Chicago Electric 98452 Operating instructions

2200 RATED WATTS/2400 MAX WATTS
PORTABLE GENERATOR
98452
Operating Instructions
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Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
Copyright© 2009 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. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Revised Manual 10e
SPECIFICATIONS
VAC Electrical Specifications
115 Volts @ 20 Amps Current Output
60 Hz
2200 Rated Watts / 2400 Max Watts
Two 120V, Household Receptacles with a 20 Amp circuit breaker
VDC Electrical Specifications
12 VDC @ 10 Amps Current Output
Voltmeter Equipped
0-150 Volts / 50 Volt Increments
Display Lights
Red (Run)
Generator Type
Brush / Revolving Field / Self Exciting
Two Pole / Sincle Phase
Gasoline Engine
5.5 HP / Unleaded Gasoline Powered
Recoil Start / 4-Cycle / OHV Air Cooled
163 CC Displacement / 3600 RPM
0.63 Quart (0.6 Liter) Oil Capacity
EPA Certified
Fuel Tank Capacity
3.96 Gallons (15 Liters) / Includes Fuel Gauge
Estimated Run Time
11.8 Continuous Running Hours
Weight
103.6 Pounds
This product requires oil and fuel to be added before starting. Attempting to start the engine
without oil WILL ruin the engine and void the warranty.
The Emission Control System for this generator’s 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 back two pages of this manual.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and assembly
diagram. Keep your invoice with this manual. Write the invoice number on the inside of the
front cover. Keep this manual and invoice in a safe and dry place for future reference.
REV 09h
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Page 2
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts LIsts on pages
20 and 22 are included. If any parts are missing or broken, please call Harbor Freight
Tools at the number shown on the cover of the manual as soon as possible.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1.
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2.
Do not operate power tools in explosive atmospheres, such as in
the presence of flammable liquids, gases, or dust. Generators create
sparks which may ignite the dust or fumes.
3.
Keep bystanders, children, and visitors away while operating a power tool.
Provide barriers or shields as needed.
ELECTRICAL SAFETY
4.
Grounded tools must be plugged into an outlet properly installed and grounded
in accordance with all codes and ordinances. Never remove the grounding
prong or modify the plug in any way. Do not use any adapter plugs. Check with
a qualified electrician if you are in doubt as to whether the outlet is properly
grounded. If the tools should electrically malfunction or break down, grounding
provides a low resistance path to carry electricity away from the user.
5.
Double insulated tools are equipped with a polarized plug (one blade is wider
than the other). This plug will fit in a polarized outlet only one way. If the plug
does not fit fully in the outlet, reverse the plug. If it still does not fit, contact
a qualified electrician to install a polarized outlet. Do not change the plug
in any way. Double insulation eliminates the need for the three wire grounded
power cord and grounded power supply system.
6.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
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7.
Do not expose power tools to rain or wet conditions. Water entering a
generator will increase the risk of electric shock.
8.
Do not abuse the Power Cords. Never use a Power Cord to carry tools or pull
the Plug from the outlet. Keep Power Cords away from heat, oil, sharp edges,
or moving parts. Replace damaged Power Cords immediately. Damaged Power
Cords increase the risk of electric Shock.
9.
When operating a power tool outside, use an outdoor extension coard marked
“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the
risk of electric shock.
PERSONAL SAFETY
10.
Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
11.
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.
12.
Avoid accidental starting. Make sure the Power Switch is in its “OFF” position, and disconnect the Spark Plug Wire when not in use.
13.
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.
14.
Do not overreach. Keep proper footing and balance at all times.
15.
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.
16.
Do not force the generator. Use the correct generator for you application.
The correct generator will do the job better and safer at the rate for whick it is designed.
17.
Do not use the Generator if the Power Switch does not turn it on or off. Any
generator that cannot be controlled with the Power Switch is dangerous and must
be replaced.
GENERATOR USE AND CARE
18.
Make sure the Power Switch is in its “OFF” position and disconnect the spark
plug wire before making any adjustments, changing accessories, or storing
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Page 4
the generator. Such preventive safety measures reduce the risk of starting the
generator accidentally.
19.
Store idle generators out of reach of children and other untrained persons.
Generators are dangerous in the hands of untrained users.
20.
Maintain generators with care. Do not use a damaged generator. Tag damaged
generators “Do not use” until repaired.
21.
Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the generator’s operation. If damaged,
have the generator serviced before using. Many accidents are caused by poorly
maintained generators.
22.
Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous when
used on another generator.
23.
CAUTION: This generator is not intended to power sensitive electronic equipment* without the addition of an appropriate power line conditioner and surge
protector (both not included). Sensitive electronic equipment should be operated
on approved inverter type generators or pure sine wave generators.
When the plugged in product operates abnormally or unusually slow, immediately
stop using the generator as a power source. Always read and adhere to the
instruction manual of the product to be powered, to make sure that it can be safely
and efficiently powered by a portable generator.
Note: When using a generator to provide home standby electricity, a transfer switch
(sold separately) is needed to prevent back feeding power into the utility line.
Connections for standby power to a building electrical system must be made by a
qualified electrician. The connection must isolate the generator power from utility
power, and must comply with all applicable laws and electrical codes.
WARNING: Improper connections 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 includes, but is not limited to, audio/video
equipment, some television sets, computers, and printers.
SERVICE
24.
Always keep fuel tank capped, even when empty, to prevent rainwater, dirt
and debris from getting into the fuel tank.
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Page 5
25.
Maintain labels and nameplates on the Generator and Engine. These carry
important information. If unreadable, or missing, contact Harbor Freight Tools for
a replacement.
26.
Generator service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk
of injury.
27.
When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual.
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
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Page 6
SPECIFIC SAFETY RULES AND PRECAUTIONS
HEART PACEMAKER PRECAUTION
WARNING! People with pacemakers should consult their physician(s) before using
this product. Electromagnetic fields in close proximity to a heart pacemaker could
cause interference to or failure of the pacemaker.
INSTALLATION PRECAUTIONS
1.
Ensure installation meets all applicable safety, and local and national
electrical codes. Have installation performed by a qualified, licensed electrician
and building contractor.
2.
All electrical work, including the earth-ground connection, should be
completed by a licensed electrician.
3.
Any separate fuel storage Generator supply facility must be built or installed
in full compliance with all relevant local, state, and federal regulations.
4.
If the generator is installed indoors, exhaust fumes must be piped out
of the building using leak-free, heat-resistant piping. Use the Generator only in a well ventilated outdoor areas. Carbon monoxide fumes
are a colorless, odorless gas that, if inhaled, can cause serious
injury or death. Pipes and silencer should not use any flammable materials, nor
should they be installed near the same. Generator exhaust fumes must within legal
limits.
5.
If the generator is installed outdoors, it must be weatherproofed and should
be sound-proofed. It should not be run outdoors without protection to the Generator and wiring conduit.
6.
Never lift the Generator using the engine or alternator lifting lugs. Connect
lifiting equipment to the Frame of the Generator.
7.
Before lifting the Generator, ensure the lift rigging and supporting structure
are in good condition, and are rated to lift such a load.
8.
Keep all personnel away from the suspended generator while relocating.
9.
The supporting floor/ground surface should be level, and strong enough to
safely hold the weight of the Generator. If the floor/ground surface is not level,
strong cross members should be placed under the full length of the Generator
Frame at its low side.
10.
For trailer installation, the Generator should be mounted on the center point
of the trailer, over the wheels.
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Page 7
11.
Install sound and weather proofing only when it is not raining or snowing to
avoid trapping moisture with the Generator’s area.
FIRE AND EXPLOSION PRECAUTIONS
1.
Gasoline fuel and fumes are flammable, and potentially explosive. Use
proper fuel storage and handling procedures. Always have multiple ABC class fire
extinguishers nearby.
2.
Keep the Generator and surrounding areas clean at all times.
3.
When spills of fuel or oil occur, they must be cleaned up immediately. Dispose
of fluids and cleaning materials as per any local, state, or federal codes and
regulations. Store oil rags in a covered metal container.
4.
Never store fuel or other flammable materials near the Generator.
5.
Do not smoke, or allow sparks, flames, or other sources of ignition around
the Generator.
6.
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.
7.
Do not refill 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.
8.
Excessive buildup of unburned fuel gases in the exhaust system can create
a potentially explosive condition. This buildup can occur after repeated failed
start attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust
system drain plugs, if equipped, and allow the gases to dissipate before attempting
to restart the Generator.
9.
Use only Engine manufacturer recommended fuel and oil.
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Page 8
MECHANICAL PRECAUTIONS
1.
ALWAYS make sure the Power Switch is in its “OFF” position. Disconnect
the spark plug wire, and allow the Engine to completely cool before carrying our
maintenance.
2.
Check for damaged parts. Before using the Generator, any part that appears
damaged should be carefully checked to determine that it will operate properly and
perform its intended function. Check for alignment and binding of moving parts,
any broken parts or mounting fitures, and any other condition that may affect proper
operation. Any part that is damaged should be properly repaired or replaced by a
qualified technician.
3.
The Generator is designed with guards for protection from moving parts. In
any case, care must still be taken to protect personnel and equipment from other
mechanical hazards when working around the generator.
4.
Do not operate the Generator with safety guards removed. While the Generator is running, do not attempt to reach around the safety guards for maintenance
or any other reason.
5.
Keep hands, arms, long hair, loose clothing, and jewelry away from oving parts.
Be aware that when engine parts are moving fast they cannot be seen clearly.
6.
Keep access doors on enclosures closed and locked when access is not
required.
7.
Whan working on or around the Generator always wear protective clothing
including ANSI approved safety gloves, safety eye goggles, and safety hat.
8.
Do not alter or adjust any part of the Generator that is assembled and supplied by the manufacturer.
9.
Always follow and complete scheduled Engine and Generator maintenance.
CHEMICAL PRECAUTIONS
1.
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.
2.
Avoid body contact with fuels, oils, and lubricants used in the Generator and
Engine. If 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 flush eyes with clean water.
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Page 9
NOISE PRECAUTION
Prolonged exposure to noise levels above 85 dBA is hazardous to hearing.
Always wear ANSI approved ear protection when operating or working around the
Generator when it is running.
ELECTRICAL PRECAUTIONS
1.
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 where applicable.
2.
The Generator must be earth-grounded in accordance with all relevant electrical codes and standards before operation.
3.
If an extension cord (not included) is used, make sure to use only UL listed
cords having the correct gauge and length. (See TABLE A)
REQUIRED MINIMUM EXTENSION CORD GAUGE - 120 VOLT
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD LENGTH
0-25 Feet
25-50 Feet
50-100 Feet
100-150 Feet
150-200 Feet
0–5
16
16
16
12
12
5.1 – 8
16
16
14
10
-
8.1 – 12
14
14
12
-
-
12.1 – 15
12
12
10
-
-
15.1 – 20
10
10
10
-
-
TABLE A
4.
Do not attempt to connect or disconnect load connections while standing in
water, or on wet or soggy ground.
5.
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.
6.
Connect the Generator only to a load or electrical system (115 volt) that is
compatible with the electrical characteristics and rated capacities of the
Generator.
7.
Before servicing equipment powered by the Generator, disconnect the equipment from its power input.
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8.
Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, abraded, or otherwise degraded. Replace terminals that
are worn, discolored, or corroded. Keep terminals clean and tight.
9.
Insulate all connections and disconnected wires.
10.
Guard against electric shock. Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.
11.
Use only Class BC or Class ABC fire extinguishers on electrical fires.
INSTALLATION
1.
NOTE: Prior to powering tools and equipment, make sure the Generator’s rated
voltage, wattage, and amperage capacity (120V - 20 Amp’s) 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 Generator.
2.
Electrical and other permits may be required for the installation of emergency or
portable power systems. Investigate the local building and electrical codes before
installing this unit. Installation must be completed by licensed contractors.
3.
WARNING: The Generator weighs 103.6 pounds. Use care and the proper lifting
or hoisting equipment when moving it to the installation location. Always connect
hoist lines to the Frame (41B) of the Generator.
GENERAL LOCATIONS
1.
It is recommended to locate the Generator (outdoors only) where cooling air is
readily available.
2.
Install 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, in
normal weather conditions, should face the prevailing wind direction.
3.
Install the Generator on a concrete slab or other area where rain drainage or flood
waters can not reach it.
4.
Generator placement should allow four feet of access to all sides for maintenance.
5.
Place the Generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords.
6.
If the Generator is located indoors the Engine exhaust must be ventilated to the
outdoors using leakproof, heat resistant, flexible, metal, flex tubing.
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GENERATOR SUPPORT AND MOUNTING
Mount the Generator on a concrete slab capable of supporting the weight of the Generator. The slab must extend on all sides beyond the Frame (41B) by a least one foot.
Contact a cement contractor for slab specifications if necessary. Attach the Frame to
the concrete slab using 3/8” diameter expansion anchor bolts (not supplied).
GROUNDING THE GENERATOR
Note: It is recommended that only a trained and licensed electrician perform this procedure.
Connect a #6 AWG grounding wire (not included) from the Grounding Connector
(8) 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 B.)
THIS UNIT CAN POWER THE FOLLOWING ITEMS
ITEM
1/3 HP Air Compressor
Belt Sander
Drum Mixer
Motor 1/2 HP
Reciprocating Saw
Microwave Oven
Refrigerator/Freezer
Sump Pump 1/2 HP
Vacuum Cleaner
Well Pump 1/2 HP
RUNNING START-UP
WATTS
WATTS
720
1000
1200
2400
700
1200
875
2300
750
1400
1000
1200
700
2200
1050
2150
1100
2200
1000
2100
NOTE: Wattages listed above are estimates for that type of equipment only. Check nameplate wattages on all loads before connecting to Generator.
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Page 12
AC Applications
1.
Before connecting an appliance or power cord to the generator: Make sure that it
is in good working order. Faulty appliances or power cords can create a potential
for electrical shock.
2.
If an appliance begins to operate abnormally, becomes sluggish or stops suddenly,
turn it off immediately. Disconnect the appliance, and determine whether the
problem is the appliance, or if the rated load capacity of the generator has been
exceeded.
3.
Make sure that the electrical rating of the tool or appliance does not exceed that of
the generator. Never exceed the maximum power rating of the generator. Power
levels between rated and maximum may be used for no more than 30 minutes.
4.
Substantial overloading will open the circuit breaker. Exceeding the time limit for
maximum power operation or slightly overloading the generator may not switch
the circuit breaker or circuit protector OFF, but will shorten the service life of the
generator.
OPERATING INSTRUCTIONS
NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagrams on pages 21 and 23.
Pre-Start Checks:
1.
Check to make sure the Engine’s Power Switch (2) is in its “OFF” position.
(See Figure B, next page.)
2.
IMPORTANT! Prior to first using the Generator, the Engine MUST be filled
with approximately 3/4 (0.63) quart of a high quality SAE 10W-30 grade
engine oil. To do so, unscrew and remove the Oil Dipstick (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). Then, screw the Dipstick back into the Oil Fill
Hole. (See Figure C, next page.)
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THIS GENERATOR
HAS AN AUTOSHUTDOWN OIL
SENSOR. IF ENGINE
STOPS OR WILL NOT
START, CHECK OIL
LEVEL.
REV 09h
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Page 14
3.
Before the first use, remove the Fuel Tank Cap (33B1) and fill the Fuel Tank (30B1)
with unleaded gasoline. Then, replace the Fuel Tank Cap. If necessary, refill the
Fuel Tank with unleaded gasoline. (See Figure C.)
To Start The Engine:
1.
Make sure the electrical powered tools/equipment that will be used is not plugged
in to the Generator.
2.
Turn the 115 volt AC Circuit Breaker (5) to its “ON” position. (See Figure D.)
3.
Open the Fuel Valve (40B). (See Figure E.)
4.
Move the Choke Lever (116C) to the CLOSED position to start a cold engine.
Leave the Choke Lever (116C) in the open position to restart a warm engine.
(See Figure E.)
REV 09a
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5.
Turn the Engine Power Switch (2) to its “ON” position. (See Figure F.)
6.
Hold the Start Handle (41A) loosely and pull it slowing several times to allow the
gasoline to flow into the Engine’s carburetor. Then hold the Start Handle firmly
and pull the rope hard and fast. Pull the rope all the way out, using two hands
if necessary. If necessary pull the tope several times until the Engine starts.
(See Figure G.)
7.
Allow the Engine to run for several seconds. Then, open the Choke Lever (21A)
all the way. (See Figure E.)
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Powering 120 Volt AC Tools and Equipment:
1.
Prior to powering tools and equipment, make sure the Generator’s rated voltage,
and amperage capacity (115 VAC / 20 AMPs) 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 generator.
2.
Once the Generator is running, simply connect the Power Cords of 115 volt AC
powered tools and equipment into the 115 bolt AC Duel Outlets (6). (See Figure
G.)
3.
NOTE: Do not allow the generator to completely run out of fuel with devices
attached. A generator’s output may sharply spike as it runs out of fuel, causing
damage to attached devices.
4.
NOTE: The Generator features an AC Non-Fuse Circuit Breaker (5) to protect the
AC circuit in case of an overload. Should an overload occur the Breaker will “trip”
to its “OFF” position, causing the Generator to automatically shut down. In this
case, refer to Step #1 above in this section. Then, reset the circuitry system by
turning the Circuit Breaker to its “ON” position. Restart the Generator and continue
powering the remaining tools and equipment. (See Figure D.)
5.
When finished using the Generator, turn the Engine Power Switch (2) to its “OFF”
position. Turn the Fuel Valve (40B) to its “OFF” position. Then, disconnect all
electrical powered tools and equipment from the Generator’s 115 volt AC Duel
Outlets (6). (See Figure E, F & G.)
6.
After the Engine and Generator have completely cooled, store the Generator in a
safe, clean, dry location (if not already installed in one).
Powering 12 Volt DC Tools and Equipment:
1.
Prior to powering a tool or equipment, make sure the Generator’s rated voltage,
and amperage capacity (12 VDC / 10 AMPs) 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 generator.
2.
Connect the Power Cord of a 12 VDC powered tool or equipment to the DC Terminals
(7). NOTE: Make sure to connect the positive (+) lead of the Power Cord to the
positive (+) Terminal on the Generator, and connect the negative (-) lead of the
Power Cord to the Negative (-) Terminal on the Generator. (See Figure H, next
page.)
3.
If using only a 12 volt DC tool or equipment, turn the 120 volt AC Circuit Breaker
(5) to its “OFF” position. (See Figure D.)
4.
Start and run the Engine as previously discussed in this manual.
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REV 10e
Page 17
5.
When finished using the Generator, turn the Engine Power Switch (2) to its “OFF”
position. Turn the Fuel Valve (40B) to its “OFF” position. Then, disconnect the
electrical powered tool or equipment from the Generator’s DC Terminals (7).
(See Figure H.)
6.
After the Engine and Generator have completely cooled, store the Generator in a
safe, clean, dry location (if not already installed in one).
7.
NOTE: The Generator features a 10 AMP DC Fuse (9) to protect the DC circuit in
case of an overload. Should an overload occur the Fuse will burn out, causing the
Genrator to automatically shut down. In this case, refer to Step #1 in this section.
Then, reset the circuitry system by replacing the burnet Fuse with a new 10 AMP
DC Fuse. Restart the Generator and continue powering the remaining tool or
equipment. (See Figure H.)
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INSPECTION, MAINTENANCE, AND CLEANING
1.
CAUTION! Always make sure the Engine Power Switch (2) is in its “OFF” position.
Disconnect the spark plug wire from the engine and allow sufficient time for the
Engine and Generator to completely cool before performing any inspection, maintenance, or cleaning.
2.
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.
3.
Follow all maintenance procedures as outlined in the Engine Maintenance Schedule
below at the specified intervals. In addition, observe the following details:
Before each use: check to make sure the Engine’s oil level is adequate. If necessary, fill
the Engine’s Crankcase until the oil level is even with the Oil Fill Hole.
Before each use: with a soft brush, sloth, or vacuum, remove all debris from the Generator
and Engine. Then, use a premium quality, lightweight machine oil to lubricate all moving
parts.
After the inital 20 hours of use and every 100 hours of use thereafter: drain the old
Engine oil and replace with approximately 3/4 (0.63) quart of a high quality SAE 10W-30
grade engine oil.
4.
Alway keep fuel tank capped, even when empty, to prevent rainwater, dirt and debris from
getting into the fuel tank.
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Page 19
REV 09a
PARTS LIST
Part
1
2
3B
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Description
Bolt (M6 x 12) w/Lock Washer
Engine Power Switch
Control Panel
Voltmeter
Circuit Breaker
Outlet
DC Terminal
Ground Connector
DC Fuse
Pilot Light
Shock Absorber
Shock Absorber Foot
Lock Washer Nut (M8)
Stator Cover
Alternator Back Cover
Automatic Voltage Regulator
Bolt (M5 x 16)
Rectifier
Bolt (M5 x 16)
Cable Sheath
Bolt (M8 x 224)
Bolt (M6 x 152)
Qty
Part
9
1
1
1
1
2
2
1
1
1
4
4
4
1
1
1
4
1
3
1
1
4
23
24
25
26
27
28
29
30B
31
32
33
34
35B
36
37
38
39
40B
41B
42
43
44
Description
Qty
Bolt (M5 x 20)
Connection Board
Nut (M5)
Stator
Rotor
Cooling Fan
Heat Insulation Board
Fuel Tank
Fuel Filter
Seal Ring
Fuel Tank Cap
Fuel Gauge
Bolt (M5 x 10)
Lock Washer Bolt (M6 x 12)
Spacer
Rub Washer
Bush
Fuel Valve
Frame
Switch Box Cover
Engine
Carbon Brush
4
1
4
1
1
1
1
1
1
1
1
1
2
4
4
4
4
1
1
1
1
1
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
PLEASE READ THE FOLLOWING CAREFULLY
The manufacturer and/or distributor has provided 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.
SKU 98452
For technical questions, please call 1-800-444-3353.
Page 20
ASSEMBLY DIAGRAM
SKU 98452
For technical questions, please call 1-800-444-3353.
Page 21
Part
1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
12A
13A
14A
15A1
16A1
17A1
18A1
19A1
20A1
21A
22A
23A
24A
25A
26A
27A
28A
29A
30A
31A
32A
33A
34A
35A
36A
37A
38A
39A
40A
41A
42B1
PARTS LIST - CONTINUED
Description
Muffler
Cylinder Head Bolt
Cylinder Head Cover Bolt
Cylinder Head Cover
Lock Nut
Adjusting Screw
Rocker Arm
Rocker Arm Bolt
Valve Push Rod Guiding Board
Valve Push Rod
Cylinder Head
Carburetor Shield
Carburetor Packing
Carburetor Assembly
Air Filter Case
Air Filter Seal
Bolt (M6)
Air Filter Cover
Air Filter Element
Air Filter Separator
Choke Lever
Carburetor Packing (II)
Stud Bolt (M6 x 109)
Intake Valve
Exhaust Valve
Cylinder Head Gasket
Exhaust Pipe Stud
Spark Plug
Valve Guide
Valve Spring
Rocker Shaft Circlip
Anti-Wear Valve Stem Protector
Cylinder Head Cover Packing
Governor Spring
Bolt
Spark Plug Wire
Ignition Coil
Nut (Special 14mm)
Starter Ratchet Spring
Starter Rope
Starter Handle
Starter Case Assembly
Qty
1
4
4
1
2
2
3
2
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
2
1
2
2
2
2
1
1
1
1
1
1
2
1
1
1
Part
43A
44A
45A
46A
47A
48B1
49A1
50A
51A
52A1
53A
54A
55A
56A
57A
58A
59A
60A
61A
62A
63A
64A
65A
66A
67A
68A
69A
70A
71A
72A
73A
74A
75A
76A
77A
78A
79A
80A
81A
82A
83A
Description
Qty
Spiral Spring
Starter Wheel
Circlip
Starter Ratchet
Friction Plate Screw
Cover
Starter Pulley
Cooling Fan
Flywheel Magneto
Cylinder Block
Speed Control Lever
Governor Arm
Governor Spring
Governor Support
Bolt (M6 x 15)
Oil Alert Nut
Plug (M10 x 15)
Plug Washer
Oil Alert
Bolt (M6)
Crankshaft
Crankshaft Gear
Oil Dipstick
Oil Dipstick Seal Ring
Gear Casing
Bolt (M8 x 35)
Gear Case Packing
Bearing
Camshaft Assembly
Locating Pin
Oil Seal
Connecting Rod Bolt
Connecting Rod Cap
Connecting Rod
Piston
Compression Ring (I)
Compression Ring (II)
Oil Scraper Ring
Piston Pin
Piston Pin Circlip
Fuel Pipe
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
1
1
2
2
1
6
2
2
1
4
2
2
1
1
1
1
1
1
1
1
1
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
SKU 98452
For technical questions, please call 1-800-444-3353.
Page 22
ASSEMBLY DIAGRAM
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
SKU 98452
For technical questions, please call 1-800-444-3353.
Page 23
Limited 1 year 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 this product is free from defects in materials
and workmanship for the period of one year from the date of purchase (90 days if used by a professional
contractor or if used as rental equipment). See engine manufacturer’s warranty which covers engine. 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 consequential
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 complaint must accompany the merchandise. If our inspection verifies the defect, we will either 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 replacement. We will
return repaired 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, CA 93011 • (800) 444-3353
Emission Control System Warranty
California and United States Emission
Control Defects Warranty Statement
The California Air Resources Board (herein CARB), 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
1995 and later Small Off-Road Engine (herein engine). In
California, the engine must be designed, built and equipped
to meet the State’s stringent anti-smog standards. Elsewhere within the United States, new off-road, spark-ignition
engines certified for model year 1997 and later, must meet
similar 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 your
engine at no cost to you including diagnosis, parts and
labor.
Manufacturer’s Warranty Coverage
The 1995 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.
SKU 98452
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.
Owner’s Warranty Responsibilities
- As the engine owner, you are responsible for the performance of the required maintenance listed in your
Owner’s Manual. HFT recommends that you retain
all receipts covering 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 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.
For technical questions, please call 1-800-444-3353.
Page 24
Emission Control System Warranty - continued
Harbor Freight Tools Emission Control Defects Warranty Provisions
1.
2.
3.
4.
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.
5.
No Charge Repair or Replacement
Repair or replacement of any warranted part will be
performed at no charge to the owner if the work is
performed through a warranty station authorized by
HFT. For emissions warranty service, contact the HFT
Customer Service Department at 1-800-444-3353.
Consequential Damages Coverage
Coverage under this warranty shall also extend to
the failure of any engine components caused by the
failure of any warranted part while it is still covered
under this warranty.
Coverage Exclusions
Warranty claims shall be filed in accordance with the
provisions 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. Warranty coverage shall also
be excluded 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:
(a) use of parts which are not authorized by HFT
(b) improper installation, adjustment or repair of the
engine or of any warranted 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 warranted parts
(e) repairs performed outside of the authorized warranty service dealers
(f) alterations by changing, adding to or removing
parts from the engine.
SKU 98452
6.
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 on page 17 of this manual.
Warranted Parts
1) Fuel Metering System
i) Carburetor and its internal parts.
ii) Fuel pump (if so equipped).
iii) Cold start enrichment system.
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.
For technical questions, please call 1-800-444-3353.
Page 25