Chicago Electric 91523 User manual

GENERATOR SET
6.5 HP - RECOIL START - 2600W/2800W RATED
Model 91523
OPERATING INSTRUCTIONS
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWebsite at: http://www.harborfreight.com
Generators
TO PREVENT SERIOUS INJURY,
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 FreightTools.
For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS
SKU 91523 PAGE 2
.
Item Description
VAC
Electrical Requirements Current Output: 110/120 Volts @ 20 AMP’s 60 Hz
Continuous/Rated Wattage: 2600
Peak Wattage: 2800
Two 110/120 VAC, 3-Prong Grounding Outlets
One 23 AMP Circuit Breaker
VDC
Electrical Requirements Current Output: 12 VDC @ 10 AMP’s
Voltmeter Equipped 0-150 Volts (50 Volt Increments)
Display Lights Red (Run)
Gasoline Engine 6.5 / Unleaded Gasoline Powered / Recoil Start
3600 RPM / 4-Cycle / OHV Air Cooled
196 CC Displacement
0.63 Quart (0.6 Liter) Oil Capacity
EPA Approved
Fuel Tank Capacity 3.96 Gallons (15 Liters) / Includes Fuel Gauge
Estimated Run Time 7.8 Continuous Operating Hours
Approx. 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.
BEFORE starting the engine, refer to the engine owner’s manual for engine
maintenance information.
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.
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.
CAUTION: THIS GENERATOR IS NOT INTENDED TO POWER SENSITIVE ELECTRONIC
EQUIPMENT (INCLUDING MEDICAL EQUIPMENT)WITHOUTTHE ADDITION OF AN APPROPRIATE
LINE CONDITIONER (SOLD SEPARATELY).

SKU 91523 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 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. 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 91523 PAGE 4
7. Do not expose Generator to rain or wet conditions. Water entering a
generator will increase the risk of electric shock.
8. Do not abuse the Power Cord. 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 PlugWire 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.
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.

SKU 91523 PAGE 5
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 FreightTools 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
ofinjury.
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.

HEART PACEMAKER PRECAUTION
SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS
SKU 91523 PAGE 6
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 or Generator supply facility must be built or installed in
full compliance with all relevant local, state, and federal regulations.
4. It is recommended to use the Generator only in well ventilated out-
door areas. A running gasoline engine will generate Carbon Monox-
ide, a colorless, odorless gas that, if inhaled, can cause serious injury
or death. 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 and installation must always meet local building codes.
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. The Generator weighs 112 lbs. Two or more people should assist when moving
or lifting this product. 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 during relocating.

SKU 91523 PAGE 7
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.
10. For trailer installation, the Generator should be mounted on the center point of the
trailer, over the wheels. The trailer must be capable of supporting the weight of
the Generator and all contents (tools, etc.)
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 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
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.

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.
SKU 91523 PAGE 8
CHEMICAL PRECAUTIONS
1. Avoid contact with hot fuel, oil, exhaust fumes, and hot 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 and seek medical attention.

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 91523 PAGE 9
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 for fixed installations 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 (110/120 volt) that is
compatible with the electrical characteristics and rated capacities of the Genera-
tor.
7. Before servicing equipment powered by the Generator, disconnect the equipment
from its power input.

SKU 91523 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.
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 approximately 112 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.