Chicago Electric 42726, 39984, 40423, 40827, 42723 User Manual

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Chicago Electric 42726, 39984, 40423, 40827, 42723 User Manual

GENERATOR USER

MANUAL

Model Numbers 39461 42723 39982 42724 39984 42725 40423 42726 40814 42727 40827 42728

MODEL & SERIAL NUMBER

Enter the Model and Serial numbers of your generator in the spaces provided below. Retain these numbers for future reference. The Model and Serial numbers are located on the generator data plate on the alternator case or generator frame, along with other important information.

Model Number

Serial Number

DOCCHI0011

1

6/14/00 Rev. 1

 

LIMITED 1 YEAR WARRANTY STATEMENT

Harbor Freight Tools makes every effort to assure that it's Chicago Electric products meet high quality and durability standards, and warrants that this product is free from defects in materials and workmanship for the following periods (from the date of purchase): For 1 year: All generator components.

Note: If this product is used by a professional contractor, we warrant that this product is free from defects in materials and workmanship for a period of 90 days (from the date of purchase). This limited warranty does not cover components or assemblies manufactured by other companies, including, but not limited to: engine, alternator, receptacles, etc. Warranties for all items not manufactured by Harbor Freight Tools are covered under the warranties of the respective manufacturers of those products.

This limited warranty extends only to the original purchaser of the product and is not assignable or transferable to any subsequent purchaser/end user.

This warranty does not apply to damage to the product, or to injuries or death to persons or property due directly or indirectly to abnormal use, abnormal conditions, improper storage, misuse, neglect, abuse, accident, repairs or alterations outside our facilities, lack of maintenance, or other acts which are not the fault of Harbor Freight Tools.

Any implied warranty of merchantability, or fitness for a particular purpose of use, shall be limited to the duration of the foregoing written warranty, otherwise, the foregoing warranty is the purchaser's sole and exclusive remedy and in lieu of all other warranties, express or implied. Harbor Freight Tools shall not be liable for incidental or consequential damages or a loss of anticipated benefits or profits resulting from the purchase or use of the product or arising from the breach of the warranty even if Harbor Freight Tools knew of the likelihood of such damages.

Some states do not allow limitation of how long an implied warranty lasts, so the above limitation may not apply to you (the original purchaser). Some states do not allow the exclusion of incidental or consequential damages, so the above limitation or exclusions may not apply to you (the original purchaser).

To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election, or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired 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 storing, and returning the product.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

Harbor Freight Tools

3491 Mission Oaks Blvd., P.O. Box 6009, Camarillo, CA 93011

Telephone Number: (800) 444-3353

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Contents

 

LIMITED 1 YEAR WARRANTY STATEMENT .................................................................................................

2

SECTION 1........................................................................................................................................................

4

GENERAL INFORMATION .............................................................................................................................

4

SAFETY RULES..............................................................................................................................................

4

BATTERY SAFET Y.........................................................................................................................................

4

GENERAL SAFETY OPERATIONAL GUIDELINES..........................................................................................

5

GENERAL MAINTENANCE ............................................................................................................................

6

GENERATOR CLEANING ...............................................................................................................................

6

GENERAL STORAGE GUIDELINES ................................................................................................................

6

GENERAL BATTERY INSTALLATION ...........................................................................................................

6

ELECTRICAL LOADS AND GUIDELINES .......................................................................................................

7

GENERATOR DESIGNED PERFORMANCE GUIDELINES ...............................................................................

7

ENGINE LIMITATIONS ON GENERATOR PERFORMANCE ............................................................................

7

RECEPTACLE DETAILS .................................................................................................................................

8

LOADING YOUR GENERATOR SET ...............................................................................................................

8

AMPERAGE RATE TABLE..............................................................................................................................

8

SECTION 2........................................................................................................................................................

9

40814/42723/42724 GENERATOR PARTS AND PART LISTS.............................................................................

9

A.C. Wiring Schematics................................................................................................................................

12

SECTION 3......................................................................................................................................................

14

39461/39982/40423/42725/42726/42727/39984/40827/42728 GENERATOR PARTS AND PART LIST...................

14

A.C. Wiring Schematics................................................................................................................................

16

SECTION 4......................................................................................................................................................

21

CONTROL PANELS ......................................................................................................................................

21

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SECTION 1

GENERAL INFORMATION

This manual is provided for you so that your generator may be properly, safely and effectively applied and operated. Please read and understand all aspects of this manual before operating your generator set. Please also read and understand the documentation supplied with this generator regarding the engine. Keep this documentation in a safe and accessible place so that reference can be made as needed. All operators, users and subsequent owners of this generator must read and understand all aspects of this documentation before operation.

SPARK ARRESTING MUFFLER

Certain States and Jurisdictions require that engine driven equipment be fitted with spark arresting mufflers. Depending on the generator model, spark arresting mufflers may or may not be fitted. If spark arresting mufflers are required for your specific local and the generator muffler is not spark arresting, contact your local dealer for instructions for a retrofit.

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system for this generator complies to the standards set forth by the California Air Resources Board (CARB) and the Environmental Protection Agency (EPA). Warranties for the exhaust emission system are administered by the respective engine manufacturers. Refer to the engine documentation for warranty information.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

THIS SYMBOL IS USED THROUGHOUT YOUR

OWNER’S MANUAL TO BRING ATTENTION TO IMPORTANT SAFETY INSTRUCTIONS. FAILURE TO FOLLOW SAFETY INSTRUCTIONS COULD ENDANGER YOU OR OTHERS AND RESULT IN PERSONAL INJURY OR DEATH. READ AND UNDERSTAND ALL SAFETY

INSTRUCTIONS BEFORE OPERATION.

DO NOT OPERATE THIS GENERATOR WITHIN AN

ENCLOSED AREA. THE EXHAUST GASES OF THIS GENERATOR EMIT “DEADLY” CARBON MONOXIDE. EXPOSURE TO CARBON MONOXIDE CAN CAUSE CARBON MONOXIDE POISONING, HEADACHES,

NAUSEA, SEVERE SICKNESS OR DEATH.

DANGER: THIS GENERATOR SET PRODUCES

ELECTRICAL CURRENT. THEREFORE, SAFETY GUIDELINES MUST BE FOLLOWED. IMPROPER USE OF THIS GENERATOR CAN RESULT IN

ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE,

SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY QUALIFIED TO DO SO.

DANGER: DO NOT OPERATE THIS GENERATOR IF THE AMBIENT TEMPATURE EXCEEDS 104ºF/40ºC.

SAFETY RULES

DANGER: This generator set is designed to be

operated in dry conditions and for outdoor areas only. Never operate this generator indoors.

Never operate this generator in rain, snow, sleet or generally wet conditions. Damage to the generator, bodily injury, or death could result from electrocution.

DANGER: If this generator is connected to a

building, home, business, or any other electrical circuit normally fed by utility power, steps must be taken to insure the generator output and the utility

power are positively isolated. Failure to isolate the utility and generator electrical systems will result in generator damage and could result in injury or death to utility workers due to the backfeed of electricity.

CAUTION: Do not exceed the rated capacity of

the generator. The total electrical loads at each outlet must be added to determine the total electrical load. The total load must not exceed the rated capacity of the generator. If the driven apparatus does not list wattage, but only amperage, wattage may be determined by multiplying amperage times voltage (watts

= amps X volts).

CAUTION: Do not tamper with the engine-

governed speed. The generator operates at a nominal speed of 3600 rpm. Increases in speed over the 3600 rpm nominal will increase the chance of

personal injury due to rotational stresses on the rotating members. Operation of the generator at speeds below the nominal 3600 rpm could cause damage to the generator or driven apparatus due to low voltage output.

CAUTION: Do not modify or misapply your

generator set. Operation of the generator other than intended, could result in generator set

damage, bodily injury or even death from electrocution.

BATTERY SAFETY

WARNING: STORAGE BATTERIES PRODUCE

AND RELEASE EXPLOSIVE HYDROGEN GAS WHEN CHARGING. THE SLIGHTEST SPARK, FLAME OR BURNING ASH CAN IGNITE THESE GASES CAUSING A SERIOUS EXPLOSION THAT COULD RESULT IN BLINDNESS OR OTHER SERIOUS

INJURIES.

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WARNING: WEAR EYE PROTECTION,

RUBBER APRON AND RUBBER GLOVES WHEN WORKING AROUND A BATTERY OR PERFORMING BATTERY SERVICE. BATTERY FLUID IS AN EXTREMELY CAUSTIC SULFURIC ACID, WHICH CAN CAUSE SEVERE BURNS. DO NOT PERMIT THE BATTERY FLUID TO COME IN

CONTACT WITH YOUR CLOTHES OR SKIN.

WARNING: ALWAYS DISCONNECT THE

NEGATIVE (-) BATTERY CABLE FROM THE BATTERY BEFORE PERFORMING BATTERY SERVICE OR BEFORE PERFORMING ANY ELECTRICAL SERVICE ON THE GENERATOR OR

ENGINE.

GENERAL SAFETY OPERATIONAL

GUIDELINES

Read and understand all the general safety operational guidelines and rules before operating this generator.

Always follow National and Local electrical codes.When moving or transporting this generator, take proper precautions to avoid fuel spillage. Further, always use common sense when lifting this generator. An adequate number of people and

proper lifting procedures must be used.

Do not wire your generator to a home or structure fed by utility power without proper isolation circuitry. Consult a local licensed electrician for proper wiring of your generator to a home, business or any facility or structure fed by utility power. Failure to properly isolate utility and generator electrical power could result in generator damage or electrocution to you or a utility worker. The main breaker, which disconnects from the utility power, must be open before the generator can safely be connected.

Do not operate this generator unless the generator is in good mechanical and electrical condition.

Do not overload this generator. Overloading this generator can cause generator damage, powered apparatus damage and excessive heat build up.

Always keep hands, body parts, hair and clothing well away from the rotating or “HOT” parts of the generator set. Exhaust systems can cause severe burns.

Do not start this generator with connected devices turned “ON”. Always make sure that connected devices are disconnected from the generator or turned “OFF” before starting the generator.

Do not operate this generator within an enclosed area. The operation area of the generator must be completely open. The exhaust gases of this generator emit “DEADLY” carbon monoxide. Exposure to carbon monoxide can cause carbon monoxide poisoning, headaches, nausea, severe sickness or death.

Do not install this generator in an enclosed area such as a RV or motorhome. All warranty will be null and void if installed within an enclosed area.

Always insure that at least 6 feet of clearance on all sides of the generator are maintained during operation. Failure to maintain proper clearance

could damage your generator and potentially lead to fires.

Never touch a receptacle or bare wire. Electrocution or shock could result.

Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Handle gasoline with extreme care. Failure to properly handle gasoline can result in explosion or fire. Do not permit smoking within 50ft of this generator set.

NEVER REFILL A HOT GENERATOR WITH FUEL.

NEVER REFILL THE GENERATOR WHILE IT IS RUNNING. Spillage onto the engine or generator could result in an explosion or fire. Always allow the generator set to cool before refilling.

Do not store this generator set in any location where gasoline fumes could potentially come into contact with sparks, a pilot light or an open flame. Improper storage of this generator could result in an explosion or fire.

GROUNDING: The NATIONAL ELECTRICAL CODE requires that the generator frame be properly grounded to earth. A ground lug is provided on the generator frame. As a general guideline, a 10 AWG wire connected to the grounding lug of the generator on one end (located on the generator frame as indicated by the International “GROUND” symbol) and connected to a copper or brass ground rod (driven into the ground) on the other end of the wire. Some locations require generator set or other grounding. Check with a local electrician to determine the grounding requirements for your area.

Electrical generators produce electricity. Therefore, never allow or perform service operations to your generator set without proper training/certification. Service operations, without proper precautions can cause severe shock and even death by electrocution.

Generators operating on job or construction sites must be equipped with GFCI (Ground Fault Circuit Interrupters) on all circuits. Certain generator models are not equipped with GFCI circuits. Therefore, customer supplied GFCI’s must be installed in the power cords connected to the generator. Consult a local licensed electrician for proper wiring.

Use only 3-Prong extension cords in good condition and make sure that the wire size within the extension cords is of sufficient size to safely carry the surge output of the generator.

Never handle extension cords or electrical circuits if standing in water or if standing in a damp area.

Operate, service or fill with fluids on a level surface only.

Do not operate this generator in a corrosive or flammable environment.

Never clean this generator with high-pressure water or a garden hose. Water can accumulate within the generator and cause fuel system, ignition system and or electrical problems or shorts. Cleaning should be done with a damp rag on a cool generator set.

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GENERAL MAINTENANCE

ENGINE FUEL: Use Unleaded Fuel - ONLY!

ENGINE OIL: Refer to the Engine related documentation.

ENGINE MAINTENANCE:

Refer to the documentation supplied regarding the engine for all engine maintenance issues.

GENERATOR CLEANING

CAUTION!: ALWAYS SHUT OFF THE

GENERATOR AND ALLOW THE GENERATOR TO COMPLETELY COOL BEFORE

PERFORMING CLEANING OPERATIONS.

WARNING! DO NOT USE HIGH PRESSURE

WATER OR A GARDEN HOSE TO CLEAN YOUR GENERATOR. WATER INTRODUCED INTO THE GENERATOR CAN CAUSE ELECTRICAL

SHORTS, GENERATOR DAMAGE OR PERSONAL INJURY.

Compressed air (max. 25 psi) may be used to blow loose dirt and dust from your generator. DO NOT DIRECT COMPRESSED AIR DIRECTLY INTO ANY OPENING IN THE GENERATOR OR ENGINE.

Use a dampened cloth to wipe clean exterior surfaces.

Use a soft bristle brush to clean/ loosen heavy dirt, oil or grease deposits.

NEVER insert rags, tools or any device into the generator or engine openings.

GENERAL STORAGE GUIDELINES

WARNING: GASOLINE FUMES ARE

FLAMMABLE. DO NOT STORE YOUR GENSET IN ANY AREA THAT IS INDOORS OR IN POORLY VENTILATED AREAS. GASOLINE FUMES

CAN IGNITE IN THE PRESENCE OF ANY OPEN FLAME, PILOT LIGHT, CLOTHES DRYER, WATER HEATER, ETC.

Your generator should be started and operated for several minutes at least every 30 days.

If the generator cannot be operated every 30 days, follow the storage recommendations within the engine documentation.

NOTE: A fuel shut-off valve is positioned at the base of the fuel tank. The valve should be closed during storage periods.

GENERAL BATTERY INSTALLATION

WARNING: DO NOT ATTEMPT TO OPERATE

THE GENERATOR WITHOUT THE BATTERY INSTALLED UNLESS BOTH THE RED(+) AND BLACK(-) CABLE ENDS ARE COMPLETELY INSULATED OR THE CABLES ARE REMOVED

ENTIRELY.

BATTERY SPECIFICATION: 145 CCA; INTERSTATE BATTERY Model SP-18 or Equivalent

With reference to the diagram below and to the safety guidelines that must be respected for handling batteries, install the battery as follows:

1.Place the battery into the battery tray.

2.Place the battery hold down bar (oriented as shown) on top of the battery.

3.Install qty (2) battery hold down bolts and washers as shown.

NOTE: Some versions require lock washers and nuts on lower side of battery tray.

4.Gently and evenly tighten the battery hold down bolts. Do not crush and or deform the battery case in the tightening process.

5.Insure that the engine key switch is in the “off” position.

6.Connect the red (+) cable to the battery (+) terminal using the supplied bolt, washers and nut. Tighten the bolt.

7.Connect the black (-) cable to the battery (-) terminal using the supplied bolt, washers and nut. Tighten the bolt.

Battery Installation Diagram

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ELECTRICAL LOADS AND GUIDELINES

Your generator set is designed to power electrical apparatuses within the electrical power output limitations of the generator. Please note that any generator overload can cause serious problems/damage to your generator. Additionally, apparatuses with electrical motors can require higher wattage requirements at start-up than when running. Some electric motors require as much as 2.5 times the rated wattage at start-up. Although the start-up wattage requirements for electric motors lasts only a few seconds, great care must be taken in connecting loads to your generator so as not to overload the generator. Refer to the label on each electrical apparatus to determine the wattage requirements of that apparatus. THE TOTAL

WATTAGE REQUIREMENTS OF ALL POWERED APPARATUSES (INCLUDING START-UP LOADS) MUST NEVER EXCEED THE CONTINUOUS RATING OF YOUR GENERATOR, CORRECTED TO THE ACTUAL ENVIRONMENTAL CONDITIONS AT THE OPERATING SITE.

As a reference only, Table 1 below shows some general wattage requirements for several common electrical devices. This chart is intended as a guide only. The actual total wattage should be determined by referring to the actual labels on each of the powered electrical devices.

Table 1 GENERAL WATTAGE GUIDE

Item

Running Watts

Air Conditioner (12000 Btu) (*)........................

1750

Air Compressor (1/2 hp) (*)............................

1400

Air Compressor (3/4 hp) (*)............................

1800

Air Compressor (1 hp) (*)...............................

2000

Battery Charger (25A).....................................

600

Belt Sander (3” belt)......................................

1000

Circle Saw (6 ½”) ...................................

825-1050

Coffee Maker.........................................

900-1100

Edger (lawn)..................................................

550

Furnace Fan (1/3 hp) (*)................................

1200

Hot Plate (single)..........................................

1500

Impact wrench ...............................................

600

Light Bulb............................................

Bulb rated

Nail Gun .....................................................

1200

Microwave.....................................................

750

Paint Sprayer (1/3 hp) (*).................................

650

Paint Sprayer, hand-airless..............................

175

Radio ......................................................

50-200

Refrigerator (*)...............................................

600

Table Saw (10”) (*) .......................................

2000

Television...............................................

250-550

Weed Trimmer...............................................

500

Note: (*) Items allow 2.5 times the listed wattage

for starting.

 

GENERATOR DESIGNED

PERFORMANCE GUIDELINES

This electrical generator is designed to produce electrical energy for the purpose of powering lights, power tools, appliances and motor loads within the intended design constraints of the generator. The generator is designed to produce single-phase electrical power at 120 or 120/ 240 VAC. This generator is not intended for installation in RV or motorhome applications. The Performance Specifications for your generator are listed in Table 2 Performance Specifications.

Table 2

PERFORMANCE SPECIFICATIONS

SKU Number

 

Voltage

Cont. Watts

Surge Watts

40814

 

120/240 VAC

4400 Watts

5000 Watts

42723

 

(Single Phase)

37.5 Amps @ 120 VAC

42 Amps @ 120 VAC

42724

 

 

18.5 Amps @ 240 VAC

21 Amps @ 240 VAC

39461

 

120/240 VAC

6100 Watts

8000 Watts

40423

 

(Single Phase)

51 Amps @ 120 VAC

67 Amps @ 120 VAC

42725

 

 

26 Amps @ 240 VAC

33 Amps @ 240 VAC

42726

 

 

 

 

39982

 

120/240 VAC

9350 Watts

10000 Watts

42727

 

(Single Phase)

78 Amps @ 120 VAC

83 Amps @ 120 VAC

 

 

 

39 Amps @ 240 VAC

41.5 Amps @ 240 VAC

39984

 

120/240 VAC

10500 Watts

12000 Watts

40827

 

(Single Phase)

88 Amps @ 120 VAC

100 Amps @ 120 VAC

42728

 

 

44 Amps @ 240 VAC

50 Amps @ 240 VAC

Table 3 Engine Type

SKU Number

Engine

HP

40814

Honda GX 270

9.0hp

42723

Honda GX 270

9.0hp

42724

Honda GX 270

9.0hp

39461

Honda GX 390

13.0hp

40423

Honda GX 390

13.0hp

42725

Honda GX 390

13.0hp

42726

Honda GX 390

13.0hp

39982

Vanguard

16.0hp

42727

Vanguard

16.0hp

39984

Vanguard

18.0hp

40827

Honda GX 620

20.0hp

42728

Honda GX 620

20.0hp

ENGINE LIMITATIONS ON GENERATOR

PERFORMANCE

Generator ratings assume 60 F (20C) and Sea Level. Operation of your generator at temperatures above 60 F (20C) or above Sea Level will result in lower electrical output. Electrical output must be derated 2% for each 9 F above 60 F and 3 ½ % for each 1000 feet above mean sea level.

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