Chicago Electric 96898 Set Up And Operating Instructions Manual Download

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SKU 96898

For technical questions, please call 1-800-444-3353.

part

description

Qty

Airhood

Side Plate Weldment, Crankcase

Plastic Clip

Screw M6×22

Grommet

Fan Case

Kick-starter

Screw M6×8

Supporting Plate

Muffler Stay

Flange Bolt M8×6

Bolt M8×25

Muffler

Nut M8

Muffler Gasket

Exhaust Pipe Comp.

Exhaust Pipe Gasket

Muffler Guard

Tube Clip

Outlet Pipe Φ9×φ4.5×130

Fuel Cock

Fuel Tank

Stripe, Fuel Tank

Cushion

Fitting Brush, Fuel Tank

Washer

Flange Bolt M6×22

Fuel Sensor

Fuel Filter

Fuel Filler Cap Comp.

Stator Cover

Stator Assy

Generator Stay

Brush Assy

Voltage Regulator

Bolt M5×4

Generator End Cover

Bolt M5×2

Flange Bolt M6×25

Bolt M8×80

Plain Washer

part

description

Qty

Bearing 6202-2rs

Rotor Comp.

Generator Fan

Stator & Rotor Assy

Wire Harness Assy

Control Panel Case

Circuit Protector

Consent

Bolt M6×2

Earth Terminal Set

Voltmeter

Ignition Switch

Frame Comp

Bottom Rubber A

Bottom Rubber B

Flange Nut M8

Nut M6

Cushion, Frame

Bolt M6x2

Rubber Pad, Frame

Packing Ring

Connector

Pipe clamp

Outlet pipe Φ8.5×Φ4.5×500

Outlet pipe Φ12×Φ6×200

Outlet pipe Φ12×Φ8×60

Outlet Pipe Connector

Pipe clamp Φ12.5

Summary of Contents for 96898

Page 1: ...lusively 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 2007 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 e...

Page 2: ...HANICAL PRECAUTIONS 7 CHEMICAL PRECAUTIONS 7 NOISE PRECAUTIONS 8 ELECTRICAL PRECAUTIONS 8 Grounding 8 PRODUCT FEATURES 12 INSTALLATION INSTRUCTIONS 13 Grounding The Generator 13 PRE START INSTRUCTIONS 14 To Add Engine Oil 14 OPERATING INSTRUCTIONS 15 To Start The Engine Generator 15 To Connect Electrical Loads 15 INSPECTION MAINTENANCE AND CLEANING 17 Troubleshooting 19 PARTS LIST 20 Assembly diag...

Page 3: ... 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 al...

Page 4: ...eight 98 Pounds The Emission Control System for this 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 last pages of this manual GENERAL SAFETY RULES This product requires oil and fuel to be added before starting Attempting to start the Engine without oil WILL ruin the ...

Page 5: ...roper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear eye protection Always wear ANSI approved safety impact goggles and hearing protection when using this product TOOL USE AND CARE The Engine s Carburetor may need to be adjusted by a qualified mechanic for ef ficient high altitude use CAUTION This Generator is not intended to ...

Page 6: ...with low or no oil will permanently damage the unit Maintain labels and nameplates on the Generator These carry important infor mation If unreadable or missing contact Harbor Freight Tools for a replacement Make sure the Generator is located on a flat level sturdy surface capable of sup porting the weight of the Generator and any additional tools and equipment Industrial applications must follow O...

Page 7: ...tion is OFF Allow the Engine and Generator to complete ly cool Then remove the spark plug from the Engine Do not alter or adjust any part of the Generator or Engine that is assembled and supplied by the manufacturer Always follow and complete scheduled Generator and Engine maintenance CHEMICAL PRECAUTIONS Avoid contact with hot oil exhaust and solid surfaces Avoid body contact with fuels oils and ...

Page 8: ...et have a proper outlet installed by a qualified electrician Grounded Tools Tools with Three Prong Plugs Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing...

Page 9: ...n cord Double Insulated tools can use either a two or three wire extension cord As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Table A The smaller the gauge number of the wire the greater the capacity of the cord F...

Page 10: ...BLE A Based on limiting the line voltage drop to five volts at 150 of the rated amperes Symbology Double Insulated V Volts Alternating Current Canadian Standards Association A Amperes Underwriters Laboratories Inc n0 xxxx min No Load Revolutions per Minute RPM All connections and conduits from the Generator to the load must only be in stalled by trained and licensed electricians and in compliance ...

Page 11: ...d cut abraded or otherwise degraded Replace terminals that are worn discolored or corroded Keep terminals clean and tight Insulate all connections and disconnected wires Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Use only Class BC or Class ABC fire extinguishers on electrical fires MISC PRECAUTIONS People with...

Page 12: ...rent Ground Terminal Connect grounding wires here to properly ground unit 120 VAC Outlet Used to connect electrical devices that run 120 volt 60 Hz single phase AC current Voltage Selector Use to switch between 120 and 240 volt output Circuit Breaker Reset switch that protects the Generator from electrical over load 12 VDC Charging Terminal Use for charging 12 volt automotive type batter ies only ...

Page 13: ...ake sure the Gen erator s rated voltage wattage and amperage capacity is adequate to supply all electrical loads the unit will power If powering exceeds the Generator s capacity it may be necessary to group one or more of the tools equipment for connection to a separate Generator General Location Locate the Generator outdoors only where cool air is readily available Locate the Generator so that th...

Page 14: ...to first use Before each use check the oil level Never run the Engine with low or no oil Running the engine with low or no oil will permanently damage the Engine The Engine must be filled with a high quality grade engine oil If the Engine will be run in temperatures above 32 degrees Fahrenheit use SAE 30 weight oil If the Engine will be run in temperatures below 32 degrees Fahrenheit use SAE 5W 30...

Page 15: ...Engine Fuel Valve to the OPEN position Then turn the Engine Choke Lever to the CHOKE position Make sure the Engine Choke Lever is in the RUN position when starting a warm Engine No choke is required if the Engine is warm Turn the Engine Ignition to the RUN position Grasp the Starter Handle on the Recoil Starter and pull slowly until resistance is felt Allow the Rope to rewind slowly Then pull the ...

Page 16: ...apacity Note The starting and running wattage for resistant loads are the same Example a 100 Watt light bulb requires only 100 Watts to start Most resistant loads will be listed in wattage Always power the item that has the largest electric draw first Then plug in other appliances tools and equipment one at a time Connect inductive load appliances tools and equipment first Inductive loads consist ...

Page 17: ...nerator or Engine 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 oc curs have the problem corrected before further use Do not use damaged equipme...

Page 18: ...y a qualified service technician 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 NEI THER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIB...

Page 19: ...Page 19 SKU 96898 For technical questions please call 1 800 444 3353 Troubleshooting ...

Page 20: ... Cylinder Head Gasket 1 35 Cylinder Head Assembly 1 36 M8 34 Bolt 2 37 Spark Plug 1 Part Description Qty 38 Bolt 4 39 Cylinder Head Cover Gasket 1 40 Cylinder Head Cover Assembly 1 41 Crankcase Gasket 1 42 Set Pin 2 43 Bearing 6205 1 44 Crankshaft Oil Seal 1 45 Seal 2 46 Oil Dipstick 1 47 Oil Dipstick Assembly 1 48 Crankcase Cover 1 49 Dust Plate 1 50 Boltm6 12 1 51 M8 32 Bolt 7 52 M6 Nut 1 53 Reg...

Page 21: ...p Comp 1 105 Stator Cover 1 106 Stator Assy 1 107 Generator Stay 1 108 Brush Assy 2 109 Voltage Regulator 1 110 Bolt M5 14 3 111 Generator End Cover 1 112 Bolt M5 12 3 113 Flange Bolt M6 125 4 114 Bolt M8 180 1 115 Plain Washer 1 Part Description Qty 116 Bearing 6202 2rs 1 117 Rotor Comp 1 118 Generator Fan 1 119 Stator Rotor Assy 1 120 Wire Harness Assy 1 121 Control Panel Case 1 122 Circuit Prot...

Page 22: ...Page 22 SKU 96898 For technical questions please call 1 800 444 3353 Assembly diagram ...

Page 23: ...Page 23 SKU 96898 For technical questions please call 1 800 444 3353 assembly diagram continued ...

Page 24: ...nd United States Emission Control Defects Warranty Statement The CaliforniaAir Resources Board herein CARB the United States Environmental ProtectionAgency 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...

Page 25: ...n 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 o...

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