Chicago Electric 90300 User Manual 2

®

Generators

Generators

GENERATOR

9 HP ROBIN® ELECTRIC START

Model 90300

OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

Copyright

manual or any artwork contained herein may be reproduced in any shape or form

©

2003 by Harbor Freight Tools®. All rights reserved. No portion of this

without the express written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

Item Description

Electrical Requirements 5400 Watt Surge Power

5 Min. Output @ 4400 Watts / Continuous Running Output 3600 Watts
15 AMPs @ 120V / 15 AMPs @ 240V
60 Hz Output
120V Dual Outlet: 15 AMP, 3 Prong Grounded
120/240V Outlet: 15 Amp, 4 Prong Twistlock
Overload Protection: Two 15 AMP Circuit Breakers
Battery Type Required: 12V with at least 24Ah capacity (not included)
Battery Size Capacity: 8" L x 5-1/4" W x 7-1/2 to 8" Tall

Engine Type 9 HP Robin® /Subaru® EX Series with Electric Start

4 Cycle / 265 CC Displacement
Model #EX-27052020

Alternator Two Pole / Single Phase / 60 Hz

Fuel Tank 6.5 Gallon

Estimated Run Time 14.5 Hours (w/ Full Tank @ 1/2 Load)

Overall Dimensions 29-3/4” x 25-1/2” x 20-5/8”

Weight 155 Pounds

IS NOT INTENDED TO POWER
SENSITIVE ELECTRONIC
EQUIPMENT WITHOUT THE
ADDITION OF AN APPROPRIATE
LINE CONDITIONER (SOLD
SEPARATELY).

THIS GENERATOR

This product requires oil and fuel to be added before starting.
Attempting to start the engine without oil
void the warranty.

Fill the engine with the following:

1.15 qt. of SAE 15W/40 oil

6.5 Gal. of unleaded gasoline with no oil added

Before starting the engine, refer to the engine owner’s manual for additional engine
maintenance information.

WILL ruin the engine and

Call Harbor Freight Tools at 1-800-444-3353
for all technical questions and all inquires
regarding GENERATOR AND ENGINE
replacement parts.

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, operating, in­spection, maintenance and cleaning procedures, parts list and assembly
diagram. Keep your invoice with this manual. Write the invoice number on the inside
of the front cover. Keep this manual and invoice in a safe and dry place for future
reference.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts List on page 18 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.

REV 12/03; 02/04; 05/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 2

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. Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

2. Do not operate generators in explosive atmospheres, such as in the presence

of flammable liquids, gases, or dust. Generators create sparks which may ignite

the dust or fumes.

3. Keep bystanders, children, and visitors away while operating a generator.

Provide barriers or shields as needed.

ELECTRICAL SAFETY

4. 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. 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

cord and grounded power supply system.

6. Avoid body contact with grounded surfaces such as pipes, radiators, ranges,

and refrigerators. There is an increased risk of electric shock if your body is

grounded.

eliminates the need for the three wire grounded power

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 3

7. Do not expose generators to rain or wet conditions. Water entering a generator

will increase the risk of electric shock.

8. 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. 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.

11. 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. Avoid accidental starting. Be sure the ON/Off Switch is in its OFF position and

the ignition key is removed from the Ignition Switch (45) when the generator is not

in use.

13. Remove adjusting keys or wrenches before turning the generator on. A wrench

or an adjusting key that is left attached to a rotating part of the generator may result

in personal injury.

14. Do not overreach. Keep proper footing and balance at all times.

15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety

shoes, hard hat, or hearing protection must be used for appropriate conditions.

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.

18. 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 properly repaired or replaced.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 4

GENERATOR USE AND CARE (Continued)

19. Disconnect the negative battery cable from the battery and remove the Ignition

Key before making any adjustments, changing accessories, or storing the

generator. Such preventive safety measures reduce the risk of starting the generator

accidentally.

20. Store idle generators out of reach of children and other untrained persons.

Generators are dangerous in the hands of untrained users.

21. Maintain generators with care. Do not use a damaged generator. Tag damaged

generators “Do not use” until repaired.

22. 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 hazardous

when used on another generator.

SERVICE

24. Generator service must be performed only by qualified repair personnel.

Service or maintenance performed by unqualified personnel could result in a risk

of injury.

25. When servicing a generator, use only identical replacement parts. Follow

instructions in the

manual. Use of unauthorized parts or failure to follow maintenance instructions

may create a risk of electric shock or injury.

“Inspection, Maintenance, And Cleaning”

section of this

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 5

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

1. 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.

2. 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. 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 becoming

caught in moving parts.

4. Do not overreach. Keep proper footing and balance at all times to prevent tripping,

falling, back injury, etcetera.

5. Industrial applications must follow OSHA requirements.

6. 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

replacement parts. Only use accessories intended for use with this product.

Approved 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 performed

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 90300 For technical questions, please call 1-800-444-3353. PAGE 6

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

manufacturer’s

precautions in

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. All electrical work, including the earth-ground connection, should be completed by

a licensed electrician.

4. Any separate fuel storage Generator supply facility must be built or installed in full

compliance with all relevant local, state, and federal regulations.

5. 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. The Generator is designed to be a portable unit. If however, the generator is to be

permanently installed outdoors, it must be weatherproofed and should be

soundproofed. Always follow local or state building codes. It should not be run

outdoors without protection to the Generator and wiring conduit.

Operation, Maintenance, and Parts manual.

this

manual. These should always be followed to reduce the risk of

Also, read the safety

Engine

7. Never lift the Generator using the engine or alternator lifting lugs. Connect lifting

equipment to the Frame of the Generator.

8. 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 90300 For technical questions, please call 1-800-444-3353. PAGE 7

11. For trailer installation, the Generator should be mounted on the center point of the

trailer, over the wheels.

12. Install sound- and weatherproofing only while 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. Keep the Generator and surrounding area clean at all times.

3. 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 regulations.

Store oil rags in a covered metal container.

4. Never store fuel or other flammable materials near the Generator.

5. 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. 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.

8. 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 turn off the Engine. Allow the Engine to completely cool, disconnect the

negative battery cable from the battery, and remove the key from the Ignition Switch

(45) before carrying out maintenance.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 8

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. 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.

4. 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. 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.

6. Keep access doors on enclosures closed and locked when access is not required.

7. When working on or around the Generator always wear protective clothing including

ANSI approved safety gloves, safety eye goggles, and safety hat.

8. Do not alter or adjust any part of the Generator that is assembled and supplied by

the manufacturer.

9. Always follow and complete scheduled Engine and Generator maintenance.

Chemical Precautions:

1. Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.

2. 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 90300 For technical questions, please call 1-800-444-3353. PAGE 9

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 properly earth-grounded by a licensed electrician in

accordance with all relevant electrical codes and standards before operation.

®

3. If an extension cord (not included) is used, make sure to use only UL

approved

cords having the correct gauge and length. (See Figure A.)

FIGURE A

REQUIRED MINIMUM EXTENSION CORD GAUGE – 120/ 240 VOLT

NAMEPLAT E

AMPERES

(At Full Load)

0 - 25

Feet

0 - 5 16 16 16 12 12

5.1 - 8 16 16 14 10 -

8.1 - 12 14 14 12 - -

12.1 - 15 12 12 10 - -

15.1 - 20 10 10 10 - -

EXT ENSION CORD LENGTH

25 - 50

Feet

50 -100

Feet

100 – 150

Feet

150– 200

Feet

4. Do not attempt to connect or disconnect load connections while standing in water,

or on wet or soggy ground.

5. Do not touch electrically 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. Before servicing equipment powered by the Generator, disconnect the equipment

from its power input.

8. Keep all electrical equipment clean and dry. Replace any wiring where the insulation

is cracked, cut, abraded or otherwise degraded. Replace terminals that are worn,

discolored, or corroded. Keep terminals clean and tight.

9. Insulate all connections and disconnected wires.

10. Guard against electric shock. Prevent body contact with grounded surfaces such

as pipes, radiators, ranges, and refrigerator enclosures.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 10

11. Use only Class BC or Class ABC fire extinguishers on electrical fires.

12. 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. 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.

3. 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 90300 For technical questions, please call 1-800-444-3353. PAGE 11

GENERAL LOCATION

1. It is recommended to locate and install the Generator in a protected outdoor area

where cooling air is readily available (see previous warning section).

2. 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. Install the Generator on a concrete slab or other area where rain drainage or flood

waters can not reach it.

4. Generator placement should allow four feet of access to all sides for maintenance.

5. Place the Generator as close as possible to the electrical tools and equipment

being powered to reduce the length of extension cords.

6. If the Generator in located indoors, 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. 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.)

2. 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 H, page 15.)

Note: Local codes and ordinances may vary. Always check local codes and install in

accord with all laws.

REV 08/04; 11/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 12

OPERATING INSTRUCTIONS

NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagram on page 19.

To Install A Battery:

1. NOTE: The Generator requires the installation of a 12 volt battery (not included).

The battery must be no larger than 5” wide x 7-3/4” long x 8-1/2” high.

2. WARNING! Battery fluid leakage may occur under extreme usage or temperature

conditions. If battery fluid comes in contact with skin, wash with soap and water and

rinse with lemon juice and vinegar. If the fluid comes into contact with the eyes,

flush with water for several minutes and contact a doctor immediately. Never burn a

battery, as it can explode in a fire. Do not use the Generator with a leaking battery.

Contact local solid waste authorities for instructions on correct disposal or recycling

of a battery.

3. Carefully place a fully charged, 12 volt battery in the Battery Holder located at the

base of the Generator.

4. The Engine has

two

power cables that must be connected to the battery. Connect
the cable with the RED (+ POSITIVE) terminal to the (+ POSITIVE) terminal on the
battery. Connect the cable with the BLACK (- NEGATIVE) terminal to the
(- NEGATIVE) terminal on the battery. (See Figure C.)

5. Insert the bottom, “L” shaped portion of one Battery Support Stud (39) in each end of
the Battery Holder. Then, insert the Battery Holding Plate (40) onto the two Battery
Support Studs and allow the Battery Holding Plate to rest on top of the battery. Secure
the battery in place by tightening the two Nuts (49) onto the two Battery Support
Studs. Do not overtighten, as it may damage the battery. (See Figure C.)

BATTERY HOLDING PLATE

NUT (49) NUT (49)

ATTACH RED

TERMINAL HERE.

BATTERY

SUPPORT

STUD

(39)

POSITIVE NEGATIVE

(40)

ATTACH BLACK

TERMINAL HERE.

12 VOLT BATTERY

(NOT INCLUDED)

BATTERY

SUPPORT

STUD

(39)

FIGURE C

BATTERY HOLDER

REV 12/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 13

Pre-Start Checks:

1. NOTE: During operation, it may be necessary to refer to the

Operation, Maintenance, and Parts manual

(included) for detailed information about

Engine manufacturer’s

starting, running, and stopping the Engine.

2. Check to make sure the Engine’s “ON/OFF” Switch is in its “OFF” position.

3. Unscrew and remove the Engine’s Oil Fill Cap located at the bottom of the Engine
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 D.)

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 E.)

FUEL GAUGE (34)FUEL TANK CAP (37)

OIL FILL CAP

FIGURE D

FUEL TANK (32)

FIGURE E

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 14

To Start The Generator:

1. Turn the Fuel Valve (31) to its vertical
“OPEN” position.

(See Figure F.)

2. Move the Engine’s Choke all the way
to the left to its “START” position.

(See Figure F.)

3. Turn the Engine’s “ON/OFF” switch to
its “

ON” position. (See Figure G.)

4. Insert the Ignition Key into the Igni­tion Switch (45), and turn the Ignition
Key to the right to start the Engine.

(See Figure H.)

5. Allow the Engine to run for several
seconds, then move the Engine’s
Choke all the way to the left to its
“RUN” position. (See Figure F.)

CHOKE

FUEL VALVE (31)

Hidden from view

FIGURE F

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 ef-

ON/OFF

Switch

ficiency and/or damage to the unit.

FIGURE G

OVERLOAD BREAKERS

(42)

120V DUAL OUTLET

(43)

120/240 V

TWISTLOCK OUTLET

(44)

GROUNDING POINT

IGNITION SWITCH

(45)

FIGURE H

REV 06/04; 08/04; 11/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 15

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 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 Outlets (43). If a 240 volt tool or equipment is
used, connect its power cord into the 240 volt Twistlock Outlet (44). (See Figure I.)

3. NOTE: The Generator features
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 I.)

AC CIRCUIT OVERLOAD BREAKER (42)

120V DUAL OUTLET (43)

two

AC Non-Fuse Overload Breakers (42) to protect

120/240 V

TWISTLOCK

OUTLET

(44)

FIGURE I

4. When finished using the Generator, turn the ON/OFF switch on the engine’s fan
shroud to its “OFF” position, and remove the Ignition Key from the Ignition Switch
(45). (See Figure H.)

5. After the Engine and Generator have completely cooled, store the Generator in a
safe, clean, dry location (if not already installed in one).

REV 06/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 16

INSPECTION, MAINTENANCE, AND CLEANING

1. NOTE: Preventative maintenance procedures and frequency will vary depending
on the amount of Generator use. Refer to the

Maintenance, and Parts manual

(included) for detailed information regarding

maintenance of the Engine.

2. CAUTION! Always turn off the Engine and remove the Ignition Key. Allow

sufficient time for the Engine and Generator to completely cool. Then,
disconnect the negative battery cable from the battery before performing any
inspection, maintenance, or cleaning.

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 fur ther
use.

Do not use damaged equipment.

4. 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.

Engine manufacturer’s Operation,

5. 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. NEITHER 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 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.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 17

PARTS LIST

WIRING DIAGRAM

REV 06/04; 12/04; 01/05

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 18

ASSEMBLY DIAGRAM

ASSEMBLY DIAGRAM

only, and are not available individually as replacement parts.

NOTE: Some parts are listed and shown for illustration purposes

49

39

41

42

44

45

43

40

8

5

4

1

2

3

15

6

7

9

10

11

12

14

13

16

36

37

35

34

48

8
3

33

32

31

30

47

46

29

28

27

26

25

24

22

18

19

20

21

REV 06/04

17

23

REV 12/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 19