMISSION CONTROL SYSTEM WARRANTY United States Emission Control Defects Warranty Statement The United States Environmental Protection Agency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 1997 and later Small Off Road Engine herein engine Within the United States new off road spark ignition engines certified for model year 1997 and later must be designed built and equipped to meet the stringent anti smog standards set forth by the EPA HFT must warrant the emission control system on your engine for the periods of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor or fuel injection system and the ignition system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists HFT will repair
29. nently damage the engine 1 Open the front panel remove the dip stick and wipe it off with a clean rag 2 the dipstick completely and remove it to check the oil level The oil level should be between the high and low marks on the dipstick 3 Ifthe oil level is below the low mark on the dipstick add the appropriate type of oil until the oil level is between the high and the low marks Oil type SAE 5W 40 4 Replace the Oil Dipstick For technical questions please call 1 800 444 3353 Page 10 5 Wipe off any spilled CAUTION Do not run the engine with too little or too much oil The engine will be permanently damaged Checking and Filling Fuel 1 Check the fuel level on the built in fuel gauge AWARNING TO PREVENT 55 SERIOUS INJURY FROM FIRE Fill the fuel tank in a well venti lated area away from ignition sourc es Do not smoke 2 To fill the Fuel Tank first wipe off the Fuel Tank Cap and the surrounding area 3 Unscrew and remove the Fuel Tank Cap 4 Fill the Fuel Tank to about 1 inch under the fill neck of the tank with 2 diesel 5 Then replace the Fuel Tank Cap Bleed the fuel line This is a two man operation Place rags under the bleeding points to catch flow of fuel 1 The fuel system should be bled to remove possible trapped air from the system before first use and after each fuel filter fuel tank flushing or general service of the diesel g
30. or technical questions please call 1 800 444 3353 People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure Caution is neces sary when near the engine s magneto or recoil starter Use only accessories that are recom mended by Harbor Freight Tools for your model Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment Do not operate in explosive atmo spheres such as in the presence of flammable liquids gases or dust Diesel powered engines may ignite the dust or fumes Stay alert watch what you are doing and use common sense when operat ing this piece of equipment Do not use this piece of equipment while tired or under the influence of drugs alcohol or medication Do not overreach Keep proper foot ing and balance at all times This en ables better control of the equipment in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep hair cloth ing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Parts especially exhaust system components get very hot during use Stay clear of hot parts Do not cover the engine or equipment during operation Page 5 20 SKU 98391 Keep the equipment engine and sur rounding area clean at a
31. plained as part of the regular op eration of the engine and equipment After Initial 20 Operation Hour Period a Change engine oil Every 50 Operation Hours a Replace fuel filter Every 100 Operation Hours a Change engine oil or with frequent use every three months Note All maintenance procedures sched uled for 25 50 and 100 operation hours should be performed at least yearly Every 250 Operation Hours a Clean fuel tank b Clean carbon build up from combus tion chamber c Replace the air filter Every 500 Operation Hours a Clean fuel tank and fuel filter Storage Wait for engine to cool then clean engine with clean cloth When the equipment is to remain idle for longer than 20 days prepare the engine for storage as follows a Wait for engine to cool b Disconnect battery c Drain fuel tank d Change engine oil Cover and store in a dry well ventilat ed area out of reach of children Diesel Fuel and Microbes Microbes can grow in Diesel fuel and can over time interfere with the Gen erator s performance When perfor mance begins to suffer and the en gine begins to produce black smoke a high quality biocide must be added to the fuel to kill the microbes If left untreated the microbes will eventually clog the fuel lines and ruin the equip ment The biocide must continue to be added to the fuel until the mi crobes are completely destroyed and the fuel runs pure ag
32. t 120V AC tools to the 120V AC Outlets Only con nect 240V NEMA L14 30 type plug tools the 240V AC Outlet Do not use this Generator to charge DC vehicle batteries The Genera tor has a Circuit Protector to protect the unit in case of an overload If an overload occurs the Circuit Breaker will switch to its OFF position and cause the Generator to shut down The Pilot Light will shut off to show that the Circuit Protector has been tripped Disconnect all devices and press the Circuit Breaker back up to reset the Generator When finished using the Generator turn the tools off and unplug them Allow the Generator to run for several minutes with no devices connected For technical questions please call 1 800 444 3353 to allow the temperature to stabilize Turn the Power Switch to its OFF position Turn the Fuel Valve to the OFF position To prevent accidents remove the key and disconnect negative battery terminal after use Wait for the en gine to cool clean external parts with clean cloth then store the equipment out of children s reach according to the Storage instructions in this man ual If the Generator is not going to be used again soon drain the diesel fuel Page 13 Mounting Hole Pattern 60 90 0 1 NT For technical questions please call 1 800 444 3353 Page 14 SKU 98391 Shaft Size Type 181 8 SKU 98391 For technical questions please call 1 800 444
33. tarter life use short starting cycles 10 seconds maximum If the engine does not start wait one minute before attempt ing to start again Break in Period 1 Breaking in the engine will help to ensure proper equipment and engine operation and will extend the en gine s lifespan The warranty is void if the engine is not broken in properly The first 20 hours of operation is the break in period 2 During the first 3 hours of use Do not apply a heavy load to the equipment 3 After the first 20 hours of use Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the MAINTE NANCE AND SERVICING section Page 12 Equipment Operation To Power Tools and Equipment 1 SKU 98391 Move the Power Selection Switch left to select 120V AC to power 120V tools or equipment or to the right to power 240V AC tools and equipment Prior to powering tools and equip ment make sure the Generator s rated wattage capacity 5000 W 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 of the tools and or equipment for connection to a separate Genera tor Start the Generator with no loads at tached Once the Generator warms up with the equipment or tools turned off connect the Power Cords of the AC tools and equipment into the AC Outlets Only connec
34. to the Assembly Diagram near call Harbor Freight Tools at the number the end of this manual shown on the cover of this manual as soon as possible Location Ss ee ee 1 The Generator must be installed SET INSTRUCTIONS outdoors where ventilation is readily Read the ENTIRE IMPORTANT available SAFETY INFORMATION 2 Install the Generator so that the air section at the beginning of this inlets and outlets are not blocked by manual including all text under obstructions such as bushes trees subheadings therein before set or snow drifts Locating it in the path up or use of this product of heavy winds or snowdrifts may require the placement of a barrier for protection The air inlet should face the prevailing wind direction SKU 98391 For technical questions please call 1 800 444 3353 Page 8 Ignition Fuse Cover Low Switch Warning Light 120V 120 Receptacles Battery SKU 98391 Fuel Filter CONTROLS Voltage Meter Run AC Power Circuit Hours Selection Breaker Meter Switch am AC 120V amp 240V Receptacle For technical questions please call 1 800 444 3353 Oil Drain Plug 120V 120V 240V DC12V 8 3A Grounding Reine 12V 8 3A DC Receptacle Oil Cap Dipstick Page 9 SKU 98391 Install the Generator on concrete slab or other area where water can not reach it Generator placement should allow four feet of access on all sides for maint
35. y and clean fuel tank fuel lines from exhaust and filter Generator runs 1 Device connected is faulty 1 Check devices for problems but does not 2 Engine overloaded 2 Turn off and unplug devices shut support all loads Generator off for several minutes restart generator connect fewer loads Every time fuel system is serviced replace the fuel filter Follow all safety precautions whenever diagnosing or servicing the equipment or engine SKU 98391 For technical questions please call 1 800 444 3353 Page 19 Troubleshooting Possible Causes Probable Solutions Engine backfires 1 Impure or low quality diesel fuel 1 Fill fuel tank with fresh 2 diesel fuel 2 Engine too cold 2 Use cold weather fuel and oil additives to prevent backfiring 3 Engine not properly adjusted for 3 Qualified technician must adjust high altitude operation engine at altitudes greater than 5 000 feet above sea level 4 Intake valve stuck incorrect timing 4 Have qualified technician diagnose clogged carburetor or overheated and service engine engine AC output but no 1 Fuse burnt out 1 Replace Fuse DC output Every time fuel system is serviced replace the fuel filter Follow all safety precautions whenever diagnosing or servicing the equipment or engine SKU 98391 For technical questions please call 1 800 444 3353 Page 20 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVI
36. your engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 1997 and later engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by HFT Harbor Freight Tools Emission Control Defects Warranty Coverage Engines are warranted for a period of two 2 years relative to emission control parts defects subject to the provisions set forth below If any emission related part on your engine is defective the part will be repaired or replaced by HFT 1 Owner s Warranty Responsibilities As the engine owner you are responsible for the perfor mance of the required maintenance listed in your Owner s Manual HFT recommends that you retain all receipts cov ering maintenance on your engine but HFT cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that HFT may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or 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
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