Chicago Electric 02514 User manual

GENERAGENERA
GENERATOR - DIESEL
20 KV20 KV
20 KV20 KV
20 KVA
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
Copyright © 2002 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.
For technical questions and replacement parts, please call 1-800-444-3353
02514
CHICAGO
Electric
Generators
Model

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Specifications
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 cover. Keep the manual and
invoice in a safe and dry place for future reference.
- Single phase, 230 VAC/115 VAC output, 60 Hz
- 87 amps (maximum)
- Rated output: 20 KVA
-Breakers:100amp(230Vside),100amp(115Vside)
- Make: Daewoo model DC - 23, diesel fuel, self-ventilating
- 32 HP
-1800RPM
- 4 cylinders, in-line, radiator cooled, overhead valve
-Displacement:2238cc
-Compressionration:17.2:1
- Ex-voltage: 92 volts; Ex-current: 5.4 amps
- Fuel consumption: At 75% load: 10.2 hours
- Battery: one 12 VDC, Marine Duty, 120 / AH / VDC
-Hightemperatureshutdown
-Emergencyshutdownpushbutton
- Emergency shutdown for low or high oil
- Battery rack
- 18 gallon fuel capacity
-Coolantcapacity:2.25gallons
- Fully enclosed bottom exhaust
-Soundproofhousing
- Meter (V.A.Hz)
-U,V, and W phase lights
-Fuel Level and oil pressure gauges
-Watertemperaturegauge
-Batterychargecurrent meter
-Powerlight
-Calculagraphcounter
- Low oil pressure light
-Highwatertemperaturelight
- Key switch: Run - Off - Preheat Start
-Emergencyshutdownpushbutton
- On / Off: 230V
- On / Off: 115V
75(L) x 57 (H) x 43-1/2 (W) inches
2,205 lbs.
Generator
Engine
Features
Indicators
Controls
OverallDimensions
Weight
ITEM DESCRIPTIONS

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Safety Warnings and Precautions
WARNING: Before using the generator, read and understand the Daewoo Engine Op-
eration,Maintenance,andPartsManuals.Alsoreadthesafetyprecautionsinthismanual
which should always be followed to reduce the risk of personal injury and damage to
equipment.
Read all instructions before installing or using this generator!
1. Ensure installation meets all applicable safety, and local and national electrical codes.
Have installation performed by a qualified, licensed electrician and building contractor.
2. Do not operate the generator with protective covers, access covers, or terminal box
coversremoved.
3. Disable closing circuits and place warning notices on any circuit breakers normally
used for connection to the mains or other generators to avoid accidental closure.
4. Do not alter or adjust any part of the generator assembled and supplied by the
manufacturer.
5. Do not attempt to operate the generator when conditions are unsafe. Disable the
generator by removing the battery until the unsafe condition is corrected.
6. Operate the generator only when in full compliance with relevant local and national
electrical codes and standards.
Handling and Installation Precautions
1. All electrical work, including earth-ground connection, should be completed by a
licensed electrician.
2. Any separate fuel storage generator supply facility, must be built or installed in full
compliance with relevant local, state, and federal regulations.
3. If the generator is installed indoors, exhaust fumes must be piped out of the building
using leak-free, heat-resistant piping. Pipes and silencer should not use any
flammable materials, nor should they be installed near the same. Generator exhaust
fumes should be within legal limits.
4. If the generator is installed outdoors, it must be weatherproofed and can be
soundproofed. It should not be run outdoors without protection to the generator and
wiring conduit.
5. Never lift the generator using the engine or alternator lifting lugs. Connect lifting
equipment to the holes on the bed frame of the generator.
6. Before lifting the generator, ensure the lift rigging and supporting structure are in good
condition, and are rated to lift such a load.
7. Keep all personnel away from the suspended generator during relocating.
8. The supporting floor should be level, and strong enough to safely hold the weight of
the generator. If the floor is not level, strong cross members should be placed under
the full length of the generator steel frame at its low side.

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9. For trailer installation, the generator must be mounted on the center point of the trailer,
over the wheels.
10. Install sound and weather proofing only when it is not raining or snowing to avoid
trapping moisture within the generator.
Fire and Explosion Precautions
1. Generator fuel and fumes are flammable, and potentially explosive. Use proper fuel
storage and handling procedures. Always have multiple ABC class fire extinguishers
nearby.
2. The generator room must be adequately ventilated. Exhaust fumes must be piped to
the outdoors.
3. Keep the generator, surrounding floors, and room clean at all times.
4. When spills of fuel, oil, battery electrolyte, or coolant occur, they must be cleaned up
immediately. Dispose of fluids and cleaning materials as per any local, state, or
federal codes and regulations. Store oil rags in a covered metal container.
5. Never store fuel or other flammable materials near the generator.
6. Do not smoke, or allow sparks, flames or other sources of ignition around the engine,
fuel tanks, or batteries. Fuel vapors are explosive. While charging, batteries emit
hydrogen gas which is highly explosive.
7. Turn off or disconnect the power to the battery charger before making or breaking
connections with the battery. Otherwise, sparking will occur.
8. 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.
9. Do not refill the generator fuel tank of the bed frame while the engine is running.
10. Do not operate the generator with known leaks in the fuel system.
11. Excessive buildup of unburned fuel gases in the exhaust system can create a
potentially explosive condition. This buildup can occur after repeated failed start
attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust system
drain plugs, if equipped, and allow the gases to dissipate before attempting to restart
the generator.
12. Use only engine manufacturer’s recommended fuel, oil, and cooling fluids (see engine
manufacturer’sinstructionmanuals).

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Mechanical Precautions
1. The generator is designed with guards for protection from moving parts. In any case,
care must still be taken to protect personnel and equipment from other mechanical
hazards when working around the generator.
2. Do not operate the generator with safety guards removed. While the generator is
running, do not attempt to reach around the safety guards for maintenance or any
other reason.
3. Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts, and
other moving parts. Be aware that when engine parts are moving fast they cannot be
seen clearly.
4. Keep access doors on enclosures closed and locked when access is not required.
5. When working in and around the generator always wear protective clothing including
gloves, safety goggles, and safety hat.
Chemical Precautions
1. Avoid contact with hot oil, coolant, exhaust gases, surfaces, and sharp edges and
corners.
2. Do not remove the radiator filler cap until the coolant has cooled. Loosen the cap
slowly to relieve any excess pressure, then remove the cap completely.
3. Avoid body contact with fuels, oils, coolants, lubricants and battery electrolyte used in
the generator. If swallowed, seek medical treatment immediately. Do not induce
vomiting if fuel is swallowed. For skin contact, immediately wash with soap and water.
For eye contact, immediately flush eyes with clean water.
4. When servicing the battery, wear an acid resistant apron and full face shield and safety
glasses. If electrolyte is spilled on skin or clothing, immediately flush with large
quantities of water.
Noise Precautions
This generator is equipped with sound attenuating enclosure. The generator can
product noise levels of up to 105 dBA. Prolonged exposure to noise levels above 85
dBA is hazardous to hearing. Always wear ear protection when operating or working
around the generator when it is running.
Electrical Precautions
1. All connections and conduit from the generator to the load must only be installed by
trained and licensed electricians, and in compliance with all relevant local, state, and
federal electrical codes and standards, and other regulations where applicable.
2. The generator must be earth-grounded in accordance with all relevant electrical
codes and standards before operation.
3. Before performing any maintenance or connecting or disconnecting any electrical load
connections, the negative (–) battery cable must be removed from the battery.

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4. Do not attempt to connect or disconnect load connections while standing in water, or
on wet or soggy ground.
5. Do not touch electrically energized parts of the generator and interconnecting cables
or conductors with any part of the body, or with any non-insulated conductive object.
6. Immediately replace the terminal box cover after making connection or disconnection
of cables within, or tightening cable lug nuts. Do not operate the generator with the
terminal box cover open.
7. All terminal box cable connections must be tight to avoid arcing. Arcing can heat up
and melt terminal lugs causing a disconnection and grounding of a live circuit.
8. Connect the generator only to a load or electrical system that is compatible with the
electrical characteristics and rated capacity of the generator.
9. Before servicing equipment powered by the generator, disconnect the equipment from
its power input.
10. Keep all electrical equipment clean and dry. Replace any wiring where the insulation
is cracked, cut, abraded or otherwise degraded. Replace terminals that are worn,
discolored, or corroded. Keep terminals clean and tight.
11. Insulate all connections and disconnected wires.
12. Use only Class BC or Class ABC fire extinguishers on electrical fires.
General Precautions
1. Check for damaged parts . Before using the generator, 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 any other condition that may affect proper
operation. Any part that is damaged should be properly repaired or replaced by a
qualified technician.
2. Guard against electric shock . Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.
3. 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 available from Harbor
FreightTools.
4. Do not operate generator 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 generator.
5. Maintenance . For your safety, service and maintenance should be performed
regularly by a qualified technician. Never work alone on the generator.
Warning: People with pacemakers should consult with their physician(s) before using this
product; operation of equipment in close proximity to a heart pacemaker could cause
interference or failure of the pacemaker.

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6. Pacemaker safety warning . People with pacemakers should consult with their
physician(s) before using this product; operation of equipment in close proximity to a
heart pacemaker could cause interference or failure of the pacemaker.
Warning: The warnings,cautions, and instructionsdiscussed inthisinstruction manual
cannot cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
First Aid for Electric Shock
1. Do not touch the victim’s skin with bare hands until the source of the electricity has
been turned off.
2. Turn the generator off.
3. Pull the plug or hot cable away from the victim using an insulated material.
4. Stand on dry insulating material and pull the victim clear of the conductor, preferably
using insulated material such as dry wood or an insulated hook.
5. Once the victim is free of the electric current, check for breathing. If not breathing,
perform CPR and keep the victim warm. Have someone call the paramedics.
Unpacking
When unpacking, handle shipping boxes and crates with care. When moving avoid drop-
ping or bumping. Verify that all parts are included and are in good condition. If any parts
are missing or broken, please call Harbor Freight Tools at the number on the cover of this
manual as soon as possible. Refer to the Daewoo maintenance manuals (supplied) for
detailed information: Operation, Maintenance, and Parts Book.
Installation
Before Installation
Prior to installation, verify that the generator’s rated wattage and amperage capacity is
adequate to supply all electrical loads that the unit will power. The transfer switch must also
be able to handle the loads.
If powering the entire facility exceeds the generator capacity, it may be necessary to group
the loads to critical and noncritical, and group the critical loads for connection to a separate
emergency distribution panel.
Note: Electrical and other permits may be required for the installation of emergency power
systems. Investigate the local building and electrical codes before installing this unit. Instal-
lation must be completed by licensed contractors.
Caution:Donotattempttostartorcrankthegeneratorenginebeforeithasbeenchecked
forsufficientand recommendedoil, coolant, andthe batteryis fully charged.Otherwise,
engine damage may occur.

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Warning: The generator weighs 2,205 lbs. Use care and the proper lifting or hoisting
equipment when moving it to the installation location. If hoisting with a crane, avoid
overhead power lines. Always connect hoist lines to the steel base of the generator.
Generator Location
• Locate and install the generator outdoors where cooling air is readily available. Do not
remove any part of the protective enclosure while operating.
• Install the generator so that the air inlets and outlets are not blocked by obstructions such
as bushes, trees, or snow drifts. Locating it in the path of heavy winds or snow drifts may
require the placement of a barrier for protection. The air inlet, in normal weather condi-
tions, should face the prevailing wind direction.
• Install the generator on a slab or other area where rain drainage or flood waters can not
reach it.
• Generator placement should allow four feet of access to all sides for maintenance.
• Place the generator as close as possible to the transfer switch and load to reduce the
length of cable runs.
• If the generator in located indoors, or in a generator house, the engine exhaust must be
ventilated to the outdoors using leakproof, heat resistant, metal flex tubing.
Transfer Switch Location
• Install the transfer switch indoors, and as close as possible to the (emergency) distribu-
tion panel, on a solid surface.
•Do not install the transfer switch where is can get wet or is exposed to moisture of any
kind. Avoid mounting in areas where there is corrosive vapors.
•Protect the transfer switch from dirt and dust.
Generator Support and Mounting
Mount the generator to a concrete slab able to support the weight of the generator. The
slab must extend beyond the steel base by at least one foot. Contact a cement contractor
for slab specifications if necessary. Attach the steel base to the concrete slab using large
and long, masonry type anchor bolts (not supplied).
Conduit and Wiring
All wiring must be of the proper AWG size and insulation, properly encased in NEC ap-
proved rigid conduit. Refer to the wiring illustrations on the next page.
Note: Specific generator voltage output, facility load, and transfer switch connections have
been left out, and should be at the discretion of the licensed electrical contractor for the
requirements of the facility load. It is important to balance all (phase) loads off the genera-
tor. If one phase draws more current than the others, damage can occur to the generator.
1. Install the 1-1/2” rigid conduit from the generator connection box to the outside of the
generator housing. Mount a junction box which connects it to the external rigid conduit
routed to the transfer switch.

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2. Pull and route the wires from the generator connection box to the transfer switch.
3. Make the appropriate connection within the transfer switch.
Warning: Remove power to the utility power supply leads by removing the master cir-
cuit breaker, and label “Do Not Touch - Wiring in Progress”.
4. Connect the utility power supply leads to the transfer switch.
5. Connect the circuit load leads from the emergency distribution panel (if used) to the
transfer switch.
Generator Connection Box
Typical Emergency Power System
115V
220V
U2 U4
U2 N U4
N

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Grounding the Generator
Drill a hole in the Generator connection box and place wire connection hardware (not sup-
plied). Connect a #6 AWG grounding wire from the wire lug to the grounding rod as shown
on page 9. The grounding rod must be an earth-driven copper or brass rod (electrode) which
can adequately ground the generator.
Battery Preparation and Installation
The generator requires one 12 volt Marine Duty battery (not supplied). Refer to the Daewoo
Engine Maintenance manuals for specific information regarding the battery.
1. Check the battery cell for the proper level of electrolyte fluid. Fill
in necessary.
2. Slow charge the battery for 24 hours prior to use.
3. Verify that the Generator keyed Power Switch is in the OFF
position.
4. Place and secure the battery inside the generator housing, to
the right of the door.
5. Connect the red cable terminal lug to the positive terminal of the
battery, and the black cable terminal lug to the negative terminal
ofthe battery.
Caution: During battery charging, explosive vapors may be emitted from the battery.
Ventilate the area and avoid smoking or other ignition points.
Post Installation Inspection
Before placing the emergency generator into service, inspect the entire installation carefully.
Some local codes may require that an inspection be performed by a building and electrical
inspector.
Operation
During operation, it may be necessary to refer to the Daewoo maintenance manuals (sup-
plied) for detailed information on engine operation, maintenance, and parts.
Pre-start Checks
1. Verify that the ON/OFF switch is in the Off position.
2. Check fuel level. If low, refill with clean diesel fuel.
3. Check oil level. Add oil if low.
4. Check coolant level. Add coolant if low.
5. Check voltage cables junction box for secure and clean connections.

Page 11SKU 02514
6. Press the circuit breaker (down) to the off position.
7. Notify facility personnel that power will shortly be restored, and that they should turn
off surge-sensitive equipment.
8. Turn off the utility power supply to the transfer switch from the utility main line circuit
breaker.
9. Set the transfer switch to the standby (generator-to-load) position.
Controls and Indicators
The table on the next page defines each item on the Control Panel.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15

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1 I Meter:Water Temperature
2 I Light:Power Supply
3 I Digital:V.A.Hz
4 I High Water Temperature Alarm
5I Meter:Oil pressure
6 I Light:Low Oil Pressure Alarm
7 C Push button:Emergency Stop
8 C Circuit Breaker
9 I Meter: Battery Change Current
11 I Calculagraph
12 C Switch:Voltage Change 230/115V
13 C Switch:Run,Off,Preheat,Start
14 I Meter:Fuel Level
Startup
1. Verify all Pre-start Checks have been completed (see page 10 and 11).
2. Insert the key into the generator keyswitch .Turn key to "Preheat" for 10 seconds
(Do this only under cold weather conditions).
3. Turn key switch to “Start” to start the engine. If it does not start in 10 seconds repeat,
step 2.Once the engine starts, turn the Key to "Run".
4. Set the generator circuit breaker (up) to On. The generator is now supplying power to
the load.
5. View the ampere and voltage meters on the control panel. Adjust voltage regulator to
change voltage, if necessary. Total ampere should not exceed the maximum capacity of the
generator.
6. Listen for unusual noises, vibration, or other indications of abnormal operation. Check
for oil leaks and evidence of overheating.
* C = Control, I = Indicator
Controls and Indicators
ITEM C / I * DESCRIPTION
15 C Push Button:Alarm Reset
10 C Voltage Regulator(A.V.R)

Page 13SKU 02514
Shutdown
1. Flip the generator circuit breakers (down) to the Off position.
2. Allow the generator to run for a few minutes without a load.
3. Press the red Emergency Stop button (7) to stop the engine .
4. Turn the key to the “Off” position.
5. Set the transfer switch to the utility power (position) once the utility power is restored.
Maintenance
Preventative Maintenance
Preventative maintenance procedures and frequency will vary depending on the amount of
generator use. Refer to the Daewoo Engine Maintenance manual for specific instructions.
Caution: All maintenance must be done by a qualified mechanic or electrican.
Every Six Months or 2500 Hours of Use
1. Check fuel, oil, and coolant levels. Refill or replace as required.
2. Check and replace fan belt if cracked, torn, deteriorated, or frayed.
3. Check oil pressure (when running) and for oil leaks. Replace oil filter when replacing
the oil.
4. Drain water from the fuel filter. Replace after 400 hours of generator use.
5. Clean or replace air filter.
6. Check battery for complete charge, electrolyte levels, and leaking fluids. Recharge, or
replace battery if it will not hold a charge.
7. Clean all battery cap vents.
8. Start the generator and observe that all gauges and meters on the control panel are
operating properly.
9. Check exhaust connections for tightness.
10. Check all electrical connections for tightness.
PLEASEREAD THE FOLLOWING CAREFULLY
THEMANUFACTURERAND/ORDISTRIBUTORHASPROVIDED THEPARTS DIAGRAMINTHIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU-
TORMAKES ANY REPRESENTATION OR WARRANTY OF ANYKINDTO THE BUYER THATHE
OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER
AND/ORDISTRIBUTOREXPRESSLYSTATESTHATALLREPAIRSANDPARTSREPLACEMENTS
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 INSTALLATION OF REPLACEMENT PARTS THERETO.

K
Page 14SKU 02514
Fig.3 Diagram For Protection Patter Plate Of
Diesel Generating Set Oil
Pressure And Water Temperature
Plug 1 (Female) Plug 2 (Male)
Fig.4Instruction For The Plug Of Diesel Generating
Set Protection Pattern Plate
KEY
BATTERY
K
WATER TEMPERATURE TRANSDUCER
OIL PRESSURE TRANSDUCER
STOP
LOW OIL PRESSUER
HIGH WATER TEMPERATURE
RESET

Page 15SKU 02514
Single-Phase A.C.Synchronous Generator
Schematic Diagram
A V R
3
4
56
1
2
Z1
Z2
F2
F1
U2
N
U1
1.Main Winding
2.Harmonic Coil Of
The Auxiliary
3.Automatic
Voltage Regulator
4.AVR Winding
5.Silicon Rectifier
6.Stator's Harmonic
Generator Layout Diagram
1.DIesel Engine
2.Couple Kit
3.Generator
4.Sound-Proof
Housing
5.Fuel Tank
6.Contorl Cables
7.Contorl Panel
8.Base Frame
9.Anti-Vibration
Mounting Base
10.Exhaust Pipe
11.Radiator

Page 16SKU 02514
1.Change Switch 2.Indicating Lamp 3.Calculagraph
4.Meter 5.Start Key 6.DC Charge Current Meter
7.Generator 8.Start Motor 9.Preheat Winding
10.Battery
Wiring Diagram Of Engine Control
£
£
£
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12
4
?
?1
Circuit breaker