Chicago Electric 95126 User manual

GASOLINE GENERATOR
3500W
Model 95126
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright 2006 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, please call 1-800-444-3353.
®
©
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
Do to continuing improvements, actual product may differ slighlty from the product described herein.
A. You do not put engine oil in the Engine’s crankcase prior to its first use.
Before each use, check the oil level. Never run the Engine with low or no engine oil.
Running the Engine with low or no oil will permanently damage the unit.
CAUTION!
Your Warranty Is Voided If:

PRODUCT SPECIFICATIONS
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
GENERAL SAFETY RULES AND PRECAUTIONS
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Power tools create
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 2
The Emission Control System for this generator’s engine is warranted for standards set by the U.S.
Environmental Protection Agency and by the California Air Resources Board (also known as CARB). For
warranty information, refer to the last pages of this manual.
Item Description
Electrical Requirements Alternator Type: Single Phase, Brushless
Output: 3000W Rated / 3500W Peak
Rated Voltage: 120 VAC, 25 Amp / 240 VAC, 12.5 Amp / 60
Hz
AC Receptacles: 120 VAC, 3-Prong Grounding Plug (Qty. 2)
240 VAC, 4-Blade Twistlock Plug (Qty. 1)
– NEMA L14-30
DC Receptacle: 12 VDC Output Terminal with Cap Screws
(Qty 1)
Circuit Breaker: 13 Amp
Overload Protection: Resettable Circuit Protection
Engine Specifications Engine Type: 4-Stroke, Overhead Valve, Single Cylinder
Engine Start Type: Recoil
Engine Displacement: 196cc
Engine Speed: 3600 RPM
Oil Capacity: 20 Fluid Ounces
Fuel Type: Unleaded Gasoline
Fuel Capacity: 3.96 Gallons
Recommended Oil Type: F-SAE 30W (Above 32°)
F-SA E 5W -30W (B elow 32°)
Run Time: 15 Hours Continuous Run Time on Full Tank @
50% Load
EPA/CARB Certified (Phase II, Category A)
Overall Dimensions 21-1/2” Long x 16-3/4” Wide x 17-1/2” High
Net Weight 98 Pounds
This product requires oil and fuel to be added before starting. Attempting to start the Engine without oil
WILL ruin the Engine and void the warranty.
CAUTION! This Generator is not intended to power sensitive electronic equipment without the addition of
an appropriate line conditioner (sold separately).
The Engine’s Carburetor may need to be adjusted by a qualified mechanic for efficient high-altitude use.

PERSONAL SAFETY
1. Stay alert. Watch what you are doing, and use common sense when
operating a power tool. Do not use a power tool while tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal injury.
2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 3
3. Avoid accidental starting. Be sure the Engine Ignition is in its “OFF”
position before moving the Generator and before performing any service,
maintenance, or cleaning procedures on the unit.
4. Remove adjusting keys or wrenches before turning the Generator on. A
wrench or a key that is left attached to a rotating part of the machine may result
in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the power tool in unexpected
situations.
6. Use safety equipment. Always wear eye protection. Always wear
ANSI approved safety impact goggles when using this product. ANSI
approved hearing protection must also be used.
TOOL USE AND CARE
1. Do not force the tool. Use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
2. Do not use the Generator if the Engine’s Ignition does not turn it on or
off. Any tool that cannot be controlled with its power switch is dangerous and
must be replaced.
3. Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
4. Maintain tools with care. Properly maintained tools are less likely to malfunction
and are easier to control. Do not use a damaged tool. Tag damaged
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Provide barriers or shields as
needed.
sparks which may ignite the dust or fumes.

any other condition that may affect the tool’s operation. If damaged, have
the tool serviced before using. Many accidents are caused by poorly
maintained tools.
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 4
6. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
1. Tool service must be performed only by qualified repair personnel. Service
or maintenance performed by unqualified personnel could result in a risk of injury.
2. When servicing a tool, use only identical replacement parts. Follow
instructions in the
“Inspection, Maintenance, And Cleaning” section of this
manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of electric shock or injury.
SPECIFIC SAFETY RULES AND PRECAUTIONS
1. WARNING! Your Warranty is voided if:
A. You do not put engine oil in the Engine’s crankcase prior to its first use.
Before each use, check the oil level. Never run the Engine with low or no
engine oil. Running the Engine with low or no oil will permanently damage the
unit.
2. Maintain labels and nameplates on the Generator. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
5. Check for misalignment or binding of moving parts, breakage of parts, and
tools “Do not use” until repaired.
3. Make sure the Generator is located on a flat, level, sturdy surface capable
of supporting the weight of the Generator and any additional tools and
equipment.
4. Industrial applications must follow OSHA guidelines.
5. Never stand on the Generator. Serious injury could result if the Generator
is tipped.
6. Never leave the Generator unattended when it is running. Turn off the
Engine before leaving.

SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 5
8. This Generator is designed for outdoor use only. Do not operate the
Generator in a closed area or in a poorly ventilated area. When running, the
Engine of this Generator produces carbon monoxide, a colorless, odorless,
toxic gas that, when inhaled, can cause serious personal injury or death.
Whenever possible, use a carbon monoxide detector (not included) to
detect excessive carbon monoxide fumes in the work area and in the
surrounding area.
9. Do not force the Generator. This tool will do the work better and safer at the
speed and capacity for which it was designed.
FIRE AND EXPLOSION PRECAUTIONS
1. Gasoline fuel and fumes are flammable, and potentially explosive. Use
proper fuel storage and handling procedures. Always have multiple ABC class
fire extinguishers nearby.
2. Keep the Generator, its Engine, and surrounding areas clean at all times.
3. When spills of fuel or oil 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.
4. Never store fuel or other flammable materials near the Generator.
5. Do not smoke, or allow sparks, flames, or other sources of ignition around
the Generator.
7. Do not allow children and other unauthorized people to handle or play with
the Generator.
6. 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.
7. Do not refill the Fuel Tank while the Engine is running or while the Engine is
still hot. Do not operate the Generator with known leaks in the fuel system.
8. Use only Engine manufacturer recommended fuel and oil.
MECHANICAL PRECAUTIONS
1. Prior to performing service, maintenance, or cleaning procedures, always
make sure the Engine’s Ignition is in its “OFF” position. Allow the Engine

and Generator to completely cool. Then, remove the spark plug from the
Engine.
2. Do not alter or adjust any part of the Generator or Engine that is assembled
and supplied by the manufacturer.
3. Always follow and complete scheduled Generator and Engine maintenance.
CHEMICAL PRECAUTIONS
1. Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.
2. Avoid body contact with fuels, oils, and lubricants used in the Generator
and Engine. 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.
NOISE PRECAUTIONS
1. Prolonged exposure to high noise levels is hazardous to hearing.
Always wear ANSI approved hearing protection when operating or working
around the Generator when it is running.
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 6
ELECTRICAL PRECAUTIONS
1. All connections and conduits 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. If an extension cord (not included) is used, make sure to use only UL listed cords
having the correct gauge and length. (See Figure A, next page.)
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.

SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 7
7. Be sure the Engine’s Ignition Switch (20) is in its “OFF” position before moving
the Generator
and before performing any service, maintenance, or cleaning
procedures on the unit.
8. 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. Use only Class BC or Class ABC fire extinguishers on electrical fires.
RECOMMENDED MINIMUMWIRE GAUGE FOR EXTENSION CORDS (120VOLT)
RECOMMENDED MINIMUMWIRE GAUGE FOR EXTENSION CORDS (240VOLT)
FIGURE A
10. Guard against electric shock. Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.
9. Insulate all connections and disconnected wires.
6. Connect the Generator only to a load or electrical system (120 volt, 240 volt, or
12 volt) that is compatible with the electrical characteristics and rated capacities
of the Generator.

MISC. PRECAUTIONS
1. WARNING! People with pacemakers should consult their physician(s)
before using this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference to or failure of the pacemaker.
2. WARNING! The warnings and precautions discussed in this 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.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on page 17
are included. 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.
PRODUCT FEATURES
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 8
1. 240 VAC Outlet (72): Use to connect electrical devices that run 240 volt, 60 Hz,
single phase, AC current. (See Figure B.)
2. Ground Terminal (10): Connect grounding wires here to properly ground unit.
(See Figure B.)
10
72
71
70
22
69
74
20
21
44
47
75
76
77
78
79
FIGURE B

3. 120 VAC Outlet (71): Used to connect electrical devices that run 120 volt, 60
Hz, single phase, AC current. (See Figure B.)
4. Voltage Selector (70): Use to switch between 120 and 240 volt output.
(See Figure B.)
5. Circuit Breaker (22): Reset switch that protects the Generator from electrical
overload. (See Figure B.)
6. 12 VDC Charging Terminal (69): Use for charging 12 volt, automotive type
batteries only. (See Figure B.)
7. Oil Dipstick (74): Location for checking and filling engine oil.(See Figure B.)
8. Ignition Switch (20): Used to enable starting and stopping of Engine.
(See Figure B.)
9. Recoil Starter (75): Pull cord for starting Engine. (See Figure B.)
10. Fuel Filter (46): Traps dirt and water from fuel before it enters Engine.
(See Figure B.)
11. Fuel Valve (78): Allows fuel to enter Engine. (See Figure B.)
12. Air Cleaner (77): A removable, cleanable, sponge-like element that limits the
amount of dirt pulled into the Engine. (See Figure B.)
13. Choke Lever (79): Adjusts the amount of air entering the Engine.
(See Figure B.)
14. Fuel Gauge (47): Indicates the amount of fuel in the Fuel Tank. (See Figure B.)
15. Fuel Cap (44): Provides access to the Fuel Tank for adding fuel. (See Figure B.)
16. Voltmeter (21): Provides readings of voltage output. (See Figure B.)
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 9

2. Electrical and other permits may be required for the installation of emergency or
portable power systems. Investigate the local building and electrical codes
before installing this unit.
3. Prior to providing Generator power to tools and equipment, make sure the
Generator’s rated voltage, wattage, and amperage capacity is adequate to
supply all electrical loads the unit will power. If powering exceeds the Generator’s
capacity, it may be necessary to group one or more of the tools/equipment for
connection to a separate Generator.
General Location:
1. It is recommended to locate the Generator (outdoors only) where cooling air is
readily available. Locate 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 snowdrifts may require the placement of a barrier for
protection. The air inlet, in normal weather conditions, should face the prevailing
wind direction.
2. Locate the Generator on a concrete slab or other area where rain drainage or
flood waters can not reach it.
3. Generator placement should allow four feet of access to all sides for maintenance
and for proper air cooling.
4. Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.
SKU 95126 For technical questions, please call 1-800-444-3353 PAGE 10
Grounding The Generator:
1. NOTE: It is recommended that only a trained and licensed electrician perform
this procedure.
2. Connect a #12 AWG grounding wire (not included) from the Ground Terminal
(10) on the Generator to a grounding rod (not included) that has been driven at
least 24 inches deep into the earth. The grounding rod must be an earth-driven
copper or brass rod (electrode) which can adequately ground the Generator.
(See Figure C, next page.)
INSTALLATION INSTRUCTIONS
1. CAUTION! Always make sure the Engine’s Ignition Switch (20) is in its
“OFF” position prior to performing any service, maintenance, or cleaning of the
Generator or Engine. Always wear ANSI approved safety impact eye goggles
when assembling and using the Generator.