5500 RATED WATTS/6500 MAX. WATTS PORTABLE GENERATOR Model 98838 Assembly And Operation Instructions 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. CAUTION! Your Warranty Is Voided If: You do not put engine oil in the Engine’s crankcase prior to its first use.
SPECIFICATIONS Electrical Specifications 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.
. Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control. Provide barriers or shields as needed. PERSONAL SAFETY 1. Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. 2. Dress properly.
the tool serviced before using. Many accidents are caused by poorly maintained tools. 6. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. 7. CAUTION: This generator is not intended to power sensitive electronic equipment* without the addition of an appropriate line conditioner and surge protector (both not included).
levels between rated and maximum may be used for no more than 30 minutes. 4. Substantial overloading will open the circuit breaker. Exceeding the time limit for 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 1. Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. 2.
ide detector (not included) to detect excessive carbon monoxide fumes in the work area and in the surrounding area. 9. Do not force the Generator. This tool will do the work better and safer at the speed and capacity for which it was designed. Do not overload the generator. Know the total running wattage necessary to power the desired items. FIRE AND EXPLOSION PRECAUTIONS 1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel storage and handling procedures.
2. Avoid body contact with fuels, oils, and lubricants used in the Generator and Engine. If swallowed, seek medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact, immediately wash with soap and water. For eye contact, immediately flush eyes with clean water. NOISE PRECAUTIONS 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.
12. Unconditioned electrical output can damage sensitive equipment. 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 EXTENSION CORD LENGTH (at full load) 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.
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 performing any service, maintenance, or cleaning of Generator or Engine.
4. Connect the end of the Positive Battery Cable (63) to the Battery’s positive (+) terminal. Then connect the Negative Battery Cable (64) to the Battery’s negative (–) terminal. (See Figure A.) INSTALLATION INSTRUCTIONS 1. 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. 2.
Grounding The Generator: GROUNDING TERMINAL (9) #6 AWG GROUNDING WIRE (NOT INCLUDED) GROUNDING ROD (NOT INCLUDED) FIGURE B Note: It is recommended that only a licensed electrician perform this procedure. Connect a #6 AWG grounding wire (not included) from the Grounding Terminal (9) on the Generator to a grounding rod (not included) that has been driven at least 24 inches deep into the earth.
(65) (2) (3) (34) (8) (6) (10) (7) (5) FIGURE C 4. 120 Volt AC Circuit Breakers (3): Each of the four 120 Volt AC Outlets have a Circuit Breaker to protect the Generator from overloading. Should a Circuit Breaker “trip”, unplug all electrical loads from the Generator. Allow the Circuit Breaker to cool down. Then, push the 120 volt Circuit Breakers. (See Figure C.) 5.
8. 12 Volt DC Fuse (8): The 12 Volt DC Outlet has one Fuse (8) to protect the Generator from overloading. The Generator is equipped with the following size and type of Fuse: F10A250V. Should a 12 VDC output exceed the fuse’s rating, always check to see if the Fuse has “blown” (a melted filament within the Fuse). If necessary, unplug all electrical loads from the Generator, replace with a new Fuse, and reattach a reduced load to the generator. (See Figure C.) 9.
the Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE 5W30 weight oil. (See Figure D, prior page.) 3. To do so, unscrew and remove the Oil Dipstick (65A). Pour engine oil into the oil fill hole until the level of oil is even with the bottom edge of the oil fill hole (if you cannot see the oil through the oil fill hole, then the oil is too low and more oil must be added). (See Figure D.) 4. Make sure to screw the Oil Dipstick (65A) firmly back into its Dipstick Hole. (See Figure D.
OPERATING INSTRUCTIONS 1. Check to make sure the Engine Ignition (2) is in its “OFF” position. (See Figure C.) 2. CAUTION! Make sure to unplug any load from the Generator before starting to prevent permanent damage to any appliances, tools, or equipment. 3. CAUTION! Engine oil MUST be added to the Engine’s crankcase prior to starting and running the Engine. Failure to add oil will damage the Engine and void its warranty. (See pages 13 and 14, and Figure D.) 4.
3. To start the Engine manually, using the Starter Handle (41A) and Starter Rope (40A), insert the Ignition Key (65) and turn the Engine Ignition (2) to its “RUN” position. Grasp the Starter Handle (41A) on the Starter Rope (40A) 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. 4.
c. Voltage sensitive appliances, tools, and equipment should be the last to be connected to the Generator and the first to be disconnected. 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. 8.
PLUG (59A) OIL DIPSTICK (65A) FIGURE F 4. Engine maintenance: a. After first 5 to 8 hours of use: Change oil. Then, change oil every 50 hours of use. Change oil every 25 hours of use when operating the Engine under a heavy load or in high temperatures. To change the oil, remove the Plug (59A) and allow the old oil to drain in a proper container. Once drained, replace the Plug. If the Engine will be run in temperatures above 32° Fahrenheit, use SAE 30 weight oil.
squeeze thoroughly to dry. Then, squirt several drops of a light weight oil onto the Element. Use compressed air to clean the Air Filter Separator. Then replace the Air Filter Separator, Air Filter Element, and Air Filter Cover. Clean more often under dusty conditions or when airborne debris is present. Replace Air Filter parts if necessary. (See Figure G.) c. After every 100 hours of use: Replace the Spark Plug (28A). To do so, remove the Spark Plug Wire (36A).
Troubleshooting Problem Engine will not start Possible Causes Likely Solutions 1. Generator not grounded to battery. 2. Battery not charged. 3. Low on fuel or oil. 4. Engine power switch is in the OFF position. 5. Faulty spark plug. 6. Choke in wrong position. 7. Fuel valve lever in CLOSED position. 8. Generator loaded during start-up. 9. Spark plug wire loose. 10. Fuel line clogged. 11. Faulting ignition system. 1. Ground negative (1) terminal on battery to engine mounting bolt on generator. 2.
PARTS LIST - GENERATOR Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 24 25 26 27 28 29 Description Bolt w/Lock Washer (M6 x 12) Engine Ignition Circuit Breaker Control Panel AC Outlet (120V) AC Outlet (240V) DC Terminal (12V) Fuse (F10A250V) Grounding Terminal Power-On Light Shock Absorber Bolt (M5 x 215) Lock Washer Nut (M8) Stator Crust Alternator Back Cover Automatic Voltage Regulator Bolt (M5 x 12) Rectifier Bolt (M6 x 180) Bolt (M5 x 20) Connection Board Nut (M5) Stator Rotor Cooling Fan SKU
ASSEMBLY DIAGRAM - GENERATOR SKU 98838 For technical questions, please call 1-800-444-3353.
PARTS LIST - ENGINE Part 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A 33A 34A 35A 36A 37A 38A 39A 40A 41A 42A 43A Description Muffler Cylinder Head Bolt Cylinder Head Cover Bolt Cylinder Head Cover Lock Nut Adjusting Screw Rocker Arm Rocker Arm Bolt Valve Push Rod Guiding Board Valve Push Rod Cylinder Head Carburetor Shield Carburetor Packing Carburetor Assembly Air Filter Case Air Filter Seal Bolt (M6) Air Filter Cover Air Filter E
SKU 98838 4A 3A 2A 1A 5A 33A 6A 7A 32A 31A 78A 79A 80A 77A 8A 9A 12A For technical questions, please call 1-800-444-3353. 15A 14A 16A 24A 23A 22A 21A 25A 56A 74A 75A 35A 57A 34A 13A 26A 27A 28A 10A 11A 29A 30A 82A 81A 76A 17A 85A 83A 20A 38A 50A 59A 58A 19A 52A 84A 51A 54A 53A 36A 37A 55A 18A 48A 62A 39A 40A 46A 41A 68A 45A 70A 69A 65A 66A 67A 71A 64A 47A 63A 72A 43A 44A 42A 86A: Spark Plug Wrench Kit Not Shown.
Limited 1 year / 90 Day warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that for a period of ninety days from date of purchase that the engine/motor is free of defects in materials and workmanship.
Emission Control System Warranty - continued Harbor Freight Tools Emission Control Defects Warranty Provisions 1. 2. Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two (2) years after the date of delivery to the first retail purchaser. 5.
Electrical Diagram Note: All electrical work must be performed by a qualified service technician. SKU 98838 For technical questions, please call 1-800-444-3353.
