Chicago Electric 98838 User manual

5500 RATED WATTS/6500 MAX. WATTS
PORTABLE GENERATOR
Model 98838
ASSEMBLY AND OPERATION INSTRUCTIONS
Using a generator indoors CAN KILL YOU IN
MINUTES.
Generatorexhaustcontainscarbonmonoxide.
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.
CAUTION!
Your Warranty Is Voided If:
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 oil will permanently damage the unit.
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2008 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual revised 10e

Page 2SKU 98838 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical
Specications
Alternator Type: 2-Pole, Single Phase
Output Frequency: 60 Hz
Output: 5,500 Rated Watts / 6,500 Max. Watts
AC Receptacles: 4 NEMA 120V 20A grounded receptacles
1 NEMA 240V 4 Prong, Twist Lock receptacle
DC Receptacle: 12 VDC Terminal with Cap Screws
Circuit Breakers: 20 A, Qty. 2 ; 25 A, Qty. 2
Fuse Type: F10A250V
Overload Protection: Resettable Circuit Protection for AC outlets, and Fuse for DC outlet
Engine
Specications
13 HP / 4-Cycle / Electronic Ignition & Recoil Start
Engine Speed: 3,600 RPM
Required Fuel Type: Unleaded Gasoline
Fuel Capacity: 6.5 Gal.
Recommended Oil Type: SAE 30W (Above 32°)
SAE 5W-30W (Below 32°)
Automatic Low Oil Shut-Down: Yes
Weight 175 Pounds
The Emission Control System for this generator’s engine is warranted for standards set
by the U.S. Environmental Protection Agency. For warranty information, refer to the back
two 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. Keep this manual and invoice in a safe and dry place for future refer-
ence.
GENERAL SAFETY RULES AND PRECAUTIONS
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 benches and dark areas invite
accidents.
2. 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.
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Page 3SKU 98838 For technical questions, please call 1-800-444-3353.
Keep bystanders, children, and visitors away while operating a power tool.3.
Distractions can cause you to lose control. Provide barriers or shields as needed.
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.
Avoid accidental starting. Be sure the Engine Ignition (2) is in its “OFF” po-3.
sition before moving the Generator and before performing any service, main-
tenance, or cleaning procedures on the unit.
Remove adjusting keys or wrenches before turning the Generator on.4. A
wrench or a key that is left attached to a rotating part of the machine may result in
personal injury.
Do not overreach. Keep proper footing and balance at all times.5. Proper foot-
ing 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
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 use the Generator if the Engine’s Ignition (2) does not turn it on or off.2.
Any tool that cannot be controlled with its power switch is dangerous and must be
replaced.
Store idle tools out of reach of children and other untrained persons.3. Tools
are dangerous in the hands of untrained users.
Maintain tools with care.4. 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, and5.
any other condition that may affect the tool’s operation. If damaged, have

Page 4SKU 98838 For technical questions, please call 1-800-444-3353.
the tool serviced before using. Many accidents are caused by poorly maintained
tools.
Use only accessories that are recommended by the manufacturer for your6.
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
CAUTION: This generator is not intended to power sensitive electronic7.
equipment* without the addition of an appropriate line conditioner and
surge protector (both not included). Sensitive electronic equipment should be
operated on approved inverter type generators or pure sine wave generators.
If the plugged in product operates abnormally or unusually slow, immediately stop
using the generator as a power source. Always read and adhere to the instruction
manual of the product to be powered, to make sure that it can be safely and
efciently powered by a portable generator.
Note: When using a generator to provide home standby electricity, a transfer
switch (sold separately) is needed to prevent back feeding power into the utility
line.
Connections for standby power to a building electrical system must be made by a
qualied electrician. The connection must isolate the generator power from utility
power, and must comply with all applicable laws and electrical codes.
WARNING: Improper connections to a building electrical system can allow
electrical current from the generator to backfeed into the utility lines. Such
backfeed may electrocute utility company workers or others who contact the lines
during a power outage, and the generator may explode, burn, or cause res when
utility power is restored. Consult the utility company or a qualied electrician.
*Sensitive electronic equipment includes, but is not limited to, audio/video
equipment, some television sets, computers, and printers.
AC APPLICATIONS
Before connecting an appliance or power cord to the generator: Make sure that it1.
is in good working order. Faulty appliances or power cords can create a potential
for electrical shock.
If an appliance begins to operate abnormally, becomes sluggish or stops suddenly,2.
turn it off immediately. Disconnect the appliance, and determine whether the
problem is the appliance, or if the rated load capacity of the generator has been
exceeded.
Make sure that the electrical rating of the tool or appliance does not exceed that of3.
the generator. Never exceed the maximum power rating of the generator. Power

Page 5SKU 98838 For technical questions, please call 1-800-444-3353.
levels between rated and maximum may be used for no more than 30 minutes.
Substantial overloading will open the circuit breaker. Exceeding the time limit for4.
maximum power operation or slightly overloading the generator may not switch
the circuit breaker or circuit protector OFF, but will shorten the service life of the
generator.
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 electric shock or injury.
SPECIFIC SAFETY RULES AND PRECAUTIONS
Your Warranty is voided if1. you do not put engine oil in the Engine’s crank-
case 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 low or no oil will perma-
nently damage the unit.
Maintain labels and nameplates on the Generator.2. 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 3.
supporting the weight of the Generator and any additional tools and equip-
ment.
Industrial applications must follow OSHA guidelines.4.
Never stand on the Generator.5. Serious injury could result if the Generator is
tipped.
Never leave the Generator unattended when it is running.6. Turn off the Engine
before leaving.
Do not allow children and other unauthorized people to handle or play with7.
the Generator.
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 fume that, when inhaled, can cause
serious personal injury or death. Whenever possible, use a carbon monox-

Page 6SKU 98838 For technical questions, please call 1-800-444-3353.
ide detector (not included) to detect excessive carbon monoxide fumes in
the work area and in the surrounding area.
Do not force the Generator.9. This tool will do the work better and safer at the
speed and capacity for which it was designed. Do not overload the generator.
Know the total running wattage necessary to power the desired items.
FIRE AND EXPLOSION PRECAUTIONS
Gasoline fuel and fumes are ammable, and potentially explosive. 1. 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.2.
When spills of fuel or oil occur, they must be cleaned up immediately.3. 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.4.
Do not smoke, or allow sparks, ames, or other sources of ignition around 5.
the Generator.
Keep grounded conductive objects, such as tools, away from exposed, live6.
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 7.
still hot. Do not operate the Generator with known leaks in the fuel system.
Use only Engine manufacturer recommended fuel and oil.8.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always1.
make sure the Engine’s Ignition (2) is in its “OFF” position. Allow the Engine
and Generator to completely cool. Then, remove the spark plug from the
Engine.
Do not alter or adjust any part of the Generator or Engine that is assembled2.
and supplied by the manufacturer.
Always follow and complete scheduled Generator and Engine maintenance.3.
CHEMICAL PRECAUTIONS
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.1.

Page 7SKU 98838 For technical questions, please call 1-800-444-3353.
Avoid body contact with fuels, oils, and lubricants used in the Generator and2.
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.
NOISE PRECAUTIONS
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.
ELECTRICAL PRECAUTIONS
All connections and conduits from the Generator to the load must only be1.
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.
The Generator must be earth-grounded in accordance with all relevant elec-2.
trical codes and standards before operation.
If an extension cord (not included) is used, make sure to use only UL listed3.
cords having the correct gauge and length. (See TABLE A, next page.)
Do not attempt to connect or disconnect load connections while standing in4.
water, or on wet or soggy ground.
Do not touch electrically energized parts of the Generator and interconnect-5.
ing cables or conductors with any part of the body, or with any non-insulated
conductive object.
Connect the Generator only to a load or electrical system (120 volt, 240 volt,6.
or 12 volt) that is compatible with the electrical characteristics and rated ca-
pacities of the Generator.
Be sure the Engine’s Ignition (2) is in its “OFF” position before moving the7.
Generator and before performing any service, maintenance, or cleaning pro-
cedures on the unit.
Keep all electrical equipment clean and dry.8. 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.
Insulate all connections and disconnected wires.9.
Guard against electric shock.10. 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.11.

Page 8SKU 98838 For technical questions, please call 1-800-444-3353.
Unconditioned electrical output can damage sensitive equipment.12. Do not use
to power sensitive electronic equipment without appropriate line conditioner (sold
separately).
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 OR 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.
MISC. PRECAUTIONS
WARNING!1. 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.
WARNING!2. 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.

Page 9SKU 98838 For technical questions, please call 1-800-444-3353.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on
pages 20 and 22 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.
ASSEMBLY INSTRUCTIONS
CAUTION! Make sure Engine’s Ignition (2) is in its “OFF” position prior to per-
forming any service, maintenance, or cleaning of Generator or Engine. Always
wear ANSI- approved safety impact eye goggles when assembling and using the
Generator.
To Install The Battery (not included):
NOTE: For proper operation, you must install a DC 12V, 18-35 Amp-hour Battery.
POSITIVE BATTERY CABLE
(63)
NEGATIVE BATTERY CABLE
(64)
BATTERY GUARD PLATE (44)
(FACTORY PRE-INSTALLED)
BATTERY TRAY (48)
(FACTORY PRE-INSTALLED)
BATTERY
(45)
Not included
BATTERY BRACKET
(47)
BOLT W/LOCK WASHER
(46) FIGURE A
1. Remove the packing from the Battery (45). Then, locate the factory pre-installed
Battery Guard Plate (44) and Battery Tray (48) beneath the Control Panel (4) of the
Generator unit. (See Figure A.)
Slide the Battery (45) into the Battery Guard Plate (44), with the Battery’s terminals2.
facing outward and with the Battery’s negative (–) terminal facing left.
(See Figure A.)
Align the two mounting holes in the Battery Bracket (46) with the two threaded3.
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 A.)
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Page 10SKU 98838 For technical questions, please call 1-800-444-3353.
Connect the end of the Positive Battery Cable (63) to the Battery’s positive4. (+) ter-
minal. Then connect the Negative Battery Cable (64) to the Battery’s negative (–)
terminal. (See Figure A.)
INSTALLATION INSTRUCTIONS
Electrical and other permits may be required for the installation of emergency or1.
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-2.
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:
It is recommended to locate the Generator (outdoors only) where cooling air is1.
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 pro-
tection. The air inlet (on Air Filter Cover 18a), 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 2.
waters can not reach it.
Generator placement should allow four feet of access to all sides for maintenance3.
and for proper air cooling.
Place the Generator as close as possible to the electrical tools and equipment be-4.
ing powered to reduce the length of extension cords.
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