Chicago Electric 95960 Set Up, Operating, And Servicing Instructions
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Chicago Electric 95960 Set Up, Operating, And Servicing Instructions

Generator set 16 hp - 7000/7500 watts
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GENERATOR SET
16 HP - 7000/7500 WATTS
SET uP, OPERATiNG, ANd SERviciNG iNSTRucTiONS
distributed exclusively by Harbor Freight Tools
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
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.
3491 Mission Oaks Blvd., Camarillo, CA 93011
®
. All rights reserved. No portion of this manual or any artwork
95960
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.
®
.
Manual Revised 08i

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Summary of Contents for Chicago Electric 95960

  • Page 1 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...

  • Page 2: Specifications

    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. SKU 95960 For technical questions, please call 1-800-444-3353. Page 2...

  • Page 3: General Safety Rules

    Always wear eye protection. Dust mask, non- skid safety shoes, hard hat, or hearing protection must be used for appro- priate conditions. SKU 95960 For technical questions, please call 1-800-444-3353. Page 3...

  • Page 4: Specific Safety Rules

    “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: SKU 95960 For technical questions, please call 1-800-444-3353. Page 4...
  • Page 5 Store oil rags in a covered metal container. Never store fuel or other flammable materials near the Generator. SKU 95960 For technical questions, please call 1-800-444-3353. Page 5...

  • Page 6: Mechanical Precautions

    Generator when it is running. ELEcTRicAL PREcAuTiONS 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, SKU 95960 For technical questions, please call 1-800-444-3353. Page 6...
  • Page 7 Insulate all connections and disconnected wires. Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. Use only Class BC or Class ABC fire extinguishers on electrical fires. SKU 95960 For technical questions, please call 1-800-444-3353. Page 7...

  • Page 8: Control Panel Features

    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 vOLTMETER vOLTMETER FiGuRE A SKU 95960 For technical questions, please call 1-800-444-3353. Page 8...

  • Page 9: Battery Installation

    To use the Engine’s electric start capability, a Battery (45, not included) must first be installed. The type and size Battery required is: 12 volt DC, 7-1/4” long by 3” wide. (See Figure B, next page.) SKU 95960 For technical questions, please call 1-800-444-3353. Page 9...
  • Page 10 (See Assy. diagram.) Slide the Axle (49) through the two Axle Brackets (53). (See Assy. diagram.) Insert one Wheel (50) onto each end of the Axle (49). (See Assy. diagram.) SKU 95960 For technical questions, please call 1-800-444-3353. Page 10...

  • Page 11: Installation Instructions

    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 no or low engine oil WILL permanently damage the Engine. SKU 95960 For technical questions, please call 1-800-444-3353. Page 11...
  • Page 12 Periodically, check the Fuel Filter (32) for excessive dirt and debris. If necessary, remove the Fuel Filter and clean with compressed air. (See Figure E.) FuEL vALvE (41) cHOKE LEvER (21A) FiGuRE F REv 07h SKU 95960 For technical questions, please call 1-800-444-3353. Page 12...

  • Page 13: To Connect Electrical Loads

    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: SKU 95960 For technical questions, please call 1-800-444-3353. Page 13...

  • Page 14: Inspection, Maintenance, And Cleaning

    Before each use: Inspect the general condition of the Generator and its Engine. Check for loose screws, misalignment or binding of moving parts, cracked or SKU 95960 For technical questions, please call 1-800-444-3353. Page 14...

  • Page 15: Generator Maintenance

    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.) SKU 95960 For technical questions, please call 1-800-444-3353. Page 15...
  • Page 16 To do so, use a 13/16” spark plug wrench (not included) to remove the Spark Plug. Use a fine-grade sandpaper to clean off carbon build-up from the electrodes of the Spark Plug (28A). Clean with compressed air to remove residue. (See Figure i.) SKU 95960 For technical questions, please call 1-800-444-3353. Page 16...

  • Page 17: Please Read The Following

    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. SKU 95960 For technical questions, please call 1-800-444-3353. Page 17...

  • Page 18: Troubleshooting

    TROuBLESHOOTiNG SKU 95960 For technical questions, please call 1-800-444-3353. Page 18...
  • Page 19 Fuel Filter Seal Ring Fuel Tank Cap Lock Washer Bolt (M6x30) NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 95960 For technical questions, please call 1-800-444-3353. Page 19...
  • Page 20 ASSEMBLY diAGRAM - GENERATOR SKU 95960 For technical questions, please call 1-800-444-3353. Page 20...

  • Page 21: Parts List - Engine

    Anti-Wear Valve Stem Protector Locating Pin Cylinder Head Cover Packing Oil Seal Governor Spring Connecting Rod Bolt Bolt Connecting Rod Cap High Tension Line Connecting Rod Ignition Coil Piston Nut (Special 14mm) SKU 95960 For technical questions, please call 1-800-444-3353. Page 21...
  • Page 22 NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. SKU 95960 For technical questions, please call 1-800-444-3353. Page 22...

  • Page 23: Assembly Diagram -Engine

    ASSEMBLY diAGRAM -ENGiNE SKU 95960 For technical questions, please call 1-800-444-3353. Page 23...

  • Page 24: Wiring Diagram

    WiRiNG diAGRAM REV 08g SKU 95960 For technical questions, please call 1-800-444-3353. Page 24...

  • Page 25: Emission Control System Warranty

    Manufacturer’s Warranty coverage The 1995 and later engines are warranted for two (2) years. If any emission-related part on your engine is defective, the part will be repaired or replaced by HFT. SKU 95960 For technical questions, please call 1-800-444-3353. Page 25...
  • Page 26 Any replacement part, provided it is equivalent in durability and performance, may be used in performance of maintenance or repairs. The owner is responsible for commissioning a qualified technician/mechanic to perform all required maintenance, as outlined in the Inspection, Cleaning, and Maintenance section in this manual. SKU 95960 For technical questions, please call 1-800-444-3353. Page 26...
  • Page 27 System (if so equipped) Exhaust pipe stud. Muffler. Catalytic converter (if so equipped). iii) Miscellaneous items used in Above Systems Vacuum, temperature and time sensitive valves and switches. Hoses, belts, connectors, and assemblies. SKU 95960 For technical questions, please call 1-800-444-3353. Page 27...

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