Chicago Electric 02514 Assembly And Operating Instructions Manual

Brand: Chicago Electric

Model: 02514

Type: Assembly And Operating Instructions Manual

Chicago Electric 02514 is a powerful and versatile generator that can provide backup power for your home or business, power tools on a job site, or provide electricity for camping or other outdoor activities. With a rated output of 20 KVA and a maximum output of 87 amps, it can handle a variety of electrical loads, including power tools, appliances, and lighting. The generator is powered by a 32 HP, 4-cylinder, diesel engine that provides reliable and efficient power.

GENERAGENERA

GENERA

TOR - DIESEL

20 KV20 KV

20 KV

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

this manual or any artwork contained herein may be reproduced in any shape

or form without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-3353

02514

CHICAGO

Electric

Generators

Model

Page 2SKU 02514

Specifications

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and

invoice in a safe and dry place for future reference.

- Single phase, 230 VAC/115 VAC output, 60 Hz

- 87 amps (maximum)

- Rated output: 20 KVA

- Breakers: 100 amp (230V side), 100 amp (115V side)

- Make: Daewoo model DC - 23, diesel fuel, self-ventilating

- 32 HP

- 1800 RPM

- 4 cylinders, in-line, radiator cooled, overhead valve

- Displacement: 2238 cc

- Compression ration: 17.2 : 1

- Ex-voltage: 92 volts; Ex-current: 5.4 amps

- Fuel consumption: At 75% load: 10.2 hours

- Battery: one 12 VDC, Marine Duty, 120 / AH / VDC

- High temperature shutdown

- Emergency shutdown pushbutton

- Emergency shutdown for low or high oil

- Battery rack

- 18 gallon fuel capacity

- Coolant capacity: 2.25 gallons

- Fully enclosed bottom exhaust

- Soundproof housing

- Meter (V.A.Hz)

- U, V, and W phase lights

- Fuel Level and oil pressure gauges

- Water temperature gauge

- Battery charge current meter

- Power light

- Calculagraph counter

- Low oil pressure light

- High water temperature light

- Key switch: Run - Off - Preheat Start

- Emergency shutdown pushbutton

- On / Off: 230V

- On / Off: 115V

75 (L) x 57 (H) x 43-1/2 (W) inches

2,205 lbs.

Generator

Engine

Features

Indicators

Controls

Overall Dimensions

Weight

ITEM DESCRIPTIONS

Page 3SKU 02514

Safety Warnings and Precautions

WARNING: Before using the generator, read and understand the Daewoo Engine Op-

eration, Maintenance, and Parts Manuals. Also read the safety precautions in this manual

which should always be followed to reduce the risk of personal injury and damage to

equipment.

Read all instructions before installing or using this generator!

1. Ensure installation meets all applicable safety, and local and national electrical codes.

Have installation performed by a qualified, licensed electrician and building contractor.

2. Do not operate the generator with protective covers, access covers, or terminal box

covers removed.

3. Disable closing circuits and place warning notices on any circuit breakers normally

used for connection to the mains or other generators to avoid accidental closure.

4. Do not alter or adjust any part of the generator assembled and supplied by the

manufacturer.

5. Do not attempt to operate the generator when conditions are unsafe. Disable the

generator by removing the battery until the unsafe condition is corrected.

6. Operate the generator only when in full compliance with relevant local and national

electrical codes and standards.

Handling and Installation Precautions

1. All electrical work, including earth-ground connection, should be completed by a

licensed electrician.

2. Any separate fuel storage generator supply facility, must be built or installed in full

compliance with relevant local, state, and federal regulations.

3. If the generator is installed indoors, exhaust fumes must be piped out of the building

using leak-free, heat-resistant piping. Pipes and silencer should not use any

flammable materials, nor should they be installed near the same. Generator exhaust

fumes should be within legal limits.

4. If the generator is installed outdoors, it must be weatherproofed and can be

soundproofed. It should not be run outdoors without protection to the generator and

wiring conduit.

5. Never lift the generator using the engine or alternator lifting lugs. Connect lifting

equipment to the holes on the bed frame of the generator.

6. Before lifting the generator, ensure the lift rigging and supporting structure are in good

condition, and are rated to lift such a load.

7. Keep all personnel away from the suspended generator during relocating.

8. The supporting floor should be level, and strong enough to safely hold the weight of

the generator. If the floor is not level, strong cross members should be placed under

the full length of the generator steel frame at its low side.

Page 4SKU 02514

9. For trailer installation, the generator must be mounted on the center point of the trailer,

over the wheels.

10. Install sound and weather proofing only when it is not raining or snowing to avoid

trapping moisture within the generator.

Fire and Explosion Precautions

1. Generator fuel and fumes are flammable, and potentially explosive. Use proper fuel

storage and handling procedures. Always have multiple ABC class fire extinguishers

nearby.

2. The generator room must be adequately ventilated. Exhaust fumes must be piped to

the outdoors.

3. Keep the generator, surrounding floors, and room clean at all times.

4. When spills of fuel, oil, battery electrolyte, or coolant occur, they must be cleaned up

immediately. Dispose of fluids and cleaning materials as per any local, state, or

federal codes and regulations. Store oil rags in a covered metal container.

5. Never store fuel or other flammable materials near the generator.

6. Do not smoke, or allow sparks, flames or other sources of ignition around the engine,

fuel tanks, or batteries. Fuel vapors are explosive. While charging, batteries emit

hydrogen gas which is highly explosive.

7. Turn off or disconnect the power to the battery charger before making or breaking

connections with the battery. Otherwise, sparking will occur.

8. Keep grounded conductive objects, such as tools, away from exposed, live electrical

parts and connections to avoid sparking or arcing. These events could ignite fumes or

vapors.

9. Do not refill the generator fuel tank of the bed frame while the engine is running.

10. Do not operate the generator with known leaks in the fuel system.

11. Excessive buildup of unburned fuel gases in the exhaust system can create a

potentially explosive condition. This buildup can occur after repeated failed start

attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust system

drain plugs, if equipped, and allow the gases to dissipate before attempting to restart

the generator.

12. Use only engine manufacturer’s recommended fuel, oil, and cooling fluids (see engine

manufacturer’s instruction manuals).

Page 5SKU 02514

Mechanical Precautions

1. The generator is designed with guards for protection from moving parts. In any case,

care must still be taken to protect personnel and equipment from other mechanical

hazards when working around the generator.

2. Do not operate the generator with safety guards removed. While the generator is

running, do not attempt to reach around the safety guards for maintenance or any

other reason.

3. Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts, and

other moving parts. Be aware that when engine parts are moving fast they cannot be

seen clearly.

4. Keep access doors on enclosures closed and locked when access is not required.

5. When working in and around the generator always wear protective clothing including

gloves, safety goggles, and safety hat.

Chemical Precautions

1. Avoid contact with hot oil, coolant, exhaust gases, surfaces, and sharp edges and

corners.

2. Do not remove the radiator filler cap until the coolant has cooled. Loosen the cap

slowly to relieve any excess pressure, then remove the cap completely.

3. Avoid body contact with fuels, oils, coolants, lubricants and battery electrolyte used in

the generator. 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.

4. When servicing the battery, wear an acid resistant apron and full face shield and safety

glasses. If electrolyte is spilled on skin or clothing, immediately flush with large

quantities of water.

Noise Precautions

This generator is equipped with sound attenuating enclosure. The generator can

product noise levels of up to 105 dBA. Prolonged exposure to noise levels above 85

dBA is hazardous to hearing. Always wear ear protection when operating or working

around the generator when it is running.

Electrical Precautions

1. All connections and conduit from the generator to the load must only be 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.

2. The generator must be earth-grounded in accordance with all relevant electrical

codes and standards before operation.

3. Before performing any maintenance or connecting or disconnecting any electrical load

connections, the negative (–) battery cable must be removed from the battery.

Page 6SKU 02514

4. Do not attempt to connect or disconnect load connections while standing in water, or

on wet or soggy ground.

5. Do not touch electrically energized parts of the generator and interconnecting cables

or conductors with any part of the body, or with any non-insulated conductive object.

6. Immediately replace the terminal box cover after making connection or disconnection

of cables within, or tightening cable lug nuts. Do not operate the generator with the

terminal box cover open.

7. All terminal box cable connections must be tight to avoid arcing. Arcing can heat up

and melt terminal lugs causing a disconnection and grounding of a live circuit.

8. Connect the generator only to a load or electrical system that is compatible with the

electrical characteristics and rated capacity of the generator.

9. Before servicing equipment powered by the generator, disconnect the equipment from

its power input.

10. Keep all electrical equipment clean and dry. 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.

11. Insulate all connections and disconnected wires.

12. Use only Class BC or Class ABC fire extinguishers on electrical fires.

General Precautions

1. Check for damaged parts . Before using the generator, any part that appears

damaged should be carefully checked to determine that it will operate properly and

perform its intended function. Check for alignment and binding of moving parts; any

broken parts or mounting fixtures; and any other condition that may affect proper

operation. Any part that is damaged should be properly repaired or replaced by a

qualified technician.

2. Guard against electric shock . Prevent body contact with grounded surfaces such

as pipes, radiators, ranges, and refrigerator enclosures.

3. Replacement parts and accessories . When servicing, use only identical

replacement parts. Use of any other parts will void the warranty. Only use accessories

intended for use with this tool. Approved accessories are available from Harbor

Freight Tools.

4. Do not operate generator if under the influence of alcohol or drugs . Read

warning labels on prescriptions to determine if your judgment or reflexes are impaired

while taking drugs. If there is any doubt, do not operate the generator.

5. Maintenance . For your safety, service and maintenance should be performed

regularly by a qualified technician. Never work alone on the generator.

Warning: People with pacemakers should consult with their physician(s) before using this

product; operation of equipment in close proximity to a heart pacemaker could cause

interference or failure of the pacemaker.

Page 7SKU 02514

6. Pacemaker safety warning . People with pacemakers should consult with their

physician(s) before using this product; operation of equipment in close proximity to a

heart pacemaker could cause interference or failure of the pacemaker.

Warning: The warnings, cautions, and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must be under-

stood by the operator that common sense and caution are factors which cannot be

built into this product, but must be supplied by the operator.

First Aid for Electric Shock

1. Do not touch the victim’s skin with bare hands until the source of the electricity has

been turned off.

2. Turn the generator off.

3. Pull the plug or hot cable away from the victim using an insulated material.

4. Stand on dry insulating material and pull the victim clear of the conductor, preferably

using insulated material such as dry wood or an insulated hook.

5. Once the victim is free of the electric current, check for breathing. If not breathing,

perform CPR and keep the victim warm. Have someone call the paramedics.

Unpacking

When unpacking, handle shipping boxes and crates with care. When moving avoid drop-

ping or bumping. Verify that all parts are included and are in good condition. If any parts

are missing or broken, please call Harbor Freight Tools at the number on the cover of this

manual as soon as possible. Refer to the Daewoo maintenance manuals (supplied) for

detailed information: Operation, Maintenance, and Parts Book.

Installation

Before Installation

Prior to installation, verify that the generator’s rated wattage and amperage capacity is

adequate to supply all electrical loads that the unit will power. The transfer switch must also

be able to handle the loads.

If powering the entire facility exceeds the generator capacity, it may be necessary to group

the loads to critical and noncritical, and group the critical loads for connection to a separate

emergency distribution panel.

Note: Electrical and other permits may be required for the installation of emergency power

systems. Investigate the local building and electrical codes before installing this unit. Instal-

lation must be completed by licensed contractors.

Caution: Do not attempt to start or crank the generator engine before it has been checked

for sufficient and recommended oil, coolant, and the battery is fully charged. Otherwise,

engine damage may occur.

Page 8SKU 02514

Warning: The generator weighs 2,205 lbs. Use care and the proper lifting or hoisting

equipment when moving it to the installation location. If hoisting with a crane, avoid

overhead power lines. Always connect hoist lines to the steel base of the generator.

Generator Location

• Locate and install the generator outdoors where cooling air is readily available. Do not

remove any part of the protective enclosure while operating.

• Install 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 snow drifts may

require the placement of a barrier for protection. The air inlet, in normal weather condi-

tions, should face the prevailing wind direction.

• Install the generator on a slab or other area where rain drainage or flood waters can not

reach it.

• Generator placement should allow four feet of access to all sides for maintenance.

• Place the generator as close as possible to the transfer switch and load to reduce the

length of cable runs.

• If the generator in located indoors, or in a generator house, the engine exhaust must be

ventilated to the outdoors using leakproof, heat resistant, metal flex tubing.

Transfer Switch Location

• Install the transfer switch indoors, and as close as possible to the (emergency) distribu-

tion panel, on a solid surface.

• Do not install the transfer switch where is can get wet or is exposed to moisture of any

kind. Avoid mounting in areas where there is corrosive vapors.

• Protect the transfer switch from dirt and dust.

Generator Support and Mounting

Mount the generator to a concrete slab able to support the weight of the generator. The

slab must extend beyond the steel base by at least one foot. Contact a cement contractor

for slab specifications if necessary. Attach the steel base to the concrete slab using large

and long, masonry type anchor bolts (not supplied).

Conduit and Wiring

All wiring must be of the proper AWG size and insulation, properly encased in NEC ap-

proved rigid conduit. Refer to the wiring illustrations on the next page.

Note: Specific generator voltage output, facility load, and transfer switch connections have

been left out, and should be at the discretion of the licensed electrical contractor for the

requirements of the facility load. It is important to balance all (phase) loads off the genera-

tor. If one phase draws more current than the others, damage can occur to the generator.

1. Install the 1-1/2” rigid conduit from the generator connection box to the outside of the

generator housing. Mount a junction box which connects it to the external rigid conduit

routed to the transfer switch.

Page 9SKU 02514

2. Pull and route the wires from the generator connection box to the transfer switch.

3. Make the appropriate connection within the transfer switch.

Warning: Remove power to the utility power supply leads by removing the master cir-

cuit breaker, and label “Do Not Touch - Wiring in Progress”.

4. Connect the utility power supply leads to the transfer switch.

5. Connect the circuit load leads from the emergency distribution panel (if used) to the

transfer switch.

Generator Connection Box

Typical Emergency Power System

115V

220V

U2 N

Page 10SKU 02514

Grounding the Generator

Drill a hole in the Generator connection box and place wire connection hardware (not sup-

plied). Connect a #6 AWG grounding wire from the wire lug to the grounding rod as shown

on page 9. The grounding rod must be an earth-driven copper or brass rod (electrode) which

can adequately ground the generator.

Battery Preparation and Installation

The generator requires one 12 volt Marine Duty battery (not supplied). Refer to the Daewoo

Engine Maintenance manuals for specific information regarding the battery.

1. Check the battery cell for the proper level of electrolyte fluid. Fill

in necessary.

2. Slow charge the battery for 24 hours prior to use.

3. Verify that the Generator keyed Power Switch is in the OFF

position.

4. Place and secure the battery inside the generator housing, to

the right of the door.

5. Connect the red cable terminal lug to the positive terminal of the

battery, and the black cable terminal lug to the negative terminal

of the battery.

Caution: During battery charging, explosive vapors may be emitted from the battery.

Ventilate the area and avoid smoking or other ignition points.

Post Installation Inspection

Before placing the emergency generator into service, inspect the entire installation carefully.

Some local codes may require that an inspection be performed by a building and electrical

inspector.

Operation

During operation, it may be necessary to refer to the Daewoo maintenance manuals (sup-

plied) for detailed information on engine operation, maintenance, and parts.

Pre-start Checks

1. Verify that the ON/OFF switch is in the Off position.

2. Check fuel level. If low, refill with clean diesel fuel.

3. Check oil level. Add oil if low.

4. Check coolant level. Add coolant if low.

5. Check voltage cables junction box for secure and clean connections.

Page 11SKU 02514

6. Press the circuit breaker (down) to the off position.

7. Notify facility personnel that power will shortly be restored, and that they should turn

off surge-sensitive equipment.

8. Turn off the utility power supply to the transfer switch from the utility main line circuit

breaker.

9. Set the transfer switch to the standby (generator-to-load) position.

Controls and Indicators

The table on the next page defines each item on the Control Panel.

1 2 3 4 5

6 7

8 9 10 11 12 13

14 15

Page 12SKU 02514

1 I Meter:Water Temperature

2 I Light:Power Supply

3 I Digital:V.A.Hz

4 I High Water Temperature Alarm

I Meter:Oil pressure

6 I

Light:Low Oil Pressure Alarm

7 C

Push button:Emergency Stop

8 C

Circuit Breaker

9 I Meter: Battery Change Current

11 I Calculagraph

12 C Switch:Voltage Change 230/115V

13 C

Switch:Run,Off,Preheat,Start

I Meter:Fuel Level

Startup

1. Verify all Pre-start Checks have been completed (see page 10 and 11).

2. Insert the key into the generator keyswitch .Turn key to "Preheat" for 10 seconds

(Do this only under cold weather conditions).

3. Turn key switch to “Start” to start the engine. If it does not start in 10 seconds repeat,

step 2.Once the engine starts, turn the Key to "Run".

4. Set the generator circuit breaker (up) to On. The generator is now supplying power to

the load.

5. View the ampere and voltage meters on the control panel. Adjust voltage regulator to

change voltage, if necessary. Total ampere should not exceed the maximum capacity of the

generator.

6. Listen for unusual noises, vibration, or other indications of abnormal operation. Check

for oil leaks and evidence of overheating.

* C = Control, I = Indicator

Controls and Indicators

ITEM C / I * DESCRIPTION

15 C Push Button:Alarm Reset

10 C Voltage Regulator(A.V.R)

Page 13SKU 02514

Shutdown

1. Flip the generator circuit breakers (down) to the Off position.

2. Allow the generator to run for a few minutes without a load.

3. Press the red Emergency Stop button (7) to stop the engine .

4. Turn the key to the “Off” position.

5. Set the transfer switch to the utility power (position) once the utility power is restored.

Maintenance

Preventative Maintenance

Preventative maintenance procedures and frequency will vary depending on the amount of

generator use. Refer to the Daewoo Engine Maintenance manual for specific instructions.

Caution: All maintenance must be done by a qualified mechanic or electrican.

Every Six Months or 2500 Hours of Use

1. Check fuel, oil, and coolant levels. Refill or replace as required.

2. Check and replace fan belt if cracked, torn, deteriorated, or frayed.

3. Check oil pressure (when running) and for oil leaks. Replace oil filter when replacing

the oil.

4. Drain water from the fuel filter. Replace after 400 hours of generator use.

5. Clean or replace air filter.

6. Check battery for complete charge, electrolyte levels, and leaking fluids. Recharge, or

replace battery if it will not hold a charge.

7. Clean all battery cap vents.

8. Start the generator and observe that all gauges and meters on the control panel are

operating properly.

9. Check exhaust connections for tightness.

10. Check all electrical connections for tightness.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS

MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU-

TOR 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.

Page 14SKU 02514

Fig.3 Diagram For Protection Patter Plate Of

Diesel Generating Set Oil

Pressure And Water Temperature

Plug 1 (Female)

Plug 2 (Male)

Fig.4Instruction For The Plug Of Diesel Generating

Set Protection Pattern Plate

KEY

BATTERY

WATER TEMPERATURE TRANSDUCER

OIL PRESSURE TRANSDUCER

STOP

LOW OIL PRESSUER

HIGH WATER TEMPERATURE

RESET

Page 15SKU 02514

Single-Phase A.C.Synchronous Generator

Schematic Diagram

A V R

1.Main Winding

2.Harmonic Coil Of

The Auxiliary

3.Automatic

Voltage Regulator

4.AVR Winding

5.Silicon Rectifier

6.Stator's Harmonic

Generator Layout Diagram

1.DIesel Engine

2.Couple Kit

3.Generator

4.Sound-Proof

Housing

5.Fuel Tank

6.Contorl Cables

7.Contorl Panel

8.Base Frame

9.Anti-Vibration

Mounting Base

10.Exhaust Pipe

11.Radiator

Page 16SKU 02514

1.Change Switch 2.Indicating Lamp 3.Calculagraph

4.Meter 5.Start Key 6.DC Charge Current Meter

7.Generator 8.Start Motor 9.Preheat Winding

10.Battery

Wiring Diagram Of Engine Control

Circuit breaker

Chicago Electric 02514 Assembly And Operating Instructions Manual

Chicago Electric 02514 Assembly And Operating Instructions Manual

Chicago Electric 02514 Assembly And Operating Instructions Manual

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