Chicago Electric 45416 Assembly and User manual

10 KW GENERA10 KW GENERA
10 KW GENERA10 KW GENERA
10 KW GENERATORTOR
TORTOR
TOR
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at http://www.harborfreight.com
Copyright © 2001 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 FreightTools.
For technical questions and replacement parts, please call 1-800-444-3353
45416
®
REV 09/03

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.
Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be followed to
reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically
powered tools in the presence of flammable gases or liquids.
3. Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
4. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit
rust. Always lock up tools and keep out of reach of children.
5. Do not force tool. It will do the job better and more safely at the rate for which it was
intended. Do not use inappropriate attachments in an attempt to exceed the tool
capacity.
6. Use the right tool for the job. Do not attempt to force a small tool or attachment to do
the work of a larger industrial tool.There are certain applications for which this tool
was designed. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.
7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
SKU 45416 Page 2 REV04/02;09/03;12/03
THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC
EQUIPMENTWITHOUTTHE ADDITION OF AN APPROPRIATELINECONDITIONER(SOLDSEPARATELY).
Specifications
ITEM DESCRIPTION
Power Output 10,000 watts (maximum), 7200 watts continuous (rated); 60 Hz
Voltage Output 2 - 120 VAC (20 amp), single phase duplex receptacle;
1 - 120 / 240 VAC (30 amp), single phase twistlock receptacle
Motor Driver Requirements 3600 RPM, 16 HP
Drive Type Belt driven
Drive Shaft 1 inch (dia.) meter; length: 2-3/8 inches;
Keyway: 1/4 (W) x 2 (L) inches
Generator operation 2-pole, revolving field, brushless excitation

8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.
9. Maintain tools with care. Keep tools sharp and clean for better and safer
performance. Follow instructions for lubricating and changing accessories. Inspect tool
cords periodically and, if damaged, have them repaired by an authorized technician.
10. Disconnect power.Unplug connected appliances when not in use.
11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches
are removed from the tool or machine work surface before turning on.
12. Avoid unintentional starting. Be sure that all connected appliances are Off before
startingthe generator.
13. Stay alert. Watch what you are doing, use common sense.Do not operate any tool
when you are tired.
14. Check for damaged parts. Before using any tool, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures;and any other condition that may affect proper operation.Any part
that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the tool if any switch does not turn On and Off properly.
15. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
16. Replacement parts and accessories. When servicing, use only identical
replacement parts.Use of any other parts will void the warranty.Only use accessories
intended for use with this tool. Approved accessories are available from Harbor Freight
Tools.
17. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
18. Use proper size and type extension cord. If an extension cord is required, it must be
of the proper size and type to supply the correct current to the tool without heating up.
Otherwise, the extension cord could melt and catch fire, or cause electrical damage to
the tool.Depending on the appliance connected to the generator, the use of an
extension cord should have a 0 to 20 amp capability (up to 50 feet), with wire size
rated at 14 AWG. Longer extension cords require larger size wire. If you are using the
tool outdoors, use an extension cord rated for outdoor use.(signified by “WA” on the
jacket).
19. Maintenance. For your safety, service and maintenance should be performed
regularly by a qualified technician.
SKU 45416 Page 3 REV 04/02
WARNING
Anextension cordthat ishotto thetouch isoverloaded. Repair orreplacedamaged extension
cords immediately.

Electric Generator Safety Precautions and Warnings
1. TheGenerator produceselectricalcurrent. Improperusecan resultinelectrocution, injury
or death. Only a qualified technician should service or repair this generator.
2. The Generator was designed to be used in a dry area.Do not expose to rain, snow, sleet,
or damp conditions.Damage to the Generator could occur.Moisture can carry electrical
current and could cause electrocution.
3. If the Generator is connected to a building, home, business, or any other electrical circuit
normally fed by utility power, steps must be taken to ensure that the Generator output
andtheutilitypower arepositivelyisolated. Donotplug otherappliancesintotheelectrical
outlet being used to power the Generator. Failure to isolate the systems will result in
Generatordamage.It couldalsoresult in personalinjuryor deathtothoseworking around
these circuits. Any connection in this regard must only be done by a licensed electrician.
4. Do not exceed the Generator’s rated capacity. The total electrical loads at each outlet
must be added to determine the total electrical load. If the electrical appliance does not
list the wattage rating, you can calculate it by multiplying amps times voltage (amps x
voltage= watts).
5. Donottamper with thedrive,engine-governedspeed.TheGeneratoroperatesatanominal
speed of 3600 RPM. Increases in speed could damage rotating parts of the Generator.
Slower speeds could damage the Generator or appliances connected to the Generator
due to low voltage.
6. Always follow national and local safety codes.
7. Do not start the Generator with appliances connected and turned on.
8. If the driver motor is a gas engine, do not used in an enclosed area due to the carbon
monoxide fumes produced.The fumes can be deadly.
9. Give the Generator at least two feet of space to dissipate heat.
10. Properly ground the Generator.The National Electrical Code requires that the Generator
frame be properly grounded to earth.This should be done by a licensed electrician.
11. Never handle electrical charged extension cords while standing in water.
12. Only use 3-prong, grounded extension cords.
13. Keep fingers and hands away from the spinning pulleys.
14. Install a safety guard around the pulleys.
15. WARNING! People with pacemakers should consult their physician(s) before using this
product. Electromagnetic fields in close proximity to a heart pacemaker could cause
interference to or failure of the pacemaker.
GroundingInstruction:Thisgeneratorshouldbegroundedtohelppreventaccidentalelectrical
shock. Drivea3/4”or1” diametercopper pipeorrodintotheground close tothegenerator
set. Thepipe mustpenetratemoist earth. Using #10gauge wire, connectone endof the
wire to the generator frame. Connect the other end of the wire to the copper pipe or rod
using an approved ground clamp.
SKU 45416 Page 4 REV 04/02;02/04

SKU 45416 Page 5 REV 04/02
MOUNTING PLATE
FOR
GENERATOR / ALTERNATOR 10KW
SKU 45416
A mounting plate (not included), similar to the one illustrated below, will need to be provided by the
customer to properly and safely mount and operate the generator/alternator. The plate is needed to
properly tension the drive belt used to drive generator/alternator. Drawing below is for reference only
and customer may need to make further modification to mounting plate and their generator frame for
the proper and safe mounting of the generator/alternator. The drawing gives dimensions for the plate
and generator/alternator footprint.
THE MANUFACTURE AND OR DISTRIBUTOR HAS PROVIDED THE MOUNTING PLATE DIAGRAM AS A
REFERENCETOOL ONLY. THE CUSTOMER CAN CHOOSETO DESIGN, MANUFACTURE AND USETHEIR
OWN MOUNTING PLATE. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
MANUFACTURING OF A MOUNTING PLATE THAT IS NOT INSTALLED PROPERLY AND SAFELY
MANUFACTURED.
DRAWING NOTTO SCALE, FOR REFERENCE ONLY !!
Note:Performance of this tool may vary depending on variations of the power driver motor.
Warning:The warnings,cautions,and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be 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.
Material: 1/2” steel plate

SKU 45416 Page 6 REV 04/02
The customer will need to supply the following hardware (not included):
1) (4) Grade 3, 5/16” -18 x 1-1/4”L hex-head bolts
2) (4) 5/16” -18 hex nuts
3) (4) 5/16” lock washers
4) (4) 5/16” flat washers
INSTRUCTIONS – INSTALLING GENERATOR/ALTERNATOR ON MOUNTING PLATE
1) Remove both fan covers (part# 26) from shaft end of generator/alternator.
2) Remove wiring box (part# 10) from opposite end of generator/alternator shaft.
3) Place generator/alternator so that through holes on bottom of generator/alternator are
readily accessible (facing up).
4) Place mounting plate, with countersinks holes facing up, on bottom of generator/
alternator and line-up holes on mounting plate and generator/alternator.
5) Insert one (1) 5/16”-18 hex-head bolt in each through hole in mounting plate and
generator/alternator.Insure that heads of bolts are below the surface of the mounting
plate.
6) Place one (1) flat washer, lock washer and hex nut on each bolt and tighten.
7) Turn and place generator/alternator back on mounting plate.
8) Replace both fan covers (part# 26) and wiring box (part#10).
This completes the installation of the mounting plate to the generator/alternator.Customer is
now to proceed to the Installation portion of the manual to complete the mounting of the
generator/alternator and mounting plate to generator frame. Again, it may be necessary for
the customer to further modify the mounting plate and generator frame to complete
installation.
MOUNTING PLATE
FOR
GENERATOR / ALTERNATOR 10KW
SKU 45416

Unpacking
When unpacking, check to make sure the Generator is complete. If any parts are missing or
broken, please call Harbor FreightTools at the number on the cover of this manual as soon
as possible.
Installation
1. Verify that the driver motor is securely mounted to a stable surface (see Mounting Plate
instructions on pages 5 and 6), and belt pulleys properly attached. Refer to the photo
below.
2. Mount the double pulley (not supplied) onto the Generator (1 inch) shaft. Make sure
that the pulley set screws are properly tightened.
3. On the same surface, mount the Generator, offset to the shaft of the motor driver.
The belts should be placed on the pulleys to determine the proper distance between
drive shafts.Allow room for adjustments after mounting the Generator.
4. For safe operation, install a pulley guard (not included) around both pulleys.
Operation
1. Plug in the extension cords or appliances, making sure they are turned off.
Refer to the connector wiring illustration on the next page. Do not overload the
Generator.Calculate the total wattage of the appliances.Generator maximum power
output is 10,000 watts.
2. Start themotor driver.
3. Begin using the appliances when the motor driver is at full speed.
4. If electricity to one of the outlets stops, it could be that the circuit was overloaded.
Check you appliance wattage, then push in on the Reset button to resume power.
Generator
DoublePulley
MotorDriveDoublePulley
MotorDrive Generator
SKU 45416 Page 7 REV 04/02

5. When you are finished using the Generator, stop the motor driver, then disconnect the
appliances.
Maintenance
WARNING:Before performing any maintenance on the Generator,the motor driver must
be off, and the Generator must be allowed to cool down after use.
1. Clean the Generator with compressed air.Do not blow directly into the heat vents.Do
not immerse in water.Use a damp cloth do wipe clean.
Never insert rags, tools, or any device into the Generator openings.
2. Periodically operate the Generator.
3. Store in a clean and dry location.
4. Check and tighten belts when they become loose.
5. Check and tighten pulley set screws.
SKU 45416 Page 8 REV02/02;04/02;09/03
120 Volt
Duplex
Outlet
Over Current
Reset Buttons
120 / 240Volt
Twistlock Outlet

Parts List
PLEASE READTHE FOLLOWING CAREFULLY
THEMANUFACTURERAND/ORDISTRIBUTORHASPROVIDEDTHEPARTSDIAGRAMINTHIS
MANUAL AS AREFERENCETOOL ONLY. NEITHERTHE MANUFACTURERNORDISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KINDTOTHE BUYER THAT HE OR
SHEISQUALIFIEDTO MAKE ANY REPAIRSTOTHEPRODUCTORTHAT HE ORSHEISQUALI-
FIEDTO REPLACE ANY PARTS OFTHE PRODUCT. IN FACT,THE MANUFACTURER AND/OR
DISTRIBUTOREXPRESSLYSTATESTHATALLREPAIRSANDPARTSREPLACEMENTSSHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSEDTECHNICIANS AND NOT BY THE BUYER.
THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRSTO
THEORIGINALPRODUCT OR REPLACEMENTPARTSTHERETO, ORARISINGOUTOFHISOR
HERINSTALLATION OF REPLACEMENTPARTSTHERETO.
SKU 45416 Page 9 REV 02/02; 04/02; 04/03; 09/03
1 Over Current Protector (20 amp) 2
1A Over Current Protector (30 amp) 2
2 Spring washer, GB93-87, M4 4
3 AC Socket, 120V/120V 1
4 AC Socket, 120V/240V 1
5 Bolt, GB818-85, M5x12 13
6 SpringWasher, GB93-87, M5 13
7 Washer, GB 97.1-85, 5 13
8 Over Current Protector Nut 2
9 OverCurrent ProtectorWasher 2
10 Wiring Box 1
11 Bolt, GB5783-B6, M4x10 4
12 Fastener Clip 2
13 Capacitor 1
14 Bolt, GB5782-86, M8x280 4
15 Spring Washer, GB 93-87, 8 4
16 Washer, 8 4
17 Front Cover 1
18 Stator 1
19 AxleTree, GB 278-89, 80204 1
20 Rotator 1
22 Fan 1
23 Baffle 1
24 Axle Tree, GB278-89, 80206 1
25 Washer, GB894.1-86-30 1
26 Fan Cover 2
27 Back Cover 1
28 Bolt, GB5783-86, M5x25 2
29 Voltmeter 2
Item # Description Qty

Assembly Drawing
NOTE:Somepartsarelistedandshown
forillustrationpurposesonlyand are not
available individually as replacement
parts.
SKU 45416 Page 10 REV 04/02; 04/03; 09/03
Note: Voltmeters(#29)locatedon
WiringBox are notshown.

SKU 45416 Page 11 REV 09/05
Schematic Diagram