CHICAGO 98838 Specifications

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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 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
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Summary of Contents

Page 1 - PORTABLE GENERATOR

5500 RATED WATTS/6500 MAX. WATTSPORTABLE GENERATORModel98838ASSEMBLY AND OPERATION INSTRUCTIONSUsing a generator indoors CAN KILL YOU IN MINUTES.Gener

Page 2 - SPECIFICATIONS

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 positive 4.

Page 3 - TOOL USE AND CARE

Page 11SKU 98838 For technical questions, please call 1-800-444-3353.Grounding The Generator:GROUNDING TERMINAL(9)#6 AWG GROUNDING WIRE(NOT INCLUDED)G

Page 4 - AC APPLICATIONS

Page 12SKU 98838 For technical questions, please call 1-800-444-3353.120 Volt AC Circuit Breakers (3): 4. Each of the four 120 Volt AC Outlets have

Page 5

Page 13SKU 98838 For technical questions, please call 1-800-444-3353.12 Volt DC Fuse (8): 8. The 12 Volt DC Outlet has one Fuse (8) to protect the G

Page 6 - CHEMICAL PRECAUTIONS

Page 14SKU 98838 For technical questions, please call 1-800-444-3353.the Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE 5W-30

Page 7 - ELECTRICAL PRECAUTIONS

Page 15SKU 98838 For technical questions, please call 1-800-444-3353.OPERATING INSTRUCTIONSCheck to make sure the Engine Ignition (2) is in its 1. “O

Page 8 - MISC. PRECAUTIONS

Page 16SKU 98838 For technical questions, please call 1-800-444-3353.To start the Engine manually, using the Starter Handle (41A) and Starter Rope 3.

Page 9 - ASSEMBLY INSTRUCTIONS

Page 17SKU 98838 For technical questions, please call 1-800-444-3353.INSPECTION, MAINTENANCE, AND CLEANING1. WARNING! Always make sure the Engine’s

Page 10 - INSTALLATION INSTRUCTIONS

Page 18SKU 98838 For technical questions, please call 1-800-444-3353.FIGURE FOIL DIPSTICK(65A)PLUG(59A)4. Engine maintenance:After rst 5 to 8 hours

Page 11 - CONTROL PANEL FEATURES

Page 19SKU 98838 For technical questions, please call 1-800-444-3353.squeeze thoroughly to dry. Then, squirt several drops of a light weight oil onto

Page 12

Page 2SKU 98838 For technical questions, please call 1-800-444-3353.SPECIFICATIONSElectricalSpecicationsAlternator Type: 2-Pole, Single PhaseOutput F

Page 13 - PRE-START INSTRUCTIONS

Page 20SKU 98838 For technical questions, please call 1-800-444-3353.REV 09hPLEASE READ THE FOLLOWING CAREFULLYTHE MANUFACTURER AND/OR DISTRIBUTOR H

Page 14

Page 21SKU 98838 For technical questions, please call 1-800-444-3353.PARTS LIST - GENERATORPart Description Qty1 Bolt w/Lock Washer (M6 x 12) 42 Engin

Page 15 - OPERATING INSTRUCTIONS

Page 22SKU 98838 For technical questions, please call 1-800-444-3353.ASSEMBLY DIAGRAM - GENERATOR

Page 16

Page 23SKU 98838 For technical questions, please call 1-800-444-3353.PARTS LIST - ENGINEPart Description Qty.1A Mufer 12A Cylinder Head Bolt 43A Cyli

Page 17

Page 24SKU 98838 For technical questions, please call 1-800-444-3353.ASSEMBLY DIAGRAM - ENGINE69A70A71A72A73A68A67A66A65A64A63A62A61A60A59A58A43A44A45

Page 18

Page 25SKU 98838 For technical questions, please call 1-800-444-3353.California and United States Emission Control Defects Warranty StatementThe the

Page 19

Page 26SKU 98838 For technical questions, please call 1-800-444-3353.1. Length of CoverageHFT warrants to a rst retail purchaser and each sub-sequen

Page 20 - Troubleshooting

Page 27SKU 98838 For technical questions, please call 1-800-444-3353.Electrical DiagramNote: All electrical work must be performed by a qualied servi

Page 21 - PARTS LIST - GENERATOR

Page 3SKU 98838 For technical questions, please call 1-800-444-3353.Keep bystanders, children, and visitors away while operating a power tool. 3. Dis

Page 22 - ASSEMBLY DIAGRAM - GENERATOR

Page 4SKU 98838 For technical questions, please call 1-800-444-3353.the tool serviced before using. Many accidents are caused by poorly maintained to

Page 23 - PARTS LIST - ENGINE

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.Substanti

Page 24 - ASSEMBLY DIAGRAM - ENGINE

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

Page 25 - Defects Warranty Coverage

Page 7SKU 98838 For technical questions, please call 1-800-444-3353.Avoid body contact with fuels, oils, and lubricants used in the Generator and 2. E

Page 26 - - continued

Page 8SKU 98838 For technical questions, please call 1-800-444-3353.Unconditioned electrical output can damage sensitive equipment. 12. Do not use t

Page 27 - Electrical Diagram

Page 9SKU 98838 For technical questions, please call 1-800-444-3353.UNPACKINGWhen unpacking, check to make sure all the parts shown on the Parts Lists

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