Harbor Freight Tools 91523 User's Manual
Contents
1. These extension cords are rated for outdoor use and reduce the risk of electric shock PERSONAL SAFETY Stay alert Watch what you are doing and use common sense when oper ating a generator Do not use a generator while tired or under the influ ence of drugs alcohol or medication A moment of inattention while operat ing generators may result in serious personal injury 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 Avoid accidental starting Make sure the Power Switch is in its OFF position and disconnect the Spark Plug Wire when not in use 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 Do not overreach Keep proper footing and balance at all times Use safety equipment Always wear eye protection Wear ANSI approved safety impact eye goggles Dust mask non skid safety shoes hard hat or hearing protection must be used for appropriate conditions Do not force the generator Use the Correct generator for your application The correct generator will do the job better and safer at the rate for which it is designed Do not use the generator if the Power Switch does not turn it on or off Any generator that cannot be controlled with the Power2. 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 If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user 5 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 contacta qualified electrician to install a polarized outlet Do not change the plug in any way Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system 6 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 SKU 91523 PAGE 3 10 Ate 12 13 14 15 16 ve Do not expose Generator to rain or wet conditions Water entering a generator will increase the risk of electric shock Do not abuse the Power Cord Keep Power Cords away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Dam aged Power Cords increase the risk of electric shock When operating a power tool outside use an outdoor extension cord marked W A or W
3. 1 1 1 fo i EES i 2 70A Bearing 30A Valve Spring 2 7A Camshaft Assy 2 E ca i cane i NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 91523 PAGE 20 SKU 91523 ASSEMBLY DIAGRAM A PAGE 21 suffix A behind the part number Example 1A Muffler When ordering parts from Parts List A and Assembly Diagram A include the NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts
4. CHEMICAL PRECAUTIONS Avoid contact with hot fuel oil exhaust fumes and hot 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 and seek medical attention SKU 91523 PAGE 8 NOISE PRECAUTIONS 1 Prolonged exposure to noise levels above 85 dBA is hazardous to hearing Always wear ANSI approved ear protection when operating or working around the Generator when it is running ELECTRICAL PRECAUTIONS 1 All connections and conduits from the Generator to the load must only be in stalled 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 for fixed installations 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 UEapproved cords having the correct gauge and length See Figure A NAMEPLATE EXTENSION CORD LENGTH AMPERES At Full Load Feet Feet Feet 146 x 6 6 12 142 O 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
5. Engine to run for several seconds Then open the Choke Lever 21A all the way See Figure E 120 VOLT DUAL OUTLETS FIGURE G SKU 91523 PAGE 14 Powering 120 Volt AC Tools And Eguipment f Prior to powering tools and equipment make sure the Generator s rated voltage and amperage capacity 110 120VAC 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 CAUTION THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC EQUIPMENT INCLUDING MEDICAL EQUIPMENT WITHOUTTHE ADDITION OF AN APPROPRIATE LINE CONDITIONER SOLD SEPARATELY 2 Once the Generator is running simply connect the Power Cords of 110 120 volt AC powered tools and equipment into the 110 120 volt AC Dual Outlets 6 See Figure G 3 NOTE The Generator features an AC Non Fuse Circuit Breaker 5 to protect the AC circuit in case of an overload Should an overload occur the Breaker will trip to its OFF position causing the Generator to automatically shut down In this case refer to Step 1 above in this section Then reset the circuitry system by turning the Circuit Breaker to its ON position Restart the Generator and continue powering the remaining tools and equipment See Figure D 4 When finished using the Generator turn the Engine Pow
6. INCLUDED PAGE 12 6AWG GROUNDING WIRE NOT INCLUDED FUEL TANK CAP 33 FUEL TANK 30 OIL DIPSTICK 65A 3 Before the first use remove the Fuel Tank Cap 33 and fill the Fuel Tank 30 with nleaded gasoline Then replace the Fuel Tank Cap Thereafter check the Engine s Fuel Gauge 34 for the amount of unleaded gasoline in the Fuel Tank If necessary refill the Fuel Tank with unleaded gasoline the Generator must be turned off and cooled down before refilling the fuel tank See Figure C To Start The Engine 1 Make sure the electrical powered tools equipment that will be used are not plugged into the Generator while the Engine is started 2 Turn the 120 volt AC Circuit Breaker 5 to its ON position See Figure D 3 Open the Fuel Valve 40 See Figure E 4 Close the Choke Lever 21A to about 1 8 clearance See Figure E CIRCUIT BREAKER FIGURE D CHOKE LEVER 21A FIGURE E SKU 91523 PAGE 13 5 Turn the Engine Power Switch 2 to its ON position See Figure F ENGINE POWER o NS AI FIGURE F 6 Hold the Start Handle 41A loosely and pull it slowly several times to allow the gasoline to flow into the Engine s carburetor Then hold the Start Handle firmly and pull the rope hard and fast Pull the rope all the way out using two hands if necessary If necessary pull the rope several times until the Engine starts See Figure G 7 Allow the
7. Switch is dangerous and must be replaced SKU 91523 PAGE 4 18 19 20 21 22 23 24 25 GENERATOR USE AND CARE 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 Store idle generators out of reach of children and other untrained persons Generators are dangerous in the hands of untrained users Maintain generators with care Do not use a damaged generator Tag dam aged generators Do not use until repaired 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 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one generator may become hazard ous when used on another generator Maintain labels and nameplates on the Generator and Engine These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Generator service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing a generator use on
8. position Then disconnect the electrical powered tools power cord from the Generator s DC Terminals 7 See Figure H 6 After the Engine and Generator have completely cooled store the Generator in a safe clean dry location if not already installed in one re NOTE The Generator features a 10 AMP DC Fuse 9 to protect the DC circuit in case of an overload Should an overload occur the Fuse will burn out causing the Generator to automatically shut down In this case refer to Step 1 in this section Then reset the circuitry system by replacing the burnt Fuse with a new 10 AMP DC Fuse Restart the Generator and continue powering the remaining tool or equipment See Figure H POSITIVE DC TERMINAL 7 10 AMP NEGATIVE DC TERMINAL 7 DC FUSE 9 FIGURE H SKU 91523 PAGE 16 INSPECTION CLEANING AND MAINTENANCE 1 CAUTION Always make sure the Engine Power Switch 2 is in its OFF position Disconnect the spark plug wire from the engine And allow suffi cient time for the Engine and Generator to completely cool before perform ing any inspection maintenance or cleaning 2 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 opera tion If an Engine problem occurs always have the Engine immediately checked out by a qualified
9. service technician before further use Do not use damaged equipment 3 Before each use check to make sure the Engine s oil level and gas level is adequate If necessary fill the Engine s Crankcase until the oil level is even with the Oil Fill Hole and fill the fuel tank 4 Before each use 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 5 Every 20 hours of use drain the old Engine oil and replace with approximately 3 4 0 63 quart of a high quality SAE 10W 30 grade engine oil 6 Every 300 hours of use have a qualified certified technician perform thorough maintenance on the Generator and its Engine 7 For long term storage either drain fuel into a suitable container or add a fuel preservative stabilizer not included to prevent breakdown of the fuel PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIA GRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR 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 T
10. CHICAGO Seif Generatorsi GENERATOR SET 6 5 HP RECOIL START 2600W 2800W RATED Model 91523 OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Website at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 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 guestions please call 1 800 444 3353 PRODUCT SPECIFICATIONS VAC Current Output 110 120 Volts 20 AMP s Electrical Requirements 60 Hz Continuous Rated Wattage 2600 Peak Wattage 2800 Two 110 120 VAC 3 Prong Grounding Outlets One 23 AMP Circuit Breaker VDC Current Output 12 VDC 10 AMP s Electrical Requirements Display Lights Gasoline Engine 6 5 Unleaded Gasoline Powered Recoil Start 3600 RPM 4 Cycle OHV Air Cooled 196 CC Displacement 0 63 Quart 0 6 Liter Oil Capacity EPA Approved Fuel Tank Capacity 3 96 Gallons 15 Liters Includes Fuel Gauge Estimated Run Time 7 8 Continuous Operating Hours Approx Weight 112 Pounds CAUTION THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC EQUIPMENT INCLUDING MEDICAL EQUIPMENT WITHOUT THE ADDITION OF AN APPROPRIATE LINE CONDITIONER SOLD SEPARATELY This product requires oil and fuel to be added before start
11. HE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR RE PLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 91523 PAGE 17 PARTS LIST Qty Part Description Qty Bolt w Lock Washer M6 x 12 9 22 Bolt M6x17 J4 Engine Power Switch 1 23 Bolt Mm5x20 4 6 Outlet Rotor s 1 Ground Connector Tt DC Fuse O 10 PilotLigt O 11 Shock Absorber 4 Shock Absorber Foot 4 Fuel Tank cap Lock Washer Nut 4 Fuel Gauge 14 Stator Cover OOO H 15 Alternator Back Cover __ 1 Bolt M8 x 242 tt 42 SwitchBoxCover dt po engine 9 41 B8 a 10o i d4 5 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 91523 PAGE 18 SKU 91523 ASSEMBLY DIAGRAM PAGE 19 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts PARTS LIST A Description Qty Part Description 1A Starting Case Assy 2A Spiral Spring 3A Starting Wheel 4A Circlip Starting Ratchet Friction Plate Screw Cover Q NO lt 24A 25A 26A 27A 2 2 2 2 2 Bolt M8 x 35 28A Spark Plug Gear Case Packing 29A Valve Guide 31A 32A 33A Cylinder Head Cover Packing 1 35A Compression Ring 1 Locating Pin Oil Seal
12. ark plug wire and allow the Engine to completely cool before carrying out maintenance 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 gualified technician The Generator is designed with guards for protection from moving parts In any case care must still be taken to protect personnel and eguipment 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 re quired When working on or around the Generator always wear protective clothing in cluding 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
13. 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 110 120 volt that is compatible with the electrical characteristics and rated capacities of the Genera tor Ls Before servicing eguipment powered by the Generator disconnect the eguipment from its power input SKU 91523 PAGE 9 8 Keep all electrical eguipment clean and dry Replace any wiring where the insu lation 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 Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures INSTALLATION Ie NOTE Prior to powering tools and equipment make sure the Generator s rated voltage wattage and amperage capacity 115V 20AMP3s 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 install ing this unit Installation must be completed by licen
14. er Switch 2 to its OFF position Turn the Fuel Valve 40 to its OFF position Then disconnect all electrical powered tools and equipment from the Generator s 110 120 volt AC Duel Outlets 6 See Figures E F and G 5 After the Engine and Generator have completely cooled store the Generator in a safe clean dry location if not already installed in one Powering 12 Volt DC Tools And Equipment 1 Prior to powering a tool or equipment make sure the Generator s rated voltage and amperage capacity 12VDC 10 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 Connect the Power Cord of a 12 VDC powered tool or equipment to the DC Terminals 7 NOTE Make sure to connect the positive lead of the Power Cord to the positive Terminal on the Generator and connect the negative lead of the Power Cord to the negative Terminal on the Generator See Figure H next page SKU 91523 PAGE 15 3 If using only a 12 volt DC tool or equipment turn the 110 120 volt AC Circuit Breaker 5 to its OFF position See Figure D Start and run the Engine as previously discussed in this manual When finished using the Generator turn the Engine Power Switch 2 to its OFF position Turn the Fuel Valve 40 to its OFF
15. ing 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 this manual for the safety warnings and precautions operating inspec tion maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on 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 all the parts shown on the Parts Lists on pages 18 and 20 are included 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 SKU 91523 PAGE 2 GENERAL SAFETY RULES N 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 WORK AREA 1 Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate power tools in explosive atmospheres such as in the pres ence of flammable liguids gases or dust Generators create sparks which may ignite the dust or fumes 3 Keep bystanders children and visitors away while operating a generator Provide barriers or shields as needed ELECTRICAL SAFETY 4
16. ly 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 regula tions 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 Fuel Tank Fuel vapors are explosive Keep grounded conductive objects such as tools away from exposed live elec trical 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 attempt ing to restart the Generator Use only engine manufacturer recommended fuel and oil SKU 91523 PAGE 7 MECHANICAL PRECAUTIONS ALWAYS make sure the Power Switch is in its OFF position Disconnect the sp
17. ly 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 SKU 91523 PAGE 5 SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS 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 to or failure of the pacemaker INSTALLATION PRECAUTIONS 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 All electrical work including the earth ground connection should be completed by a licensed electrician 3 Any separate fuel storage or Generator supply facility must be built or installed in full compliance with all relevant local state and federal regulations 4 It is recommended to use the Generator only in well ventilated out door areas A running gasoline engine will generate Carbon Monox ide a colorless odorless gas that if inhaled can cause serious injury or death 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 Generat
18. ns if necessary Attach the Frame to the concrete slab using 3 8 diameter expansion anchor bolts not supplied GROUNDING THE GENERATOR 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 8 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 cop per or brass rod electrode which can adequately ground the Generator See Figure B next page OPERATING INSTRUCTIONS NOTE For additional references to the parts listed in the following pages refer to the Assembly Diagrams on pages 19 and 21 Pre Start Checks Ie Check to make sure the Engine Power Switch 2 is in its OFF position See Figure B next page 2 IMPORTANT Prior to first using the Generator the Engine MUST be filled with approximately 3 4 0 63 quart of a high quality SAE 10W 30 grade engine oil To do so unscrew and remove the Engine s Oil Dipstick 65A located at the bottom of the Engine Crankcase Fill the Engine s Crankcase until the oil level is level with the upper marked line on the Dipstick Then screw the Dip stick back into the Oil Fill Hole See Figure C next page SKU 91523 PAGE 11 ENGINE POWER SWITCH 2 FIGURE B FIGURE C SKU 91523 GROUND CONNECTOR 8 GROUNDING ROD NOT
19. or exhaust fumes must be within legal limits and installation must always meet local building codes 5 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 6 The Generator weighs 112 lbs Two or more people should assist when moving or lifting this product Never lift the Generator using the engine or alternator lifting lugs Connect lifting equipment to the Frame of the Generator 7 Before lifting the Generator ensure the lift rigging and supporting structure are in good condition and are rated to lift such a load 8 Keep all personnel away from the suspended generator during relocating SKU 91523 PAGE 6 10 11 9 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 For trailer installation the Generator should be mounted on the center point of the trailer over the wheels The trailer must be capable of supporting the weight of the Generator and all contents tools etc 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 Gasoline fuel and fumes are flammable and potential
20. sed contractors 3 A WARNING The Generator weighs approximately 112 pounds Use care and the proper lifting or hoisting equipment when moving it to the installation location Always connect hoist lines to the Frame 41 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 obstruc tions 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 mainte nance SKU 91523 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 the Engine exhaust must be ventilated to the outdoors using leak proof heat resistant flexible metal flex tubing GENERATOR SUPPORT AND MOUNTING 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 41 by at least one foot Contact a cement contractor for slab specificatio
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