Chicago Electric Portable Generator 92456 User Manual

GENERATOR SET  
6.5 HP - RECOIL START - 2600W/2800W RATED  
Model 92456  
OPERATING INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
TO PREVENT SERIOUS INjURy OR DEATH,  
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 FreightTools.  
For technical questions and replacement parts, please call 1-800-444-3353  
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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.  
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 power tools 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.  
1.  
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.  
2.  
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.  
SKU 92456  
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3.  
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.  
4.  
5.  
Do not expose power tools to rain or wet conditions. Water entering a  
generator will increase the risk of electric shock.  
Do not abuse the Power Cords. Never use a Power Cord to carry tools or pull  
the Plug from an outlet. 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.  
6.  
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  
1.  
2.  
Stay alert. Watch what you are doing, and use common sense when operat-  
ing a generator. Do not use a generator while tired or under the influence of  
drugs, alcohol, or medication. A moment of inattention while operating genera-  
tors 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” posi-  
tion, 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. Dust mask, nonskid 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 de-  
signed.  
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.  
SKU 92456  
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GENERATOR USE AND CARE  
1.  
Make sure the Power Switch is in itsOFFposition 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.  
2.  
3.  
4.  
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.  
5.  
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  
1.  
2.  
3.  
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 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 92456  
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SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS  
HEART PACEMAKER PRECAUTION  
1.  
1.  
WARNING! People with pacemakers should consult their physician(s) be-  
fore using this product. Electromagnetic fields in close proximity to a heart pace-  
maker could cause interference to or failure of the pacemaker.  
INSTALLATION PRECAUTIONS  
Ensure installation meets all applicable safety, and local and national electrical  
codes. Have installation performed by a qualified, licensed electrician and building  
contractor.  
2.  
3.  
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.  
4.  
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 color-  
less, 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.  
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.  
7.  
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.  
8.  
9.  
Keep all personnel away from the suspended generator while relocating.  
The supporting floor/ground surface should be level, and strong enough to safely  
hold the weight of the Generator. If the floor/ground surface is not level, strong cross  
members should be placed under the full length of the Generator Frame at its low  
side.  
SKU 92456  
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10.  
11.  
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 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 extin-  
guishers 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 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 elec-  
trical 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 sys-  
tem 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.  
SKU 92456  
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MECHANICAL PRECAUTIONS  
1.  
2.  
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.  
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 me-  
chanical 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 includ-  
ing 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 swal-  
lowed, 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.  
SKU 92456  
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NOISE PRECAUTIONS  
1.  
1.  
Prolonged exposure to noise levels above 85 dBA is hazardous to hearing. Al-  
ways wear ANSI approved ear protection when operating or working around the  
Generator when it is running.  
ELECTRICAL PRECAUTIONS  
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.  
3.  
The Generator must be earth-grounded 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 listed  
cords having the correct gauge and length. (See Figure A.)  
REQUIRED MINIMUM EXTENSION CORD GAUGE – 120 VOLT  
NAMEPLATE  
AMPERES  
EXTENSION CORD LENGTH  
(At Full Load)  
0 - 25 Feet  
25 - 50 Feet  
50 -100 Feet  
100 – 150 Feet 150– 200 Feet  
0 - 5  
16  
16  
14  
12  
10  
16  
16  
14  
12  
10  
16  
14  
12  
10  
10  
12  
10  
-
12  
-
5.1 - 8  
8.1 - 12  
-
12.1 - 15  
15.1 - 20  
-
-
-
-
FIGURE A  
4.  
5.  
Do not attempt to connect or disconnect load connections while standing in wa-  
ter, 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 conduc-  
tive object.  
6.  
7.  
Connect the generator only to a load or electrical system (115 volt) that is com-  
patible with the electrical characteristics and rated capacities of the Generator.  
Before servicing equipment powered by the Generator, disconnect the equipment  
from its power input.  
SKU 92456  
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8.  
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.  
1.  
Use only Class BC or Class ABC fire extinguishers on electrical fires.  
INSTALLATION  
NOTE: Prior to powering tools and equipment, make sure the Generator’s rated  
voltage, wattage, and amperage capacity (115 V - 20 Amps) is adequate to  
supply all electrical loads that the unit will power. If powering exceeds the Gen-  
erator’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 is quite heavy. Use care and the proper lifting or  
hoisting equipment when moving it to the installation location. Always connect  
hoist lines to the Frame (41B) 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 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.  
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 mainte-  
nance.  
SKU 92456  
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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 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 (41B) 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 (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 copper  
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:  
1.  
Check to make sure the Engine’s 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 en-  
gine 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 92456  
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ENGINE  
POWER  
SWITCH  
(2)  
GROUND CONNECTOR  
(8)  
#6 AWG  
GROUNDING WIRE  
(NOT INCLUDED)  
GROUNDING ROD  
(NOT INCLUDED)  
FIGURE b  
FUEL GAUGE (34)  
FUEL TANK CAP  
(33)  
FUEL TANK  
(30b)  
OIL DIPSTICK  
(65A)  
FIGURE C  
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3.  
Before the first use, remove the Fuel Tank Cap (33) and fill the Fuel Tank (30B)  
with unleaded 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. (See Figure C.)  
To Start The Engine:  
1.  
Make sure the electrical powered tools/equipment that will be used is not  
plugged in to the Generator.  
2.  
Turn the 115 volt AC Circuit Breaker (5) to its “ON” position. (See Figure D.)  
CIRCUIT bREAKER  
(5)  
ON  
OFF  
FIGURE D  
CLOSED  
OPEN  
CHOKE LEVER  
(21A)  
FUEL VALVE (40b)  
OFF  
ON  
FIGURE E  
3.  
4.  
Turn on the Fuel Valve (40B). (See Figure E.)  
Close the Choke Lever (21A) to about 1/8” clearance. (See Figure E.)  
REV 03/06  
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ENGINE  
POWER  
SWITCH  
(2)  
ON  
OFF  
FIGURE F  
5.  
Turn the Engine Power Switch (2) to its “ON” position. (See Figure F.)  
120 VOLT  
DUEL  
OUTLETS  
(6)  
START  
HANDLE  
(41A)  
FIGURE G  
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 Engine to run for several seconds. Then, open the Choke Lever (21A)  
all the way. (See Figure E.)  
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Powering 120 Volt AC Tools And Equipment:  
1.  
Prior to powering tools and equipment, make sure the Generator’s rated voltage,  
and amperage capacity (115 VAC / 20 Amps) is adequate to supply all electri-  
cal 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 con-  
nection to a separate generator.  
2.  
3.  
Once the Generator is running, simply connect the Power Cords of 115 volt AC  
powered tools and equipment into the 115 volt AC Duel Outlets (6).  
(See Figure G.)  
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 con-  
tinue powering the remaining tools and equipment. (See Figure D.)  
4.  
5.  
When finished using the Generator, turn the Engine Power Switch (2) to its “OFF”  
position. Turn the Fuel Valve (40B) to its “OFF” position. Then, disconnect all  
electrical powered tools and equipment from the Generator’s 115 volt AC Duel  
Outlets (6). (See Figures E, F, and G.)  
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.  
2.  
Prior to powering a tool or equipment, make sure the Generator’s rated voltage,  
and amperage capacity (12 VDC / 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 con-  
nection to a separate generator.  
Connect the Power Cord of a 12 VDC powered tool or equipment to the DC Ter-  
minals (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.)  
3.  
4.  
If using only a 12 volt DC tool or equipment, turn the 120 volt AC Circuit Breaker  
(5) to its “OFF” position. (See Figure D.)  
Start and run the Engine as previously discussed in this manual.  
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POSITIVE (+) DC TERMINAL (7)  
NEGATIVE (-) DC TERMINAL (7)  
10 AMP  
DC FUSE  
(9)  
FIGURE H  
5.  
When finished using the Generator, turn the Engine Power Switch (2) to its “OFF”  
position. Turn the Fuel Valve (40B) to its “OFF” position. Then, disconnect the  
electrical powered tool or equipment from the Generator’s DC Terminals (7).  
(See Figure H.)  
6.  
7.  
After the Engine and Generator have completely cooled, store the Generator in a  
safe, clean, dry location (if not already installed in one).  
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.)  
INSPECTION, CLEANING, AND MAINTENANCE  
1.  
2.  
CAUTION! Always make sure the Engine Power Switch (2) is in its “OFF” po-  
sition. 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, dam-  
aged 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.  
SKU 92456  
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3.  
Follow all maintenance procedures as outlined in the Engine Maintenance Sched-  
ule below at the specified intervals. In addition, observe the following details:  
before each use: check to make sure the Engine’s oil level is adequate. If neces-  
sary, ll the Engine’s Crankcase until the oil level is even with the Oil Fill Hole.  
before each use: with a soft brush, cloth, or vacuum, remove all debris from the  
Generator and engine. Then, use a premium quality, lightweight machine oil to  
lubricate all moving parts.  
After the initial 20 hours of use and every 100 hours of use thereafter: drain  
the old Engine oil and replace with approximately 3/4 (0.63) quart of a high quality  
SAE 10W-30 grade engine oil.  
Engine Maintenance Schedule  
Interval  
8 hours or  
daily, before  
use  
50 hours  
or  
weekly  
100 hours 200 hours 500 hours 1000 hours  
(More frequent maintenance  
will be necessary in dusty or  
severe conditions.)  
or  
or  
monthly  
or every 6  
months  
or  
yearly  
Details  
biweekly  
Clean engine and  
check bolts & nuts  
Check and refill engine  
oil  
*Initial change immediately  
after 20 hour break-in period  
Change engine oil*  
Clean spark plug (28A)  
Clean and adjust spark  
plug (28A) electrodes  
Replace spark plug  
(28A)  
Clean air cleaner  
element (19A)  
Wear dust mask and vacuum or  
blow clean with compressed air.  
Replace air cleaner  
element (19A)  
Clean/replace fuel  
filter(s)^  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
Replace fuel lines and  
filter(s)^  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
Remove carbon from  
cylinder head (11A)^  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
Check and adjust valve  
clearance^  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
Clean and adjust  
carburetor^  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
^QUALIFIED TECHNICIAN/  
MECHANIC ONLy  
Overhaul engine^  
4.  
Storage: Before storing, drain all fuel out of the generator’s gas tank. If this is not  
followed, old fuel in the generator’s fuel tank may clog the generator and prevent it  
from starting until cleaned out.  
REV 10/06  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 17  
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PARTS LIST  
Part  
1
Description  
Bolt (M6 x 12) w/Lock Washer  
Engine Power Switch  
Qty.  
9
Part  
Description  
Qty.  
4
23 Bolt (M5 x 20)  
24 Connection Board  
25 Nut (M5)  
2
1
1
3B Control Panel  
1
4
4
5
6
7
8
9
Voltmeter  
1
26 Stator  
1
Circuit Breaker  
Outlet  
1
27 Rotor  
1
2
28 Cooling Fan  
29 Heat Insulation Board  
30B Fuel Tank  
31 Fuel Filter  
1
DC Terminal  
Ground Connector  
DC Fuse  
2
1
1
1
1
1
10 Pilot Light  
1
32 Seal Ring  
1
11 Shock Absorber  
12 Shock Absorber Foot  
13 Lock Washer Nut  
14 Stator Cover  
4
33 Fuel Tank Cap  
34 Fuel Gauge  
35B Bolt (M6 x 12)  
36 Lock Washer Bolt (M6 x 12)  
37 Spacer  
1
4
1
4
2
1
4
15 Alternator Back Cover  
16 Capacitor  
1
4
1
38 Rub Washer  
39 Bush  
4
17 Bolt (M5 x 16)  
18 Rectifier  
4
4
1
40B Fuel Valve  
41B Frame  
1
19 Bolt (M5 x 16)  
20 Cable Sheath  
21 Bolt (M8 x 242)  
22 Bolt (M6 x 172)  
3
1
1
42 Switch Box Cover  
43 Engine  
1
1
1
4
NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement 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. NEITHER THE MANUFACTURER OR  
DISTRIBUTOR MAKES ANY REPRESENTATION ORWARRANTY OF ANY KINDTOTHE BUYERTHAT  
HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS  
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR  
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD  
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE  
BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE  
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER  
INSTALLATION OF REPLACEMENT PARTS THERETO.  
REV 06/06  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 18  
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ASSEMbLy DIAGRAM  
REV 06/06  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 19  
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PARTS LIST - CONTINUED  
Part  
1A Muffler  
Description  
Qty.  
1
4
4
1
2
2
3
2
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
2
1
2
2
2
2
1
1
1
1
1
1
2
1
1
Part  
Description  
Qty.  
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
1
1
2
2
1
6
2
2
1
4
2
2
1
1
1
1
1
1
1
2
42B Starting Case Assy.  
43A Spiral Spring  
44A Starting Wheel  
45A C-clip  
46A Starting Ratchet  
47A Friction Plate Screw  
48B Cover  
2A Cylinder Head Bolt  
3A Cylinder Head Cover Bolt  
4A Cylinder Head Cover  
5A Lock Nut  
6A Adjusting Screw  
7A Rocker Arm  
8A Rocker Arm Bolt  
9A Valve Push Rod Guiding Board  
10A Valve Push Rod  
11A Cylinder Head  
12A Carburetor Shield  
13A Carburetor Packing I  
14A Carburetor Assembly  
15A Air Cleaner Case  
16A Air Cleaner Seal  
17A Bolt (M6)  
18A Air Cleaner Cover  
19A Air Cleaner Element  
20A Air Cleaner Separator  
21A Choke Lever  
22A Carburetor Packing II  
23A Stud Bolt (M6 x 109)  
24A Intake Valve  
49A Starter Pulley  
50A Cooling Fan  
51A Flywheel Magneto  
52A Cylinder Block  
53A Speed Control Lever  
54A Governor Arm  
55A Governor Spring  
56A Governor Support  
57A Bolt (M6 x 15)  
58A Oil Alert Nut  
59A Plug (M10 x 15)  
60A Plug Washer  
61A Oil Alert  
62A Bolt (M6)  
63A Crankshaft  
64A Crankshaft Gear  
65A Oil Dipstick  
25A Exhaust Valve  
66A Oil Dipstick Seal Ring  
67A Gear Casing  
68A Bolt (M8 x 35)  
69A Gear Case Packing  
70A Bearing  
71A Camshaft Assy.  
72A Locating Pin  
73A Oil Seal  
74A Connecting Rod Bolt  
75A Connecting Rod Cap  
76A Connecting Rod  
77A Piston  
78A Compression Ring I  
79A Compression Ring II  
80A Oil Scraper Ring  
81A Piston Pin  
26A Cylinder Head Gasket  
27A Exhaust Pipe Stud  
28A Spark Plug  
29A Valve Guide  
30A Valve Spring  
31A Rocker Shaft C-clip  
32A Anti-Wear Valve Stem Protector  
33A Cylinder Head Cover Packing  
34A Governor Spring  
35A Bolt  
36A High Tension Line  
37A Ignition Coil  
38A Nut (Special 14mm)  
39A Starter Ratchet Spring  
40A Start Rope  
41A Start Handle  
82A Piston Pin C-clip  
NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
REV 06/06  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 20  
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ASSEMbLy DIAGRAM - CONTINUED  
73A  
71A  
72A  
69A  
70A  
77A  
76A  
75A  
74A  
81A  
79A 80A  
82A  
78A  
55A 54A  
58A  
59A  
56A  
57A  
1A  
63A  
64A  
60A  
62A  
61A  
49A  
53A  
52A  
68A  
67A  
66A  
65A  
50A  
28A  
51A  
30A  
17A  
35A  
26A  
48b  
29A  
25A  
27A  
2A  
32A  
45A 44A  
43A  
46A  
33A  
31A  
47A  
24A  
23A  
22A  
21A  
36A  
37A  
3A  
11A  
10A  
38A  
9A  
7A  
4A 5A  
39A  
40A  
8A  
13A  
20A  
12A  
6A  
41A  
19A  
42b  
14A  
18A  
15A 16A  
17A  
NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
REV 06/06  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 21  
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WIRING DIAGRAM  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 22  
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1YEAr  
WArrAnTY  
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability  
standards, and warrants to the original purchaser that this product is free from defects in materials and  
workmanship for the period of one year from the date of purchase (90 days if used by a professional contractor  
or if used as rental equipment).This warranty does not apply to damage due directly or indirectly, to misuse,  
abuse, negligence or accidents, repairs or alterations outside our facilities, or to lack of maintenance. We  
shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or  
consequential damages arising from the use of our product.Some states do not allow the exclusion or limitation  
of incidental or consequential damages, so the above limitation of exclusion may not apply to you.  
To take advantage of this warranty, the product or part must be returned to us with transportation charges  
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If  
our inspection verifies the defect, we will either repair or replace the product at our election or we may elect  
to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return  
repaired products at our expense, but if we determine there is no defect, or that the defect resulted from  
causes not within the scope of our warranty, then you must bear the cost of returning the product.  
This warranty gives you specific legal rights and you may also have other rights which vary from state to  
state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
Emission Control System Warranty  
California and United States Emission  
Control Defects Warranty Statement  
Defects Warranty Coverage  
Engines are warranted for a period of two (2) years relative  
to emission control parts defects, subject to the provisions  
set forth below. If any emission related part on your engine  
is defective, the part will be repaired or replaced by HFT.  
The California Air Resources Board (herein CARB), the  
United States Environmental Protection Agency (herein  
®
EPA), and Harbor Freight Tools (herein HFT) are pleased  
to explain the emission control system warranty on your  
1995 and later Small Off-Road Engine (herein engine). In  
California, the engine must be designed, built and equipped  
to meet the State’s stringent anti-smog standards. Else-  
where within the United States, new off-road, spark-ignition  
engines certified for model year 1997 and later, must meet  
similar standards set forth by the EPA. HFT must warrant  
the emission control system on your engine for the periods  
of time described below, provided there has been no abuse,  
neglect or improper maintenance of your engine.  
Owner’s Warranty Responsibilities  
- As the engine owner, you are responsible for the per-  
formance of the required maintenance listed in your  
Owner’s Manual. HFT recommends that you retain  
all receipts covering maintenance on your engine,  
but HFT cannot deny warranty solely for the lack of  
receipts or for your failure to ensure the performance  
of all scheduled maintenance.  
- As the engine owner, you should, however, be aware  
that HFT may deny you warranty coverage if your  
engine or a part has failed due to abuse, neglect,  
improper maintenance, or unapproved modifications.  
Your emission control system may include parts such as the  
carburetor or fuel-injection system, and the ignition system.  
Also included may be hoses, belts, connectors and other  
emission-related assemblies.  
- You are responsible for shipping your engine to a HFT  
warranty station as soon as a problem exists. Contact  
the HFT Customer Service department at the number  
below to make shipping arrangements. The warranty  
repairs should be completed in a reasonable amount  
of time, not to exceed 30 days.  
Where a warrantable condition exists, HFT will repair your  
engine at no cost to you including diagnosis, parts and  
labor.  
Manufacturer’s Warranty Coverage  
The 1995 and later engines are warranted for two (2) years.  
If any emission-related part on your engine is defective, the  
part will be repaired or replaced by HFT.  
If you have any questions regarding your warranty rights  
and responsibilities, you should contact the Harbor Freight  
Tools Customer Service Department at 1-800-444-3353.  
Harbor Freight Tools Emission Control  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 23  
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Emission Control System Warranty - continued  
Harbor Freight Tools Emission Control Defects Warranty Provisions  
(f) alterations by changing, adding to or removing  
1.  
2.  
Length of Coverage  
parts from the engine.  
HFT warrants to a first retail purchaser and each sub-  
sequent purchaser that the engine is free from defects  
in materials and workmanship that cause the failure of  
warranted parts for a period of two (2) years after the  
date of delivery to the first retail purchaser.  
5.  
Service and Maintenance  
Component parts which are not scheduled for replace-  
ment as required maintenance or are scheduled only  
for regular inspection to the effect of “repair or replace  
as necessary” are warranted for the warranty period.  
Any warranted part which is scheduled for replace-  
ment as required maintenance is warranted for the  
period of time up to the first scheduled replacement  
point for that part. Any replacement part, provided it  
is equivalent in durability and performance, may be  
used in performance of maintenance or repairs. The  
owner is responsible for commissioning a qualified  
technician/mechanic to perform all required mainte-  
nance, as outlined in the Inspection, Cleaning, and  
Maintenance section on page 17 of this manual.  
N o C h a r g e R e p a i r o r  
Replacement  
Repair or replacement of any warranted part will be  
performed at no charge to the owner if the work is  
performed through a warranty station authorized by  
HFT. For emissions warranty service, contact the HFT  
Customer Service Department at 1-800-444-3353.  
3.  
C o n s e q u e n t i a l D a m a g e s  
Coverage  
Coverage under this warranty shall also extend to  
the failure of any engine components caused by the  
failure of any warranted part while it is still covered  
under this warranty.  
6.  
Warranted Parts  
1) Fuel Metering System  
i) Carburetor and its internal parts.  
ii) Fuel pump (if so equipped).  
iii) Cold start enrichment system.  
4.  
Coverage Exclusions  
Warranty claims shall be filed in accordance with the  
provisions of the HFT warranty policy explained in the  
box at the top of the previous page. HFT shall not be  
liable for any loss of use of the engine, for any alter-  
native usage, for any damage to goods, loss of time,  
or inconvenience. Warranty coverage shall also be  
excluded for any part which fails, malfunctions, or is  
damaged due to failure to follow the maintenance and  
operating instructions set forth in the Owner’s Manual  
including, but not limited to:  
2) Air Induction System  
i) Intake pipe/manifold.  
ii) Air cleaner.  
3) Ignition System  
i) Spark plug.  
ii) Magneto ignition system.  
4) Catalyst System (if so equipped)  
i) Exhaust pipe stud.  
ii) Muffler.  
iii) Catalytic converter (if so equipped).  
(a) use of parts which are not authorized by HFT  
(b) improper installation, adjustment or repair of the  
engine or of any warranted part unless performed  
by an authorized warranty center  
5) Miscellaneous items Used in Above Systems  
i) Vacuum, temperature and time sensitive  
valves and switches.  
(c) failure to follow recommendations on fuel use  
contained in the Owner’s Manual  
(d) improper or inadequate maintenance of any war-  
ranted parts  
(e) repairs performed outside of the authorized war-  
ranty service dealers  
SKU 92456  
For technical questions, please call 1-800-444-3353.  
Page 24  
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