Chicago Electric 92456 User manual

GENERATOR SET

6.5 HP - RECOIL START - 2600W/2800W RATED

Model 92456

OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

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

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

TO PREVENT SERIOUS INJURY OR DEATH,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

SKU 92456 For technical questions, please call 1-800-444-3353. Page 2

PRODUCT SPECIFICATIONS

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, operating, inspec-

tion, 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.

Wattage 2,600 / 2,800 (Continuous-Rated/Peak)

Electrical Output 20 Amps @ 110/120 VAC, 60 Hz

10 Amps @ 12 VDC

Electrical Supply Two 110/120 VAC, 3-Prong Grounding Outlets

One 23 Amp Circuit Breaker

Voltmeter 0-150 Volts / 50 Volt Increments

Display Lights Red (Run)

Generator Type Brush-less / Revolving Field / Self Exciting

Two Pole / Single Phase

Gasoline Engine 6.5 HP / Unleaded Gasoline Powered / Recoil Start / 4-Cycle

OHV / Air-Cooled / 196 cc Displacement / 3600 RPM

0.63 Quart (0.6 Liter) Oil Capacity / CARB and EPA Certiﬁed

Fuel Tank Capacity 3.96 Gallons (15 Liters) / Includes Fuel Gauge

Estimated Run Time 7.8 Continuous Running Hours

Weight 112 Pounds

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 informa-

tion, refer to the back two pages of this manual.

The engine’s carburetor may need to be adjusted by a qualiﬁed mechanic

for efﬁcient high-altitude use.

REV 11/06

SKU 92456 For technical questions, please call 1-800-444-3353. Page 3

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

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.

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.

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.

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.

SKU 92456 For technical questions, please call 1-800-444-3353. Page 4

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 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.

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

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.

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.

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.

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 For technical questions, please call 1-800-444-3353. Page 5

GENERATOR USE AND CARE

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.

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.

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

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

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

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

HEART PACEMAKER PRECAUTION

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. 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. 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.

SKU 92456 For technical questions, please call 1-800-444-3353. Page 7

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. 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 regula-

tions. 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 elec-

trical 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 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.

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

SKU 92456 For technical questions, please call 1-800-444-3353. Page 8

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 me-

chanical 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 re-

quired.

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

ing 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 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 For technical questions, please call 1-800-444-3353. Page 9

NOISE PRECAUTIONS

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

1. 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. The Generator must be earth-grounded 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®listed

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

FIGURE A

4. Do not attempt to connect or disconnect load connections while standing in wa-

ter, 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 conduc-

tive object.

6. 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.

7. Before servicing equipment powered by the Generator, disconnect the equipment

from its power input.

REQUIRED MINIMUM EXTENSION CORD GAUGE – 120 VOLT

NAMEPLATE

AMPERES

(At Full Load)

EXTENSION CORD LENGTH

0 - 25 Feet 25 - 50 Feet 50 -100 Feet 100 – 150 Feet 150– 200 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 - -

SKU 92456 For technical questions, please call 1-800-444-3353. Page 10

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. 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 (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. 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.

3. 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. It is recommended to locate and install the Generator outdoors where cooling air

is readily available.

2. Install the Generator so that the air inlets and outlets are not blocked by obstruc-

tions such as bushes, trees, or snow drifts. Locating it in the path of heavy winds

or snowdrifts may require the placement of a barrier for protection. The air inlet,

in normal weather conditions, should face the prevailing wind direction.

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

ﬂood waters can not reach it.

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

nance.

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