Harbor Freight Tools 91377 User's Manual
Contents
1. The Engine governor will regulate the throttle automatically depending on the electrical load applied to the generator If electricity to one of the outlets stops it could be that the circuit was overloaded Check the appliance s wattage then push in on the corresponding Circuit Breaker Reset Button to resume power When you are finished using the Generator Turn off then unplug all appliances Stop the motor driver by turning the Engine On Off switch to the Off position Turn the Gas Valve clockwise and close it completely INSPECTION MAINTENANCE AND CLEANING A WARNING Disconnect the wire to the Spark Plug of the Engine before performing any inspection maintenance or cleaning procedures 1 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 Periodically recheck all nuts bolts and screws for tightness Store in a clean and dry location For Engine maintenance and troubleshooting refer to the Robin Subaru Engine Operator s Manual After the Engine has cooled down remove the remaining gasoline into a gasoline container before storing the unit After the first five hours of use drain and replace the Engine2. cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician Generator Ground Terminal Connect a 6 AWG solid copper wire from the ground terminal to an earth grounding point Grounded Tools Tools with Three Prong Plugs 1 Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool SKU 91377 For technical questions please call 1 800 444 3353 Page 7 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 See Figure A The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal See Figure A Your tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See Figure A Gy 5 Figure Figure Double Insu
3. handling procedures Always have multiple ABC class fire extinguishers nearby The generator room must be adequately ventilated Exhaust fumes must be piped to the outdoors Keep the generator surrounding floors and room 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 fuel tanks or batteries 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 SKU 91377 For technical questions please call 1 800 444 3353 Page 4 Do not refill the generator fuel tank of the bed frame while the engine is running Do not operate the generator with known leaks in the fuel system 10 Use only engine manufacturer recommended fuel and oil fluids 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 Donotoperate the generator with safety guards removed While the generator is runnin
4. CHICAGO 3E Generators 7 900 WATT PEAK 6 600 WATT RATED GENERATOR WITH ROBIN ENGINE 111191377 ASSEMBLY AND OPERATING INSTRUCTIONS Distributed exclusively by Harbor Freight Tools 3491 MISSION OAKS BLVD CAMARILLO CA 93011 VISIT OUR WEB SITE AT HTTP WWW HARBORFREIGHT COM TO HELP PREVENT SERIOUS INJURY OR DEATH READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright O 2004 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 and replacement parts please call 1 800 444 3353 REV 07h SPECIFICATIONS Generator Wattage 240V 6 600 rated 7 500 peak Wattage 125V 6 000 rated Alternator single phase 6 KVA Voltage 240 125 VAC 60Hz Nominal current 50 amps at 125 VAC 25 amps at 240 VAC Outlets 120 VAC Standard 120 VAC twist lock 3 prong L530 240 120 VAC twist lock L430 Triple circuit breaker system resettable Engine 13 5 HP Robin Subaru EH41 with heavy cast iron sleeve EPA and Carb approved Four cycle engine 7 0 gallon gas tank 404 cc displacement Fuel unleaded gasoline Automatic Low Oil shut off Dual isolator mounts Oil capacity 40 56 fl oz Starter Recoil amp electric Frame Full roll cage Estimated Run Time 14 5 hours per full tank under load Overall Di
5. ND 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 SKU 91377 For technical questions please call 1 800 444 3353 Page 14 WIRING DIAGRAM Note Only a licensed electrician should perform electrical repairs on this generator SKU 91377 For technical questions please call 1 800 444 3353 Page 15 SCHEMATIC DRAWING RE STARTER SWITCH WITH E 7 RUS CO PARTS LIST ASSEMBLY OF CABLE amp TERMINALS ee A E Ur 1 Re starter 20 517 E T Resta 25072572507 __ 1 F Wiring Harness per qweewe 7 able ot Caliber White HR ui IS craj ToF L teure orcaiter Tz Re L9 2 5 imi for HEN UNE Ss jim TUE 4 m3 N emaro carm B 9 White 1 ms l Gos renter terra 6 8 0 pe 26 eae cater TB 05 able of Caliber reen 5 Ce a Df GG oe eS SKU 91377 For technical questions please call 1 800 444 3353 Page 16
6. Read all instructions before installing or using this generator Ensure installation meets all applicable safety and local and national electrical codes Have installation performed by a qualified licensed electrician and building contractor Do not operate the generator with protective covers access covers or terminal box covers removed Disable engine starting circuits before carrying out maintenance 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 Do not alter or adjust any part of the generator assembled and supplied by the manufacturer Always follow and complete scheduled engine and generator maintenance Do not attempt to operate the generator when conditions are unsafe Disable the generator until the unsafe condition is corrected Before performing any internal generator maintenance remove the negative lead from the batteries to prevent accidental starting Operate the generator only when in full compliance with relevant local and national electrical codes and standards 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 and any other condition that may affect proper operation Any part that is damaged sh
7. aker Reset Button 20A Circuit Breaker Reset Button 240 120 VAC Outlet Twist Lock NEMA L430 120 VAC Outlet 3 Prong Standard 120 VAC Outlet 3 Prong Locking NEMA 530 REV 07h SKU 91377 For technical questions please call 1 800 444 3353 Page 10 Generator Setup and Cable Connections 1 Place the Generator outdoors where it will be used This should be on a flat surface and away from flammable materials Do not allow the Generator to get wet If used indoors the area must be well ventilated to allow dissipation of exhaust fumes 2 Fill the Gas Tank outdoors with up to seven gallons of unleaded gasoline Do not top off tank 3 Add 40 oz of oil to the Engine by removing either Dip Stick and adding through its hole If the area temperature is above freezing use F SAE 30 weight oil If below freezing use F SAE 5W 30 weight oil Use a siphon to avoid spilling the oil Check the oil level with the Dip Stick It should be up to the Full mark Carefully screw the plastic Dip Stick back into the metal Engine crankcase to avoid stripping the plastic threads on the Dip Stick 4 Plugin the extension cords or appliances making sure that the appliance loads are turned off Refer to the section on Extension Cords on page 9 Do not overload the Generator Calculate the total wattage of the appliances The Generator has a maximum power output of 6 600 watts total from all outlets being used Warning If the Gener
8. ator will be used to replace facility power in times of outages the facility power input must be isolated Refer to the Electric Generator Safety Precautions on page 6 These connections must only be made by a licensed electrician Starting the Generator A WARNING This product contains or when used produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq 1 Open the Gas Valve by turning it counterclockwise until it stops Refer to the Generator Engine Controls photo on page 10 Turn the Engine On Off Switch to the On position Verify all connected appliances are turned off If the Engine is cold pull the Choke Button out Otherwise continue with the next step 5 NOTE DO NOT ATTEMPT TO ADJUST THE ENGINE S THROTTLE This engine uses a governor device to automatically control the engine s speed Ifthe throttle is adjusted it may result in decreased efficiency and or damage to the unit 6 Gently pull the Start Pull Cord until it engages Then pull it hard and all the way out on SKU 91377 For technical questions please call 1 800 444 3353 Page 11 The Engine should start Try again if it does not start Refer to the Robin Subaru Operator s Manual under Troubleshooting if problems persist Let the engine run for five minutes to warm up Push in the Choke Button Begin to turn on the connected appliances
9. electrical current and could cause electrocution 4 Ifthe Generator is connected to a building home business or any other electrical circuit normally fed by utility power steps must be taken to ensure that the Generator output and the utility power are positively isolated Failure to isolate the systems will result in Generator damage It could also result in personal injury or death to those working around these circuits Any connection in this regard must only be done by a licensed electrician 5 Avoid damaging the Generator by exceeding its rated capacity The total electrical loads at each outlet must be added to determine the total electrical load If the electrical appliance does not list the wattage rating you can calculate it by multiplying amps times voltage amps x voltage watts 6 Donot tamper with the engine governed speed The Generator operates at a nominal speed of 3600 RPM Increases in speed could damage rotating parts of the Generator Slower speeds could damage the Generator or appliances connected to the Generator due to low voltage 7 Always follow national and local safety codes Do not start the Generator with appliances connected and turned on Give the Generator at least two feet of space to dissipate heat 10 Properly ground the Generator The National Electrical Code requires that the Generator frame be properly grounded to earth This should be done by a licensed electrician Refer to Grounding on the nex
10. ensed electrician Any separate fuel storage generator supply facility must be built or installed in full compliance with 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 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 If the generator is installed outdoors it must be weatherproofed and can be soundproofed It should not be run outdoors without weather 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 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 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 Install sound and weather proofing only when it is not raining or snowing to avoid trapping moisture within the generator Fire and Explosion Precautions Generator fuel and fumes are flammable and potentially explosive Use proper fuel storage and
11. g 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 When working in and around the generator always wear protective clothing including gloves ANSI approved safety goggles and safety hat Noise Precautions The generator can product high noise levels Prolonged exposure to noise levels above 85 dBAis 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 engine must be disabled 4 Donot attempt to connect or disconnect load connections while standing in water or on wet or soggy ground 5 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 ob
12. ject 6 Connect the generator only to a load or electrical system that is compatible with the electrical characteristics and rated capacity of the generator 7 Before servicing equipment powered by the generator disconnect the equipment from its power input SKU 91377 For technical questions please call 1 800 444 3353 Page 5 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 Keep terminals clean and tight 9 Insulate all connections and disconnected wires 10 Use only Class BC or Class ABC fire extinguishers on electrical fires ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS 1 Carbon Monoxide Inhalation Hazard any other sealed structure Carbon monoxide is produced during operation and is deadly in a closed environment Early signs of carbon Monoxide poisoning resemble the flu with headaches dizziness or nausea If you have these signs get fresh air immediately This engine run generator must never be used indoors a house 2 The Generator produces electrical current Improper use can result in electrocution injury or death Only a qualified technician should service or repair this generator 3 The Generator was designed to be used in a dry area Do not expose to rain snow sleet or damp conditions Damage to the Generator could occur Moisture can carry
13. lated Tools Tools with Two Prong Plugs Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Standard Association and the National Electrical Code See Figure B above Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration See Figure B above EXTENSION CORDS Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Table A The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Table A When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Table A If you are using one extension cord for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Table A SKU 91377 For technical questions please call 1 800 444 3353 Page 8 6 If you are using an exte
14. mensions 27 1 2 L x 19 3 4 W x 28 1 8 H inches Suggested Oil Above 32 F SAE 30 Below 32 F SAE 5W 30 CAUTION THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE ADDITION OF AN APPROPRIATE LINE CONDITIONER SOLD SEPARATELY This product requires oil and fuel to be added before starting Attempting to start the engine without oil WILL ruin the engine and void the warranty BEFORE starting the engine refer to the engine owner s manual for engine maintenance information 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 GENERAL SAFETY RULES ZNWARNING 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 WARNING Before using the generator read and understand the Robin Subaru Engine Operation Maintenance and Parts Manual Also read the safety precautions in this manual which should always be followed to reduce the risk of personal injury and damage to equipment REV 07h SKU 91377 For technical questions please call 1 800 444 3353 Page 2 10 11 12 13 14 15 16
15. nsion cord outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use 7 sure your extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it 8 Protect your extension cords from sharp objects excessive heat and damp or wet areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT NAMEPLATE EXTENSION CORD LENGTH AMPERES at full load mis 2 9 wicmo 2 9 1 1 TABLE A Based on limiting the line voltage drop to five volts at 150 of the rated amperes Symbology Double Insulated Volts Alternating Current Underwriters Laboratories Inc eM Revolutions per Minute SKU 91377 For technical questions please call 1 800 444 3353 Page 9 UNPACKING When unpacking check to make sure that all the parts are included Refer to the Assembly section and the Assembly Drawing and Parts List at the end of this manual 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 OPERATING INSTRUCTIONS Generator Engine Controls m ee Gas Valve Choke Engine On Off Switch Starter Pull Cord Generator Electrical Controls and Outlets 30A Circuit Breaker Reset Button 30A Circuit Bre
16. oil After that replace the oil after every 25 hours of use REV 04k SKU 91377 For technical questions please call 1 800 444 3353 Page 12 SKU 91377 PARTS LIST Part Code D GA ENGINE 13 5 HP ROBIN SINGLE PHASE ALTERNATOR 6 KVA MOUNTING FLANGE END COVER 6 15051079 TUBE FRAME FUEL TANK 7 GAL CONTROL PANEL 11 45040103 CONTACT BOX HEAT SHIELD FUEL CAP BRACKET BRACKET 16 10160102 RUBBER SUPPORT 17 70130202 5 16 BIG BUMPERS 18 60130703 1 4 X 1 HEX HEAD TAPPING SCREW 5 16 SEQUENCE With PLAIN WASHER 5 16 HELICAL SPRING LOCK WASHER 5 16 HEX NUT 5 16 X 1 1 2 HEX BOLT 5 16 X 1 2 HEX BOLT 3 8 X 1 NC HEX BOLT GALVANIZED TIE ROD NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts For technical questions please call 1 800 444 3353 Page 13 ASSEMBLY DRAWING 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 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 A
17. ould be properly repaired or replaced by a qualified technician People with pacemakers should consult their physician s before using this product Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures 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 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 Maintenance For your safety service and maintenance should be performed regularly by a qualified technician Never work alone on the generator Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor Only a qualified service technician may adjust parts that may increase or decrease governed engine speed REV 071 SKU 91377 For technical questions please call 1 800 444 3353 Page 3 Handling and Installation Precautions All electrical work including earth ground connection should be completed by a lic
18. t page 11 Never handle electrically charged extension cords while standing in water SKU 91377 For technical questions please call 1 800 444 3353 Page 6 12 Only use 3 prong 125 VAC or 4 prong 240 VAC grounded extension cords Warning The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood 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 Turn the generator off Pull the plug or hot cable away from the victim using an insulated material 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 GROUNDING Warning This generator must be grounded to earth ground before using Refer to the photo at the top of the next page AWARNING Improperly connecting the grounding wire can result in the risk of electric shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power
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