Chicago Electric 96898 Installationshandbuch

Page 1SKU 96898 For technical questions, please call 1-800-444-3353.

3500 WATT GASOLINE

GENERATOR

Model

96898

SET UP AND OPERATING INSTRUCTIONS

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.

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.

Page 2SKU 96898 For technical questions, please call 1-800-444-3353.

CONTENTS

IMPORTANT SAFETY INFORMATION ............................ 3

PRODUCT SPECIFICATIONS ..........................................4

GENERAL SAFETY RULES.............................................4

WORK AREA......................................................................... 4

PERSONAL SAFETY ........................................................... 5

TOOL USE AND CARE ......................................................... 5

SERVICE ............................................................................... 6

SPECIFIC SAFETY RULES..............................................6

FIRE AND EXPLOSION PRECAUTIONS ............................. 6

MECHANICAL 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 DIAGRAM.................................................... 22

LIMITED 1 YEAR / 90 DAY WARRANTY ........................24

EMISSION CONTROL SYSTEM WARRANTY................ 24

Page 3SKU 96898 For technical questions, please call 1-800-444-3353.

SAVE THIS MANUAL

Keep this manual for the safety warnings and precautions, assembly, operating,

inspection, maintenance and cleaning procedures. Write the product’s serial number

in the back of the manual near the assembly diagram (or month and year of purchase if

product has no number). Keep this manual and the receipt in a safe and dry place for

future reference.

IMPORTANT SAFETY INFORMATION

In this manual, on the labeling, and all other information

provided with this product:

This is 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 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.

DANGERDANGER

WARNINGWARNING

CAUTIONCAUTION

NOTICENOTICE

CAUTIONCAUTION

Page 4SKU 96898 For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

Electrical Requirements Alternator Type: Single Phase, Brushless

Output: 3000W Rated / 3500W Peak

Rated Voltage: 120 VAC, 25 Amp / 240 VAC, 12.5 Amp / 60 Hz

AC Receptacles: 120 VAC, 3-Prong Grounding Plug (Qty. 2)

240 VAC, 4-Blade Twistlock Plug (Qty. 1) – NEMA L14-30

DC Receptacle: 12 VDC Output Terminal with Cap Screws (Qty 1)

Circuit Breaker: 13 Amp

Overload Protection: Resettable Circuit Protection

Engine Specications Engine Type: 4-Stroke, Overhead Valve, Single Cylinder, Recoil

Engine Displacement: 196cc

Engine Speed: 3600 RPM

Oil Capacity: 20 Fluid Ounces

Fuel Type: Unleaded Gasoline

Fuel Capacity: 3.96 Gallons

Recommended Oil Type: F-SAE 30W (Above 32°)

F-SAE 5W-30W (Below 32°)

Run Time: 15 Hours Continuous Run Time on Full Tank @ 50% Load

EPA/CARB Certied (Phase II, Category A)

Overall Dimensions 21-1/2” Long x 16-3/4” Wide x 17-1/2” High

Net Weight 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 Engine and void the warranty.

WARNING! Read all instructions

Failure to follow all instructions listed below may result in electric shock,

re, and/or serious injury. The term “power tool” in all of the warnings listed

below refers to your Gasoline Generator.

SAVE THESE INSTRUCTIONS

WORK AREA

Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

Do not operate power tools in explosive atmospheres, such as in the

presence of ammable liquids, gases, or dust. Power tools create sparks

which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while operating a power tool. Dis-

tractions can cause you to lose control. Provide barriers or shields as needed.

Page 5SKU 96898 For technical questions, please call 1-800-444-3353.

PERSONAL SAFETY

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 inuence of drugs,

alcohol, or medication. A moment of inattention while operating power tools may

result in serious personal injury.

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.

Avoid accidental starting. Be sure the Engine Ignition is “OFF” before moving the

Generator and before performing any service, maintenance, or cleaning proce-

dures on the unit.

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 per-

sonal injury.

Do not overreach. Keep proper footing and balance at all times. Proper 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 qualied mechanic for ef-

cient high-altitude use.

CAUTION! This Generator is not intended to power sensitive electronic equip-

ment without the addition of an appropriate line conditioner (sold separately).

Do not force the tool. Use the correct tool for your application. The correct tool

will do the job better and safer at the rate for which it is designed.

Do not use the Generator if the Engine’s Ignition does not turn it on or off. Any

tool that cannot be controlled with the power switch is dangerous and must be

replaced.

Store idle tools out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

Maintain tools with care. Properly maintained tools are less likely to malfunction

and are easier to control. Do not use a damaged tool. Tag damaged tools “Do

not use” until repaired.

Page 6SKU 96898 For technical questions, please call 1-800-444-3353.

Check for misalignment or binding of moving parts, breakage of parts, and any

other condition that may affect the tool’s operation. If damaged, have the tool

serviced before using. Many accidents are caused by poorly maintained tools.

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 tool.

SERVICE

Have your Gasoline Generator serviced by a qualied repair person using only

identical replacement parts. This will ensure that the safety of the Gasoline Gen-

erator is maintained.

SPECIFIC SAFETY RULES

WARNING! Your Warranty is voided if you do not put engine oil in the

Engine’s crankcase prior to the rst use. Before each use, check the oil level.

Never run the Engine with low or no engine oil. Running the Engine 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 at, level, sturdy surface capable of sup-

porting the weight of the Generator and any additional tools and equipment.

Industrial applications must follow OSHA guidelines.

Never stand on the Generator. Serious injury could result if the Generator falls.

Never leave the Generator unattended when it is running. Turn off the Engine

before leaving.

Do not allow children and other unauthorized people to handle or play with the

Generator.

Do not force the Generator. This tool will do the work better and safer at the

speed and capacity for which it was designed.

FIRE AND EXPLOSION PRECAUTIONS

Gasoline fuel and fumes are ammable, and potentially explosive. Use proper

fuel storage and handling procedures. Always have multiple ABC class re extin-

guishers nearby.

Keep the Generator, Engine, and the surrounding area clean at all times.

Page 7SKU 96898 For technical questions, please call 1-800-444-3353.

Clean fuel or oil spills up immediately. Dispose of uids and cleaning materials

as per any local, state, or federal codes and regulations. Store oil rags in a bot-

tom-ventilated, covered metal container.

Never store fuel or other ammable materials near the Generator.

Do not smoke, or allow sparks, ames, or other sources of ignition around the

Generator.

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.

Do not rell 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.

Use only recommended fuel and oil.

MECHANICAL PRECAUTIONS

Prior to performing service, maintenance, or cleaning procedures, always make

sure the Engine’s Ignition 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 lubricants used in the Generator and

Engine. If swallowed, seek medical treatment immediately. Do not induce vomit-

ing if fuel is swallowed. For skin contact, immediately wash with soap and water.

For eye contact, immediately ush eyes with clean water.

This Generator is designed for outdoor use only. Do not operate the

Generator in a closed area or in a poorly ventilated area. When

running, the Engine of this Generator produces carbon monoxide, a

colorless, odorless, toxic fume that, when inhaled, can cause serious

personal injury or death. Whenever possible, use a carbon monoxide detector

(not included) to detect excessive carbon monoxide fumes in the work area and

in the surrounding area.

Page 8SKU 96898 For technical questions, please call 1-800-444-3353.

NOISE PRECAUTIONS

Prolonged exposure to high noise levels is hazardous to hearing. Always wear

ANSI approved hearing protection when operating or working around the Gen-

erator when it is running.

ELECTRICAL PRECAUTIONS

GROUNDING

Improperly connecting the grounding wire can result in

electric shock.

Check with a qualied electrician if you are in doubt as to

whether the outlet is properly grounded. Do not modify

the power cord plug provided with the tool. Never remove

the grounding prong from the plug. Do not use the tool if

the power cord or plug is damaged. If damaged, have it

repaired by a service facility before use. If the plug will not

t the outlet, have a proper outlet installed by a qualied

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 the risk of electric

shock. (See 3-Prong Plug and Outlet.)

The grounding prong in the plug is connected through the green wire inside the

cord to the grounding system in the tool. The green wire in the cord must be the

only wire connected to the tool’s grounding system and must never be attached

to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)

The tool must be plugged into an appropriate outlet, properly installed and

grounded in accordance with all codes and ordinances. The plug and outlet

WARNINGWARNING

Page 9SKU 96898 For technical questions, please call 1-800-444-3353.

should look like those in the following illustration.

(See 3-Prong Plug and Outlet.)

3-Prong Plug and Outlet Outlets for 2-Prong Plug

Double Insulated Tools: Tools with Two Prong Plugs

Tools marked “Double Insulated” do not require grounding. They have a special

double insulation system which satises OSHA requirements and complies with

the applicable standards of Underwriters Laboratories, Inc., the Canadian Stan-

dard Association, and the National Electrical Code.

(See Outlets for 2-Prong Plug.)

Double insulated tools may be used in either of the 120 volt outlets shown in the

preceding illustration. (See Outlets for 2-Prong Plug.)

Extension Cords

Grounded tools require a three wire extension 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.

For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Table A.)

When using more than one extension cord to make up the total length, make

sure each cord contains at least the minimum wire size required. (See Table A.)

If you are using one extension cord 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 outdoors, make sure it is marked with the suf-

x “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

Page 10SKU 96898 For technical questions, please call 1-800-444-3353.

Make sure the extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualied elec-

trician before using it.

Protect the extension cords from sharp objects, excessive heat, and damp or wet

areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD LENGTH

25 Feet 50 Feet 75 Feet 100 Feet 150 Feet

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

TABLE A * Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.

Symbology

Double Insulated V~ Volts Alternating Current

Canadian Standards Association AAmperes

Underwriters Laboratories, Inc. n0xxxx/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 with all relevant

local, state, and federal electrical codes and standards, and other regulations.

The Generator must be earth-grounded in accordance with all relevant electrical

codes and standards before operation.

If an extension cord (not included) is used, make sure to use only UL listed cords

having the correct gauge and length.

Do not attempt to connect or disconnect load connections while standing in wa-

ter, or on wet or soggy ground.

10.

11.

12.

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