Chicago Electric 98391 User Manual
DIESEL GENERATOR
98391
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.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Only use OUTSIDE
and far away from
windows, doors, and
vents.
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 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. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,
actual product may differ slightly from the product described herein.
For technical questions or replacement parts, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 4
BASIC SPECIFICATIONS ............. 8
UNPACKING .................................. 8
SET UP INSTRUCTIONS ............... 8
LOCATION ..........................................8
CONTROLS ................................... 9
GROUNDING ....................................10
AFTER INITIAL 20
OPERATION HOUR PERIOD: . 15
EVERY 50 OPERATION
HOURS: .................................... 15
EVERY 100 OPERATION
HOURS: .................................... 15
EVERY 250 OPERATION
HOURS: .................................... 15
EVERY 500 OPERATION
HOURS: .................................... 15
STORAGE ........................................16
DIESEL FUEL AND MICROBES ...... 16
TROUBLESHOOTING ...................... 17
OPERATING INSTRUCTIONS .... 10
STARTING THE ENGINE .................10
CHECKING AND FILLING
ENGINE OIL .............................10
CHECKING AND FILLING FUEL 11
BLEED THE FUEL LINE ............. 11
CONNECT THE BATTERY ......... 11
START PROCEDURE ................. 11
TO START THE ENGINE: ........... 11
BREAK-IN PERIOD ....................12
EQUIPMENT OPERATION ...............12
TO POWER TOOLS AND
EQUIPMENT: ............................12
TECHNICAL SPECIFICATIONS .. 13
MOUNTING HOLE PATTERN .......... 13
SHAFT SIZE/TYPE ...........................13
SERVICING .................................. 13
MAIN ASSEMBLY PARTS LIST .. 19
MAIN ASSEMBLY DIAGRAM ...... 20
CYLINDER BLOCK ASSEMBLY
PARTS LIST .............................. 21
CYLINDER BLOCK ASSEMBLY
DIAGRAM .................................. 22
CYLINDER HEAD ASSEMBLY
PARTS LIST & DIAGRAM ......... 23
CYLINDER VALVE COVER
PARTS LIST & DIAGRAM ......... 24
PISTON & CONNECTING ROD
PARTS LIST & DIAGRAM ......... 25
CRANK SHAFT & FLYWHEEL
PARTS LIST & DIAGRAM ......... 26
MAINTENANCE PROCEDURES ..... 14
ENGINE OIL CHANGE ...............14
AIR FILTER ELEMENT
MAINTENANCE .......................14
FUEL FILTER REPLACEMENT .. 14
REPLACING THE AC FUSE ....... 15
CAMSHAFT ASSEMBLY PARTS
LIST & DIAGRAM ...................... 27
AIR CLEANER ASSEMBLY
PARTS LIST & DIAGRAM ......... 28
OIL SYSTEM PARTS LIST &
CLEANING, MAINTENANCE, AND
LUBRICATION SCHEDULE .......... 15
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DIAGRAM .................................. 29
FUEL INJECTION PUMP PARTS
LIST & DIAGRAM ...................... 30
FUEL NOZZLE PARTS LIST &
DIAGRAM .................................. 31
GOVERNOR & CONTROL
SYSTEM PARTS LIST &
DIAGRAM .................................. 32
FUEL TANK AND PIPE PARTS
LIST & DIAGRAM ...................... 33
MUFFLER PARTS LIST &
DIAGRAM .................................. 34
STARTING MOTOR PARTS
LIST & DIAGRAM ...................... 34
GENERATOR PARTS LIST &
DIAGRAM .................................. 35
CONTROL PANEL PARTS LIST
& DIAGRAM .............................. 36
WIRING DIAGRAM ...................... 37
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 38
SKU 98391 For technical questions, please call 1-800-444-3353. Page 3
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.
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 re,
serious injury and/or DEATH.
The warnings and precautions
discussed in this 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, but must be supplied
by the operator.
SAVE THESE INSTRUCTIONS
SET UP PRECAUTIONS
Diesel fuel and fumes are ammable, 1.
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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 4
and potentially explosive. Use proper
fuel storage and handling procedures. Do not store fuel or other
ammable materials nearby.
Have multiple ABC class re extin-2.
guishers nearby.
Operation of this equipment may cre-3.
ate sparks that can start res around
dry vegetation.
A spark arrestor may be required.
The operator should contact local re
agencies for laws or regulations relat-
ing to re prevention requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.
Wear ANSI-approved safety goggles, 5.
heavy-duty work gloves, and dust
mask/respirator during set up.
Use only oil and fuel recommended 6.
in the “Specications” section of this
manual.
People with pacemakers should 5.
consult their physician(s) before
use. Electromagnetic elds 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.
OPERATING PRECAUTIONS
1. CARBON MONOXIDE
HAZARD
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.
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 the presence of
ammable liquids, gases, or dust.
Diesel-powered engines may ignite
the dust or fumes.
Stay alert, watch what you are doing 8.
and use common sense when operating this piece of equipment. Do not
use this piece of equipment while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper foot-9.
ing and balance at all times. This enables better control of the equipment
in unexpected situations.
Only use OUTSIDE and far away
from windows, doors, and vents.
Keep children away from the equip-2.
ment, especially while it is operating.
Do not leave the equipment unat-3.
tended when it is running. Turn off
the equipment (and remove safety
keys, if available) before leaving the
work area.
Wear ANSI-approved safety goggles 4.
and hearing protection during use.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 5
Dress properly. Do not wear loose 10.
clothing or jewelry. Keep hair, clothing and gloves away from moving
parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
Parts, especially exhaust system 11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment 12.
during operation.
Keep the equipment, engine, and sur-13.
rounding area clean at all times.
for a purpose for which it is not intended.
Use the equipment, accessories, etc., 14.
in accordance with these instructions
and in the manner intended for the
particular type of equipment, taking
into account the working conditions
and the work to be performed. Use
of the equipment for operations different from those intended could result
in a hazardous situation.
Do not operate the equipment with 15.
known leaks in the engine’s fuel system.
This product contains or, when used, 16.
produces a chemical known to the
State of California to cause cancer
and birth defects or other reproductive harm. (California Health & Safety
Code § 25249.5, et seq.)
When spills of fuel or oil occur, they 17.
must be cleaned up immediately.
Dispose of uids and cleaning materials as per any local, state, or federal
codes and regulations. Store oil rags
in a bottom-ventilated, covered, metal
container.
Keep hands and feet away from 18.
moving parts. Do not reach over or
across equipment while operating.
Before use, check for misalignment 19.
or binding of moving parts, breakage
of parts, and any other condition that
may affect the equipment’s operation.
If damaged, have the equipment
serviced before using. Many ac-
cidents are caused by poorly maintained equipment.
Use the correct equipment for the 20.
application. Do not modify the equipment and do not use the equipment
Wash hands with soap and water 21.
after handling diesel fuel or lubricating oil.
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its a.
“OFF” position.
Allow the engine to completely b.
cool.
Keep all safety guards in place and in 2.
proper working order. Safety guards
include mechanical guards, and heat
shields, among other guards.
Do not alter or adjust any part of 3.
the equipment or its engine that is
sealed by the manufacturer or dis-
tributor. Only a qualied 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/respirator during service.
All connections from the Generator to 5.
the load must be installed by a licensed electrician in compliance with
local, state, and federal laws.
The generator must be grounded in 6.
accordance with applicable electrical
codes and standards before operation.
Insulate all connections and discon-7.
nected wires.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 6
Do not connect or disconnect load 8.
connections while standing in water
or on wet ground.
or any procedures that you are uncertain about your ability to perform
safely or correctly.
Do not overload the generator. Over-9.
loading can cause res in the electri
cal cords, in addition to generator and
appliance damage.
Connect the generator only to a load 10.
or electrical system (120 volt or 240
volt) that is compatible with the electrical characteristics and rated capacities of the generator.
Set up the generator outdoors in a 11.
well-ventilated, dry area, away from
building air intakes. The generator should be protected from direct
exposure to rain and snow. Do not
set up the generator on a conductive
surface such as a metal deck.
Do not connect generator directly 12.
into a home’s electrical lines. Do not
plug a generator into an outlet in
the home. Connecting a generator
directly to a utility power supply can
‘back feed’ along the power lines and
kill or injure utility workers working on
the lines.
Store equipment out of the reach of 16.
children.
Follow scheduled engine and equip-17.
ment maintenance.
Refueling Precautions:18.
Do not smoke, or allow sparks, a.
ames, or other sources of ignition
around the equipment, especially
when refuelling.
Do not rell the fuel tank while the b.
engine is running or hot.
Do not ll fuel tank to the top. Leave c.
a little room for fuel expansion.
Refuel in a well-ventilated area only.d.
SAVE THESE
INSTRUCTIONS.
Do not charge vehicle batteries with 13.
this Generator.
Maintain labels and nameplates on 14.
the equipment. These carry important information. If unreadable or
missing, contact Harbor Freight Tools
for a replacement.
Have the equipment serviced by a 15.
qualied repair person using only
identical replacement parts. This will
ensure that the safety of the equipment is maintained. Do not attempt
any service or maintenance procedures not explained in this manual
SKU 98391 For technical questions, please call 1-800-444-3353. Page 7
BASIC SPECIFICATIONS
Type #2 Diesel Fuel
Fuel
Capacity 4.2 Gallons
Type SAE 5W40
Engine Oil
Capacity 1-3/4 qts.
Rated Wattage 5,000 Watts
Maximum Wattage 6,000 Watts
Run Time @ 75% Load 8.5 Hours with full tank
Sound Level 75 dB @ 23’
Note: Additional specications found in
the TECHNICAL ENGINE SPECIFICATIONS chart in this manual.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
STARTING:
Turn the Power Switch of the
equipment to its “OFF”
position, wait for the engine to
cool before assembling or
making any adjustments to
the equipment.
TO PREVENT
SERIOUS INJURY:
Operate only with proper
spark arrestor installed.
At high altitudes, the engine’s carburetor, governor, and any other parts that
control the fuel-air ratio will need to be
adjusted by a qualied mechanic to allow
efcient highaltitude use and to prevent
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 all text under
subheadings therein before set
up or use of this product.
Operation of this equipment
may create sparks that
can start res around dry
vegetation.
A spark arrestor may be
required.
The operator should contact
local re agencies for laws
or regulations relating to re
prevention requirements.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Location
The Generator must be installed 1.
outdoors where ventilation is readily
available.
Install the Generator so that the air 2.
inlets and outlets are not blocked by
obstruc tions such as bushes, trees,
or snow drifts. Locating it in the path
of heavy winds or snowdrifts may
require the placement of a barrier for
protection. The air inlet should face
the prevailing wind direction.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 8
CONTROLS
Ignition
Switch
Fuse Cover Voltage
Low Oil
Warning
Light
Meter
Run
Hours
Meter
AC Power
Selection
Switch
Circuit
Breaker
Fuel
Shut-off
Valve
120V GFCI
Receptacles
Battery
Fuel Filter
120V & 240V
Receptacle
Oil Drain Plug
Grounding
Point
Oil Cap/Dipstick
12V 8.3A DC
Receptacle
Engine
Control
Handle
Fuel
Cut-off
SKU 98391 For technical questions, please call 1-800-444-3353. Page 9
Install the Generator on a concrete 3.
slab or other area where water can
not reach it.
Generator placement should allow 4.
four feet of access on all sides for
mainte nance.
Place the Generator as close as pos-5.
sible to the electrical tools and equip-
ment be ing powered to reduce the
length of extension cords.
Grounding
Connect a #12 AWG grounding wire 1.
(not included) from the Grounding
Point on the Generator to a ground-
ing 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 ad-
equately ground the Generator. Only
a trained and licensed electrician
should perform this procedure.
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION
section at the beginning of this
manual including all text under
subheadings therein before set
up or use of this product.
Starting the Engine
Inspect engine and equipment
looking for damaged, loose,
leaking and missing parts
before set up and starting. If
any problems are found, do
not use equipment until xed
properly.
Checking and Filling Engine Oil
CAUTION! Your Warranty is VOID if the
engine’s crankcase is not properly
lled with oil before each use. Before
each use, check the oil level. Do not
run the engine with low or no engine
oil. Running the engine with no or
low engine oil WILL permanently
damage the engine.
Open the front panel; remove the dip-1.
stick and wipe it off with a clean rag.
Reinsert the dipstick completely and 2.
remove it to check the oil level. The
oil level should be between the high
and low marks on the dipstick.
Grounding Point
2. Electrical and other permits may be
required for the installation of emer-
gency power systems. Investigate
local building and electrical codes
before installing this unit. Installa-
tion must be completed by a licensed
contractor.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 10
If the oil level is below the low mark 3.
on the dipstick add the appropriate
type of oil until the oil level is between
the high and the low marks.
Oil type:
SAE 5W-40
Replace the Oil Dipstick.4.
Wipe off any spilled oil.5.
CAUTION! Do not run the engine with too
little or too much oil. The engine will
be permanently damaged.
Checking and Filling Fuel
Check the fuel level on the built-in 1.
fuel gauge.
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-venti-
lated area away from ignition sources. Do not smoke.
To ll the Fuel Tank, rst wipe off the 2.
Fuel Tank Cap and the surrounding
area.
Unscrew, and remove the Fuel Tank 3.
Cap.
Fill the Fuel Tank to about 1 inch 4.
under the ll neck of the tank with #2
diesel.
out. Turn the fuel valve to its open
position. Depress the decompression
lever and while holding it down crank
the engine for a few seconds at a
time. Fuel and trapped air will emerge
from the line and as soon as just fuel
ows without traces of air, push the
fuel line back onto the intake of the
pump and stop cranking the engine.
Reattach the hose clamp. Note:
Never crank the engine more than
ten seconds at a time. Allow at least
one minute prior to further cranking.
Using two wrenches, hold the injector 3.
with one and back off the steel feed
line nut with the other wrench. Repeat
the above mentioned ushing cycle
to bleed the air from the injector.
Wipe all spilled fuel from the engine
and components. Note: Do not
close the fuel valve with the engine
running. This may only be done for
the intention of shutting the engine off
should the fuel shut-off system fail.
Connect the Battery
Then replace the Fuel Tank Cap.5.
Bleed the fuel line
This is a two man operation. Place rags
under the bleeding points to catch ow of
fuel.
The fuel system should be bled to 1.
remove possible trapped air from
the system before rst use and after
each fuel lter, fuel tank ushing,
or general service of the diesel
generator. Note: Place rags at the
bleeding points to capture spilled fuel.
Turn the fuel valve to the off position. 2.
Top off fuel tank with fresh diesel
fuel. Slide the hose clamp away from
the fuel pump end. Loosen the hose
at the pump to allow fuel to bleed
SKU 98391 For technical questions, please call 1-800-444-3353. Page 11
The Generator ships with the nega-1.
tive battery cable disconnected.
Before the generator can be started
the covering on the battery cable
must be removed and the cable must
be secured to the negative ground
terminal on the battery. Recheck battery’s positive terminal connection for
tightness.
How to Shut Engine Off
A diesel engine is not operated like a
gasoline engine. When operating a
diesel engine, one should be aware
of various options of how to shut the
engine off.
Turn the ignition key to the off posi-1.
tion.
Push down on the fuel shut off lever 2.
to release the Control Handle (13).
Turn the fuel valve to its “OFF” posi-3.
tion.
Start Procedure
Control
Handle
Release
Button
Before starting the engine:
Follow the Set Up Instruc-a.
tions to prepare the equipment.
Inspect the equipment and b.
engine.
Fill the engine with the prop-c.
er amount and type of fuel
and oil.
Read the Equipment Opera-d.
tion section that follows.
To start the engine:
Unplug all loads from the Generator 1.
before starting to prevent permanent
damage to any appliances or tools.
Depress the Decompression Handle 2.
(16) all the way (Cold starting only).
Decompression
Handle
Insert the en-5.
gine key into the ignition and turn it to
“START” position for up to 10 seconds. Note: To prolong starter life,
use short starting cycles (10 seconds
maximum). If the engine does not
start, wait one minute before attempting to start again.
Break-in Period
Breaking-in the engine will help to 1.
ensure proper equipment and engine
operation, and will extend the engine’s lifespan. The warranty is void
if the engine is not broken in properly.
The rst 20 hours of operation is the
break-in period.
During the rst 3 hours of use:2.
Do not apply a heavy load to the •
equipment.
After the rst 20 hours of use:3.
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
Open the front 3.
panel and turn the fuel shut-off valve
schedule explained in the MAINTENANCE AND SERVICING section.
to its “OPEN” position.
Rotate the Control Handle (13) to the 4.
right until release button on the Right
hand side of the Handle Bracket (12)
pops up and locks in place.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 12
Equipment Operation
To Power Tools and Equipment:
Move the AC Power Selection Switch 1.
left to select 120V AC to power 120V
tools or equipment or to the right to
power 240V AC tools and equipment.
Prior to powering tools and equip-2.
ment, make sure the Generator’s
rated watt age capacity (5000 W) is
adequate to supply all electrical loads
that the unit will power. If powering
exceeds the Generator’s capacity, it
may be necessary to group one or
more of the tools and/or equipment
for connection to a separate Generator.
Start the Generator with no loads at-3.
tached. Once the Generator warms
up, with the equipment or tools turned
off, connect the Power Cords of the
AC tools and equipment into the AC
Outlets. Only connect 120V AC tools
to the 120V AC Outlets. Only connect 240V AC NEMA L14-30 type
plug tools the 240V AC Outlet. Do
not use this Generator to charge
DC vehicle batteries. The Genera-
tor has a Circuit Protector to protect
the unit in case of an overload. If an
overload occurs, the Circuit Breaker
will switch to its “OFF” position and
cause the Generator to shut down.
The Pilot Light will shut off to show
that the Circuit Protector has been
tripped. Disconnect all devices and
press the Circuit Breaker back up to
reset the Generator.
to allow the temperature to stabilize.
Turn the Power Switch to its “OFF”
position. Turn the Fuel Valve to the
“OFF” position.
To prevent accidents remove the 5.
key and disconnect negative battery
terminal 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. If the Generator is not going to
be used again soon, drain the diesel
fuel.
When nished using the Generator 4.
turn the tools off and unplug them.
Allow the Generator to run for several
minutes with no devices connected
SKU 98391 For technical questions, please call 1-800-444-3353. Page 13
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