Chicago Electric 91213 User manual

GENERATOR SET
5.5 HP - RECOIL START - 2200W/2400W RATED
Model 91213
OPERATING INSTRUCTIONS
Generators
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
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
TO PREVENT SERIOUS INJURY OR DEATH,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.

SKU 91213 PAGE 2
PRODUCT SPECIFICATIONS
.
Item Description
VAC Electrical
Requirements
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
VDC Electrical
Requirements
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 5.5 HP / Unleaded Gasoline Powered
Recoil Start / 4-Cycle / OHV Air Cooled
163 CC Displacement / 3600 RPM
0.63 Quart (0.6 Liter) Oil Capacity
EPA Approved
Fuel Tank Capacity 3.96 Gallons (15 Liters) / Includes Fuel Gauge
Estimated Run Time 11.8 Continuous Running Hours
Weight 103.6 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).
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.

SKU 91213 PAGE 3
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 prop-
erly 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.
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
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 91213 PAGE 4
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. 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.
PERSONAL SAFETY
10. Stay alert. Watch what you are doing, and use common sense when oper-
ating a generator. Do not use a generator while tired or under the influ-
ence of drugs, alcohol, or medication. A moment of inattention while operat-
ing 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. Make sure the Power Switch is in its “OFF”
position, 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, non-skid 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 91213 PAGE 5
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 dam-
aged 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 hazard-
ous 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 “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 91213 PAGE 6
HEART PACEMAKER PRECAUTION
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
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 build-
ing 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 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 lim-
its.
5. If the generator is installed outdoors, it must be weatherproofed and should be sound-
proofed. It should not be run outdoors without protection to the Generator and wir-
ing 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 91213 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
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 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
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 attempt-
ing 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 91213 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
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 re-
quired.
7. When working on or around the Generator always wear protective clothing in-
cluding 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 91213 PAGE 9
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 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 approved
cords having the correct gauge and length. (See Figure A.)
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 - -
FIGURE A
®
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 (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.

SKU 91213 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 (115V - 20AMPs) 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 install-
ing this unit. Installation must be completed by licensed contractors.
3. WARNING! The Generator weighs 103.6 pounds. Use care and the proper
lifting or hoisting equipment when moving it to the installation location. Always
connect hoist lines to the Frame (41) 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.