GENERATOR SET 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.
PRODUCT SPECIFICATIONS Electrical Specifications 115 VAC @ 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 VDC Electrical Specifications 12 VDC @ 10 Amps Current Output Voltmeter Equipped 0-150 Volts / 50 Volt Increments Display Lights Red (Run) Generator Type Brushless / Revolving Field / Self Exciting Two Pole / Single Phase Gasoline Engine 5.
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.
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. Do not expose power tools to rain or wet conditions. Water entering a generator will increase the risk of electric shock. 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.
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.
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.
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.
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.
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. 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.
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. 11. Use only Class BC or Class ABC fire extinguishers on electrical fires.
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 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 (41) by at least one foot.
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 SKU 92455 For technical questions, please call 1-800-444-3353.
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.
5. Turn the Engine Power Switch (2) to its “ON” position. (See Figure F.) ENGINE POWER SWITCH (2) ON OFF FIGURE F 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.
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 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.
4. Start and run the Engine as previously discussed in this manual. 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. After the Engine and Generator have completely cooled, store the Generator in a safe, clean, dry location (if not already installed in one). 7.
abnormal noise or vibration occurs, have the problem corrected before further use. Do not use damaged equipment. 3. Follow all maintenance procedures as outlined in the Engine Maintenance Schedule 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 necessary, fill the Engine’s Crankcase until the oil level is even with the Oil Fill Hole.
PARTS LIST Part 1 2 3B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Description Bolt (M6 x 12) w/Lock Washer Engine Power Switch Control Panel Voltmeter Circuit Breaker Outlet DC Terminal Ground Connector DC Fuse Pilot Light Shock Absorber Shock Absorber Foot Lock Washer Nut Stator Cover Alternator Back Cover Capacitor Bolt (M5 x16) Rectifier Bolt (M5x16) Cable Sheath Bolt (M8 x 242) Bolt (M6 x 172) Q’ty 9 1 1 1 1 2 2 1 1 1 4 4 4 1 1 1 4 1 3 1 1 4 Part 23 24 25 26 27 28 29 30B 31 32 33 34 35B 36 37
ASSEMBLY DIAGRAM REV 06/06 SKU 92455 For technical questions, please call 1-800-444-3353.
PARTS LIST - CONTINUED Part 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A 33A 34A 35A 36A 37A 38A 39A 40A 41A Description Muffler Cylinder Head Bolt Cylinder Head Cover Bolt Cylinder Head Cover Lock Nut Adjusting Screw Rocker Arm Rocker Arm Bolt Valve Push Rod Guiding Board Valve Push Rod Cylinder Head Carburetor Shield Carburetor Packing I Carburetor Assembly Air Cleaner Case Air Cleaner Seal Bolt (M6) Air Cleaner Cover Air Cleaner E
ASSEMBLY DIAGRAM - CONTINUED 73A 77A 76A 78A 79A 80A 81A 82A 33A 32A 31A 70A 69A 75A 74A 55A 54A 57A 56A 1A 2A 72A 71A 30A 28A 17A 26A 35A 29A 27A 25A 58A 59A 63A 62A 64A 61A 53A 65A 52A 51A 50A 49A 60A 66A 67A 68A 48B 47A 46A 45A 44A 43A 23A 24A 22A 3A 4A 11A 10A 7A 5A 6A 21A 36A 37A 38A 9A 8A 12A 13A 14A 39A 20A 40A 19A 41A 42B 18A 15A 16A 17A NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.
Wiring Diagram SKU 92455 For technical questions, please call 1-800-444-3353.
1 Year 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).
Emission Control System Warranty - continued Harbor Freight Tools Emission Control Defects Warranty Provisions 1. Length of Coverage (f) HFT warrants to a first retail purchaser and each subsequent 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. 2. No Charge Replacement Repair 5.