Harbor Freight Tools 92863 User's Manual
Contents
1. and supporting structure are in good condition and are rated to lift such a load Keep all personnel away from the suspended Generator during relocating The supporting floor ground surface should be level and strong enough to safely hold the weight of the Generator If the floor ground surface is not level strong cross members should be placed under the full length of the Generator Frame at its low side SKU 92863 For technical questions please call 1 800 444 3353 PAGE 6 11 12 For trailer installation the Generator should be mounted on the center point of the trailer over the wheels Consult your local DMV for possible installation regulations Install sound and weather proofing only when it is not raining or snowing to avoid trapping moisture within the Generator s area Fire And Explosion Precautions 1 9 Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Always have multiple ABC class fire extinguishers nearby Keep the Generator and surrounding area clean at all times When spills of fuel or oil 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 Never store fuel or other flammable materials near the Generator Do not smoke or allow sparks flames or other sources of ignition around the Engine and Fu2. its OFF position to stop the Generator See Figure E 5 After the Engine and Generator have completely cooled store the Generator in a safe clean dry location out of reach of children and other unauthorized people INSPECTION MAINTENANCE AND CLEANING 1 NOTE Preventative maintenance procedures and frequency will vary depending on the amount of Generator use Refer to the Engine manufacturer s Operation Maintenance and Parts manual included for detailed information regarding maintenance of the Engine N Always make sure the ON OFF Switch is in its OFF position Disconnect the spark plug wire from the engine And allow sufficient time for the Engine and Generator to completely cool before performing any inspection maintenance or cleaning SKU 92863 For technical questions please call 1 800 444 3353 PAGE 15 3 Before each use Inspect the general condition of the Generator Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged electrical wiring and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 4 Before each use Check to make sure the Engine s oil level is adequate Refer to the Engine manufacturer s Operation Maintenance and Parts Manual included for specific information 5 Prior to refilling the Fuel Tank Remove the Fuel Ta
3. 3 8 diameter expansion anchor bolts not supplied GROUNDING THE GENERATOR ie NOTE It is recommended that only a trained and licensed electrician perform this procedure 2 Connect a 6 AWG grounding wire not included from the Ground Connector 17 on the Generator to a grounding rod not included that has been driven at least 24 inches deep into the earth The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the Generator See Figure B GROUND CONNECTOR 17 6 AWG WIRE NOT INCLUDED GROUNDING ROD NOT INCLUDED FIGURE B SKU 92863 For technical questions please call 1 800 444 3353 PAGE 11 OPERATING INSTRUCTIONS NOTE For additional references to the parts discussed in the following pages refer to the Assembly Diagram on page 18 of this manual Pre Start Checks 1 Before operation it will be necessary to refer to the Engine manufacturer s Operation Maintenance and Parts manual included for detailed information about starting running and stopping the Engine IMPORTANT Engine oil MUST be added to the Engine s crankcase prior to starting and running the Engine Failure to add oil according to the Engine manufacturer s recommendations will damage the Engine and void its warranty Check to make sure the Engine s ON OFF Switch is in its OFF position See Figure C Unscrew and remove one of the Engine s Oil Dipstick
4. CHICAGO aXeittejGenerators GENERATOR 6 HP ROBIN ENGINE RECOIL START 2800 WATT PEAK Model 92863 OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http Awww harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 2005 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 For technical questions please call 1 800 444 3353 REV 08 05 PRODUCT SPECIFICATIONS Electrical Requirements 2800 Watt Output Peak 60 Hz Output Two Pole Single Phase Alternator Overload Protection 18 Amp Circuit Breaker Outlet Type 20 AMP 120 VAC 3 Prong Grounding Engine Type 6 HP Robin Subaru Model EX170D52011 Recoil Start Unleaded Gasoline Powered 3600 RPM Engine Speed 169cc Displacement Suggested Oil F SAE 30 Above 32 F F SAE 5W 30 Below 32 F Engine Approval CARB amp EPA Phase 2 Emission Compliance Fuel Tank Capacity 3 2 Gallon Tank Run Time 13 Hours On Full Fuel Tank 50 Load 23 3 4 Lx 15 5 8 W x 21 1 8 H SAVE THIS MANUAL You will need this manual for the safety warnings and precautions operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on
5. PLACEMENT PARTS THERETO PARTS LIST Description Description 1 Connection Board 1 Bolt M5 4 2 Bolt M6 x 130 4 Heat Insulation Board 1 3 Bolt M5 x 12 2 Bolt M6 4 4 Cable Sheath 1 Bolt M5 x 35 4 5 _ Rear Cover 1 Fuel Valve 1 6 Bolt 2 Fuel Tank 1 7 Capacitor 1 Fuel Gauge 1 8 Alternator Back Cover 1 Bolt M5 x 12 2 9 Stator 1 Bolt M6 x 25 4 Bridge Combination 2 Fuel Tank Cap 1 Voltage Dependent Resistor 2 Seal Ring 1 Rotor 1 Filter 1 Hex Bolt 5 16 24 4 Bolt M5 4 14 Alternator Front Cover 1 34 Circuit Breaker 1 15 Shock Absorber Support 4 35 Outlet 20A 120V 2 16 Bolt M10 4 36 Bolt 5 16 24 x 170 1 17 Ground Connector 4 37 Bolt M5x16 2 18 Frame 1 38 Bolt M5 4 19 Bolt M10 4 39 Bolt M5x25 2 20 Shock Absorber 4 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts REV 08 05 SKU 92863 For technical questions please call 1 800 444 3353 PAGE 17 ASSEMBLY DIAGRAM Te Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts REV 08 05 SKU 92863 For technical questions please call 1 800 444 3353 PAGE 18 ELECTRICAL SCHEMATIC IOJEWIS YY euibuy pal Goyvoedes alg CEL E r opie bt aa eens mdg yas m o p des alos opel C Oe peg Wei uaal
6. b uasai Zl ayya aad uses to aN T HIND REV 08 05 PAGE 19 For technical questions please call 1 800 444 3353 SKU 92863
7. el Tank Fuel vapors are explosive 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 Do not refill the Fuel Tank while the Engine is running or while the Engine is still hot Do not operate the Generator with known leaks in the fuel system 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 Use only engine manufacturer recommended fuel and oil Mechanical Precautions 1 ALWAYS make sure the Power Switch is in its OFF position Disconnect the spark plug wire and allow the Engine to completely cool before carrying out maintenance SKU 92863 For technical questions please call 1 800 444 3353 PAGE 7 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 techn
8. he Plug from the Generator s outlet Keep Power Cords away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Damaged Power Cords increase the risk of electric shock PERSONAL SAFETY 1 Stay alert Watch what you are doing and use common sense when operating the Generator Do not use the Generator while tired or under the influence of drugs alcohol or medication A moment of inattention while operating the Generator may result in serious personal injury 2 Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts 3 Avoid accidental starting Make sure the Power Switch is in its OFF position and disconnect the Spark Plug Wire when not in use 4 Remove adjusting keys or wrenches before turning the Generator on A wrench or a key that is left attached to a rotating part of the Generator may result in personal injury 5 Do not overreach Keep proper footing and balance at all times 6 Use safety equipment Always wear eye protection Wear ANSI approved safety impact eye goggles when operating the Generator Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions 7 Do not force the Generator Use the Correct Generator for your application The correct Generator will do the job better and safer at
9. ician 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 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 Keep hands arms long hair loose clothing and jewelry away from moving parts Be aware that when engine parts are moving fast they cannot be seen clearly Keep access doors on enclosures closed and locked when access is not required When working on or around the Generator always wear protective clothing including ANSI approved safety gloves safety eye goggles and safety hat Do not alter or adjust any part of the Generator that is assembled and supplied by the manufacturer Always follow and complete scheduled Engine and Generator maintenance Chemical Precautions ibs 2 Avoid contact with hot fuel oil exhaust fumes and solid surfaces Avoid body contact with fuels oils and lubricants 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 Noise Precautions 1 Prolonged exposure to noise levels above 85 dBA is hazardous to hearing Always wear ANSI a
10. nerator use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS 1 N WARNING The warnings precautions and instructions discussed in this manual cannot cover all possible conditions and situations that may occur The operator must understand that common sense and caution are factors which cannot be built into this product but must be supplied by the operator 2 N WARNING People with pacemakers should consult their physician s before using this product Electromagnetic fields in close proximity to a heart pacemaker could cause interference or failure of the pacemaker In addition people with pacemakers should adhere to the following Caution is necessary when near the coil spark plugs or distributor of a running engine The engine should always be off if adjustments are to be made to the distributor 3 Industrial applications must follow OSHA requirements SKU 92863 For technical questions please call 1 800 444 3353 PAGE 5 4 Maintain labels and nameplates on the Generator These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Installation Precautions 10 A WARNING Before using the Generator read and unders
11. nk Cap 30 to expose the Filter 32 Remove the Filter and inspect it for an accumulation of dirt and debris If necessary clean the Filter using unleaded gasoline or a mild solvent Then replace the Filter Fill the Fuel Tank 26 with unleaded gasoline and replace the Fuel Tank Cap See Figure G 6 Daily With a soft brush cloth or vacuum remove all debris from the Generator Then use a premium quality lightweight machine oil to lubricate all moving parts FUEL TANK 26 7 FILTER 2 All maintenance service and repairs not listed in this manual are only to be attempted by a qualified technician FIGURE G SKU 92863 For technical questions please call 1 800 444 3353 PAGE 16 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR 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 RE
12. own grounding provides a low resistance path to carry electricity away from the user Double insulated tools are equipped with a polarized plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation Gj eliminates the need for the three wire grounded power cord and grounded power supply system Tools marked with Grounding Required have a three wire cord and a three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric shock Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose the Generator or power tools to rain or wet conditions Water entering the Generator or power tools will increase the risk of electric shock SKU 92863 For technical questions please call 1 800 444 3353 PAGE 3 6 Do not abuse Power Cords on tools Never use a Power Cord to carry the tools or pull t
13. p terminals clean and tight 110 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES At Full Load Pe nee r ee FEET FEET FEET FEET FEET Xs 18 138 138 18 16 21 34 18s dt ie ma 355 0 J 1e f i w a a2 5 1 7 0 o is J e yo a S ana S aa 7 1 12 0 r T r es 12 1 16 0 Based on limiting the line voltage drop to five volts at 150 of the rated am FIGURE A SKU 92863 For technical questions please call 1 800 444 3353 PAGE 9 9 Insulate all connections and disconnected wires 10 Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures 11 Use only Class BC or Class ABC fire extinguishers on electrical fires INSTALLATION 1 NOTE Prior to powering tools and equipment make sure the Generator s rated voltage wattage and amperage capacity 120V 20 AMPs is adequate to supply all electrical loads that the unit will power If powering exceeds the Generator s capacity it may be necessary to group one or more of the tools and or equipment for connection to a separate Generator 2 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 Installation must be completed by licensed contractors A WARNING The Generator weighs 95 7 Lbs without fuel Use care and the proper lifting or hoisting equipmen
14. pproved ear protection when operating or working around the Generator when it is running SKU 92863 For technical questions please call 1 800 444 3353 PAGE 8 Electrical Precautions T 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 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 If an extension cord not included is used make sure to use only UL listed cords having the correct gauge and length See Figure A 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 Connect the generator only to a load or electrical system 120 volt that is compatible with the electrical characteristics and rated capacities of the Generator re Before servicing equipment powered by the Generator disconnect the equipment from its power input 8 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 Kee
15. s then move the Engine s Fuel Choke all the way to the left to its RUN position See Figure E SKU 92863 For technical questions please call 1 800 444 3353 PAGE 13 FUEL VALVE 25 ON OFF SWITCH FUEL CHOKE STARTER ROPE FIGURE E Powering Tools And Equipment 1 Prior to powering tools and equipment make sure the Generators rated voltage wattage and amperage capacity 120V 20 AMPs is adequate to supply all electrical loads that the unit will power If powering exceeds the Generator s capacity it may be necessary to group one or more of the tools and or equipment for connection to a separate generator 2 Once the Generator is running simply connect the Power Cords of 120 volt powered tools and equipment into the 120 volt Dual Outlets 35 See Figure F next page SKU 92863 For technical questions please call 1 800 444 3353 PAGE 14 120 VOLT OUTLET 35 DG 120 VOLT OUTLET 35 CIRCUIT BREAKER 34 FIGURE F 3 NOTE The Generator features an AC Non Fuse Circuit Breaker 34 to protect the AC circuit in case of an overload Should an overload occur the Circuit Breaker will trip causing the Generator to automatically shut down In this case refer to Step 1 Then reset the circuitry system by depressing the Circuit Breaker Restart the Generator and continue powering the remaining tools and equipment See Figure F 4 When finished using the Generator turn the ON OFF Switch to
16. s located on both sides at the bottom of the Engine Crankcase Fill the Engine s crankcase with the proper type and amount of engine oil as recommended by the Engine manufacturer Then replace the Oil Dipstick See Figure C ON OFF SWITCH FIGURE C SKU 92863 For technical questions please call 1 800 444 3353 PAGE 12 5 Before the first use remove the Fuel Tank Cap 30 and fill the Fuel Tank 26 with unleaded gasoline Then replace the Fuel Tank Cap Thereafter check the Engine s Fuel Gauge 27 for the amount of unleaded gasoline in the Fuel Tank If necessary refill the Fuel Tank with unleaded gasoline See Figure D FUEL TANK CAP 30 FUEL TANK FUEL GAUGE 26 27 FIGURE D To Start The Generator 1 IMPORTANT Engine oil MUST be added to the Engine s crankcase prior to starting and running the Engine Failure to add oil according to the Engine manufacturers recommendations will damage the Engine and void its warranty 2 Turn the Fuel Valve 25 to its OPEN position See Figure E next page 3 Move the Engine s Fuel Choke to its START position See Figure E 4 Turn the Engine s ON OFF Switch to its ON position See Figure E 5 Grasp the Handle of the Engine s Starter Rope and rapidly pull the Starter Rope to start the Engine NOTE It may take one or more pulls on the Starter Rope to start the Engine 6 Allow the Engine to run for several second
17. t when moving it to the installation location Always connect hoist lines to the Frame 18 of the Generator GENERAL LOCATION 1 It is recommended to locate and install the Generator outdoors where cooling air is readily available 2 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 snowdrifts may require the placement of a barrier for protection The air inlet in normal weather conditions should face the prevailing wind direction 3 Install the Generator on a concrete slab or other area where rain drainage or flood waters can not reach it 4 Generator placement should allow four feet of access to all sides for maintenance SKU 92863 For technical questions please call 1 800 444 3353 PAGE 10 5 Place the Generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords 6 If the Generator in located indoors or in a Generator house the Engine exhaust must be ventilated to the outdoors using leakproof heat resistant flexible metal flex tubing GENERATOR SUPPORT AND MOUNTING 1 Mount the Generator on a concrete slab capable of supporting the weight of the Generator The slab must extend on all sides beyond the Frame 18 by at least one foot Contact a cement contractor for slab specifications if necessary Attach the Frame to the concrete slab using
18. tand the Engine manufacturers Operation Maintenance and Parts manual Also read the safety precautions in this manual These should always be followed to reduce the risk of personal injury and damage to equipment Ensure installation meets all applicable safety and local and national electrical codes Have installation performed by a qualified licensed electrician and building contractor All electrical work including the earth ground connection should be completed by a licensed electrician Any separate fuel storage Generator supply facility must be built or installed in full compliance with all relevant local state and federal regulations If the Generator is installed indoors exhaust fumes must be piped out of the building using leak free heat resistant piping Use the Generator only in well ventilated outdoor areas Carbon monoxide fumes are a colorless odorless gas that if inhaled can cause serious injury or death Pipes and silencer should not use any flammable materials nor should they be installed near the same Generator exhaust fumes must be within legal limits If the Generator is installed outdoors it must be weatherproofed and should be soundproofed It should not be run outdoors without protection to the Generator and wiring conduit Never lift the Generator using the engine or alternator lifting lugs Connect lifting equipment to the Frame of the Generator Before lifting the Generator ensure the lift rigging
19. the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference UNPACKING When unpacking check to make sure the product is intact and undamaged 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 GENERAL SAFETY RULES WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS REV 08 05 SKU 92863 For technical questions please call 1 800 444 3353 PAGE 2 WORK AREA Keep your work area clean and well lit Cluttered benches and dark areas invite accidents Do not operate the Generator and power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Generators and power tools create sparks which may ignite the dust or fumes Keep bystanders children and visitors away while operating the Generator and power tools Provide barriers or shields as needed ELECTRICAL SAFETY Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the tools should electrically malfunction or break d
20. the rate for which it is designed 8 Do not use the Generator if the Power Switch does not turn it on or off Any Generator that cannot be controlled with the Power Switch is dangerous and must be replaced GENERATOR USE AND CARE 1 Make sure the Power Switch is in its OFF position and disconnect the spark plug wire before making any adjustments changing accessories or storing the Generator Such preventive safety measures reduce the risk of starting the Generator accidentally SKU 92863 For technical questions please call 1 800 444 3353 PAGE 4 2 Store idle generators out of reach of children and other untrained persons Generators are dangerous in the hands of untrained users 3 Maintain the Generator with care Do not use a damaged Generator Tag damaged Generators Do not use until repaired 4 Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the generator s operation If damaged have the Generator serviced before using Many accidents are caused by poorly maintained Generators 5 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one Generator may become hazardous when used on another Generator 1 Generator service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing a Ge
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