Chicago Electric 98391 Guida utente

DIESEL GENERATOR

98391

SET UP, OPERATING, AND SERVICING

INSTRUCTIONS

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

a home or garage,

EVEN IF doors and

windows are open.

Only use OUTSIDE

and far away from

windows, doors, and

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.

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.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 2

CONTENTS

IMPORTANT SAFETY

INFORMATION ............................ 4

BASIC SPECIFICATIONS ............. 8

UNPACKING .................................. 8

SET UP INSTRUCTIONS............... 8

LOCATION.......................................... 8

CONTROLS ................................... 9

GROUNDING....................................10

OPERATING INSTRUCTIONS .... 10

STARTING THE ENGINE .................10

CHECKING AND FILLING

ENGINE OIL .............................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

EQUIPMENT:............................12

TECHNICAL SPECIFICATIONS.. 13

MOUNTING HOLE PATTERN ..........13

SHAFT SIZE/TYPE...........................13

SERVICING.................................. 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

AFTER INITIAL 20

OPERATION HOUR PERIOD: . 15

EVERY 50 OPERATION

HOURS:....................................15

EVERY 100 OPERATION

HOURS:....................................15

EVERY 250 OPERATION

HOURS:....................................15

EVERY 500 OPERATION

HOURS:....................................15

STORAGE ........................................16

DIESEL FUEL AND MICROBES......16

TROUBLESHOOTING......................17

MAIN ASSEMBLY PARTS LIST .. 19

MAIN ASSEMBLY DIAGRAM...... 20

CYLINDER BLOCK ASSEMBLY

PARTS LIST .............................. 21

CYLINDER BLOCK ASSEMBLY

DIAGRAM .................................. 22

CYLINDER HEAD ASSEMBLY

PARTS LIST & DIAGRAM......... 23

CYLINDER VALVE COVER

PARTS LIST & DIAGRAM......... 24

PISTON & CONNECTING ROD

PARTS LIST & DIAGRAM......... 25

CRANK SHAFT & FLYWHEEL

PARTS LIST & DIAGRAM......... 26

CAMSHAFT ASSEMBLY PARTS

LIST & DIAGRAM...................... 27

AIR CLEANER ASSEMBLY

PARTS LIST & DIAGRAM......... 28

OIL SYSTEM PARTS LIST &

DIAGRAM .................................. 29

SKU 98391 For technical questions, please call 1-800-444-3353. Page 3

FUEL INJECTION PUMP PARTS

LIST & DIAGRAM...................... 30

FUEL NOZZLE PARTS LIST &

DIAGRAM .................................. 31

GOVERNOR & CONTROL

SYSTEM PARTS LIST &

DIAGRAM .................................. 32

FUEL TANK AND PIPE PARTS

LIST & DIAGRAM...................... 33

MUFFLER PARTS LIST &

DIAGRAM .................................. 34

STARTING MOTOR PARTS

LIST & DIAGRAM...................... 34

GENERATOR PARTS LIST &

DIAGRAM .................................. 35

CONTROL PANEL PARTS LIST

& DIAGRAM .............................. 36

WIRING DIAGRAM ...................... 37

LIMITED 1 YEAR / 90 DAY

WARRANTY .............................. 38

SKU 98391 For technical questions, please call 1-800-444-3353. Page 4

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 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.

WARNING! Read all instructions.

Failure to follow all instructions

listed below may result in re,

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.

SAVE THESE INSTRUCTIONS

SET UP PRECAUTIONS

Diesel fuel and fumes are ammable, 1.

and potentially explosive. Use proper

fuel storage and handling proce-

dures. Do not store fuel or other

ammable materials nearby.

Have multiple ABC class re extin-2.

guishers nearby.

Operation of this equipment may cre-3.

ate sparks that can start res around

dry vegetation.

A spark arrestor may be required.

The operator should contact local re

agencies for laws or regulations relat-

ing to re prevention requirements.

Set up and use only on a at, level, 4.

well-ventilated surface.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 5

Wear ANSI-approved safety goggles,5.

heavy-duty work gloves, and dust

mask/respirator during set up.

Use only oil and fuel recommended6.

in the “Specications” section of this

manual.

OPERATING PRECAUTIONS

1. CARBON MONOXIDE

HAZARD

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 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-2.

ment, especially while it is operating.

Do not leave the equipment unat-3.

tended when it is running. Turn off

the equipment (and remove safety

keys, if available) before leaving the

work area.

Wear ANSI-approved safety goggles4.

and hearing protection during use.

People with pacemakers should5.

consult their physician(s) before

use. Electromagnetic elds 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-6.

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-7.

spheres, such as in the presence of

ammable liquids, gases, or dust.

Diesel-powered engines may ignite

the dust or fumes.

Stay alert, watch what you are doing8.

and use common sense when operat-

ing this piece of equipment. Do not

use this piece of equipment while

tired or under the inuence of drugs,

alcohol or medication.

Do not overreach. Keep proper foot-9.

ing and balance at all times. This en-

ables better control of the equipment

in unexpected situations.

Dress properly. Do not wear loose10.

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 system11.

components, get very hot during use.

Stay clear of hot parts.

Do not cover the engine or equipment12.

during operation.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 6

Keep the equipment, engine, and sur-13.

rounding area clean at all times.

Use the equipment, accessories, etc.,14.

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 with15.

known leaks in the engine’s fuel sys-

tem.

This product contains or, when used,16.

produces a chemical known to the

State of California to cause cancer

and birth defects or other reproduc-

tive harm. (California Health & Safety

Code § 25249.5, et seq.)

When spills of fuel or oil occur, they17.

must be cleaned up immediately.

Dispose of uids 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 from18.

moving parts. Do not reach over or

across equipment while operating.

Before use, check for misalignment19.

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 the20.

application. Do not modify the equip-

ment and do not use the equipment

for a purpose for which it is not in-

tended.

Wash hands with soap and water21.

after handling diesel fuel or lubricat-

ing oil.

SERVICE PRECAUTIONS

Before service, maintenance, or1.

cleaning:

Turn the engine switch to itsa.

“OFF” position.

Allow the engine to completelyb.

cool.

Keep all safety guards in place and in2.

proper working order. Safety guards

include mechanical guards, and heat

shields, among other guards.

Do not alter or adjust any part of3.

the equipment or its engine that is

sealed by the manufacturer or dis-

tributor. Only a qualied service

technician may adjust parts that

may increase or decrease gov-

erned engine speed.

Wear ANSI-approved safety goggles,4.

heavy-duty work gloves, and dust

mask/respirator during service.

All connections from the Generator to5.

the load must be installed by a li-

censed electrician in compliance with

local, state, and federal laws.

The generator must be grounded in6.

accordance with applicable electrical

codes and standards before opera-

tion.

Insulate all connections and discon-7.

nected wires.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 7

Do not connect or disconnect load8.

connections while standing in water

or on wet ground.

Do not overload the generator. Over-9.

loading can cause res in the electri

cal cords, in addition to generator and

appliance damage.

Connect the generator only to a load10.

or electrical system (120 volt or 240

volt) that is compatible with the elec-

trical characteristics and rated capac-

ities of the generator.

Set up the generator outdoors in a11.

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 directly12.

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 with13.

this Generator.

Maintain labels and nameplates on14.

the equipment. These carry impor-

tant information. If unreadable or

missing, contact Harbor Freight Tools

for a replacement.

Have the equipment serviced by a15.

qualied 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

or any procedures that you are un-

certain about your ability to perform

safely or correctly.

Store equipment out of the reach of16.

children.

Follow scheduled engine and equip-17.

ment maintenance.

Refueling Precautions:18.

Do not smoke, or allow sparks,a.

ames, or other sources of ignition

around the equipment, especially

when refuelling.

Do not rell the fuel tank while the b.

engine is running or hot.

Do not ll fuel tank to the top. Leave c.

a little room for fuel expansion.

Refuel in a well-ventilated area only.d.

SAVE THESE

INSTRUCTIONS.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 8

BASIC SPECIFICATIONS

Fuel Type #2 Diesel Fuel

Capacity 4.2 Gallons

Engine Oil Type SAE 5W40

Capacity 1-3/4 qts.

Rated Wattage 5,000 Watts

Maximum Wattage 6,000 Watts

Run Time @ 75% Load 8.5 Hours with full tank

Sound Level 75 dB @ 23’

Note: Additional specications found in

the TECHNICAL ENGINE SPECIFI-

CATIONS chart in this manual.

At high altitudes, the engine’s carbu-

retor, governor, and any other parts that

control the fuel-air ratio will need to be

adjusted by a qualied mechanic to allow

efcient highaltitude use and to prevent

damage to the engine and any other de-

vices used with this product.

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.

TO PREVENT

SERIOUS INJURY

FROM ACCIDENTAL

STARTING:

Turn the Power Switch of the

equipment to its “OFF”

position, wait for the engine to

cool before assembling or

making any adjustments to

the equipment.

TO PREVENT

SERIOUS INJURY:

Operate only with proper

spark arrestor installed.

Operation of this equipment

may create sparks that

can start res around dry

vegetation.

A spark arrestor may be

required.

The operator should contact

local re agencies for laws

or regulations relating to re

prevention requirements.

Note: For additional information regarding

the parts listed in the following pages,

refer to the Assembly Diagram near

the end of this manual.

Location

The Generator must be installed1.

outdoors where ventilation is readily

available.

Install the Generator so that the air2.

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 should face

the prevailing wind direction.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 9

Ignition

Switch

Low Oil

Warning

Light

Fuse Cover Voltage

Meter

Run

Hours

Meter

AC Power

Selection

Switch

Circuit

Breaker

120V GFCI

Receptacles

120V & 240V

Receptacle

12V 8.3A DC

Receptacle

Grounding

Point

CONTROLS

Oil Cap/Dipstick

Battery Fuel Filter

Fuel

Shut-off

Valve Engine

Control

Handle

Fuel

Cut-off

Oil Drain Plug

SKU 98391 For technical questions, please call 1-800-444-3353. Page 10

Install the Generator on a concrete3.

slab or other area where water can

not reach it.

Generator placement should allow4.

four feet of access on all sides for

maintenance.

Place the Generator as close as pos-5.

sible to the electrical tools and equip-

ment being powered to reduce the

length of extension cords.

Grounding

Connect a #12 AWG grounding wire1.

(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

2. 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

looking for damaged, loose,

leaking and missing parts

before set up and starting. If

any problems are found, do

not use equipment until xed

properly.

Checking and Filling Engine Oil

CAUTION! Your Warranty is VOID if the

engine’s crankcase is not properly

lled 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 permanently

damage the engine.

Open the front panel; remove the dip-1.

stick and wipe it off with a clean rag.

Reinsert the dipstick completely and2.

remove it to check the oil level. The

oil level should be between the high

and low marks on the dipstick.

If the oil level is below the low mark3.

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

Replace the Oil Dipstick.4.

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