Chicago Electric 96898 Installation manual

Page 1SKU 96898 For technical questions, please call 1-800-444-3353.
3500 WATT GASOLINE
GENERATOR
Model 96898
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
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.
For technical questions or replacement parts, please call 1-800-444-3353.

Page 2SKU 96898 For technical questions, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY INFORMATION ............................ 3
PRODUCT SPECIFICATIONS ..........................................4
GENERAL SAFETY RULES.............................................4
WORK AREA......................................................................... 4
PERSONAL SAFETY ........................................................... 5
TOOL USE AND CARE ......................................................... 5
SERVICE ............................................................................... 6
SPECIFIC SAFETY RULES..............................................6
FIRE AND EXPLOSION PRECAUTIONS ............................. 6
MECHANICAL PRECAUTIONS............................................ 7
CHEMICAL PRECAUTIONS ................................................. 7
NOISE PRECAUTIONS......................................................... 8
ELECTRICAL PRECAUTIONS ............................................. 8
GROUNDING......................................................................... 8
PRODUCT FEATURES....................................................12
INSTALLATION INSTRUCTIONS.................................... 13
Grounding The Generator: .................................................13
PRE-START INSTRUCTIONS ......................................... 14
To Add Engine Oil:...............................................................14
OPERATING INSTRUCTIONS......................................... 15
To Start The Engine/Generator: .........................................15
To Connect Electrical Loads: .............................................15
INSPECTION, MAINTENANCE, AND CLEANING.......... 17
TROUBLESHOOTING .....................................................19
PARTS LIST .....................................................................20
ASSEMBLY DIAGRAM.................................................... 22
LIMITED 1 YEAR / 90 DAY WARRANTY ........................24
EMISSION CONTROL SYSTEM WARRANTY................ 24

Page 3SKU 96898 For technical questions, please call 1-800-444-3353.
SAVE THIS MANUAL
Keep this manual for the safety warnings and precautions, assembly, operating,
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.
DANGERDANGER
WARNINGWARNING
CAUTIONCAUTION
NOTICENOTICE
CAUTIONCAUTION

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PRODUCT SPECIFICATIONS
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 Specications Engine Type: 4-Stroke, Overhead Valve, Single Cylinder, 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-SAE 5W-30W (Below 32°)
Run Time: 15 Hours Continuous Run Time on Full Tank @ 50% Load
EPA/CARB Certied (Phase II, Category A)
Overall Dimensions 21-1/2” Long x 16-3/4” Wide x 17-1/2” High
Net Weight 98 Pounds
The Emission Control System for this 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.
GENERAL SAFETY RULES
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.
WARNING! Read all instructions
Failure to follow all instructions listed below may result in electric shock,
re, and/or serious injury. The term “power tool” in all of the warnings listed
below refers to your Gasoline Generator.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do not operate power tools in explosive atmospheres, such as in the
presence 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. Dis-
tractions can cause you to lose control. Provide barriers or shields as needed.
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Page 5SKU 96898 For technical questions, please call 1-800-444-3353.
PERSONAL SAFETY
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 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. Keep
your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry,
or long hair can be caught in moving parts.
Avoid accidental starting. Be sure the Engine Ignition is “OFF” before moving the
Generator and before performing any service, maintenance, or cleaning proce-
dures on the unit.
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 per-
sonal injury.
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.
Use safety equipment. Always wear eye protection. Always wear ANSI-
approved safety impact goggles and hearing protection when using this
product.
TOOL USE AND CARE
The Engine’s Carburetor may need to be adjusted by a qualied mechanic for ef-
cient high-altitude use.
CAUTION! This Generator is not intended to power sensitive electronic equip-
ment without the addition of an appropriate line conditioner (sold separately).
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.
Do not use the Generator if the Engine’s Ignition does not turn it on or off. Any
tool that cannot be controlled with the power switch is dangerous and must be
replaced.
Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
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 tools “Do
not use” until repaired.
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Check for misalignment or binding of moving parts, breakage of parts, and 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 your model.
Accessories that may be suitable for one tool may become hazardous when used
on another tool.
SERVICE
Have your Gasoline Generator serviced by a qualied repair person using only
identical replacement parts. This will ensure that the safety of the Gasoline Gen-
erator is maintained.
SPECIFIC SAFETY RULES
WARNING! Your Warranty is voided if you do not put engine oil in the
Engine’s crankcase prior to the rst 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.
Maintain labels and nameplates on the Generator. These carry important infor-
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.
Make sure the Generator is located on a at, level, sturdy surface capable of sup-
porting the weight of the Generator and any additional tools and equipment.
Industrial applications must follow OSHA guidelines.
Never stand on the Generator. Serious injury could result if the Generator falls.
Never leave the Generator unattended when it is running. Turn off the Engine
before leaving.
Do not allow children and other unauthorized people to handle or play with the
Generator.
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
Gasoline fuel and fumes are ammable, and potentially explosive. Use proper
fuel storage and handling procedures. Always have multiple ABC class re extin-
guishers nearby.
Keep the Generator, Engine, and the surrounding area clean at all times.
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Page 7SKU 96898 For technical questions, please call 1-800-444-3353.
Clean fuel or oil spills up immediately. Dispose of uids and cleaning materials
as per any local, state, or federal codes and regulations. Store oil rags in a bot-
tom-ventilated, covered metal container.
Never store fuel or other ammable materials near the Generator.
Do not smoke, or allow sparks, ames, or other sources of ignition around the
Generator.
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.
Do not rell 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.
Use only recommended fuel and oil.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always make
sure the Engine’s Ignition is “OFF”. Allow the Engine and Generator to complete-
ly cool. Then, remove the spark plug from the Engine.
Do not alter or adjust any part of the Generator or Engine that is assembled and
supplied by the manufacturer.
Always follow and complete scheduled Generator and Engine maintenance.
CHEMICAL PRECAUTIONS
Avoid contact with hot oil, exhaust, and solid surfaces.
Avoid body contact with fuels, oils, and lubricants used in the Generator and
Engine. If swallowed, seek medical treatment immediately. Do not induce vomit-
ing if fuel is swallowed. For skin contact, immediately wash with soap and water.
For eye contact, immediately ush eyes with clean water.
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 fume 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.
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Page 8SKU 96898 For technical questions, please call 1-800-444-3353.
NOISE PRECAUTIONS
Prolonged exposure to high noise levels is hazardous to hearing. Always wear
ANSI approved hearing protection when operating or working around the Gen-
erator when it is running.
ELECTRICAL PRECAUTIONS
GROUNDING
Improperly connecting the grounding wire can result in
electric shock.
Check with a qualied electrician if you are in doubt as to
whether the outlet is properly grounded. Do not modify
the power cord plug provided with the tool. Never remove
the grounding prong from the plug. Do not use the tool if
the power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not
t the outlet, have a proper outlet installed by a qualied
electrician.
Grounded Tools: Tools with Three Prong Plugs
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If
the tool should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user, reducing the risk of electric
shock. (See 3-Prong Plug and Outlet.)
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached
to an electrically “live” terminal. (See 3-Prong Plug and Outlet.)
The tool must be plugged into an appropriate outlet, properly installed and
grounded in accordance with all codes and ordinances. The plug and outlet
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Page 9SKU 96898 For technical questions, please call 1-800-444-3353.
should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)
3-Prong Plug and Outlet Outlets for 2-Prong Plug
Double Insulated Tools: Tools with Two Prong Plugs
Tools marked “Double Insulated” do not require grounding. They have a special
double insulation system which satises OSHA requirements and complies with
the applicable standards of Underwriters Laboratories, Inc., the Canadian Stan-
dard Association, and the National Electrical Code.
(See Outlets for 2-Prong Plug.)
Double insulated tools may be used in either of the 120 volt outlets shown in the
preceding illustration. (See Outlets for 2-Prong Plug.)
Extension Cords
Grounded tools require a three wire extension cord. Double Insulated tools can
use either a two or three wire extension cord.
As the distance from the supply outlet increases, you must use a heavier gauge
extension cord. Using extension cords with inadequately sized wire causes a
serious drop in voltage, resulting in loss of power and possible tool damage.
(See Table A.)
The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Table A.)
When using more than one extension cord to make up the total length, make
sure each cord contains at least the minimum wire size required. (See Table A.)
If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.
(See Table A.)
If you are using an extension cord outdoors, make sure it is marked with the suf-
x “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
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Page 10SKU 96898 For technical questions, please call 1-800-444-3353.
Make sure the extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualied elec-
trician before using it.
Protect the extension cords from sharp objects, excessive heat, and damp or wet
areas.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD LENGTH
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
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.
Symbology
Double Insulated V~ Volts Alternating Current
Canadian Standards Association AAmperes
Underwriters Laboratories, Inc. n0xxxx/min. No Load Revolutions per Minute
(RPM)
All connections and conduits from the Generator to the load must only be in-
stalled by trained and licensed electricians, and in compliance with all relevant
local, state, and federal electrical codes and standards, and other regulations.
The Generator must be earth-grounded in accordance with all relevant electrical
codes and standards before operation.
If an extension cord (not included) is used, make sure to use only UL listed cords
having the correct gauge and length.
Do not attempt to connect or disconnect load connections while standing in wa-
ter, or on wet or soggy ground.
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Page 11SKU 96898 For technical questions, please call 1-800-444-3353.
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 conduc-
tive object.
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.
Be sure the Engine’s Ignition Switch is “OFF” before moving the Generator and
before performing any service, maintenance, or cleaning procedures on the unit.
Keep all electrical equipment clean and dry. Replace any wiring where the insu-
lation 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.
Guard against electric shock. Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.
Use only Class BC or Class ABC re extinguishers on electrical res.
MISC. PRECAUTIONS
People with pacemakers should consult their physician(s) before use. Electro-
magnetic elds in close proximity to heart pacemaker could cause pacemaker
interference or pacemaker failure.
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 prod-
uct, but must be supplied by the operator.
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Page 12SKU 96898 For technical questions, please call 1-800-444-3353.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List 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
b
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m
FIGURE B
240 VAC Outlet: Use to connect electrical devices that run 240 volt, 60 Hz,
single phase, AC current.
Ground Terminal: Connect grounding wires here to properly ground unit.
120 VAC Outlet: Used to connect electrical devices that run 120 volt, 60 Hz,
single phase, AC current.
Voltage Selector: Use to switch between 120 and 240 volt output.
Circuit Breaker: Reset switch that protects the Generator from electrical over-
load.
12 VDC Charging Terminal: Use for charging 12 volt, automotive type batter-
ies only.
Oil Dipstick: Location for checking and lling engine oil.
Ignition Switch: Used to enable starting and stopping of Engine.
Recoil Starter: Pull cord for starting Engine.
Fuel Filter: Traps dirt and water from fuel before it enters Engine.
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Fuel Valve: Allows fuel to enter Engine, or as a fuel cut-off to Engine.
Air Cleaner: A removable, cleanable, sponge-like element that limits the
amount of dirt pulled into the Engine.
Choke Lever: Adjusts the amount of air entering the Engine.
Fuel Gauge: Indicates the amount of fuel in the Fuel Tank.
Fuel Cap: Provides access to the Fuel Tank for adding fuel.
Voltmeter: Provides readings of voltage output.
INSTALLATION INSTRUCTIONS
CAUTION! Always make sure the Engine’s Ignition Switch is “OFF”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.
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.
Prior to providing Generator power to tools and equipment, make sure the Gen-
erator’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:
Locate the Generator outdoors only where cool 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.
Locate the Generator on a at and level concrete slab or other area where rain
drainage or ood waters can not reach it.
Generator placement should allow four feet of access to all sides for mainte-
nance and for proper air cooling.
Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.
Grounding The Generator:
Note: It is recommended that only a licensed electrician perform this procedure.
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Page 14SKU 96898 For technical questions, please call 1-800-444-3353.
Connect a #12 AWG grounding wire (not included) from the Ground Terminal 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)
FIGURE C
#12 AWG
GROUNDING WIRE
(NOT INCLUDED)
GROUND
TERMINAL
GROUNDING ROD
(NOT INCLUDED)
DRIVE
GROUNDING ROD
AT LEAST
24” DEEP
PRE-START INSTRUCTIONS
To Add Engine Oil:
CAUTION! The warranty is voided if you do not put engine oil in the Engine’s
crankcase prior to rst use. Before each use, check the oil level. Never run the
Engine with low or no oil. Running the engine with low or no oil will permanently
damage the Engine.
The Engine must be lled with a high quality grade engine oil. 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 do so, unscrew and remove the Oil Dipstick. Pour engine oil into the Dipstick
Hole until the level of oil is even with lower edge of the Dipstick Hole (approxi-
mately 20 uid ounces).
Make sure to screw the Oil Dipstick rmly back into the Dipstick Hole.
(See Figure D.)
To Fill The Fuel Tank:
Prior to rst use of the Generator, the Fuel Tank MUST be lled with high
octane unleaded gasoline (approximately 3.96 gallons).
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Page 15SKU 96898 For technical questions, please call 1-800-444-3353.
Remove the Fuel Cap and ll the Fuel Tank with unleaded gasoline. Replace the
Fuel Cap. Thereafter, check the Fuel Gauge for the amount of unleaded gaso-
line. Rell the Fuel Tank, as needed, only when Engine is OFF and cooled down.
FUEL
FILTER
FUEL
CAP
FUEL
GAUGE
OIL DIPSTICK
FUEL
TANK
FIGURE D
NOTE: Periodically, make sure to check the Fuel Filter for excessive dirt and
debris. If necessary, remove the Fuel Filter and clean with compressed air.
OPERATING INSTRUCTIONS
Note: Unplug any load from the Generator before starting to prevent permanent dam-
age to any appliances, tools, or equipment.
To Start The Engine/Generator:
Turn the Engine Fuel Valve to the “OPEN” position. Then, turn the Engine Choke
Lever to the “CHOKE” position. Make sure the Engine Choke Lever is in the
“RUN” position when starting a warm Engine. No choke is required if the Engine
is warm.
Turn the Engine Ignition to the “RUN” position. Grasp the Starter Handle on the
Recoil Starter and pull slowly until resistance is felt. Allow the Rope to rewind
slowly. Then, pull the 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 to the “RUN” position.
IMPORTANT: 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
minutes after starting with no electrical load.
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Page 16SKU 96898 For technical questions, please call 1-800-444-3353.
WARNING! Connect 120V AC appliances, tools, and equipment only to the two
120 VAC Outlets. Connect 240 AC appliances, tools, and equipment only to the
one 240 VAC Outlet. Connect 12V DC appliances, tools, and equipment only to
the 12 VDC Charging Terminal. (See Figure B.)
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 calcu-
lated when matching this Generator’s wattage capacity to the appliance, tool, or
equipment.
Most appliances, tools, and equipment will list on the motor nameplate the start-
ing and running voltage and amperage requirements. Use the following formula
to convert voltage and amperage to wattage:
Volts x Amps = Watts (example: 120 volts x 3 amps = 360 Watts)
To determine the approximate wattage requirement for most appliances, tools,
and equipment with “inductive” type motors, multiply the wattage that was calcu-
lated by 2 times to assure adequate Generator capacity.
Note: The starting and running wattage for “resistant” loads are the same.
Example: a 100 Watt light bulb requires only 100 Watts to start. Most resistant
loads will be listed in wattage.
Always power the item that has the largest electric draw rst. Then, plug in other
appliances, tools, and equipment one at a time.
Connect “inductive” load appliances, tools, and equipment rst. Inductive
loads consist of small hand tools and some small appliances. Connect the
items that require the most wattage rst.
Connect any lights next.
Voltage sensitive appliances, tools, and equipment should be the last to be
connected to the Generator. Plug voltage sensitive items such as T. V.’s,
VCR’s, microwaves, and cordless telephones into a UL listed voltage surge
protector (not included). Then, connect the UL Listed surge protector into the
Generator.
Failure to connect and operate appliances, tools, and equipment in this sequence
can cause damage to the Generator, appliances, tools, and equipment and will
void the warranty on this Generator.
Once the Engine is running, simply connect the 120 volt appliances, tools, and
equipment into the 120 VAC Outlets. Connect a 240 volt appliance, tool, or
equipment into the 240 VAC Outlet. Or connect a 12 volt appliance, tool, or
equipment into the 12 VDC Charging Terminal.
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Page 17SKU 96898 For technical questions, please call 1-800-444-3353.
If Engine speed or voltage uctuates with a load below 250 Watts, move the En-
gine Choke Lever to the “HALF-CHOKE” position.
When nished using the Generator, disconnect all electrical loads. Close Fuel
Valve until carburetor runs dry, then shut off Ignition Switch.
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Always make sure the Engine’s Ignition Switch is “OFF” and that the
Engine has cooled down, prior to performing any service, maintenance, or clean-
ing of the Generator or Engine.
Before each use, inspect the general condition of the Generator and Engine.
Check for loose screws, misalignment or binding of moving parts, cracked or
broken parts, loose hose connections, and any other condition that may affect the
safe operation of the Generator and Engine. If abnormal noise or vibration oc-
curs, have the problem corrected before further use.
Do not use damaged equipment.
Generator maintenance:
Keep the Generator clean and dry at all times.
The Generator should not be operated or stored in locations with excessive
moisture, dust, ammable or corrosive vapors.
Do not use liquids to clean the Generator. Liquid may enter the cooling slots
and damage the internal mechanisms of the Generator.
10.
11.
1.
2.
3.
a.
b.
c.

Page 18SKU 96898 For technical questions, please call 1-800-444-3353.
Recommended Maintenance Schedule:
NOTE: For additional reference to the care and maintenance of the Engine, refer
to the Engine manufacturer’s service manual.
When storing the Generator: Before storing, drain all fuel out of the Genera-
tor’s Fuel Tank. If this is not followed, old fuel in the Generator’s Fuel Tank may
clog the Carburetor of the Engine and prevent the Generator from starting until
cleaned out. Store the unit in a clean, dry, safe location out of reach of children
and other unauthorized people.
CAUTION! All maintenance, service, or repairs not mentioned in this manu-
al must only be performed by a qualied service technician.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST
AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEI-
THER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION
OR WARRANTY OF ANY KIND TO THE BUYER 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 BUYER ASSUMES ALL RISKS AND
LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTAL-
LATION OF REPLACEMENT PARTS THERETO.
4.
5.
6.
7.
Engine Oil
Air Cleaner
Fuel Filter Cup
Spark Plug
Fuel Tank
Engine Oil
Air Cleaner
Fuel Filter Cup
Spark Plug
Fuel Tank

Page 19SKU 96898 For technical questions, please call 1-800-444-3353.
TROUBLESHOOTING

Page 20SKU 96898 For technical questions, please call 1-800-444-3353.
PARTS LIST
Part Description Qty
1 Oil Drain Plug 2
2 Washer 2
3 Bearing 6205 1
4 Crankshaft Oil Seal 1
5 Crankcase 2
6 Regulating Sway Bar 1
7 Washer 1
8 Split Pin 1
9 Oil Sensor 1
10 Regulator Gear Assembly 1
11 Connecting Rod Assembly 1
12 Crankshaft Assembly 1
13 Piston Pin Clip 2
14 Piston Pin 1
15 Piston 1
16 Piston Ring Assembly 1
17 Camshaft Assembly 1
18 Tappet 1
19 Pusher 2
20 Pusher Guide 1
21 Adjusting Bolt For Valve Gap 2
22 Valve Rocker Assembly 2
23 Exhaust Valve 1
24 Intake Valve 1
25 Valve Spring 2
26 Exhaust Valve Spring Seat 1
27 Intake Valve Spring Seat 1
28 Cap 1
29 M6×12 Bolt 6
30 Air Duct 1
31 Wind Cover 1
32 M6×113 Bolt 2
33 Set Pinφ10×16 2
34 Cylinder Head Gasket 1
35 Cylinder Head Assembly 1
36 M8×34 Bolt 2
37 Spark Plug 1
Part Description Qty
38 Bolt 4
39 Cylinder Head Cover Gasket 1
40 Cylinder Head Cover Assembly 1
41 Crankcase Gasket 1
42 Set Pin 2
43 Bearing 6205 1
44 Crankshaft Oil Seal 1
45 Seal 2
46 Oil Dipstick 1
47 Oil Dipstick Assembly 1
48 Crankcase Cover 1
49 Dust Plate 1
50 Boltm6×12 1
51 M8×32 Bolt 7
52 M6 Nut 1
53 Regulating Arm 1
54 Lock Bolt 1
55 Back Spring 1
56 Regulating Spring 1
57 Pulling Rod 1
58 Regulating Frame Assembly 1
59 Boltm6×12 1
60 Air Cleaner Stay 1
61 Air Cleaner 1
62 Inlet Gasket 1
63 Connecting Block 1
64 Carburetor Gasket 1
65 Carburetor Assembly 1
66 Air Cleaner Gasket 1
67 M6 Nut 2
68 Ignition Coil Assembly 1
69 Flywheel 1
70 Flywheel Fan 1
71 Starting Flange 1
72 M14×1.5 Nut 1
73 Diode 1
74 Screw M6×12 7
NOTE:
Some parts are listed and shown for illustration purposes only
and are not available individually as replacement parts.