Harbor Freight Tools 92455 User Manual
GENERATOR SET
Generators
5.5 HP - RECOIL START - 2200W/2400W RATED
Model 92455
OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
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 Freight Tools.
For technical questions and replacement parts, please call 1-800-444-3353
REV 03/06
PRODUCT SPECIFICATIONS
Item Description
VAC Electrical
Specifications
VDC Electrical
Specifications
Voltmeter Equipped 0-150 Volts / 50 Volt Increments
Display Lights Red (Run)
Generator Type Brushless / Revolving Field / Self Exciting
Gasoline Engine 5.5 HP / Unleaded Gasoline Powered
Fuel Tank Capacity 3.96 Gallons (15 Liters) / Includes Fuel Gauge
Estimated Run Time 11.8 Continuous Running Hours
Weight 103.6 Pounds
115 Volts @ 19 Amps Current Output
60 Hz
Continuous/Rated Wattage: 2,200
Peak Wattage: 2,400
Two 115 VAC, 3-Prong Grounding Outlets
One 19 AMP Circuit Breaker
12 VDC @ 10 Amps Current Output
Two Pole / Single Phase
.
Recoil Start / 4-Cycle / OHV Air Cooled
163 CC Displacement / 3600 RPM
0.63 Quart (0.6 Liter) Oil Capacity
CARB and EPA Certified
This product requires oil and fuel to be added before starting.
Attempting to start the engine without oil WILL ruin the engine and
void the warranty.
Caution: This generator is not intended to power sensitive electronic
equipment without the addition of an appropriate line conditioner
(sold separately).
The Emission Control System for this generator’s engine is warranted
for standards set by the U.S. Environmental Protection Agency and by the
California Air Resources Board (also known as CARB). For warranty information, refer to the back two pages of this manual.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, operating, in-
spection, 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.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 2
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. Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable 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, ground-
ing 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 eliminates the need for the three wire grounded
power cord and grounded power supply system.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 3
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.
7.
8. 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.
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.
10. 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.
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.
Do not expose power tools to rain or wet conditions. Water entering a
generator will increase the risk of electric shock.
PERSONAL SAFETY
12. Avoid accidental starting. Make sure the Power Switch is in its “OFF” posi-
tion, and disconnect the Spark Plug Wire when not in use.
13. Remove adjusting keys or wrenches before turning the generator on. A
wrench or a key that is left attached to a rotating part of the generator may result in
personal injury.
14. Do not overreach. Keep proper footing and balance at all times.
15. 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.
16. 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.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 4
17. 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
18. 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.
19. Store idle generators out of reach of children and other untrained persons.
Generators are dangerous in the hands of untrained users.
20. Maintain generators with care. Do not use a damaged generator. Tag damaged
generators “Do not use” until repaired.
21. 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.
22. 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
23. Maintain labels and nameplates on the Generator and Engine. These carry
important information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
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 92455 For technical questions, please call 1-800-444-3353. Page 5
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
HEART PACEMAKER PRECAUTION
1. WARNING! People with pacemakers should consult their physician(s)
before using this product. Electromagnetic fields in close proximity to a heart
pacemaker could cause interference to or failure of the pacemaker.
INSTALLATION PRECAUTIONS
1. Ensure installation meets all applicable safety, and local and national electrical
codes. Have installation performed by a qualified, licensed electrician and building contractor.
2. All electrical work, including the earth-ground connection, should be completed by
a licensed electrician.
3. Any separate fuel storage Generator supply facility must be built or installed in full
compliance with all relevant local, state, and federal regulations.
4.
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. Never lift the Generator using the engine or alternator lifting lugs. Connect lifting
equipment to the Frame of the Generator.
7. Before lifting the Generator, ensure the lift rigging and supporting structure are in
good condition, and are rated to lift such a load.
8. Keep all personnel away from the suspended generator while relocating.
9. The supporting floor/ground surface should be level, and strong enough to safely
hold the weight of the Generator. If the floor/ground surface is not level, strong cross
members should be placed under the full length of the Generator Frame at its low
side.
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.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 6
10. For trailer installation, the Generator should be mounted on the center point of the
trailer, over the wheels.
11. 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. Keep the Generator and surrounding area clean at all times.
3. 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. 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.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 7
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.
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.
SKU 92455 For technical questions, please call 1-800-444-3353. Page 8
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