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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.
Distractions can cause you to lose control.  Protect others in the work area from
debris such as chips and sparks.  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.

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.

SKU 54516

PAGE 3

Summary of Contents for 54516

Page 1: ... 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 please call 1 800 444 3353 Generators ...

Page 2: ...perating 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 Item Description Electrical 4 700 Watts continuous Requirements 5 200 Watts peak 20 AMPs 120 Volts Current Output 20 AMPs 240 Volts Current Outpu...

Page 3: ...area from debris such as chips and sparks 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 pro...

Page 4: ... hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Always wear heavy duty leather work gloves 12 Avoid accidental starting Be sure the ON Off Switch is in its OFF position Disconnect the spark plug wire and remove the Key from the Ignition 13 Remove adjusting keys or wrenches before turning the generator on A wrench or a...

Page 5: ...ds of untrained users 20 Maintain generators with care Keep cutting tools sharp and clean Do not use a damaged generator Tag damaged tools 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...

Page 6: ...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 9 WARNING The warnings precautions and instructions discussed in this manual cannot cover all possible conditions and si...

Page 7: ...entilated areas Running the Generator in an enclosed area such as a garage will produce carbon monoxide a colorless odorless vapor 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 6 If the generator is installed outdoors it must be weatherproofed...

Page 8: ...f 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 ...

Page 9: ... 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 ...

Page 10: ...g the correct gauge and length See Figures A and B FIGURE A REQUIRED MINIMUM EXTENSION CORD GAUGE 240 VOLT NAMEPLATE AMPERES EXTENSION CORD LENGTH _______________________________________________ At Full Load 0 25 Feet 25 50 Feet 50 100 Feet 100 150 Feet 6 18 16 14 12 8 18 16 12 10 10 18 14 12 10 12 16 14 10 8 14 16 12 10 8 16 16 12 10 8 18 14 12 8 8 20 14 12 8 6 22 14 10 8 6 24 14 10 8 6 26 12 10 ...

Page 11: ...lass BC or Class ABC fire extinguishers on electrical fires 12 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 1 NOTE Prior to powering tools and equipment make sure the Generator s rated voltage wattage and amperage capacity ...

Page 12: ... in located indoors or in a Generator house the Engine exhaust must be ventilated to the outdoors using leak proof 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 21 by at least one foot Contact a cement contractor for slab specifica...

Page 13: ...water for several minutes and contact a doctor immedi ately 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 on the Battery Holder located in the lower right corner of the Generator See Figure D next p...

Page 14: ...t using the Generator fill the Fuel Tank with unleaded gasoline NOTE The Fuel Tank will hold up to x x gallons of unleaded gasoline Do not overfill Thereafter check the Fuel Gauge for the amount of unleaded gasoline in the Fuel Tank If necessary remove the Fuel Tank Cap and refill the Fuel Tank with unleaded gasoline Then replace the Fuel Tank Cap See Figure E NUT 36 NUT 36 BATTERY SUPPORT STUD 37...

Page 15: ...l OPEN position See Figure F 2 Move the Engine s Fuel Choke all the way to the right to its START position See Figure F 3 Turn the Engine s ON OFF Switch to its ON position See Figure F FIGURE E OIL FILL CAP FUEL TANK CAP FUEL TANK FUEL VALVE FUEL CHOKE IGNITION SWITCH ON OFF SWITCH FIGURE F ...

Page 16: ...ment maximum 20 AMP into the 120 volt Outlets 31 If a 240 volt tool or equipment maximum 20 AMP is used connect its power cord into the 240 volt Twist Lock Outlet 30 See Figure G 3 NOTE The Generator features two AC Non Fuse Overload Breakers 32 to protect the AC circuit in case of an overload Should an overload occur one or both of the Breakers will trip causing the Generator power to be interrup...

Page 17: ...ck 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 PROVI...

Page 18: ...th 1 24 Lock Washer M10 4 6 Rear Cover 1 25 Shock Absorber 4 7 Bolt M6 x 16 2 26 Rail 2 8 Bolt M6 x 125 4 27 Battery Holder 1 9 Capacitor 1 28 Bolt M8 x 55 4 10 Motor Back Cover 1 29 Lock Washer M8 4 11 Bolt 5 16 x 175 1 30 Twist Lock Outlet 240V 1 12 Stator 1 31 Outlet 120V 2 13 Bridge Combination 2 32 Circuit Breaker 2 14 Voltage Dependent Resistor 2 33 Switch Box Cover 1 15 Rotor 1 34 Ground Co...

Page 19: ...ASSEMBLY DIAGRAM ELECTRICAL SCHEMATIC NOTE Some parts are listed and shown for illustration purposes only and are not available as replacement parts SKU 54516 PAGE 19 27 37 36 ...

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