GENERATOR
6 HP ROBIN ENGINE RECOIL START
2800 WATT (PEAK)
Model 92863
OPERATING INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
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
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WORK AREA
1.
2.
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.
3.
1.
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 down, grounding provides a low resistance path to carry electricity away
from the user.
2.
3.
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.
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.
4.
5.
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
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6.
Do not abuse Power Cords on tools. Never use a Power Cord to carry the
tools or pull the 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.
2.
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.
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.
4.
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.
5.
6.
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 when operating the Generator. Dust mask, non-skid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
7.
8.
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 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
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2.
3.
Store idle generators out of reach of children and other untrained persons.
Generators are dangerous in the hands of untrained users.
Maintain the Generator with care. Do not use a damaged Generator. Tag
damaged Generators “Do not use” until repaired.
4.
5.
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
hazardous when used on another Generator.
SERVICE
1.
2.
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.
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
1.
2.
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.
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
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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:
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. 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.
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 92863
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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.
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 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.
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 FuelTank 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.
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 92863
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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
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:
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 92863
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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.
The Generator must be earth-grounded in accordance with all relevant electrical
codes and standards before operation.
®
3.
4.
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.)
Do not attempt to connect or disconnect load connections while standing in water,
or on wet or soggy ground.
5.
6.
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.
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.
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
insulation is cracked, cut, abraded or otherwise degraded. Replace terminals that
are worn, discolored, or corroded. Keep terminals clean and tight.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(110 VOLT)
NAMEPLATE
AMPERES
EXTENSION CORD LENGTH
(At Full Load)
25
FEET
18
18
18
18
16
14
12
50
FEET
18
18
18
16
14
12
10
75
FEET
18
18
16
14
12
10
-
100
FEET
18
16
14
12
10
-
150
FEET
0-2.0
2.1-3.4
3.5-5.0
16
14
12
12
-
5.1-7.0
7.1-12.0
12.1-16.0
16.1-20.0
-
-
-
*Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.
FIGURE A
SKU 92863
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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.
3.
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.
WARNING! The Generator weighs 95.7 Lbs. (without fuel). Use care and
the proper lifting or hoisting equipment when moving it to the installation location.
Always connect hoist lines to the Frame (18) of the Generator.
GENERAL LOCATION
1.
2.
It is recommended to locate and install the Generator outdoors where cooling air
is readily available.
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.
4.
Install the Generator on a concrete slab or other area where rain drainage or
flood waters can not reach it.
Generator placement should allow four feet of access to all sides for
maintenance.
SKU 92863
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5.
6.
Place the Generator as close as possible to the electrical tools and equipment
being powered to reduce the length of extension cords.
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 3/8” diameter expansion anchor bolts (not
supplied).
GROUNDING THE GENERATOR
1.
2.
NOTE: It is recommended that only a trained and licensed electrician perform
this procedure.
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
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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.
2.
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.
3.
4.
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 Dipsticks 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
OIL
DIPSTICK
FIGURE C
SKU 92863
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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
(26)
FUEL GAUGE
(27)
FIGURE D
FUEL TANK (32)
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
manufacturer’s 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.
4.
Move the Engine’s Fuel Choke to its “START” position. (See Figure E.)
Turn the Engine’s “ON/OFF” Switch to its “ON” position
(See Figure E.)
5.
6.
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.
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.)
SKU 92863
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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 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.
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.)
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120 VOLT OUTLET (35)
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.
5.
When finished using the Generator, turn the ON/OFF Switch to its “OFF”
position to stop the Generator. (See Figure E.)
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.
2.
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.
SKU 92863
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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.
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.
Prior to refilling the Fuel Tank: Remove the Fuel Tank 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.
7.
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)
WARNING!
FILTER (32)
All maintenance, service,
and repairs not listed in
this manual are only to be
attempted by a qualified
technician.
FIGURE G
SKU 92863
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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 ORWARRANTY OF ANY KINDTO THE BUYERTHAT HE
OR SHE IS QUALIFIEDTO MAKE ANY REPAIRSTO THE PRODUCT, ORTHAT HE OR SHE IS QUALIFIED
TO REPLACE ANY PARTS OFTHE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR
EXPRESSLY STATESTHAT 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 PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT
PARTSTHERETO.
PARTS LIST
Part
1
Description
Connection Board
Qty.
1
Part
Description
Qty.
4
21 Bolt (M5)
2
Bolt (M6 x 130)
Bolt (M5 x 12)
Cable Sheath
Rear Cover
Bolt
4
22 Heat Insulation Board
23 Bolt (M6)
1
3
2
4
4
1
24 Bolt (M5 x 35)
25 Fuel Valve
4
5
1
1
6
2
26 Fuel Tank
1
7
Capacitor
1
27 Fuel Gauge
28 Bolt (M5 x 12)
29 Bolt (M6 x 25)
30 Fuel Tank Cap
31 Seal Ring
1
8
Alternator Back Cover
Stator
1
2
9
1
4
10 Bridge Combination
11 Voltage Dependent Resistor
12 Rotor
2
1
2
1
1
32 Filter
1
13 Hex Bolt (5/16"-24)
14 Alternator Front Cover
15 Shock Absorber Support
16 Bolt (M10)
4
33 Bolt (M5)
4
1
34 Circuit Breaker
35 Outlet 20A/120V
36 Bolt (5/16"-24 x 170)
37 Bolt(M5x16)
38 Bolt(M5)
1
4
2
4
1
17 Ground Connector
18 Frame
4
2
1
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
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ASSEMBLY DIAGRAM
NOTE:
Some parts are listed and shown for illustration
purposes only, and are not available individually as replacement parts.
REV 08/05
SKU 92863
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ELECTRICAL SCHEMATIC
REV 08/05
SKU 92863
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