Chicago Electric 98391 User guide

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.
Only use OUTSIDE
and far away from
windows, doors, and
vents.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
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.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 2
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 4
BASIC SPECIFICATIONS ............. 8
UNPACKING .................................. 8
SET UP INSTRUCTIONS............... 8
LOCATION.......................................... 8
CONTROLS ................................... 9
GROUNDING....................................10
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
MAINTENANCE PROCEDURES .....14
ENGINE OIL CHANGE ............... 14
AIR FILTER ELEMENT
MAINTENANCE .......................14
FUEL FILTER REPLACEMENT..14
REPLACING THE AC FUSE.......15
CLEANING, MAINTENANCE, AND
LUBRICATION SCHEDULE ..........15
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
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
CAMSHAFT ASSEMBLY PARTS
LIST & DIAGRAM...................... 27
AIR CLEANER ASSEMBLY
PARTS LIST & DIAGRAM......... 28
OIL SYSTEM PARTS LIST &
DIAGRAM .................................. 29

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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

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SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
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.
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.
and potentially explosive. Use proper
fuel storage and handling proce-
dures. 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.

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Wear ANSI-approved safety goggles,5.
heavy-duty work gloves, and dust
mask/respirator during set up.
Use only oil and fuel recommended6.
in the “Specications” section of this
manual.
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.
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 goggles4.
and hearing protection during use.
People with pacemakers should5.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to a heart pacemaker could
cause pacemaker interference or
pacemaker failure. Caution is neces-
sary when near the engine’s magneto
or recoil starter.
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 doing8.
and use common sense when operat-
ing this piece of equipment. Do not
use this piece of equipment while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper foot-9.
ing and balance at all times. This en-
ables better control of the equipment
in unexpected situations.
Dress properly. Do not wear loose10.
clothing or jewelry. Keep hair, cloth-
ing and gloves away from moving
parts. Loose clothes, jewelry or long
hair can be caught in moving parts.
Parts, especially exhaust system11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment12.
during operation.

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Keep the equipment, engine, and sur-13.
rounding area clean at all times.
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 differ-
ent from those intended could result
in a hazardous situation.
Do not operate the equipment with15.
known leaks in the engine’s fuel sys-
tem.
This product contains or, when used,16.
produces a chemical known to the
State of California to cause cancer
and birth defects or other reproduc-
tive harm. (California Health & Safety
Code § 25249.5, et seq.)
When spills of fuel or oil occur, they17.
must be cleaned up immediately.
Dispose of uids and cleaning materi-
als 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 from18.
moving parts. Do not reach over or
across equipment while operating.
Before use, check for misalignment19.
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 main-
tained equipment.
Use the correct equipment for the20.
application. Do not modify the equip-
ment and do not use the equipment
for a purpose for which it is not in-
tended.
Wash hands with soap and water21.
after handling diesel fuel or lubricat-
ing oil.
SERVICE PRECAUTIONS
Before service, maintenance, or1.
cleaning:
Turn the engine switch to itsa.
“OFF” position.
Allow the engine to completelyb.
cool.
Keep all safety guards in place and in2.
proper working order. Safety guards
include mechanical guards, and heat
shields, among other guards.
Do not alter or adjust any part of3.
the equipment or its engine that is
sealed by the manufacturer or dis-
tributor. Only a qualied service
technician may adjust parts that
may increase or decrease gov-
erned engine speed.
Wear ANSI-approved safety goggles,4.
heavy-duty work gloves, and dust
mask/respirator during service.
All connections from the Generator to5.
the load must be installed by a li-
censed electrician in compliance with
local, state, and federal laws.
The generator must be grounded in6.
accordance with applicable electrical
codes and standards before opera-
tion.
Insulate all connections and discon-7.
nected wires.

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Do not connect or disconnect load8.
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.
Connect the generator only to a load10.
or electrical system (120 volt or 240
volt) that is compatible with the elec-
trical characteristics and rated capac-
ities of the generator.
Set up the generator outdoors in a11.
well-ventilated, dry area, away from
building air intakes. The genera-
tor 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 directly12.
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.
Do not charge vehicle batteries with13.
this Generator.
Maintain labels and nameplates on14.
the equipment. These carry impor-
tant information. If unreadable or
missing, contact Harbor Freight Tools
for a replacement.
Have the equipment serviced by a15.
qualied repair person using only
identical replacement parts. This will
ensure that the safety of the equip-
ment is maintained. Do not attempt
any service or maintenance proce-
dures not explained in this manual
or any procedures that you are un-
certain about your ability to perform
safely or correctly.
Store equipment out of the reach of16.
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 rell 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.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 8
BASIC SPECIFICATIONS
Fuel Type #2 Diesel Fuel
Capacity 4.2 Gallons
Engine Oil Type SAE 5W40
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 specications found in
the TECHNICAL ENGINE SPECIFI-
CATIONS chart in this manual.
At high altitudes, the engine’s carbu-
retor, governor, and any other parts that
control the fuel-air ratio will need to be
adjusted by a qualied mechanic to allow
efcient highaltitude use and to prevent
damage to the engine and any other de-
vices 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.
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.
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 installed1.
outdoors where ventilation is readily
available.
Install the Generator so that the air2.
inlets and outlets are not blocked by
obstructions 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.

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Ignition
Switch
Low Oil
Warning
Light
Fuse Cover Voltage
Meter
Run
Hours
Meter
AC Power
Selection
Switch
Circuit
Breaker
120V GFCI
Receptacles
120V & 240V
Receptacle
12V 8.3A DC
Receptacle
Grounding
Point
CONTROLS
Oil Cap/Dipstick
Battery Fuel Filter
Fuel
Shut-off
Valve Engine
Control
Handle
Fuel
Cut-off
Oil Drain Plug

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Install the Generator on a concrete3.
slab or other area where water can
not reach it.
Generator placement should allow4.
four feet of access on all sides for
maintenance.
Place the Generator as close as pos-5.
sible to the electrical tools and equip-
ment being powered to reduce the
length of extension cords.
Grounding
Connect a #12 AWG grounding wire1.
(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.
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.
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 and2.
remove it to check the oil level. The
oil level should be between the high
and low marks on the dipstick.
If the oil level is below the low mark3.
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.

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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-in1.
fuel gauge.
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-venti-
lated area away from ignition sourc-
es. 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 Tank3.
Cap.
Fill the Fuel Tank to about 1 inch4.
under the ll neck of the tank with #2
diesel.
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 to1.
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
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 injector3.
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
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 bat-
tery’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.

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Turn the ignition key to the off posi-1.
tion.
Push down on the fuel shut off lever2.
to release the Control Handle (13).
Turn the fuel valve to its “OFF” posi-3.
tion.
Start Procedure
Before starting the engine:
Follow the Set Up Instruc-a.
tions to prepare the equip-
ment.
Inspect the equipment andb.
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 Generator1.
before starting to prevent permanent
damage to any appliances or tools.
Depress the Decompression Handle2.
(16) all the way (Cold starting only).
Open the front3.
panel and turn the fuel shut-off valve
to its “OPEN” position.
Rotate the Control Handle (13) to the4.
right until release button on the Right
hand side of the Handle Bracket (12)
pops up and locks in place.
Insert the en-5.
gine key into the ignition and turn it to
“START” position for up to 10 sec-
onds. Note: To prolong starter life,
use short starting cycles (10 seconds
maximum). If the engine does not
start, wait one minute before attempt-
ing to start again.
Break-in Period
Breaking-in the engine will help to1.
ensure proper equipment and engine
operation, and will extend the en-
gine’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
schedule explained in the MAINTE-
NANCE AND SERVICING section.
Decompression
Handle
Release
Button
Control
Handle

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Equipment Operation
To Power Tools and Equipment:
Move the AC Power Selection Switch1.
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 wattage 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 Genera-
tor.
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 con-
nect 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.
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
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 the5.
key and disconnect negative battery
terminal after use. Wait for the en-
gine to cool, clean external parts with
clean cloth, then store the equipment
out of children’s reach according to
the Storage instructions in this man-
ual. If the Generator is not going to
be used again soon, drain the diesel
fuel.

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Mounting Hole Pattern

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Shaft Size/Type

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TECHNICAL
SPECIFICATIONS
Engine Type
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 Type #2 Diesel Fuel
Capacity 4.2 Gallons
Engine Oil Type 5W-40
Capacity 1-3/4 qts
Valve
Clearance
(COLD)
Intake 0.10~0.15 mm
Exhaust 0.10~0.15 mm
Speed Idle 1,100 RPM
Maximum 3,600 RPM
The emission control system for
this Generator’s Engine is warranted for
standards set by the U.S. Environmental
Protection Agency. For warranty information,
refer to the last pages of this manual.
SERVICING
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 performing any
inspection, maintenance, or
cleaning procedures.
TO PREVENT
SERIOUS INJURY
FROM EQUIPMENT FAILURE:
Do not use damaged
equipment. If abnormal noise,
vibration, or excess smoking
occurs, have the problem
corrected before further use.
Maintenance Procedures
Many maintenance procedures,
including those not detailed
in this manual, will need to
be performed by a qualied
technician for safety. If you
have any doubts about your
ability to safely service the
equipment or engine, have a
qualied technician service the
equipment instead.
Note: Warranty is void if proper mainte-
nance and servicing procedures are
not followed.
Engine Oil Change
CAUTION! Oil is very hot during opera-
tion and can cause burns. Wait for
engine to cool before changing oil.
Place a drain pan (not included) un-1.
derneath the crankcase’s drain plug.
Remove the drain plug and empty oil.2.
Recycle used oil.
Inspect drain plug gasket for damage3.
or tears. Replace gasket if damaged.
Replace the drain plug and tighten it.
Rell the oil to the proper level follow-4.
ing the instructions under the Starting
the Engine section.
REV 09a

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Air Filter Element Maintenance
Routine maintenance to the air1.
cleaner helps maintain proper airow
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.
Wipe off the air cleaner cover.2.
Remove the air cleaner maintenance3.
panel by unscrewing the bolts with
10-mm wrench.
Remove the wing nut from the bolt4.
holding the air cleaner cover. Re-
move the air cleaner cover.
Take out the used air cleaner ele-5.
ment. Replace with a new element.
Reinstall the air cleaner cover, tighten6.
the wing nut, then screw back the air
cleaner maintenance panel.
Fuel Filter Replacement
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Replace the fuel lter in a
well-ventilated area away from igni-
tion sources. Do not smoke.
Wait for engine to cool completely1.
before proceeding.
Wear protective gear including, ANSI-2.
approved safety goggles.
Turn the fuel valve to the “off” posi-3.
tion.
Unscrew the bolt holding the fuel lter 4.
to the frame using a 13 mm wrench.
Pull the fuel valve/lter assembly out
of the enclosure. Place a bucket un-
der the assembly to catch the fuel.
Remove the fuel lter cup, and the 5.
lter element.
Clean the cup of all sediment using a6.
rag or brush.
Replace the fuel lter element 7.
Reinstall the fuel lter element, ll 8.
the cup with fresh and clean diesel
fuel and assemble per stps 5 and 4
above.
Open the fuel valve until the lter is 9.
lled.
Remove the hose clamp and slightly10.
remove fuel outlet hose to purge out
any trapped air in the line. Re-attach
the hose and clamp.
Remove four screws and Injector11.
Inspection Cover (49) from top of
Sound Shield Panel (41). Place a
clean rag under the injector inlet and
using two wrenches loosen input line
nut by one turn. Tap starter to force
fuel out of injector line. When air
bubbles stop, re-tighten the input line
nut.
REV 09a

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. The maintenance
needs of each piece of equipment will
differ depending on factors such as
duty cycle, temperature, air quality,
fuel quality, and other factors.
Note: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular op-
eration of the engine and equipment.
After Initial 20 Operation Hour Period:
Change engine oil.a.
Every 50 Operation Hours:
Replace fuel lter.a.
Every 100 Operation Hours:
Change engine oil (or with frequenta.
use; every three months).
Note: All maintenance procedures sched-
uled for 25, 50, and 100 operation
hours should be performed at least
yearly.
Every 250 Operation Hours:
Clean fuel tank.a.
Clean carbon build-up from combus-b.
tion chamber.
Replace the air lter.c.
Every 500 Operation Hours:
Clean fuel tank and fuel lter.a.
Storage
Wait for engine to cool, then clean1.
engine with clean cloth.
When the equipment is to remain idle2.
for longer than 20 days, prepare the
engine for storage as follows:
Wait for engine to cool.a.
Disconnect battery.b.
Drain fuel tank.c.
Change engine oil.d.
Cover and store in a dry, well-ventilat-3.
ed area out of reach of children.
Diesel Fuel and Microbes
Microbes can grow in Diesel fuel and1.
can, over time, interfere with the Gen-
erator’s performance. When perfor-
mance begins to suffer and the en-
gine begins to produce black smoke,
a high-quality biocide must be added
to the fuel to kill the microbes. If left
untreated the microbes will eventually
clog the fuel lines and ruin the equip-
ment. The biocide must continue
to be added to the fuel until the mi-
crobes are completely destroyed and
the fuel runs pure again.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 19
Troubleshooting
Problem Possible Causes Probable Solutions
Engine will not
start
FUEL RELATED:
No fuel in tank or fuel valve closed.1.
Air trapped in fuel line/Filter.2.
Low quality or deteriorated, old3.
diesel.
Not enough oil in crankcase.4.
Dirty fuel passageways blocking5.
fuel ow.
Low oil sensor failure.6.
Generator is not on level surface.7.
Load connected.8.
Air lter dirty.9.
Battery dead.10.
FUEL RELATED: *
Open fuel valve and ll fuel tank.1.
Bleed fuel line.2.
Use only fresh #2 diesel fuel.3.
Add or replace oil.4.
Clean out passageways using5.
diesel fuel additive or biocide.
Heavy deposits may require further
cleaning.
Add oil, disconnect low oil6.
sensor, start engine and allow to
run for several minutes before
reconnecting the sensor.
Move the generator to a level7.
surface to prevent low oil shutdown
from triggering.
Disconnect load.8.
Change air lter.9.
Replace battery.10.
Black smoke from
exhaust
Generator overloaded.1.
Oil in cylinder.2.
Contaminated diesel fuel.3.
Fuel injection malfunction.4.
Clogged air lter.5.
Improper setting for specic altitude.6.
Reduce load.1.
Check oil level and drain excess2.
from crankcase.
Treat engine with biocide.3.
Have the Generator serviced by a4.
qualied mechanic.
Replace air lter.5.
Have a qualied technician inspect/6.
reset the engine fuel system.
White smoke
from exhaust
Water in fuel.1. Empty and clean fuel tank, fuel lines1.
and lter.
Generator runs
but does not
support all loads.
Device connected is faulty.1.
Engine overloaded.2.
Check devices for problems.1.
Turn off and unplug devices, shut2.
Generator off for several minutes,
restart generator, connect fewer
loads.
* Every time fuel system is serviced, replace the fuel lter.
Follow all safety precautions whenever diagnosing or servicing the
equipment or engine.

SKU 98391 For technical questions, please call 1-800-444-3353. Page 20
Troubleshooting
Problem Possible Causes Probable Solutions
Engine backres Impure or low quality diesel fuel.1.
Engine too cold.2.
Engine not properly adjusted for3.
high altitude operation.
Intake valve stuck, incorrect timing,4.
clogged carburetor, or overheated
engine.
Fill fuel tank with fresh #2 diesel1.
fuel.
Use cold weather fuel and oil2.
additives to prevent backring.
Qualied technician must adjust 3.
engine at altitudes greater than
5,000 feet above sea level.
Have qualied technician diagnose 4.
and service engine.
AC output, but no
DC output
Fuse burnt out.1. Replace Fuse.1.
* Every time fuel system is serviced, replace the fuel lter.
Follow all safety precautions whenever diagnosing or servicing the
equipment or engine.