Chicago Electric Portable Generator 38862 User Manual

GENERATOR USER  
MANUAL  
Model Numbers  
38862  
38863  
39408  
39321  
38863 Model Shown  
MODEL & SERIAL NUMBERS  
Enter the Model and Serial numbers of your generator in  
the spaces provided below. Retain these numbers for  
future reference. The Model and Serial numbers are  
located on the generator data plate on the alternator  
case or generator frame, along with other important  
information.  
Model Number  
Serial Number  
DOCCHI0009  
06/14/00 Rev. 1  
1
 
Contents  
LIMITED 1 YEAR WARRANTY STATEMENT .................................................................................................2  
SECTION 1........................................................................................................................................................4  
GENERAL INFORMATION .............................................................................................................................4  
SAFETY RULES..............................................................................................................................................4  
GENERAL SAFETY OPERATIONAL GUIDELINES..........................................................................................5  
GENERAL MAINTENANCE ............................................................................................................................5  
GENERATOR CLEANING...............................................................................................................................5  
GENERAL STORAGE GUIDELINES ................................................................................................................6  
ELECTRICAL LOADS AND GUIDELINES .......................................................................................................6  
GENERATOR DESIGNED PERFORMANCE GUIDELINES ...............................................................................6  
RECEPTACLE DETAILS .................................................................................................................................7  
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE ............................................................................7  
LOADING YOUR GENERATOR SET ...............................................................................................................7  
AMPERAGE RATE TABLE..............................................................................................................................7  
SECTION 2........................................................................................................................................................8  
38862/38863 GENERATOR PARTS AND PART LISTS ......................................................................................8  
A.C. Wiring Schematic................................................................................................................................. 10  
SECTION 3...................................................................................................................................................... 11  
39408/39321 GENERATOR PARTS AND PART LISTS .................................................................................... 11  
A.C. Wiring Schematic................................................................................................................................. 12  
3
 
SECTION 1  
DANGER:  
IF THE  
104ºF/40ºC.  
DO NOT OPERATE THIS GENERATOR  
AMBIENT TEMPATURE EXCEEDS  
GENERAL INFORMATION  
This manual is provided for you so that your  
generator may be properly, safely and effectively  
applied and operated. Please read and understand  
all aspects of this manual before operating your  
generator set. Please also read and understand the  
documentation supplied with this generator  
regarding the engine. Keep this documentation in a  
safe and accessible place so that reference can be  
made as needed. All operators, users and  
subsequent owners of this generator must read and  
understand all aspects of this documentation before  
operation.  
SAFETY RULES  
DANGER: This generator set is designed to be  
operated in dry conditions and for outdoor areas  
only. Never operate this generator indoors.  
Never operate this generator in rain, snow, sleet or  
generally wet conditions. Damage to the generator, bodily  
injury, or death could result from electrocution.  
DANGER: If this generator is connected to a  
building, home, business, or any other electrical  
circuit normally fed by utility power, steps must  
be taken to insure the generator output and the utility  
power are positively isolated. Failure to isolate the utility  
and generator electrical systems will result in generator  
damage and could result in injury or death to utility  
workers due to the backfeed of electricity.  
SPARK ARRESTING MUFFLER  
Certain States and Jurisdictions require that engine  
driven equipment be fitted with spark arresting mufflers.  
Depending on the generator model, spark arresting  
mufflers may or may not be fitted. If spark arresting  
mufflers are required for your specific local and the  
generator muffler is not spark arresting, contact your  
local dealer for instructions for a retrofit.  
CAUTION: Do not exceed the rated capacity of  
the generator. The total electrical loads at each  
outlet must be added to determine the total  
electrical load. The total load must not exceed the rated  
capacity of the generator. If the driven apparatus does not  
list wattage, but only amperage, wattage may be  
determined by multiplying amperage times voltage (watts  
= amps X volts).  
EXHAUST EMISSION CONTROL SYSTEM  
The exhaust emission control system for this generator  
complies to the standards set forth by the California Air  
Resources Board (CARB) and the Environmental  
Protection Agency (EPA). Warranties for the exhaust  
emission system are administered by the respective  
engine manufacturers. Refer to the engine  
documentation for warranty information.  
CAUTION: Do not tamper with the engine-  
governed speed. The generator operates at a  
nominal speed of 3600 rpm. Increases in speed  
over the 3600 rpm nominal will increase the chance of  
personal injury due to rotational stresses on the rotating  
members. Operation of the generator at speeds below the  
nominal 3600 rpm could cause damage to the generator  
or driven apparatus due to low voltage output.  
WARNING  
The engine exhaust from this product contains  
chemicals known to the State of California to cause  
cancer, birth defects, or other reproductive harm.  
CAUTION: Do not modify or misapply your  
generator set. Operation of the generator other  
than intended, could result in generator set  
damage, bodily injury or even death from electrocution.  
THIS SYMBOL IS USED THROUGHOUT YOUR  
OWNERS MANUAL TO BRING ATTENTION TO  
IMPORTANT SAFETY INSTRUCTIONS. FAILURE TO  
FOLLOW SAFETY INSTRUCTIONS COULD ENDANGER YOU  
OR OTHERS AND RESULT IN PERSONAL INJURY OR  
DEATH.  
READ  
AND  
UNDERSTAND  
ALL  
SAFETY  
INSTRUCTIONS BEFORE OPERATION.  
DO NOT OPERATE THIS GENERATOR WITHIN AN  
ENCLOSED AREA. THE EXHAUST GASES OF THIS  
GENERATOR  
EMIT  
DEADLY”  
CARBON  
MONOXIDE. EXPOSURE TO CARBON MONOXIDE CAN  
CAUSE CARBON MONOXIDE POISONING, HEADACHES,  
NAUSEA, SEVERE SICKNESS OR DEATH.  
DANGER: THIS GENERATOR SET PRODUCES  
ELECTRICAL  
GUIDELINES MUST BE FOLLOWED. IMPROPER  
OF THIS GENERATOR CAN RESULT IN  
CURRENT.  
THEREFORE, SAFETY  
USE  
ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE,  
SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY  
QUALIFIED TO DO SO.  
4
 
with sparks, a pilot light or an open flame. Improper  
storage of this generator could result in an explosion  
or fire.  
GENERAL SAFETY OPERATIONAL  
GUIDELINES  
 GROUNDING: The NATIONAL ELECTRICAL  
CODE requires that the generator frame be properly  
grounded to earth. A ground lug is provided on the  
generator frame. As a general guideline, a 10 AWG  
wire connected to the grounding lug of the generator  
on one end (located on the generator frame as  
indicated by the International GROUNDsymbol)  
and connected to a copper or brass ground rod  
(driven into the ground) on the other end of the wire.  
Some locations require generator set or other  
grounding. Check with a local electrician to  
determine the grounding requirements for your area.  
 Electrical generators produce electricity; Therefore,  
never allow or perform service operations to your  
generator set without proper training/certification.  
Service operations, without proper precautions can  
cause severe shock and even death by  
electrocution.  
 Generators operating on job or construction sites  
must be equipped with GFCI (Ground Fault Circuit  
Interrupters) on all circuits. Certain generator models  
are not equipped with GFCI circuits. Therefore,  
customer supplied GFCIs must be installed in the  
power cords connected to the generator. Consult a  
local licensed electrician for proper wiring.  
 Use only 3-Prong extension cords in good condition  
and make sure that the wire size within the  
extension cords is of sufficient size to safely carry  
the surge output of the generator.  
 Read and understand all the general safety  
operational guidelines and rules before operating  
this generator.  
 Always follow National and Local electrical codes.  
 When moving or transporting this generator, take  
proper precautions to avoid fuel spillage. Further,  
always use common sense when lifting this  
generator. An adequate number of people and  
proper lifting procedures must be used.  
 Do not wire your generator to a home or structure  
fed by utility power without proper isolation circuitry.  
Consult a local licensed electrician for proper wiring  
of your generator to a home, business or any facility  
or structure fed by utility power. Failure to properly  
isolate utility and generator electrical power could  
result in generator damage or electrocution to you or  
a
utility worker. The main breaker, which  
disconnects from the utility power, must be open  
before the generator can safely be connected.  
 Do not operate this generator unless the generator  
is in good mechanical and electrical condition.  
 Do not overload this generator. Overloading this  
generator can cause generator damage, powered  
apparatus damage and excessive heat build up.  
 Always keep hands, body parts, hair and clothing  
well away from the rotating or HOTparts of the  
generator set. Exhaust systems can cause severe  
burns.  
 Do not start this generator with connected devices  
turned ON. Always make sure that connected  
devices are disconnected from the generator or  
turned OFFbefore starting the generator.  
 Do not operate this generator within an enclosed  
area. The operation area of the generator must be  
completely open. The exhaust gases of this  
generator emit DEADLYcarbon monoxide.  
Exposure to carbon monoxide can cause carbon  
monoxide poisoning, headaches, nausea, severe  
sickness or death.  
 Never handle extension cords or electrical circuits if  
standing in water or if standing in a damp area.  
 Operate, service or fill with fluids on a level surface  
only.  
 Do not operate this generator in a corrosive or  
flammable environment.  
 Never clean this generator with high-pressure water  
or a garden hose. Water can accumulate within the  
generator and cause fuel system, ignition system  
and or electrical problems or shorts. Cleaning should  
be done with a damp rag on a cool generator set.  
 Do not install this generator in an enclosed area  
such as a RV or motorhome. All warranty will be null  
and void if installed within an enclosed area.  
 Always insure that at least 6 feet of clearance on all  
sides of the generator are maintained during  
operation. Failure to maintain proper clearance  
could damage your generator and potentially lead to  
fires.  
GENERAL MAINTENANCE  
ENGINE FUEL: Use Unleaded Fuel - ONLY!  
ENGINE OIL:  
Refer to the Engine related  
documentation.  
 Never touch a receptacle or bare wire. Electrocution  
ENGINE MAINTENANCE:  
Refer to the documentation supplied regarding the  
engine for all engine maintenance issues.  
or shock could result.  
 Gasoline is highly FLAMMABLE and its vapors  
are EXPLOSIVE. Handle gasoline with extreme  
care. Failure to properly handle gasoline can result  
in explosion or fire. Do not permit smoking within  
50ft of this generator set.  
GENERATOR CLEANING  
 NEVER REFILL A HOT GENERATOR WITH FUEL.  
NEVER REFILL THE GENERATOR WHILE IT IS  
RUNNING. Spillage onto the engine or generator  
could result in an explosion or fire. Always allow the  
generator set to cool before refilling.  
CAUTION!: ALWAYS SHUT OFF THE GENERATOR  
AND ALLOW THE GENERATOR TO COMPLETELY  
COOL  
BEFORE  
PERFORMING  
CLEANING  
OPERATIONS.  
WARNING! DO NOT USE HIGH PRESSURE WATER  
OR GARDEN HOSE TO CLEAN YOUR  
GENERATOR. WATER INTRODUCED INTO THE  
 Do not store this generator set in any location where  
A
gasoline fumes could potentially come into contact  
5
 
GENERATOR  
GENERATOR DAMAGE OR PERSONAL INJURY.  
CAN  
CAUSE  
ELECTRICAL  
SHORTS,  
Table 1  
Item  
GENERAL WATTAGE GUIDE  
Running Watts  
Air Conditioner (12000 Btu) (*)....................... 1750  
Air Compressor (1/2 hp) (*)............................ 1400  
Air Compressor (3/4 hp) (*)............................ 1800  
Air Compressor (1 hp) (*).............................. 2000  
Battery Charger (25A)..................................... 600  
Belt Sander (3belt)..................................... 1000  
Circle Saw (6 ½)................................... 825-1050  
Coffee Maker........................................ 900-1100  
Edger (lawn)................................................. 550  
Furnace Fan (1/3 hp) (*)................................ 1200  
Hot Plate (single)......................................... 1500  
Impact wrench............................................... 600  
Light Bulb............................................Bulb rated  
Nail Gun..................................................... 1200  
Microwave .................................................... 750  
Paint Sprayer (1/3 hp) (*)................................ 650  
Paint Sprayer, hand-airless ............................. 175  
Radio.......................................................50-200  
Refrigerator (*) .............................................. 600  
Table Saw (10) (*)....................................... 2000  
Television...............................................250-550  
Weed Trimmer .............................................. 500  
Note: (*) Items allow 2.5 times the listed wattage  
for starting.  
 Compressed air (max. 25 psi) may be used to blow  
loose dirt and dust from your generator. DO NOT  
DIRECT COMPRESSED AIR DIRECTLY INTO ANY  
OPENING IN THE GENERATOR OR ENGINE.  
 Use a dampened cloth to wipe clean exterior  
surfaces.  
 Use a soft bristle brush to clean/ loosen heavy dirt, oil  
or grease deposits.  
 NEVER insert rags, tools or any device into the  
generator or engine openings.  
GENERAL STORAGE GUIDELINES  
WARNING: GASOLINE FUMES ARE FLAMMABLE.  
DO NOT STORE YOUR GENSET IN ANY AREA  
THAT IS INDOORS OR IN POORLY VENTILATED  
AREAS. GASOLINE FUMES CAN IGNITE IN THE PRESENCE  
OF ANY OPEN FLAME, PILOT LIGHT, CLOTHES DRYER,  
WATER HEATER, ETC.  
 Your generator should be started and operated for  
several minutes at least every 30 days.  
 If the generator cannot be operated every 30 days,  
follow the storage recommendations within the engine  
documentation.  
 NOTE: A fuel shut-off valve is positioned at the base  
of the fuel tank. The valve should be closed during  
storage periods.  
GENERATOR DESIGNED  
PERFORMANCE GUIDELINES  
This electrical generator is designed to produce electrical  
energy for the purpose of powering lights, power tools,  
appliances and motor loads within the intended design  
constraints of the generator. The generator is designed to  
produce single-phase electrical power at 120 or 120/ 240  
VAC. This generator is not intended for installation in RV  
ELECTRICAL LOADS AND GUIDELINES  
Your generator set is designed to power electrical  
apparatuses within the electrical power output limitations  
of the generator. Please note that any generator overload  
can cause serious problems/damage to your generator.  
Additionally, apparatuses with electrical motors can  
require higher wattage requirements at start-up than when  
running. Some electric motors require as much as 2.5  
times the rated wattage at start-up. Although the start-up  
wattage requirements for electric motors lasts only a few  
seconds, great care must be taken in connecting loads to  
your generator so as not to overload the generator. Refer  
to the label on each electrical apparatus to determine the  
wattage requirements of that apparatus. THE TOTAL  
WATTAGE REQUIREMENTS OF ALL POWERED  
APPARATUSES (INCLUDING START-UP LOADS)  
MUST NEVER EXCEED THE CONTINUOUS RATING  
OF YOUR GENERATOR, CORRECTED TO THE  
ACTUAL ENVIRONMENTAL CONDITIONS AT THE  
OPERATING SITE.  
or  
motorhome  
applications.  
The  
Performance  
Specifications for your generator are listed in Table 2  
Performance Specifications.  
Table 2 PERFORMANCE SPECIFICATIONS  
38862  
38863  
120 VAC  
2600 Watts  
22 Amps @ 120 VAC  
3100 Watts  
3100 Watts  
(Single Phase)  
120/240 VAC  
(Single Phase)  
25.8 Amps @ 120 VAC  
3600 Watts  
25.8 Amps @ 120 VAC  
12.9 Amps @ 240 VAC  
3750 Watts  
30 Amps @ 120 VAC  
15 Amps @ 240 VAC  
4500 Watts  
39408  
39321  
120/240 VAC  
(Single Phase)  
31.2 Amps @ 120 VAC  
15.6 Amps @ 240 VAC  
4400 Watts  
37.5 Amps @ 120 VAC  
18.8 Amps @ 240 VAC  
5000 Watts  
120/240 VAC  
(Single Phase)  
36 Amps @ 120 VAC  
18 Amps @ 240 VAC  
41.6 Amps @ 120 VAC  
20.8 Amps @ 240 VAC  
Table 3 Engine Type  
Engine  
SKU Number  
HP  
38862  
38863  
39408  
39321  
Honda GX 160  
Honda GX 200  
Honda GX 240  
Honda GX 270  
5.5hp  
6.5hp  
8.0hp  
9.0hp  
As a reference only, Table 1 below shows some general  
wattage requirements for several common electrical  
devices. This chart is intended as a guide only. The actual  
total wattage should be determined by referring to the  
actual labels on each of the powered electrical devices.  
6
 
RECEPTACLE DETAILS  
The receptacles configurations shown in this section are for reference only. Each receptacle is not available on  
all generators.  
NEMA 5-20R  
125V - 20A  
NEMA L5-30R  
125V - 30A  
NEMA L6-30R  
250V - 30A  
NEMA L6-20R  
250V - 20A  
NEMA 14-50R  
125/250V - 50A  
NEMA L14-20R  
125/250V - 20A  
NEMA L14-30R  
125/250V - 30A  
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE  
Generator ratings assume 60F (20C) and Sea Level. Operation of your generator at temperatures above 60F (20C) or  
above Sea Level will result in lower electrical output. Electrical output must be derated 2% for each 9F above 60F and 3 ½  
% for each 1000 feet above mean sea level.  
LOADING YOUR GENERATOR SET  
WITH REFERENCE TO THE RECEPTACLE DETAILS SECTION, PLEASE REVIEW THE POWER RECEPTACLES FITTED TO YOUR  
GENERATOR.  
THE ACTUAL LOAD THAT MAY BE PULLED FROM EACH RECEPTACLE IS DRIVEN BY THE CIRCUIT BREAKER  
RATING AND THE GENERATOR RATING. ALL GENERATOR UNITS ARE EQUIPPED WITH A PUSH TO RESETCIRCUIT BREAKER.  
DO NOT EXCEED THE INDIVIDUAL RECEPTACLE RATINGS AS SHOWN IN THE TABLE BELOW. DO NOT EXCEED THE TOTAL  
GENERATOR RATING SHOWN IN TABLE 2 PERFORMANCE SPECIFICATIONS.  
AMPERAGE RATE TABLE  
Model  
SKU  
38862  
38863  
39408  
39321  
Figure 1  
120V Duplex 120V Duplex  
Figure 2  
Figure 3  
120V GFCI  
20Amps  
20Amps  
20Amps  
Figure 4  
Figure 5  
125/250V Twistlock 125V/250V Twistlock  
20Amps  
20Amps  
20Amps  
20Amps  
20Amps  
20Amps  
20Amps  
20Amps  
N/A  
N/A  
N/A  
N/A  
N/A  
15Amps  
20Amps  
20Amps  
20Amps  
PLEASE READ THE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS AND  
WIRING DIAGRAM(S) IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER  
THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR  
WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE  
ANY REPAIRS TO THE PRODUCT OR 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 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. PARTS MAY CHANGE OR VARY FROM THOSE  
SHOWN.  
7
 
SECTION 2  
38862 AND 38863 GENERATOR PARTS AND PART LISTS  
8
 
9
 
A.C. WIRING SCHEMATIC  
10  
 
SECTION 3  
39408/39321 GENERATOR PARTS AND PART LISTS  
Frame and Parts list for  
SKU # 39408/39321  
11  
 
A.C. WIRING SCHEMATIC  
12  
 
Notes  
13  
 

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