Instruction/ maintenance manual of the product 98391 Chicago Electric
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DIESEL GENERA T OR 98391 SET UP , OPERA TING, AND SER VICING 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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 2 CONTENTS IMPORT ANT SAFETY INFORMA TION ............................ 4 BASIC SPECIFICA TIONS ............. 8 UNP ACKING .................................. 8 SET UP INSTRUCTIONS ....
SKU 98391 For technical questions, please call 1-800-444-3353. Page 3 FUEL INJECTION PUMP P ARTS LIST & DIAGRAM ...................... 30 FUEL NOZZLE P ARTS LIST & DIAGRAM .................................. 31 GOVERNOR & CONTROL SYSTEM P ARTS LIST & DIAGRAM .
SKU 98391 For technical questions, please call 1-800-444-3353. Page 4 SA VE THIS MANUAL Keep this manual for the safety warn- ings and precautions, assembly , operat- ing, inspection, maintenance and cleaning procedures.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 5 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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 6 Keep the equipment, engine, and sur- 13. rounding area clean at all times. Use the equipment, accessories, etc.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 7 Do not connect or disconnect load 8. connections while standing in water or on wet ground. Do not overload the generator . Over- 9. loading can cause res in the electri cal cords, in addition to generator and appliance damage.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 8 BASIC SPECIFICA TIONS Fuel T ype #2 Diesel Fuel Capacity 4.2 Gallons Engine Oil T ype SAE 5W40 Capacity 1-3/4 qts. Rated W attage 5,000 W atts Maximum W attage 6,000 W atts Run T ime @ 75% Load 8.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 9 Ignition Switch Low Oil W arning Light Fuse Cover V oltage Meter Run Hours Meter AC Power Selection Switch Circuit Breaker 120V GFCI Receptacles 120V & 240V Receptacle 12V 8.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 10 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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 1 1 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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 12 T urn the ignition key to the off posi- 1. tion. Push down on the fuel shut off lever 2. to release the Control Handle (13). T urn the fuel valve to its “OFF” posi - 3. tion. Start Procedure Before starting the engine: Follow the Set Up Instruc- a.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 13 Equipment Operation T o Power T ools 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.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 14 Mounting Hole Pattern.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 15 Shaft Size/T ype.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 16 TECHNICAL SPECIFICA TIONS Engine T ype Four Stroke Single Cylinder OHV Diesel, 10HP Bore x Stroke 86x72 mm Compression Ratio 19±:1 Displacement 418 cc Rotation viewed from PTO (power takeoff - the output shaft) Counterclockwise Fuel T ype #2 Diesel Fuel Capacity 4.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 17 Air Filter Element Maintenance Routine maintenance to the air 1. cleaner helps maintain proper airow to the engine. Service the air cleaner according to the following steps every 250 or 500 hours, or more often when using the generator in a dusty area.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 18 Cleaning, Maintenance, and Lubrication Schedule Note: This maintenance schedule is intended solely as a general guide. If performance decreases or if equip- ment operates unusually , check sys- tems immediately .
SKU 98391 For technical questions, please call 1-800-444-3353. Page 19 T roubleshooting Problem Possible Causes Probable Solutions Engine will not start FUEL RELA TED: No fuel in tank or fuel valve closed. 1. Air trapped in fuel line/Filter . 2. Low quality or deteriorated, old 3.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 20 T roubleshooting Problem Possible Causes Probable Solutions Engine backres Impure or low quality diesel fuel. 1. Engine too cold. 2. Engine not properly adjusted for 3. high altitude operation.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 21 MAIN ASSEMBL Y P ARTS LIST Part Description Qty 1 Upper Mufer 1 2 Lower Mufer 1 3 Mufer Gasket 2 4 Mufer Connection P.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 22 MAIN ASSEMBL Y DIAGRAM 39 49 50 Note: Wheels and Handles not shown..
SKU 98391 For technical questions, please call 1-800-444-3353. Page 23 CYLINDER BLOCK ASSEMBL Y P ARTS LIST Part Description Qty 1A Drain Plug 1 2A Drain Plug Gasket 1 3A Oil Seal 35x50x10 1 4A Cylind.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 24 CYLINDER BLOCK ASSEMBL Y DIAGRAM Note: Use the sufx “A” when ordering parts for this assembly . Note: Some parts are listed and shown for illustration purposes only , and are not avail- able individually as replacement parts.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 25 Note: Use the sufx “B” when ordering parts for this assembly . Note: Some parts are listed and shown for illustration purposes only , and are not available individually as replacement parts.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 26 CYLINDER HEAD BONNET P ARTS LIST & DIAGRAM Part Description Qty 1C V alve Cover 1 2C Ball 1 3C Breather 1 4C Pin 1 5C O-ring 12x1.9 1 6C Cover Gasket 1 7C Plunger 1 8C Decompression Spring 1 9C Decompression Shaft 1 10C O-ring 10x1.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 27 PIST ON & CONNECTING ROD P ARTS LIST & DIAGRAM Part Description Qty 1D Oil Ring 1 2D First Compression Ring 1 3D Second C.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 28 CRANK SHAFT & FL YWHEEL P ARTS LIST & DIAGRAM Part Description Qty 1E Ball Bearing 2 2E Balancer Shaft 1 3E Key 5x7 2 4E .
SKU 98391 For technical questions, please call 1-800-444-3353. Page 29 CAMSHAFT ASSEMBL Y P ARTS LIST & DIAGRAM Part Description Qty 1G Push Rods 2 2G V alve T appet 2 3G Camshaft Timing Gear 1 CA.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 30 AIR CLEANER ASSEMBL Y P ARTS LIST & DIAGRAM Part Description Qty 1H Air Cleaner Gasket 1 2H Intake Manifold 1 3H Air Cleaner .
SKU 98391 For technical questions, please call 1-800-444-3353. Page 31 OIL SYSTEM P ARTS LIST & DIAGRAM Part Description Qty 1J Bolt M6x8 3 2J Oil Pump Cover 1 3J O-ring 1 4J Outer Rotator 1 5J In.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 32 FUEL INJECTION PUMP P ARTS LIST & DIAGRAM Part Description Qty 1K Delivery Holder 1 2K Delivery Spring 1 3K Delivery Gasket 1.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 33 FUEL NOZZLE P ARTS LIST & DIAGRAM Part Description Qty 1M Nozzle Holder 1 2M Shim Set 1 3M Nozzle Holder Spring 1 4M Spring R.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 34 GOVERNOR & CONTROL SYSTEM P ARTS LIST & DIAGRAM Part Description Qty 1N Control Handle Shaft 1 2N Governor Handle Shaft 2 3N Governor Spring 1 4N Return Spring 1 5N High Speed Limit Screw 1 6N Nut M6 1 7N Bolt M6x14 1 8N Bolt M6x20 1 9N Nut M10x1.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 35 FUEL T ANK AND PIPE P ARTS LIST & DIAGRAM Part Description Qty 1P Fuel Level Gauge 1 2P Fuel T ank 1 3P Fuel Injection Pipe 1.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 36 MUFFLER P ARTS LIST & DIAGRAM Part Description Qty 1R Mufer 1 2R W asher 8 2 3R W asher 8 2 4R Nut M8 2 5R Bolt M8x12 2 Note: Use the sufx “R” when ordering parts for this assembly .
SKU 98391 For technical questions, please call 1-800-444-3353. Page 37 GENERA T OR P ARTS LIST & DIAGRAM Part Description Qty 1U Front Cover 1 2U Flange Bolt M8x30 4 3U Rotor Assembly 1 4U Bolt M6.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 38 CONTROL P ANEL P ARTS LIST & DIAGRAM Part Description Qty 1W AC Plug 2 2W Wiring Harness Assembly 1 3W Screw M4x10 2 4W Capac.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 39 WIRING DIAGRAM REV 09a Circuit Breaker.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 40 LIMITED 1 YEAR / 90 DA Y W ARRANTY Harbor Freight T ools Co. makes every ef fort to assure that its products meet high quality an.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 41 EMISSION CONTROL SYSTEM W ARRANTY United States Emission Control Defects W arranty Statement The United States Environmental Prot.
SKU 98391 For technical questions, please call 1-800-444-3353. Page 42 2) Air Induction System Intake pipe/manifold. i) Air cleaner . ii) 3) Ignition System Spark plug. i) Magneto ignition system. ii) 4) Catalyst System (if so equipped) Exhaust pipe stud.
An important point after buying a device Chicago Electric 98391 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Chicago Electric 98391 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Chicago Electric 98391 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Chicago Electric 98391 you will learn all the available features of the product, as well as information on its operation. The information that you get Chicago Electric 98391 will certainly help you make a decision on the purchase.
If you already are a holder of Chicago Electric 98391, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Chicago Electric 98391.
However, one of the most important roles played by the user manual is to help in solving problems with Chicago Electric 98391. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Chicago Electric 98391 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
