Chicago Electric 98391 Set Up, Operating, And Servicing Instructions Download Page 23

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SKU 98391

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

Page 23

cYlinDer BlocK

asseMBlY parts list

part

Description

qty

Drain Plug

Drain Plug Gasket

Oil Seal 35x50x10

Cylinder Block

Fuel Controller

O-ring 24x24

Oil Depth Gauge

Needle Bearing

Short Stud Plate

10A Long Stud Plate

11A Fuel Injection Pump Gasket

12A Seal Gasket

13A Seal Plate

14A Nut M6

15A Retainer

16A Washer 8

17A Bolt M8x12

18A Needle Bearing

19A Short Cylinder Head Stud

20A Cylinder Head Washer

21A Short Cylinder Head Nut

cYlinDer BlocK

asseMBlY parts list

part

Description

qty

22A Cylinder Head Gasket

23A Long Cylinder Head Nut

24A Long Cylinder Head Stud

25A Ring

26A Crank Case Gasket

27A Ball Bearing

28A Main Bearing

29A Pin 8x12

30A Crank Case Cover

31A Oil Seal

32A Bolt M8x34

33A Plug

34A Plunger

36A Bolt M6x14

37A Air Shroud

38A Air Shroud Collar

39A Shock Absorber

40A Shock Absorber Seat

41A Flat Washer 8mm

42A Spring Washer 8mm

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.

Summary of Contents for 98391

Page 1: ...lo 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 FreightTools Diagramswithinthi...

Page 2: ...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 M...

Page 3: ...0 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 ...

Page 4: ...hich 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 fire serious injury and or DEATH The warnings and precautions discussed in this ...

Page 5: ...eart 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...

Page 6: ...akage 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 20 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 water 21 after handling diesel f...

Page 7: ...n back feed along the power lines and kill or injure utility workers working on the lines Do not charge vehicle batteries with 13 this Generator Maintain labels and nameplates on 14 the equipment These carry impor tant information If unreadable or missing contact Harbor Freight Tools for a replacement Have the equipment serviced by a 15 qualified repair person using only identical replacement part...

Page 8: ...ction 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 Opera...

Page 9: ...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 ...

Page 10: ...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 equipme...

Page 11: ...fuel to bleed 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 ...

Page 12: ...ion Rotate the Control Handle 13 to the 4 right until release button on the Right hand side of the Handle Bracket 12 pops up and locks in place Insert the en 5 gine key into the ignition and turn it to START position for up to 10 sec onds Note To prolong starter 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...

Page 13: ...14 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 ...

Page 14: ...SKU 98391 For technical questions please call 1 800 444 3353 Page 14 Mounting Hole Pattern ...

Page 15: ...SKU 98391 For technical questions please call 1 800 444 3353 Page 15 Shaft Size Type ...

Page 16: ...e or cleaning procedures To prevent 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 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 abilit...

Page 17: ...or engine to cool completely 1 before proceeding Wear protective gear including ANSI 2 approved safety goggles Turn the fuel valve to the off posi 3 tion Unscrew the bolt holding the fuel filter 4 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 Remove the fuel filter cup and the 5 filter element Clean t...

Page 18: ...hours should be performed at least yearly Every 250 Operation Hours Clean fuel tank a Clean carbon build up from combus b tion chamber Replace the air filter c Every 500 Operation Hours Clean fuel tank and fuel filter a Storage Wait for engine to cool then clean 1 engine with clean cloth When the equipment is to remain idle 2 for longer than 20 days prepare the engine for storage as follows Wait f...

Page 19: ...generator to a level 7 surface to prevent low oil shutdown from triggering Disconnect load 8 Change air filter 9 Replace battery 10 Black smoke from exhaust Generator overloaded 1 Oil in cylinder 2 Contaminated diesel fuel 3 Fuel injection malfunction 4 Clogged air filter 5 Improper setting for specific altitude 6 Reduce load 1 Check oil level and drain excess 2 from crankcase Treat engine with bi...

Page 20: ...ogged carburetor or overheated engine Fill fuel tank with fresh 2 diesel 1 fuel Use cold weather fuel and oil 2 additives to prevent backfiring Qualified technician must adjust 3 engine at altitudes greater than 5 000 feet above sea level Have qualified technician diagnose 4 and service engine AC output but no DC output Fuse burnt out 1 Replace Fuse 1 Every time fuel system is serviced replace the...

Page 21: ...el 1 42 Rear Panel 1 43 Right Panel 1 44 Air Cleaner Cover Plate 1 45 Electric Panel 1 46 Fuel Gauge 1 47 Fuel Tank 1 48 Fuel Valve Assembly 1 49 Injector Decompressor Access Door 1 50 Securing Flex Screws M10x25 4 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...

Page 22: ...SKU 98391 For technical questions please call 1 800 444 3353 Page 22 Main ASSEMBLY DIAGRAM 39 49 50 Note Wheels and Handles not shown ...

Page 23: ...d 2 20A Cylinder Head Washer 4 21A Short Cylinder Head Nut 2 Cylinder Block Assembly PARTS LIST Part Description Qty 22A Cylinder Head Gasket 1 23A Long Cylinder Head Nut 2 24A Long Cylinder Head Stud 2 25A Ring 1 26A Crank Case Gasket 1 27A Ball Bearing 1 28A Main Bearing 1 29A Pin 8x12 2 30A Crank Case Cover 1 31A Oil Seal 1 32A Bolt M8x34 16 33A Plug 1 34A Plunger 3 36A Bolt M6x14 1 37A Air Shr...

Page 24: ...1 800 444 3353 Page 24 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 41A 42A ...

Page 25: ...Head 1 3B Intake Valve 1 4B Exhaust Valve 1 5B Silencer 1 6B Pin 4x8 1 7B Valve Spring Washer 2 8B Valve Spring 2 9B Spring Retainer 2 10B Valve Screw 2 11B Nut M6 2 12B Rocker Arm Bolt 1 13B Exhaust Valve Rocker Arm 1 14B Rocker Arm Support 1 Cylinder head assembly PARTS LIST diagram Part Description Qty 15B Rocker Arm Shaft 1 16B Intake Valve Rocker Arm 1 17B Valve Adjusting Plate 2 18B Cotter 4...

Page 26: ...1 9 1 11C Bolt M6x70 2 CYLINDER HEAD BONNET PARTS LIST diagram Part Description Qty 12C Pin 3x16 1 13C Plunger 2 14C Decompression Wire Collar 1 15C Decompression Wire 1 16C Decompression Handle 1 17C Decompression Handle Support 2 18C Washer 6 2 19C Bolt M6x15 3 20C Decompression Handle Bushing 2 21C Nut M6 1 Note Use the suffix C when ordering parts for this assembly Note Some parts are listed a...

Page 27: ...1 5D Piston Pin 1 6D Washer 23 1 7D Rod Bolt 2 Piston connecting rod PARTS LIST diagram Part Description Qty 8D Connecting Rod Body 1 9D Rod Nut 2 10D Pin 3x10 2 11D Connecting Rod 1 12D Rod Bolt Washer 2 13D Crank Pin Bearing 2 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 repl...

Page 28: ...Plug 6 1 8E Key 5x12 1 9E Key 5x14 1 Crank shaft flywheel PARTS LIST diagram Part Description Qty 10E Key 6x50 1 11E Flywheel 1 12E Flywheel Gear 1 13E Flywheel Washer 1 14E Flywheel Nut 1 15E Starter Pulley 1 16E Bolt M6x12 4 17E Ball Bearing 1 18E Balancer Gear 1 Note Use the suffix E when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and ar...

Page 29: ...1G Push Rods 2 2G Valve Tappet 2 3G Camshaft Timing Gear 1 Camshaft assembly PARTS LIST diagram Part Description Qty 4G Key 5x14 1 5G Camshaft 1 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 ...

Page 30: ...Element Bolt 1 6H Nut M6 3 7H Air Cleaner Element 1 Air cleaner assembly PARTS LIST diagram Part Description Qty 8H Element Shock Absorber 1 9H Shock Absorber Washer A 1 10H Ring 1 11H Air Cleaner Shock Absorber 1 12H Nut M8 1 13H Washer 8 1 14H Air Cleaner Cover 1 Note Use the suffix H when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and ar...

Page 31: ...tator 1 5J Inner Rotator 1 6J Oil Pump Shaft 1 Oil System PARTS LIST diagram Part Description Qty 7J Pin 3x16 1 8J Oil Pump Gear 1 9J Oil Filter 1 10J O ring 1 11J Bolt M6x14 1 12J Intake Pipe 1 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 ...

Page 32: ...Valve 1 7K O ring 1 8K Pump Body 1 9K Plunger 1 10K Shim Set 1 Fuel injection pump PARTS LIST diagram Part Description Qty 11K Pin 2x6 2 12K Packing 1 13K Control Lever 1 14K Snap Ring 1 15K Pin 3x8 1 16K Spring Seat 2 17K Pump Spring 1 18K Spring Seat 1 19K Tappet Note Use the suffix K when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes only and ar...

Page 33: ...t 1 3M Nozzle Holder Spring 1 4M Spring Retainer 1 FUEL NOZZLE PARTS LIST DIAGRAM Part Description Qty 5M Stop Plate 1 6M Pin 2 7M Nozzle Valve 1 8M Nozzle Case Nut 1 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 ...

Page 34: ...N Bolt M6x20 1 9N Nut M10x1 25 1 10N Cover 1 11N Spring 1 GOVERNOR CONTROL SYSTEM PARTS LIST DIAGRAM Part Description Qty 12N Handle Bracket 1 13N Control Handle 1 14N Bracket 1 15N Pin 3x22 2 16N Lever Fork 1 17N Lever Shaft 1 18N Washer 3 19N Seal 1 20N Tappet 1 21N Fly Block 2 22N Fly Block Pin 2 Note Use the suffix N when ordering parts for this assembly Note Some parts are listed and shown fo...

Page 35: ...1 9P Fuel Tank Cock 1 10P Bolt M6x14 2 Fuel tank and pipe PARTS LIST diagram Part Description Qty 11P Fuel Oil Return Pump 1 12P Clamp 2 13P Fuel Tank Damper 4 14P Bolt M6x30 4 15P Fuel Oil Filter 1 16P Fuel Cap Gasket 1 17P Fuel Tank Cap 1 18P Fuel Cap 1 19P Fuel Feed Pipe 1 Note Use the suffix P when ordering parts for this assembly Note Some parts are listed and shown for illustration purposes ...

Page 36: ...ses only and are not avail able individually as replacement parts Starting motor PARTS LIST diagram Part Description Qty 1T Alternator 1 2T Bolt M6x30 3 3T Screw M6x12 3 4T Bolt M8x12 1 5T Clamp 1 Starting motor PARTS LIST diagram Part Description Qty 6T Regulator 1 7T Starting Motor 1 8T Bolt M10x35 2 9T Washer 10 2 10T Note Use the suffix T when ordering parts for this as sembly Note Some parts ...

Page 37: ...r 1 10U Stator Assembly 1 11U Rear Cover 1 Generator PARTS LIST Diagram Part Description Qty 12U Flange Bolt M8x125 4 13U Plate 1 14U Flat Washer 2 15U Spring Washer 2 16U Bolt M6x16 2 17U Washer 8 18U Bolt M6x16 4 19U Washer 1 20U Bolt M10x250x1 25 1 21U End Cover 1 22U Bolt M6x10 2 Note Use the suffix U when ordering parts for this assembly Note Some parts are listed and shown for illustration p...

Page 38: ...10W Rectifier 1 Control panel PARTS LIST diagram Part Description Qty 11W DC Circuit Breaker 1 12W Bolt M4x20 2 13W Faceplate 1 14W Nut M6 2 15W Terminal 2 16W Screw M5x20 4 17W Oil Warning Light 1 18W Screw M5x20 1 19W Voltmeter 1 20W Engine Switch 1 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 ab...

Page 39: ...SKU 98391 For technical questions please call 1 800 444 3353 Page 39 Wiring diagram REV 09a Circuit Breaker ...

Page 40: ... 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 advantag...

Page 41: ...e Department at 1 800 444 3353 Harbor Freight Tools Emission Control Defects Warranty Provisions 1 Length of Coverage 1 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 No Charge Repa...

Page 42: ...eaner ii 3 Ignition System Spark plug i Magneto ignition system ii 4 Catalyst System if so equipped Exhaust pipe stud i Muffler ii Catalytic converter if so equipped iii 5 Miscellaneous Items Used in Above Systems Vacuum temperature and time sensitive valves i and switches Hoses belts connectors and assemblies ii REV 09a ...

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