Generators
GENERATOR
9 HP ROBIN® RECOIL START
Model 90236
OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
©
®
Copyright 2003 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.
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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
WORK AREA
1.
2.
Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
Do not operate generators in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Generators create sparks which
may ignite the dust or fumes.
3.
4.
Keep bystanders, children, and visitors away while operating a generator.
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 down, grounding provides a low resistance path to carry electricity away
from the user.
5.
6.
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
eliminates the need for the
three wire grounded power cord and grounded power supply system.
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 90236
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7.
8.
Do not expose power tools to rain or wet conditions. Water entering a generator
will increase the risk of electric shock.
Do not abuse Power Cords. Never use a Power Cord to carry any tool or pull
the Plug from an 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.
9.
When operating a power tool outside, use an outdoor extension cord marked
“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the
risk of electric shock.
PERSONAL SAFETY
10.
11.
Stay alert. Watch what you are doing, and use common sense when operating
a generator. Do not use a generator while tired or under the influence of
drugs, alcohol, or medication. A moment of inattention while operating 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.
12.
13.
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.
14.
15.
Do not overreach. Keep proper footing and balance at all times.
Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriateconditions.
16.
Never run the generator in an enclosed garage or any other type of enclosed
structure without a proper, leak-free ventilation shaft. Carbon Monoxide, an
odorless, colorless deadly gas may accumulate and cause serious injury or death.
GENERATOR USE AND CARE
17.
Do not overload 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.
SKU 90236
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GENERATOR USE AND CARE (Continued)
18.
19.
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.
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.
20.
21.
22.
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 damaged
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.
23.
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.
SERVICE
24.
25.
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 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.
SKU 90236
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SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.
2.
Do not use this product if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgement or reflexes are
impaired while taking drugs. If there is any doubt, do not attempt to use this
product.
Use eye and hearing protection. Wear ANSI approved safety impact eye
goggles and hearing protection when using this product. ANSI approved safety
impact eye goggles and hearing protectors are available from Harbor Freight
Tools.
3.
4.
Dress safely. Do not wear loose clothing or jewelry, as they can become caught
in moving parts. Wear a protective hair covering to prevent long hair from be-
coming caught in moving parts.
Do not overreach. Keep proper footing and balance at all times to prevent
tripping, falling, back injury, etcetera.
5.
6.
Industrial applications must follow OSHA requirements.
Stay alert. Watch what you are doing at all times. Use common sense. Do not
use this product when you are tired or distracted from the job at hand.
7.
Check for damaged parts. Before using this product, carefully check that it will
operate properly and perform its intended function. Check for damaged parts
and any other conditions that may affect the operation of this product. Replace
or repair damaged or worn parts immediately.
8.
Replacement parts and accessories: When servicing, use only identical re-
placement parts. Only use accessories intended for use with this product. Ap-
proved accessories are available from Harbor Freight Tools.
9.
Maintain this product with care. Keep this product clean and dry for better and
safer performance. For your safety, service and maintenance should be per-
formed regularly by a qualified technician.
10.
Use the right generator for the job. Do not attempt to force a small generator
to do the work of a larger industrial generator. There are certain applications for
which this generator was designed. It will do the job better and more safely at
the rate for which it was intended. Do not modify this generator, and do not use
this generator for a purpose for which it was not intended.
11.
WARNING! The warnings, precautions, and instructions discussed in this
SKU 90236
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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.
Installation Precautions:
1.
WARNING! Before using the Generator, read and understand the Engine
manufacturer’s 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.
2.
Ensure installation meets all applicable safety, and local and national electrical
codes. Have installation performed by a qualified, licensed electrician and
building contractor.
3.
4.
5.
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. 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, including all local codes and ordinances.
6.
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.
7.
8.
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.
9.
Keep all personnel away from the suspended generator during relocating.
10.
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 90236
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11.
12.
For trailer installation, the Generator should be mounted on the center point of the
trailer, over the wheels.
Install sound- and weather-proofing only when it is not raining or snowing to
avoid trapping moisture within the Generator’s enclosure.
Fire And Explosion Precautions:
1.
Gasoline fuel and fumes are flammable, and potentially explosive. Use proper
fuel storage and handling procedures. Always have multiple ABC class fire
extinguishers nearby.
2.
3.
Keep the Generator and surrounding area clean at all times.
When spills of fuel, 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.
4.
5.
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.
6.
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.
7.
8.
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.
9.
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 90236
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2.
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.
3.
4.
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.
5.
6.
7.
8.
9.
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.
Chemical Precautions:
1.
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 approved ear protection when operating or working around
the Generator when it is running.
SKU 90236
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Electrical Precautions:
1.
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.
3.
The Generator must be properly earth-grounded by a licensed electrician in
accordance with all relevant electrical codes and standards before operation.
If an extension cord (not included) is used, make sure to use only UL® approved
cords having the correct gauge and length. (See Figure A.)
FIGURE A
REQUIRED MINIMUM EXTENSION CORD GAUGE – 120/ 240 VOLT
NAMEPLATE
EXTENSION CORD LENGTH
AMPERES
(At Full Load)
0 - 25
Feet
16
16
14
12
10
25 - 50
Feet
16
16
14
12
50 -100
Feet
16
100 – 150
150– 200
Feet
Feet
12
-
-
-
-
0 - 5
5.1 - 8
8.1 - 12
12.1 - 15
15.1 - 20
12
10
-
-
-
14
12
10
10
10
SKU 90236
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4.
5.
Do not attempt to connect or disconnect load connections while standing in
water, or on wet or soggy ground.
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 and 240 volt)
that is compatible with the electrical characteristics and rated capacities of the
Generator.
7.
8.
Before servicing equipment powered by the Generator, disconnect the equipment
from its power input.
Keep all electrical equipment 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.
11.
12.
Use only Class BC or Class ABC fire extinguishers on electrical fires.
WARNING! People with pacemakers should consult their physician(s)
before using this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference or failure of the pacemaker.
INSTALLATION
1.
NOTE: Prior to powering tools and equipment, make sure the Generator’s rated
voltage, wattage, and amperage capacity (120V/ 15 AMPs and 240V/ 15 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.
3.
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 licensed contractors.
WARNING! The Generator weighs 155 pounds. Use care and the proper
lifting or hoisting equipment when moving it to the installation location. Always
connect hoist lines to the Frame (21) of the Generator.
SKU 90236
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GENERAL LOCATION
1.
2.
It is recommended to locate and install the Generator in a protected outdoor area
where cooling air is readily available (see previous warning section).
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.
5.
Generator placement should allow four feet of access to all sides for maintenance.
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 professionally installed, leakproof, heat
resistant, flexible, metal 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 (21) by at least
one foot. Contact a cement contractor for slab specifications if necessary. Attach
the Frame to the concrete slab using 3/8” diameter masonry type anchor bolts (not
supplied).
GROUNDING THE GENERATOR
1.
2.
NOTE: It is recommended that only a trained and licensed electrician perform this
procedure. (Generators without a permanent installation may not need to be
grounded, check local codes and ordinances.)
Connect a #6 AWG grounding wire (not included) from the Grounding Point on the
front panel 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 G, page 14.)
Note: Local codes and ordinances may vary. Always check local codes and install in
accord with all laws.
REV 11/04
SKU 90236
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OPERATING INSTRUCTIONS
NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagram on page 18.
Pre-Start Checks:
1.
NOTE: During operation, it may 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.
2.
3.
Check to make sure the Engine’s “ON/OFF” Switch is in its “OFF” position.
Unscrew and remove the Engine’s Oil Fill Cap located at the bottom of the En-
gine Crankcase. Check to make sure the oil level is even with the top of the Oil
Fill Hole. If necessary, add oil until its level is even with the Oil Fill Hole. Then,
screw the Oil Fill Cap back into the Oil Fill Hole. NOTE: Check with the Engine
manufacturer’s manual for the proper type of engine oil required for use.
(See Figure C.)
4.
Check the Fuel Gauge (34) for the amount of unleaded gasoline in the Fuel Tank
(32). If necessary, remove the Fuel Tank Cap (37) and refill the Fuel Tank with
unleaded gasoline. Then, replace the Fuel Tank Cap.
(See Figure D.)
FUELTANK CAP (37) FUEL GAUGE (34)
FUELTANK (32)
OIL FILL CAP
FIGURE C
FIGURE D
REV 11/04
SKU 90236
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To StartThe Generator:
1.
2.
3.
4.
Turn the Fuel Valve (31) to its vertical
“OPEN” position.
(See Figure E.)
CHOKE
Move the Engine’s Fuel Choke all the
way to the right to its “START” posi-
tion. (See Figure E.)
Turn the Engine’s “ON/OFF” Switch
(46) to its “ON” position
(See Figure F.)
FUELVALVE (31)
Hidden from view
Grasp the Handle of the Engine’s
Starter Pulley and rapidly pull the
Starter Pulley to start the Engine.
NOTE: It may take more than one pull
on the Starter Pulley to start the En-
gine.
FIGURE E
5.
Allow the Engine to run for several
seconds, then move the Engine’s Fuel
Choke all the way to the left to its
“RUN” position. (See Figure E.)
NOTE: DO NOT ATTEMPT TO ADJUST
THE ENGINE’S THROTTLE! This
engine uses a governor device to
automatically control the engine’s
speed. If the throttle is adjusted, it
may result in decreased efficiency
and/or damage to the unit.
ON/OFF
Switch
FIGURE F
120/240V
TWISTLOCK OUTLET
(44)
OVERLOAD BREAKERS
(42)
120V DUAL OUTLET
(43)
GROUNDING POINT
FIGURE G
REV 06/04; 11/04
SKU 90236
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Powering Tools And Equipment:
1.
Prior to powering tools and equipment, make sure the Generator’s rated voltage,
wattage, and amperage capacity (120V/ 15 AMP and 240V/ 15 AMP) is ad-
equate 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.
3.
Once the Generator is running, simply connect the Power Cords of 120 volt
powered tools and equipment into the 120 volt Dual Outlets (41). If a 240 volt
tool or equipment is used, connect its power cord into the 240 volt Twistlock
Outlet (42). (See Figure H.)
NOTE:The Generator features two AC Non-Fuse Overload Breakers (40) to protect
the AC circuit in case of an overload. Should an overload occur one or both of the
Breakers will “trip”, interrupting the circuit (disconnecting power to the connected
tools and/or equipment). In this case, refer to Step #1 in this section. Then, reset
the circuitry system by depressing the Breaker(s). Restart the Generator and
continue powering the remaining tools and equipment. (See Figure H.)
AC CIRCUIT OVERLOAD BREAKER (40)
120/240V
TWISTLOCK
OUTLET
(42)
120V DUAL OUTLET (41)
FIGURE H
4.
5.
When finished using the Generator, turn the ON/OFF switch on the engine’s fan
shroud to its “OFF”position to stop the Generator.
(See Figure G.)
After the Engine and Generator have completely cooled, disconnect the spark plug
wire and store the Generator in a safe, clean, dry location (if not already installed in
one).
REV 06/04
SKU 90236
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INSPECTION, MAINTENANCE, AND CLEANING
1.
2.
3.
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.
CAUTION! 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.
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 abnormal noise or vibration occurs, have the problem corrected before
further use. Do not use damaged equipment.
4.
5.
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.
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.
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. NEI-
THER 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 REPLACE-
MENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS,
AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARIS-
ING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACE-
MENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF
REPLACEMENT PARTS THERETO.
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PARTS LIST
-
-
-
-
-
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
Wiring Diagram
REV 06/04; 01/05
SKU 90236
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ASSEMBLY DIAGRAM
REV 06/04
SKU 90236
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Page 18
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