Chicago Electric 45416 User Manual

10 KW GENERA10 KW GENERA

®

10 KW GENERA

10 KW GENERA10 KW GENERA

TORTOR

TOR

TORTOR

45416

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www .harborfreight.com

Copyright © 2001 by Harbor Freight Tools®. All rights reser ved. 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 Freight Tools.

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

REV 09/03

Specifications

ITEM DESCRIPTION

Power Output 10,0 00 watts (maximum), 7200 watts continuous (rated); 60 Hz
Voltage Output
Motor Driver Requirements 3600 RPM, 16 HP

Drive Type Belt driven
Driv e Shaft
Generato r operat i on 2-pol e, revolving field, brush le ss excitati on

THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC

EQUIPMENT WITHOUT THE ADDITION OF AN APPROPRIA TE LINE CONDITIONER (SOLD SEPARA TEL Y).

2 - 120 VAC (20 amp) , s i ngl e phase d upl ex r eceptacl e;

1 - 120 / 240 VAC (30 amp), single phase twistlock receptac le

1 inch (dia.) meter; length: 2-3/8 inche s;
Keyway: 1/4 (W ) x 2 (L) inches

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front co v er. Keep the man ual and
invoice in a safe and dry place for future reference.

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to
reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically
powered tools in the presence of flammable gases or liquids.

3. Keep children awa y. Children must never be allo w ed in the work area. Do not let
them handle machines, tools, or extension cords.

4. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit
rust. Always lock up tools and keep out of reach of children.

5. Do not force tool. It will do the job better and more safely at the rate for which it was
intended. Do not use inappropriate attachments in an attempt to exceed the tool
capacity.

6. Use the right tool for the job. Do not attempt to f orce a small tool or attachment to do
the work of a larger industrial tool. There are certain applications for which this tool
was designed. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.

7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.

SKU 45416 Page 2 REV 04/02; 09/03; 12/03

8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.

9. Maintain tools with care. K eep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories. Inspect tool
cords periodically and, if damaged, have them repaired by an authorized technician.

10. Disconnect power. Unplug connected appliances when not in use.

11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or machine work surface before turning on.

12. Av oid unintentional starting. Be sure that all connected appliances are Off bef ore
starting the generator.

13. Stay alert. Watch what you are doing, use common sense. Do not oper ate any tool
when you are tired.

14. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and an y other condition that ma y aff ect proper operation. Any part
that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the tool if any switch does not turn On and Off properly.

15. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.

16. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are av ailable from Harbor Freight
Tools.

17. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.

18. Use proper size and type extension cord. If an extension cord is required, it must be
of the proper size and type to supply the correct current to the tool without heating up.
Otherwise, the extension cord could melt and catch fire, or cause electrical damage to
the tool. Depending on the appliance connected to the gener ator, the use of an
extension cord should have a 0 to 20 amp capability (up to 50 feet), with wire size
rated at 14 A WG. Longer extension cords require larger size wire. If you are using the
tool outdoors, use an extension cord r ated f or outdoor use . (signified by “WA” on the
jacket).

19. Maintenance. F or y our saf ety, service and maintenance should be performed
regularly by a qualified technician.

WARNING

An extension cord that is hot to the touch is overloaded. Repair or replace damaged extension
cords immediately.

SKU 45416 Page 3 REV 04/02

Electric Generator Safety Precautions and Warnings

1. The Generator produces electrical current. Improper use can result in electrocution, injury
or death. Only a qualified technician should service or repair this generator .

2. The Gener ator was designed to be used in a dry area. Do not e xpose to rain, snow , sleet,
or damp conditions. Damage to the Generator could occur . Moisture can carry electrical
current and could cause electrocution.

3. If the Generator is connected to a building, home, business, or any other electrical circuit
normally fed by utility power, steps must be taken to ensure that the Generator output
and the utility power are positively isolated. Do not plug other appliances into the electrical
outlet being used to power the Generator. Failure to isolate the systems will result in
Generator damage. It could also result in personal injury or death to those working around
these circuits. Any connection in this regard must only be done by a licensed electrician.

4. Do not exceed the Generator’s rated capacity. The total electrical loads at each outlet
must be added to determine the total electrical load. If the electrical appliance does not
list the wattage rating, you can calculate it by multiplying amps times voltage (amps x
voltage = watts).

5. Do not tamper with the drive, engine-go verned speed. The Generator operates at a nominal
speed of 3600 RPM. Increases in speed could damage rotating parts of the Generator.
Slower speeds could damage the Generator or appliances connected to the Generator
due to low voltage.

6. Always follow national and local safety codes.

7. Do not start the Generator with appliances connected and turned on.

8. If the driver motor is a gas engine, do not used in an enclosed area due to the carbon
monoxide fumes produced. The fumes can be deadly.

9. Give the Generator at least two feet of space to dissipate heat.

10. Properly ground the Generator . The National Electrical Code requires that the Generator
frame be properly grounded to earth. This should be done b y a licensed electrician.

11. Never handle electr ical charged extension cords while standing in water.

12. Only use 3-prong, grounded extension cords.

13. Keep fingers and hands away from the spinning pulleys.

14. Install a safety guard around the pulleys.

15. WARNING! People with pacemak ers should consult their physician(s) bef ore using this
product. Electromagnetic fields in close proximity to a heart pacemaker could cause
interference to or f ailure of the pacemaker.

Grounding Instruction: This generator should be g rounded to help prevent accidental electrical

shock. Drive a 3/4” or 1” diameter copper pipe or rod into the ground close to the generator
set. The pipe must penetrate moist earth. Using #10 gauge wire, connect one end of the
wire to the generator frame. Connect the other end of the wire to the copper pipe or rod
using an approved ground clamp.

SKU 45416 Page 4 REV 04/02; 02/04

Note: Performance of this tool may vary depending on variations of the power driver motor .
Warning: The warnings, cautions, and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must be under­stood by the operator that common sense and caution are factors which cannot be
built into this product, b ut m ust be supplied b y the operator.

MOUNTING PLATE

FOR

GENERATOR / ALTERNATOR 10KW

SKU 45416

A mounting plate (not included), similar to the one illustrated below, will need to be provided by the
customer to properly and safely mount and operate the generator/alternator. The plate is needed to
properly tension the drive belt used to drive generator/alternator. Drawing below is for reference only
and customer may need to make further modification to mounting plate and their generator frame for
the proper and safe mounting of the generator/alternator. The drawing gives dimensions for the plate
and generator/alternator footprint.

Material: 1/2” steel plate

DRAWING NOT TO SCALE, FOR REFERENCE ONLY !!

THE MANUFACTURE AND OR DISTRIBUTOR HAS PROVIDED THE MOUNTING PLATE DIAGRAM AS A
REFERENCE TOOL ONL Y. THE CUSTOMER CAN CHOOSE TO DESIGN, MANUFACTURE AND USE THEIR
OWN MOUNTING PLATE. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
MANUFACTURING OF A MOUNTING PLATE THAT IS NOT INSTALLED PROPERLY AND SAFELY
MANUF ACTURED .

SKU 45416 Page 5 REV 04/02

MOUNTING PLATE

FOR

GENERATOR / ALTERNATOR 10KW

SKU 45416

The customer will need to supply the following hardware (not included):

1) (4) Grade 3, 5/16” -18 x 1-1/4”L hex-head bolts

2) (4) 5/16” -18 hex nuts

3) (4) 5/16” lock washers

4) (4) 5/16” flat washers

INSTRUCTIONS – INSTALLING GENERATOR/ALTERNATOR ON MOUNTING PLATE

1) Remo ve both f an cov ers (part# 26) from shaft end of generator/alternator.

2) Remo ve wiring bo x (part# 10) from opposite end of generator/alternator shaft.

3) Place generator/alternator so that through holes on bottom of generator/alternator are

readily accessible (facing up).

4) Place mounting plate , with countersinks holes facing up, on bottom of generator/

alternator and line-up holes on mounting plate and generator/alternator.

5) Insert one (1) 5/16”-18 hex-head bolt in each through hole in mounting plate and

generator/alternator. Insure that heads of bolts are belo w the surface of the mounting
plate.

6) Place one (1) flat w asher, lock washer and hex nut on each bolt and tighten.

7) Turn and place generator/alternator back on mounting plate.

8) Replace both fan covers (part# 26) and wiring box (part#10).

This completes the installation of the mounting plate to the generator/alternator. Customer is
now to proceed to the Installation portion of the manual to complete the mounting of the
generator/alternator and mounting plate to generator frame. Again, it may be necessary for
the customer to further modify the mounting plate and generator frame to complete
installation.

SKU 45416 Page 6 REV 04/02

Unpacking

When unpacking, check to mak e sure the Generator is complete. If any parts are missing or
broken, please call Harbor F reight Tools at the number on the cover of this man ual as soon
as possible.

Installation

1. Verify that the driver motor is securely mounted to a stable surface (see Mounting Plate
instructions on pages 5 and 6), and belt pulleys properly attached. Refer to the photo
below.

2. Mount the double pulley (not supplied) onto the Generator (1 inch) shaft. Make sure
that the pulley set screws are properly tightened.

3. On the same surf ace, mount the Generator , offset to the shaft of the motor driver .

The belts should be placed on the pulleys to determine the proper distance between

drive shafts. Allow room f or adjustments after mounting the Generator .

4. For safe operation, install a pulley guard (not included) around both pulleys.

Generator

Double Pulley

Generator

Motor Drive

Motor Drive Double Pulley

Operation

1. Plug in the extension cords or appliances, making sure they are turned off.

Refer to the connector wiring illustration on the next page. Do not overload the

Generator. Calculate the total wattage of the appliances. Generator maxim um po wer
output is 10,000 watts.

2. Start the motor driver.

3. Begin using the appliances when the motor driver is at full speed.

4. If electricity to one of the outlets stops, it could be that the circuit was overloaded.
Check you appliance w attage , then push in on the Reset button to resume power.

SKU 45416 Page 7 REV 04/02

5. When y ou are finished using the Generator, stop the motor driver , then disconnect the
appliances.

Over Current
Reset Buttons

120 V olt
Duplex
Outlet

120 / 240 Volt
T wistlock Outlet

Maintenance

W ARNING: Before perf orming any maintenance on the Generator , the motor driver m ust
be off, and the Generator must be allowed to cool down after use.

1. Clean the Gener ator with compressed air. Do not blo w directly into the heat v ents. Do
not immerse in water . Use a damp cloth do wipe clean.

Nev er insert rags, tools, or an y device into the Generator openings.

2. Periodically operate the Generator .

3. Store in a clean and dry location.

4. Check and tighten belts when they become loose.

5. Check and tighten pulley set screws.

SKU 45416 Page 8 REV 02/02; 04/02; 09/03

Parts List

Item # Description Qty

1 Over Current Protector (20 amp) 2
1A Over Current Protector (30 amp) 2
2 Spring washer, GB93-87, M4 4
3 AC Socket, 120V/120V 1
4 AC Socket, 120V/240V 1
5 Bolt, GB818-85, M5x12 13
6 Spring W asher , GB93-87, M5 13
7 Washer , GB 97.1-85, 5 13
8 Over Current Protector Nut 2
9 Over Current Protector Washer 2
10 Wiring Box 1
11 Bolt, GB5783-B6, M4x10 4
12 Fastener Clip 2
13 Capacitor 1
14 Bolt, GB5782-86, M8x280 4
15 Spring W asher , GB 93-87, 8 4
16 Washer , 8 4
17 Front Cover 1
18 Stator 1
19 Axle Tree, GB 278-89, 80204 1
20 Rotator 1
22 Fan 1
23 Baffle 1
24 Axle Tree, GB278-89, 80206 1
25 Washer , GB 894.1-86-30 1
26 Fan Cover 2
27 Back Cover 1
28 Bolt, GB5783-86, M5x25 2
29 Voltmeter 2

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE PARTS DIA GRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY . NEITHER THE MANUF ACTURER NOR DISTRIBU TOR
MAKES ANY REPRESENTA TION OR WARRANTY OF ANY KIND TO THE B UYER THAT HE OR
SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THA T HE OR SHE IS QU ALI­FIED T O REPLA CE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUF A CTURER AND/OR
DISTRIBUTOR EXPRESSLY ST A TES THA T ALL REP AIRS AND PARTS REPLACEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER.
THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO
THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO , OR ARISING OUT OF HIS OR
HER INST ALLATION OF REPLACEMENT PARTS THERET O .

SKU 45416 Page 9 REV 02/02; 04/02; 04/03; 09/03

Assembly Drawing

Note: Voltmeters (#29) located on

Wiring Box are not shown.

NOTE: Some parts are listed and shown
for illustration purposes only and are not
available individually as replacement
parts.

SKU 45416 Page 10 REV 04/02; 04/03; 09/03

Schematic Diagram

SKU 45416 Page 11 REV 09/05