Chicago Electric 95960 User guide

GENERATOR SET
16 HP - 7000/7500 WATTS
95960
SET UP, OPERATING, AND SERVICING INSTRUCTIONS
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator 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©2007 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. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual Revised 08i

Page 2SKU 95960 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical Requirements
7000 Watts (Rated) / 7500 Watts (Maximum) / 60 Hz / 3600 RPM
Output Receptacles:
20 A / 120 V~ / 3-Prong / (Qty. 1 Duplex) with a 20 A Circuit Breaker
30 A / 120 V~ / 3-Prong Twist Lock / (Qty. 1) with a 30 A Circuit Breaker
30 A / 240/120 V~ / 4-Blade Twist Lock / (Qty. 1) with two 30 A Circuit Breakers
Input Power: 12 VDC Battery / 7-1/4” Long x 3” Wide (not included) with an In-Line
Circuit Breaker
Voltmeters:
0 < - > 150 Volts / 50 Volt Marked Increments
0 < - > 300 Volts / 100 Volt Marked Increments w/50 Volt Hash Marks
Engine Specications
16 HP / 4 Cycle / Air Cooled / Electric & Recoil Start / 3600 RPM
420cc Displacement / 6.6 Gallon Fuel Tank
Powered with Mid to High Octane, Unleaded Gasoline
Engine Family: 5CSG.41925C
Recommended Oil:
37 Fluid Ounces
SAE 30W (Above 32 Fahrenheit) / SAE 5W-30 (Below 32 Fahrenheit)
Recommended Spark Plug Gap: 0.028” ~ 0.031”
Estimated Run Time: 8 Hours @ 50% Load
Automatic Low Oil Shutdown
Additional Features Locking ON/OFF with 2 Keys
Overall Dimensions 24-1/8” Long x 20-1/2” Wide x 24-1/2” High
Net Weight 188 Pounds
IMPORTANT! This product requires oil and fuel to be added before starting. Attempt-
ing to start the Engine without oil WILL ruin the Engine and void the warranty.
NOTE: The Engine’s carburetor may need to be adjusted by a qualied mechanic for
efcient high-altitude use.
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
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. Write the product’s serial number in the back of the manual near the as-
sembly diagram, or write month and year of purchase if product has no number. Keep
this manual and invoice in a safe and dry place for future reference.

Page 3SKU 95960 For technical questions, please call 1-800-444-3353.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, re, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit.1. Cluttered and dark areas invite acci-
dents.
Do not operate power tools in explosive atmospheres, such as in the pres-2.
ence of ammable liquids, gases, or dust. Power tools create sparks which
may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool.3. Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed. Children
should never be allowed in the work area.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when operat-1.
ing a power tool. Do not use a power tool while tired or under the inuence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.2. Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
Remove adjusting keys or wrenches before turning the power tool on.3. A
wrench or a key that is left attached to a rotating part of the power tool may result
in personal injury.
Do not overreach. Keep proper footing and balance at all times.4. Proper foot-
ing and balance enables better control of the power tool in unexpected situations.
5. Use safety equipment. Always wear eye protection. Dust mask, non-
skid safety shoes, hard hat, or hearing protection must be used for appro-
priate conditions.

Page 4SKU 95960 For technical questions, please call 1-800-444-3353.
Tool Use And Care
Do not force the tool. Use the correct tool for your application.1. The correct
tool will do the job better and safer at the rate for which it is designed. Do not force
the tool and do not use the tool for a purpose for which it is not intended.
Do not use the power tool if the Engine Switch does not turn it on or off.2. Any
tool that cannot be controlled with the Engine Switch is dangerous and must be
replaced.
Disconnect the Spark Plug Wire from the Engine before making any adjust-3. ments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally. Always disconnect the
Spark Plug Wire before performing any inspection, maintenance, or cleaning
procedures.
Store idle tools out of reach of children and other untrained persons.4. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Keep the Generator clean.5. Properly maintained tools
are less likely to malfunction and are easier to control. Do not use a damaged tool.
Tag damaged tools “Do not use” until repaired.
Check for misalignment or binding of moving parts, breakage of parts, and6. 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.
Use only accessories that are recommended by the manufacturer for your7. model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
Tool service must be performed only by qualied repair personnel. 1. Service or
maintenance performed by unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instruc-2. tions 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 injury.
SPECIFIC SAFETY RULES
IMPORTANT! Your Warranty is voided if:1.

Page 5SKU 95960 For technical questions, please call 1-800-444-3353.
You do not put engine oil in the Engine’s crankcase prior to its rst use. Be-
fore each use, check the oil level. Never run the Engine with low or no engine oil.
Running the Engine with low or no Engine oil will permanently damage the Engine.
Maintain labels and nameplates on the Generator.2. These carry important infor-
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.
Maintain a safe working environment.3. Make sure there is adequate surrounding
workspace.
Avoid unintentional starting.4. Make sure you are prepared to begin work before
turning on the Generator.
People with pacemakers should consult their physician(s) before use.5. Elec-
tromagnetic elds in close proximity to a heart pacemaker could cause pacemaker
interference or pacemaker failure. Caution is necessary when near the Engine’s
magneto or recoil starter.
Never leave the Generator unattended when it is running.6. Turn off the Engine
of the Generator before leaving the work area.
Always use the Generator on a at, level surface.7.
Make sure to keep hands, ngers, and feet away from all moving parts of the 8. Generator.
Keep all safety guards of the Generator in place and in proper working order.9.
TOXIC FUMES, FIRE, AND EXPLOSION PRECAUTIONS
This Generator is designed for outdoor use only. Do not operate the Genera-1. tor in a closed area or in a poorly ventilated area. When running, the Engine
of this unit produces carbon monoxide, a colorless, odorless, toxic fume
that, when inhaled, can cause serious personal injury or death. Whenever
possible, use a carbon monoxide detector (not included) to detect excessive car-
bon monoxide fumes in the work area and in the surrounding area.
Gasoline fuel and fumes are ammable, and potentially explosive. 2. Use
proper fuel storage and handling procedures. Always have multiple ABC class re
extinguishers nearby.
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.4. Dis-
pose of uids and cleaning materials as per any local, state, or federal codes and
regulations. Store oil rags in a covered metal container.
Never store fuel or other ammable materials near the Generator.5.

Page 6SKU 95960 For technical questions, please call 1-800-444-3353.
Do not smoke, or allow sparks, ames, or other sources of ignition around 6. the Generator.
Keep grounded conductive objects, such as tools, away from exposed, live7. electrical parts and connections to avoid sparking or arcing. These events
could ignite fumes or vapors.
Do not rell the Fuel Tank while the Engine is running or hot. 8.
Do not operate the Generator with known leaks in the Engine’s fuel system.9.
Use only oil and fuel recommended in the “Product Specications” section 10. of this manual.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always1.
make sure the Engine Switch is in its “OFF” position. Allow the Engine to
completely cool. Then, remove the Spark Plug Wire from the Spark Plug.
Do not alter or adjust any part of the Generator or its Engine that is assem-2. bled and supplied by the manufacturer or distributor.
Always follow and complete scheduled Engine maintenance.3.
CHEMICAL PRECAUTIONS
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.1.
Avoid body contact with fuels, oils, and lubricants used in the Engine.2. If
swallowed, seek immediate medical treatment. Do not induce vomiting if fuel is
swallowed. For skin contact, immediately wash with soap and water. For eye con-
tact, immediately ush eyes with clean water.
NOISE PRECAUTION
Prolonged exposure to high noise levels is hazardous to hearing.1. Always
wear ANSI-approved hearing protection when operating or working around the
Generator when it is running.
ELECTRICAL PRECAUTIONS
All connections and conduits from the Generator to the load must only be installed1. by trained and licensed electricians, and in compliance with all relevant local, state,

Page 7SKU 95960 For technical questions, please call 1-800-444-3353.
and federal electrical codes and standards, and other regulations where applica-
ble.
The Generator must be earth-grounded in accordance with all relevant electrical2. codes and standards before operation.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE AMPERES
(at full load)
EXTENSION CORD LENGTH
25’ 50’ 75’ 100’ 150’
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A * Based on limiting the line voltage drop to ve volts at 150% of the rated
amperes.
If an extension cord (not included) is used, make sure to use only UL® listed cords3. having the correct gauge and length. (See Table A.)
Do not attempt to connect or disconnect load connections while standing in water,4. or on wet or soggy ground.
Do not touch electrically energized parts of the Generator and interconnecting5. cables or conductors with any part of the body, or with any non-insulated conduc-
tive object.
Connect the Generator only to a load or electrical system (120 volt or 240 volt) that6. is compatible with the electrical characteristics and rated capacities of the Genera-
tor.
Make sure the Engine Switch is in its “OFF” position before moving the Generator7. and before performing any service, maintenance, or cleaning procedures on the
unit.
Keep all electrical equipment clean and dry. Replace any wiring where the insula-8. tion is cracked, cut, abraded, or otherwise degraded. Replace terminals that are
worn, discolored, or corroded. Keep terminals clean and tight.
Insulate all connections and disconnected wires.9.
Guard against electric shock. Prevent body contact with grounded surfaces such10. as pipes, radiators, ranges, and refrigerators.
Use only Class BC or Class ABC re extinguishers on electrical res.11.

Page 8SKU 95960 For technical questions, please call 1-800-444-3353.
UNPACKING
When unpacking, check to make sure all of the parts shown on the Parts List in this
manual are included. If any parts are missing or broken, please call Harbor Freight
Tools at the number shown on the cover (and at the bottom of each page) of this manu-
al as soon as possible.
CONTROL PANEL FEATURES
2
3
5 5
5
9
8
10
10B
VOLTMETER VOLTMETER
7 7
FIGURE A
MISC. PRECAUTION
WARNING! 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.
Symbology
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute
(RPM)

Page 9SKU 95960 For technical questions, please call 1-800-444-3353.
Engine Switch (2):1. Used to start and stop the Engine. To start, insert the En-
gine Switch Key and turn to the right to its “START” position. Then immediately
release the Key. To turn off the Engine, turn the Key all the way to the left to its
“OFF” position. Always remove the Key from the Engine Switch when the unit is
not in use.
(See Figure A, previous page.)
Outlet Sockets (8, 10, 10B):2. The Generator features three Outlet Sockets with
which to power tools and equipment. The type and voltage of the Outlet Sockets
are as follows:
3-Prong, 120 volt Outlet Socket (8)a.
3-Prong, Twistlock, 120 volt Outlet Socket (10)b.
4-Prong, Twistlock, 240/120 volt Outlet Socket (10B)c.
WARNING! Connect tools and equipment only to the Outlet Socket (120 volt or
240 volt) that is compatible with the electrical characteristics and rated capacities
of the tools and equipment being used. (See Figure A.)
Circuit Breakers (3, 5):3. The Generator features ve Circuit Breakers to protect
the unit from overloading.
Onea. Circuit Breaker controls the 3-Prong, 120 volt Outlet Socket (8).
Oneb. Circuit Breaker controls the 3-Prong, Twistlock, 120 volt Outlet Socket (10).
Twoc. Circuit Breakers control the 4-Prong, Twistlock, 240/120 volt Outlet Socket
(10B).
Oned. In-Line Circuit Breaker to protect the Engine’s Starter (83A).
Should any of the four Circuit Breakers “trip”, the Engine will automatically shut
down. In this event, unplug all loads from the Generator. Allow the Generator to
cool down. Then, press the tripped Circuit Breaker and restart the Engine. (See
Figure A.)
Voltmeters (7):4. The Generator features two Voltmeters which provide readings
of voltage output depending on which of the three Outlet Sockets (8, 10, 10B) are
being used. (See Figure A.)
Grounding Terminal (9):5. Prior to each use, always connect a ground wire (not
included) to the Grounding Terminal to properly ground the Generator.
(See Figure C, page 11.)
BATTERY INSTALLATION
1. The Engine of the Generator may be started manually or electrically.
To use the Engine’s electric start capability, a Battery (45, not included) must rst 2. be installed. The type and size Battery required is: 12 volt DC, 7-1/4” long by 3”
wide. (See Figure B, next page.)

Page 10SKU 95960 For technical questions, please call 1-800-444-3353.
Locate the factory pre-installed Battery Guard Plate (44) and Battery Tray (48) be-3. neath the Control Panel of the Generator. (See Figure B.)
Slide the Battery into the Battery Guard Plate (44) with the Battery’s terminals fac-4. ing outward and with the Battery’s negative (--) terminal facing left. (See Figure
B.)
Align the two mounting holes in the Battery Bracket (47) with the two threaded5. mounting holes in the Battery Guard Plate (44). Then secure the Battery Bracket
to the Battery Guard Plate, using two Bolts with Lock Washers (46).
(See Figure B.)
BOLT WITH LOCK WASHER (46)
NEGATIVE BATTERY CABLE
POSITIVE BATTERY CABLE
BATTERY GUARD PLATE (44)
BATTERY TRAY (48)
BATTERY BRACKET (47)
12 VDC BATTERY
(NOT INCLUDED)
FIGURE B
Connect the Engine’s Positive Battery Cable (RED +) to the Battery’s positive (+)6. terminal. Then connect the Engine’s Negative Battery Cable (BLACK --) to the
Battery’s negative (--) terminal. (See Figure B.)
TO ATTACH THE WHEEL ASSEMBLY
With additional assistance, and a proper lifting device, raise the left side of the1.
Generator about 6 to 8 inches off the oor surface.
Attach the two Axle Brackets (53) to the lower Frame (42), using two Bolts (52) and2. two Lock Washer Nuts (13) for each Axle Bracket.
(See Assy. Diagram.)
Slide the Axle (49) through the two Axle Brackets (53).3. (See Assy. Diagram.)
Insert one Wheel (50) onto each end of the Axle (49).4. (See Assy. Diagram.)

Page 11SKU 95960 For technical questions, please call 1-800-444-3353.
Secure the Axle (49) and Wheels (50) in place, using four Pins (51).5.
(See Assy. Diagram.)
INSTALLATION INSTRUCTIONS
IMPORTANT:1. Electrical and other permits may be required for the installation of
emergency or portable power systems. Make sure to investigate the local building
and electrical codes before installing this unit.
Locate the Generator (outdoors only) where cooling air is readily available. Locate2. the Generator so that the air inlets and outlets are not blocked by obstructions
such as bushes, trees, walls, snow drifts, etc. Locating the Generator in the path
of heavy winds may require the placement of a barrier for protection. The air inlet,
in normal weather conditions, should face the prevailing wind direction.
Locate the Generator on a concrete slab or other area where rain drainage or ood 3. waters can not reach it.
Generator placement should allow four feet of access to all sides for maintenance4. and proper air cooling.
Place the Generator as close as possible to the electrical tools and equipment be-5. ing powered to reduce the length of extension cords.
To ground the Generator, connect a #6 AWG grounding wire (not included) from6. the Grounding Terminal (9) on the Control Panel 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.)
GROUNDING TERMINAL (9)
CONCRETE SLAB
#6 AWG GROUNDING WIRE
(NOT INCLUDED)
GROUNDING ROD
(NOT INCLUDED)
FIGURE C
PRE-START INSTRUCTIONS
IMPORTANT: Your Warranty is voided if you do not put engine oil in the1.
Engine’s crankcase prior to its rst use. Before each use, check the oil level.
Never run the Engine with low or no engine oil. Running the Engine with no or low
engine oil WILL permanently damage the Engine.

Page 12SKU 95960 For technical questions, please call 1-800-444-3353.
The Engine MUST be lled with a high quality engine oil. If the Engine will be 2. run in temperatures above 32 degrees Fahrenheit, use SAE 30 weight oil. If the
Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE 5W-30
weight oil.
To add engine oil, unscrew and remove the Oil Dipstick (65A). Pour engine oil into3. the Dipstick Hole until the level of oil is even with the top edge of the Dipstick Hole.
Then, make sure to screw the Oil Dipstick back into its Dipstick Hole.
(See Figure D.)
FUEL TANK (31)
FUEL TANK
GAUGE
FUEL TANK CAP (34)
FUEL FILTER (32)
FIGURE E
4. To ll the Fuel Tank (31), unscrew and remove the Fuel Tank Cap (34). Fill the
Fuel Tank with mid-to-high octane unleaded gasoline. Then replace the Fuel
Tank Cap. Thereafter, check the Fuel Tank Gauge for the amount of unleaded
gasoline. When necessary, rell the Fuel Tank. (See Figure E.)
Periodically, check the Fuel Filter (32) for excessive dirt and debris. If necessary,5. remove the Fuel Filter and clean with compressed air. (See Figure E.)
FUEL VALVE (41)
FIGURE F
CHOKE LEVER (21A)
REV 07h

Page 13SKU 95960 For technical questions, please call 1-800-444-3353.
OPERATING INSTRUCTIONS
Check to make sure the Engine Switch (2) is in its1. “OFF” position.
(See Figure A.)
IMPORTANT:2. Make sure to unplug any load from the Generator before starting to
prevent permanent damage to any appliances, tools, or equipment.
Turn the Engine Fuel Valve (41) to its3. “OPEN” position. Then turn the Engine
Choke Lever (21A) to its “CHOKE” position. No choke is required if the Engine is
warm. Make sure the Choke Lever is in the “RUN” position when starting a warm
Engine. (See Figure F.)
To start the Engine, using the Battery (45) for cranking power, insert the Engine4. Switch Key into the Engine Switch (2). Then turn the Key to the “START” position.
NOTE: To prolong Starter life, use short starting cycles (5 seconds maximum).
Then wait one minute before attempting to start again. (See Figure A.)
To start the Engine manually, using the Starter Handle (41A), insert the Engine5. Switch Key and turn the Key to its “RUN” position. Grasp the Starter Handle, and
pull slowly until resistance is felt. Allow the Starter Rope to rewind slowly. Then,
pull the Starter Handle with a rapid, full arm stroke. Allow the Rope to rewind
slowly. If necessary, repeat this procedure until the Engine starts.
When the Engine starts, slowly move the Choke Lever (21A) to its6. “RUN” position.
(See Figure F.)
IMPORTANT:7. Allow the Generator to run at no load for ve minutes after each
start-up so that the Engine and Generator can stabilize.
TO CONNECT ELECTRICAL LOADS
Start the Engine, and allow the Engine and Generator to run and warm up for ve 1. minutes after starting with no electrical load.
2. WARNING! Connect 120 VAC appliances, tools, and equipment only to the two
120 VAC Outlet Sockets (8, 10). Connect 240 VAC appliances, tools, and equip-
ment only to the one 240 VAC Outlet Socket (10B). (See Figure A.)
3. CAUTION! Never exceed the rated capacity for this Generator, as serious dam-
age to the Generator and/or appliances, tools, and equipment could result from an
overload. Starting and running wattage requirements should always be calculated
when matching this Generator’s wattage capacity to the appliance, tool, or equip-
ment.
Most appliances, tools, and equipment will list on the motor nameplate the start-4. ing and running voltage and amperage requirements. Use the following formula to
convert voltage and amperage to wattage:

Page 14SKU 95960 For technical questions, please call 1-800-444-3353.
Volts x Amps = Watts (example: 120 Volts x 3 Amps = 360 Watts)a.
To determine the approximate wattage requirement for most appliances, tools,b. and equipment with “inductive” type motors, multiply the wattage that was calcu-
lated by 2 times to assure adequate Generator capacity.
The starting and running wattage for “resistant” loads are the same. Example: ac. 100 watt light bulb requires only 100 watts to turn on. Most resistant loads will be
listed in wattage.
Always power the largest electric motor rst. The, plug in other appliances, tools, 5. and equipment.
Connect “inductive” load appliances, tools, and equipment rst. Inductive loads a. consist of small hand tools and some small appliances. Connect the items that
require the most wattage rst.
Connect any lights next.b.
Voltage sensitive appliances, tools, and equipment should be the last to be con-c. nected to the Generator. Plug voltage sensitive items such as T.V.’s, VCR’s, mi-
crowaves, and cordless telephones into a UL® Listed voltage surge protector (not
included). Then, connect the surge protector into the Generator.
IMPORTANT!6. Failure to connect and operate appliances, tools, and equipment in
this sequence can cause damage to the Generator, appliances, tools, and equip-
ment and will void the Warranty of this Generator.
Once the Engine is running, simply connect the 120 VAC appliances, tools, and7. equipment into the 120 VAC Outlet Sockets (8, 10). Also, connect a 240 VAC ap-
pliance, tool, or equipment into the 240 VAC Outlet Socket (10B). (See Figure A.)
NOTE:8. If Engine speed or voltage uctuates with a load below 250 watts, move
the Engine Choke Lever (21A) to the “HALF-CHOKE” position. (See Figure F.)
When nished using the Generator, disconnect all electrical loads. Turn the En-9. gine Switch (2) to its “OFF” position to stop the Engine. Then, close the Engine
Fuel Valve (41). (See Figures A and F.)
Allow the Generator and its Engine to completely cool. Then store the unit in a10. clean, dry, safe location out of reach of children and other unauthorized people.
INSPECTION, MAINTENANCE, AND CLEANING
1. WARNING! Always make sure the Engine Switch (2) is in its ‘OFF” position and
the Spark Plug Wire is removed from the Spark Plug (28A) prior to performing any
inspection, maintenance, or cleaning procedures.
Before each use:2. Inspect the general condition of the Generator and its Engine.
Check for loose screws, misalignment or binding of moving parts, cracked or

Page 15SKU 95960 For technical questions, please call 1-800-444-3353.
broken parts, loose hose connections, and any other condition that may affect the
safe operation of the unit. If abnormal noise or vibration occurs, have the problem
corrected before further use.
GENERATOR MAINTENANCE
Keep the Generator clean and dry at all times.1.
The Generator should not be operated or stored in locations that include exces-2.
sive moisture, dust, ammable or corrosive vapors. If these substances are on the
Generator, clean with a soft cloth or brush.
Do not use a garden hose or anything with liquid to clean the Generator. Liquid3. may enter the cooling air slots and could damage the interior workings of the Gen-
erator.
ENGINE MAINTENANCE
After the rst 5 to 8 hours of use: 1. Change the oil. Then, change the oil every
50 hours of use. Change the oil every 25 hours of use when operating the Engine
under a heavy load or in high temperatures.
PLUG (59A)
OIL DIPSTICK (65A)
FIGURE G
2. To change the oil, remove the Plug (59A) and allow the old oil to drain in a proper
container. Once drained, replace the Plug. (See Figure G.)
NOTE:3. If the Engine will be run in temperatures above 32 degrees Fahrenheit,
use SAE 30 weight oil. If the Engine will be run in temperatures below 32 degrees
Fahrenheit, use SAE 5W-30 weight oil.
To add engine oil, unscrew and remove the Oil Dipstick (65A). Pour engine oil into4. the Dipstick Hole until the level of oil is even with the top edge of the Dipstick Hole.
Then, make sure to screw the Oil Dipstick back into its Dipstick Hole.
(See Figure G.)

Page 16SKU 95960 For technical questions, please call 1-800-444-3353.
AIR CLEANER SEPARATOR (20A)
AIR CLEANER ELEMENT (19A)
AIR CLEANER COVER (18A)
FIGURE H
5. After every 25 hours of use: Service the Air Cleaner Element (19A) and Air
Cleaner Separator (20A). (See Figure H.)
To do so, remove the Air Cleaner Cover (18A). Remove the Air Cleaner Element6. (19A). Immerse the Air Cleaner Element in a mild solvent and squeeze the Ele-
ment several times to clean. Remove the Element from the solvent and squeeze
thoroughly to dry. Then, squirt several drops of a light weight oil into the Element
and squeeze the Element so oil reaches all parts of the Element. (See Figure H.)
Use compressed air to clean the Air Element Separator (20A). Then replace the7. Air Element Separator, Air Cleaner Element, and Air Cleaner Cover (18A).
(See Figure H.)
Clean more often under dusty conditions or when airborne debris is present. Re-8. place Air Cleaner parts if necessary. (See Figure H.)
FIGURE I
SPARK PLUG (28A)
0.028” - 0.031”
9. After every 100 hours of use: Clean and re-gap the Spark Plug (28A).
(See Figure I.)
To do so, use a 13/16” spark plug wrench (not included) to remove the Spark Plug.10.
Use a ne-grade sandpaper to clean off carbon build-up from the electrodes of the 11. Spark Plug (28A). Clean with compressed air to remove residue. (See Figure I.)

Page 17SKU 95960 For technical questions, please call 1-800-444-3353.
Measure the electrode gap with a suitable gauge. The gap should be12. 0.028” to
0.031”. If necessary, correct the gap by carefully bending the side of the elec-
trode.
(See Figure I.)
Reinstall the Spark Plug (28A) carefully to avoid cross-threading.13. (See Figure I.)
Daily:14. Inspect the Fuel Filter (32).
FUEL TANK (31)
FUEL TANK
GAUGE
FUEL TANK CAP (34)
FUEL FILTER (32)
FIGURE J
15. To do so, remove the Fuel Tank Cap (34) from the Fuel Tank (31).
(See Figure J.)
If necessary, use compressed air to remove any dirt and debris from the Fuel Filter16. (32). Then replace the Fuel Filter and Fuel Tank Cap (34). (See Figure J.)
When storing the Generator for extended periods: Before storing, drain all fuel
out of the Engine’s Fuel Tank (31). If this is not followed, old fuel in the Fuel Tank
may clog the Carburetor of the Engine and prevent it from starting until cleaned
out. Then make sure to store the unit in a clean, dry, safe location out of
reach of children and other unauthorized people.
PLEASE READ THE FOLLOWING
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT
HE 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/OR
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE
UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUY-
ER 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.

Page 18SKU 95960 For technical questions, please call 1-800-444-3353.
TROUBLESHOOTING

Page 19SKU 95960 For technical questions, please call 1-800-444-3353.
PARTS LIST - GENERATOR
NOTE:
Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
Part Description Qty.
1 Bolt w/Lock Washer (M6x12) 4
2 Engine Switch 1
3 Circuit Breaker (30 Amp) 1
4 Control Panel 1
5 Circuit Breaker (20 Amp) 4
6 Bolt (M5x12) 2
7 Voltmeter 2
8 Outlet Socket (120V) 2
9 Grounding Terminal 1
10 Outlet Socket (120V) 1
10B Outlet Socket (240V/120V) 1
11 Shock Absorber 4
12 Bolt (M5x215) 2
13 Lock Washer Nut (M8) 12
14 Stator Cover 1
15 Alternator Back Cover 1
16 Automatic Voltage Regulator 1
17 Bolt (M5x12) 7
18 Rectier 1
19 Bolt (M5x20) 2
20 Cable Sheath 1
21 Carbon Brush 1
22 Bolt (M10x1.25x265) 1
23 Bolt (M6x180) 4
24 Bolt (M5x20) 4
25 Connection Board 1
26 Nut (M5) 4
27 Stator 1
28 Rotor 1
29 Cooling Fan 1
30 Heat Insulation Board Assy. 1
31 Fuel Tank 1
32 Fuel Filter 1
33 Seal Ring 1
34 Fuel Tank Cap 1
37 Lock Washer Bolt (M6x30) 4
Part Description Qty.
38 Spacer 4
39 Rub Washer 4
40 Bushing 4
41 Fuel Valve 1
42 Frame 1
43 Switch Box Cover 1
44 Battery Guard Plate 1
45 Battery (Not Included) 1
46 Bolt w/Lock Washer (M6x12) 2
47 Battery Bracket 1
48 Battery Tray 1
49 Axle 1
50 Wheel 2
51 Pin 4
52 Bolt (M8x20) 8
53 Axle Bracket 2
54 Shock Absorbing Foot 2
55 Bolt (M8x25) 2
56 Bracket 2
57 Nut (M8) 2
58 Connection Board (Mufer) 1
59 Bolt (M8x20) 4
60 Bolt w/Lock Washer (M6x12) 8
61 Handle 2
62 Bolt (M8x45) 2
63 Pin (8x45) 2
64 Bolt (M6x45) 4
65 Link 2
66 Washer (M6) 4
67 Lock Washer 4
68 Nut (M6) 4
69 Nut (M8) 2
70 Pin (2x20) 2

Page 20SKU 95960 For technical questions, please call 1-800-444-3353.
ASSEMBLY DIAGRAM - GENERATOR