Chicago Electric 90300 User manual

GENERATOR
9 HP ROBIN®ELECTRIC START
Model 90300
OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at: http://www.harborfreight.com
Copyright©2003 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, please call 1-800-444-3353.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 2
PRODUCT SPECIFICATIONS
Item Description
Electrical Requirements 4,500W Maximum Output; 4,000W Continuous Output
20 AMPs @ 120V / 20 AMPs @ 240V
60 Hz Output
120V Dual Outlet: 20 AMP, 3 Prong Grounded
120/240V Outlet: 20 AMP, 4 Prong Twistlock (L14-20)
Overload Protection: Two 20 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
THIS GENERATOR
IS NOT INTENDED TO POWER
SENSITIVE ELECTRONIC
EQUIPMENT WITHOUT THE
ADDITION OF AN APPROPRIATE
LINE CONDITIONER (SOLD
SEPARATELY).
REV 12/03; 02/04; 05/04; REV 03/06
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.
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.
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.
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.
Call Harbor FreightTools at 1-800-444-3353
for all technical questions and all inquires
regarding GENERATOR AND ENGINE
replacement parts.

SKU 90300 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
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 eliminates the need for the three wire grounded power
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.

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

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 5
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.
GENERATOR USE AND CARE (Continued)
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 “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 90300 For technical questions, please call 1-800-444-3353. PAGE 6
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
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.
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 7
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 Engine
manufacturer’s Operation, Maintenance, and Parts manual. Also, read the safety
precautions in this manual. These should always be followed to reduce the risk of
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.
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 8
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 9
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 10
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
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 - -
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 11
INSTALLATION
1. NOTE: Prior to powering tools and equipment, make sure the Generator’s rated
voltage, wattage, and amperage capacity (120V/ 20 AMPs and 240V/ 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. 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.
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.
REV 03/06

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 12
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 13
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.)
NUT (49) NUT (49)
BATTERY
SUPPORT
STUD
(39)
BATTERY
SUPPORT
STUD
(39)
BATTERY HOLDING PLATE
(40)
BATTERY HOLDER
12 VOLT BATTERY
(NOT INCLUDED)
POSITIVE NEGATIVE
ATTACH BLACK
TERMINAL HERE.
ATTACH RED
TERMINAL HERE.
FIGURE C
REV 12/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 14
Pre-Start Checks:
1. NOTE: During operation, it may be necessary to refer to the Engine manufacturer’s
Operation, Maintenance, and Parts manual (included) for detailed information about
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 un-
leaded gasoline. Then, replace the Fuel Tank Cap.
(See Figure E.)
FIGURE D
OIL FILL CAP
FUEL GAUGE (34)FUELTANK CAP (37)
FUELTANK (32)
FIGURE E

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 15
To StartThe 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 Igni-
tion 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.)
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-
ficiency and/or damage to the unit.
120V DUAL OUTLET
(43)
OVERLOAD BREAKERS
(42)
IGNITION SWITCH
(45)
FIGURE H
120/240V
TWISTLOCK OUTLET
(44) GROUNDING POINT
FIGURE G
ON/OFF
Switch
FUELVALVE (31)
Hidden from view
CHOKE
FIGURE F
REV 06/04; 08/04; 11/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 16
Powering Tools And Equipment:
1. Prior to powering tools and equipment, make sure the Generator’s rated voltage,
wattage, and amperage capacity (120V/ 20 AMP and 240V/ 20 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 two AC Non-Fuse Overload Breakers (42) to protect
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)
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; REV 03/06

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 17
INSPECTION, MAINTENANCE, AND CLEANING
1. NOTE: Preventative maintenance procedures and frequency will vary depending
on the amount of Generator use. Refer to the Engine manufacturer’s Operation,
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 further
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.
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 BUYERTHAT HE
OR SHE IS QUALIFIEDTO 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 PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT
PARTS THERETO.

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 18
REV 06/04; 12/04; 01/05; REV 03/06
PARTS LIST
WIRING DIAGRAM
20
20

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 19
ASSEMBLY DIAGRAM
33
32
31
30
29
28
27
26
25
24 22
21 20 19
23
18
17
16 15
14
13 12 11
10 97
6
5
8
4
321
40
43
45
44
42
41
39
46
47
48
38
37
36
35
34 NOTE: Some parts are listed and shown for illustration purposes
only, and are not available individually as replacement parts.
ASSEMBLY DIAGRAM
REV 06/04
49
REV 12/04

SKU 90300 For technical questions, please call 1-800-444-3353. PAGE 20
1 YEAR
WARRANTY
Harbor FreightTools 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). See engine manufacturer’s warranty which covers engine.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. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
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) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]
WARRANTY CARD
REV 03/06