Chicago Electric 97906 Set Up, Operating, And Servicing Instructions Download

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2.5 hp 1,000 watt ohv

generator

Model

97906

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.

Diagrams within this manual may not be drawn proportionally.

Due to continuing improvements, actual product may differ slightly from the product described herein.

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.

2008 by Harbor Freight Tools

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

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

Summary of Contents for 97906

Page 1: ...uing improvements actual product may differ slightly from the product described herein 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 Copyright 2008 by Harbor Freight Tools All rights reserved No porti...

Page 2: ...d Type Batteries 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 Spark Plug Maintenance 14 Fuel Filter Replacement if equipped 15 Cleaning Maintenance and Lubrication Schedule 15 After Initial 20 Operation Hour Period 16 Every 25 Operation Hours Thereafter 16 Every 50 Operation ...

Page 3: ...ich 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 m...

Page 4: ...art 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 5: ...nt 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 Service precautions Before service maintenance or 1 cleaning Turn the engine switch to its a OFF position Allow the engine ...

Page 6: ...y power supply can back feed along the power lines and kill or injure utility workers working on the lines All connections from the Generator to 2 a load must be installed by a licensed electrician in compliance with all lo cal state and federal electrical codes and standards The generator must be grounded in 3 accordance with all relevant electrical codes and standards before opera tion Insulate ...

Page 7: ...conductive object Use only Class BC or Class ABC fire 3 extinguishers on electrical fires Do not overload the generator Over 4 loading can cause fires in the electri cal cords in addition to generator and appliance damage Service Keep all electrical equipment clean 1 and dry Replace any wiring where the insulation is damaged Replace terminals that are worn or corroded Keep terminals clean and tigh...

Page 8: ... damage to the engine and any other devices 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 ...

Page 9: ...nt be ing powered to reduce the length of extension cords Grounding Connect a 6 AWG grounding wire 1 not included from the Grounding Point 55a on the Generator to a grounding 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 adequately ground the Generator Only a trained and licensed electri cian should perform this p...

Page 10: ...ck 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 mark 3 add the appropriate type of oil until the oil level is between the high and the low marks Oil type 32 F or above SAE 10W30 Below 32 F SAE 5W30 Replace the Oil Dipstick 4 CAUTION Do not run the engine with too little or too much oil The engine will be permanently damaged ...

Page 11: ...ver to its RUN position IMPORTANT Allow the engine to run 7 at no load until warm 1 5 minutes with no load after each start up to al low the engine to stabilize Break in Period Breaking in the engine will help to 1 ensure proper equipment and engine operation and will extend the en gine s lifespan The warranty is void if the engine is not broken in properly The first 20 hours of operation is the b...

Page 12: ...n handling Installing an inline regulator is recom 5 mended before charging Lead acid batteries are hazardous 6 Follow all instructions safety precau tions and charging procedures in cluded with the battery Start the Generator with no loads 7 attached Connect the clamps on the Battery Charging Cord 1a to the battery to be charged first red clamp to positive terminal and black clamp to negative ter...

Page 13: ...ine Oil Type SAE 10W30 above 32 F SAE 5W30 at 32 F or below Capacity 0 42 Quarts Spark Plug Type E6TC DENSO W2OFP U Gap 0 6 0 7mm Valve Clearance Intake 0 15mm Exhaust 0 2mm Speed Maximum 3 600 RPM Mounting hole pattern mm mm M8 size thread hole 4 5 depth Shaft size type Servicing To prevent serious injury from accidental starting Turn the Power Switch of the equipment to its OFF position wait for...

Page 14: ...e proper level follow 4 ing the instructions under the Starting the Engine section Air Filter Element Maintenance Wipe off the air cleaner cover 1 The air cleaner cover is held in place 2 by a wing nut or clamps Remove it Remove the air filter element 3 Cleaning 4 For paper filter elements To prevent injury from dust and debris wear ANSI approved safety goggles NIOSH approved dust mask respirator ...

Page 15: ...d dust mask respirator and nitrile gloves Close fuel valve leading from gas 3 tank completely Take note of the fuel filter s orienta 4 tion Place a suitable container under the 5 fuel filter Disconnect the fuel lines leading to 6 and from the fuel filter and allow fuel to drain onto the container Install new fuel filter in the same 7 orientation Make sure to properly secure both fuel lines Clean u...

Page 16: ...ith a fuel stabilizer intended for long term engine stor age not included After filling run engine for about 5 10 minutes to cir culate the treated gasoline through the carburetor Wait for engine to cool before proceeding Clean out area around spark plug c Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole Reinstall spark plug but leave spark d plug wire ...

Page 17: ... and set choke to start position Clean or replace fuel filter 8 Ignition spark Related Spark plug wire not connected 1 securely Spark plug electrode wet or dirty 2 Incorrect spark plug gap 3 Spark plug wire or spark plug 4 broken Incorrect spark timing or faulty 5 ignition system Ignition spark Related Connect spark plug wire properly 1 Clean spark plug 2 Correct spark plug gap 3 Replace spark plu...

Page 18: ...asoline Test replace fuel tank cap 3 Properly adjust idle speed 4 Have qualified technician diagnose 5 and service engine Engine knocks Old or low quality gasoline 1 Engine overloaded 2 Incorrect spark timing deposit 3 buildup worn engine or other mechanical problems Fill fuel tank with fresh 89 octane 1 unleaded gasoline Do not exceed equipment s load 2 rating Have qualified technician diagnose 3...

Page 19: ... 50a Panel 1 51a Bolt M6x25 4 52a Power Switch 1 53a AC Circuit Protector 1 54a AC Outlet 2 55a Grounding Point 1 57a Battery Charging Socket 1 59a DC Circuit Protector 1 60a Rubber Gasket 1 61a Bracket for Capacitor 1 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 manufact...

Page 20: ...Page 20 SKU 97906 For technical questions please call 1 800 444 3353 ASSEMBLY DIAGRAM REV 09b ...

Page 21: ... Piston Ring Set 1 39 Piston 1 40 Piston Pin 1 41 Piston Pin Clip 18mm 2 42 Connecting Rod Assembly 1 43 Connecting Rod Assembly 1 44 Connecting Rod Assembly 2 45 Cylinder Head Gasket 1 46 Oil Seal 1 47 Flange Bolt M8x25 6 48 Dipstick 1 49 Crankcase Cover 1 50 Ball Bearing 6303 1 51 8x14 Dowel Pin 2 52 Case Cover Packing 1 53 Camshaft 1 Engine PARTS LIST Part Description Qty 54 Valve Lifter 2 55 C...

Page 22: ...Page 22 SKU 97906 For technical questions please call 1 800 444 3353 Engine diagram ...

Page 23: ...epaired 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 warran ty 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 Sy...

Page 24: ...e filed in accordance with the provi sions 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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