Chicago Electric 98706 Set Up, Operating, And Servicing Instructions Download Page 21

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Page 21

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

SKU 98706

Main parts list

REv 08g

part

Description

qty

Gasoline Engine

Front Cover

Flange Screw M8x25

Spring Washer 8

Washer 8

Rotor asm

Stator asm

Plain washer 8

Screw 7/16(24UNC)-210

10 Protection board

11 Rear cover

12 Carbon brush

13 5KW Automatic Voltage Regulator

14 Flange Screw M5x16

15 Connection pole

16 Screw M5

17 Spring Washer 5

18 Washer 5

19 Spring Washer 6

20 Toothed Washer 5

21 Flange Screw M6x130

22 Rear cover

23 Flange Screw M5x12

24 Exhaust Gasket

Muffler

26 Flange Screw M8

27 Frame

part

Description

qty

28 Shock Absorber

29 Shock Absorber

30 Flange Screw M6x12

31 Plain washer 6

32 Flange Screw M6

Grounding Wire (10cm) φ6+φ6

34 Toothed Washer 6

Muffler Hood (YAMA)

37 Control Panel Assembly

38 Flange Bolt M6x16

39 Fuel Tank (CARB Standard Black)

40 Fuel Marker

41 Fuel Tank Cap Assembly

42 Strainer

43 Fuel Tank Connector

44 Fuel Tank Cock Assembly

45 Carbon Box

46 Flange Screw M6x45

Fuel Pipe φ7.5*180mm

Fuel Pipe φ4.5*300mm

Fuel Pipe φ7.5*380mm

Fuel Pipe φ4.5*200mm

Clamp φ8

Clamp φ13

Clamp φ8

54 Shock Absorber

Summary of Contents for 98706

Page 1: ...r 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 Manual Revised 09g 09j Using an engine in...

Page 2: ... 16 After Initial 20 Operation Hour Period 16 Every 25 Operation Hours Thereafter 16 Every 50 Operation Hours 16 Every 100 Operation Hours 16 Every 300 Operation Hours 16 Storage 16 Engine Troubleshooting 18 Equipment Troubleshooting 20 Main Parts List 21 Main Assembly Diagram 22 Parts List and Diagram A Crankcase Assembly 23 Parts List and Diagram B Cylinder Head Assembly 24 Parts List and Diagra...

Page 3: ...t 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 lis...

Page 4: ...ction during use People with pacemakers should 5 consult their physician s before use Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure Caution is necessary when near the engine s magneto or recoil starter Use only accessories that are 6 recommended by Harbor Freight Tools for your model Accessories that may be suitable for one p...

Page 5: ...ment and do not use the equipment for a purpose for which it is not intended CAUTION 21 This generator is not intended to power sensitive electronic equipment without the addition of an appropriate line conditioner and surge protector both not included Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators If the plugged in product opera...

Page 6: ...rking order Safety guards include muffler air cleaner mechanical guards and heat shields among other guards Do not alter or adjust any part of the 3 equipment or its engine that is sealed by the manufacturer or distributor Only a qualified service technician may adjust parts that may increase or decrease governed engine speed Wear ANSI approved safety goggles 4 heavy duty work gloves and dust mask...

Page 7: ...A If you are using one extension cord 5 for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Table A If you are using an extension cord 6 outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use Make sure the extension cord is 7 properly wired and in good electrical condition Always repl...

Page 8: ... altitudes the engine s carburetor governor if so equipped and any other parts that control the fuel air ratio will need to be adjusted by a qualified mechanic to allow efficient high altitude use and to prevent damage to the engine and any other devices used with this product Functions This unit can power items such as the following ITEM RUNNING WATTS START UP WATTS Belt Sander 1200 2400 Refriger...

Page 9: ... Plug for up to 20A Figure 1 Plug for up to 15A 120V Duplex Receptacle for 15A or 20A plugs Engine Power Switch Power Indicator Light AC Circuit Breaker Switch 120 V Duplex Receptacle 120 V Twist Lock Receptacle AC Reset Switch DC Circuit Breaker Switch Ground Wire Connection 12 VDC Outlet MAIN BREAKER 20A RESET 120V AC OUTLETS ONLY ...

Page 10: ...o not run the engine with low or no engine oil Running the engine with no or low engine oil WILL permanently damage the engine Check the oil level with the engine stopped and in a level position Wipe dipstick exterior with a clean 1 cloth Remove the dipstick and wipe it off with a clean rag Pour engine oil into the oil fill hole until the level of oil is even with the bottom edge of the oil fill h...

Page 11: ...line mixture Then replace the Fuel Tank Cap 6 Start Procedure Before starting the engine Inspect the equipment and a engine Fill the engine with the b proper amount and type of fuel and oil Read the Equipment c Operation section that follows Unplug loads from the Generator and 1 make sure the AC Circuit Breaker switch is in the OFF position before starting to prevent permanent generator damage Tur...

Page 12: ...rly 1 grounded to avoid electrical shocks Connect a 10 gauge or larger insulated copper wire to the Ground Connection on the Control Panel Connect this wire to a suitable external ground such as a metal stake in the ground Don t overload the generator The 2 total wattage used by the appliances should be less than the output rating of the generator If you put too many appliances on the generator it...

Page 13: ... the 8 generator before shutting off To prevent accidents turn off the engine and disconnect its spark plug wire after use Wait for the engine to cool clean external parts with clean cloth then store the equipment out of children s reach according to the Storage instructions in this manual Control Panel Features Engine Power Switch must be in ON 1 position for engine to start and run Move to OFF p...

Page 14: ...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 ability to safely service the equipment or engine have a qualified technician service the equipment instead Note Warranty is void if proper mainten...

Page 15: ...k plug wrench remove 2 the spark plug Inspect the spark plug 3 If the electrode is oily clean it using a clean dry rag If the electrode has deposits on it polish it using emery paper If the white insulator is cracked or chipped the spark plug needs to be replaced When installing a new spark 4 plug adjust the plug s gap to the specification on the Technical specification chart Do not pry against th...

Page 16: ... 50 and 100 operation hours should be performed at least yearly Every 300 Operation Hours Clean fuel tank and carburetor a Clean carbon build up from b combustion chamber Check oil tube condition and replace c as needed 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 Change...

Page 17: ...eated gasoline will deteriorate quickly Place a container below the carbure a tor bowl and drain the fuel from the fuel tank and carburetor bowl Discard the drained fuel properly as b per local ordinance Change to fresh fuel if untreated c gasoline has been sitting for a month if treated gasoline has been sitting beyond the fuel stabilizer s recommended time period or if the engine does not start ...

Page 18: ...1 tolerances repair or replace as needed Check compression replace as 2 needed Check wear tolerances repair or 3 replace as needed Problem Engine does not start or does not run smoothly See chart below Symptom Possible Cause Possible Solution Engine is Pinging Excess wear of Piston Cylinder Wall or Rings Piston Pin or Piston Pin Hole Connecting Rod Wrist Pin Crankshaft Roller Bearing Check wear re...

Page 19: ...plug wire 4 replace as needed Check coil continuity and output 5 Mechanical problem Engine Piston Piston Rod Valve 1 or Crankshaft may be damaged Generator Shaft may be seized 2 Have serviced by a qualified 1 technician Disconnect engine and attempt to 2 rotate generator shaft by hand Repair or replace as needed Problem Engine runs excessively hot See chart below Problem Possible Cause Possible So...

Page 20: ...ician No or not enough power at the AC outlets AC Breaker switch in the OFF 1 position AC circuits overloaded 2 Reset the Breaker Switch to the ON 1 position Disconnect some appliances to 2 reduce the load No power at the 12 VDC outlet DC Breaker Switch open Disconnect the 12 Volt appliance then press the 12 VDC breaker switch IN Reconnect the 12 V accessory Follow all safety precautions whenever ...

Page 21: ...2 Rear cover 1 23 Flange Screw M5X12 2 24 Exhaust Gasket 1 25 Muffler 1 26 Flange Screw M8 18 27 Frame 1 Part Description Qty 28 Shock Absorber 4 29 Shock Absorber 4 30 Flange Screw M6X12 10 31 Plain washer 6 4 32 Flange Screw M6 10 33 Grounding Wire 10cm φ6 φ6 1 34 Toothed Washer 6 1 35 Muffler Hood YAMA 1 36 Muffler Hood YAMA 1 37 Control Panel Assembly 1 38 Flange Bolt M6X16 4 39 Fuel Tank CARB...

Page 22: ...Page 22 For technical questions please call 1 800 444 3353 SKU 98706 Main Assembly Diagram REV 08g REV 09g ...

Page 23: ...lt m8 x 33 5 6 NOTE Not all engine sub assembly components shown on the following pages are available as separate replacement parts They may be shown for informational purposes only NOTE All part numbers listed on the following pages have a letter suffix For example the Crankcase Cover shown in the above diagram is part 12a Whenever refer ring to engine sub assembly parts be sure to include the co...

Page 24: ...et 1 b 4 Valve Rocker Assembly 1 b 5 Push Guide 1 b 6 Cap 1 b 7 Exhaust Spring Seat 1 b 8 Intake Spring Seat 1 b 9 Valve Spring 2 b 10 Bolt m 8 x 60 4 b 11 Stud AM 8 x 34 2 Part Description QTY b 12 Cylinder Head Assembly 1 b 13 Cylinder Head Gasket 1 b 14 Set Pin 2 b 15 Exhaust Valve 1 b 16 Intake Valve 1 b 17 Tappet 2 b 18 Pusher 2 b 19 Stud AM 6 x 112 2 b 20 Lead Wind Cover 1 b 21 Oil Pipe Seal...

Page 25: ...ting Rod Camshaft and Flywheel Assemblies Part Description QTY c 1 Piston Ring Set 1 c 2 Piston Ring Circlip 2 c 3 Piston 1 c 4 Piston Pin 1 c 5 Connecting Rod Assembly 1 c 6 Crankshaft Assembly 1 Part Description QTY c 7 Camshaft Assembly 1 c 8 Flywheel 1 c 9 Flywheel Fan 1 c 10 Starting Flange 1 c 11 Nut m 14 x 1 5 1 ...

Page 26: ... Ignition Coil Assembly Part Description QTY d 1 Engine Switch 1 d 2 Fan Hood 2 d 3 Bolt m 6 x 12 5 d 4 Bolt m 6 x 8 4 d 5 Recoil Starter Assembly 1 d 6 Complete Shroud 1 Part Description QTY d 7 Diode 1 d 8 Oil Sensor 1 d 9 Bolt m 6 x 14 2 d 10 Bolt m 6 x 22 2 d 11 Ignition Coil Assembly 1 d 12 Spark Plug F6TC 1 ...

Page 27: ... 3353 SKU 98706 Parts List and Diagram E Air Cleaner and Muffler Assembly Part Description QTY e 1 Air Cleaner Assembly 1 e 2 Nut m6 2 e 3 Bolt m6 x 22 1 e 4 Air Duct 1 Part Description QTY e 5 Exhaust Muffler Assembly 1 e 6 Exhaust Gasket 1 e 7 Nut m8 2 ...

Page 28: ...lt m6 x 28 1 f 4 Connector 1 f 5 Nut m6 2 f 6 Filter Cup 1 f 7 Fuel Tank Cap 1 f 8 Fuel Tank 1 f 9 Inlet Gasket 1 f 10 Connecting Block 1 Part Description QTY f 11 Carburetor Gasket 1 f 12 Carburetor Assembly 1 f 13 Air Cleaner gasket 1 f 14 Regulating Control Assembly 1 f 15 Back Spring 1 f 16 Regulating Spring 1 f 17 Pulling Rod 1 f 18 Lock Bolt 1 f 19 Regulating Arm 1 f 20 Nut m6 1 ...

Page 29: ...Parts List and Diagram G Starter and Generator Assembly Part Description QTY g 1 Starting Motor Assembly 1 g 2 Bolt m6 x 28 1 g 3 Bolt m6 x 32 1 g 4 Crankcase 1 g 5 Charge Coil 1 Part Description QTY g 6 Bolt m6 x 35 2 g 7 Clamper Cord 1 g 8 Bolt m6 x 12 2 g 9 Flywheel 1 ...

Page 30: ...Page 30 For technical questions please call 1 800 444 3353 SKU 98706 Wiring Diagram REV 08g ...

Page 31: ...red 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 ...

Page 32: ...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 o...

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Chicago Electric 98706, Set Up, Operating, And Servicing Instructions

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