Harbor Freight Tools Outboard Motor 92103 User Manual

MOTOR - 1/4 HP  
MOTOR - 1/3 HP  
92103  
92104  
MOTOR - 1/2 HP  
92105  
ASSEMBLY AND OPERATING INSTRUCTIONS  
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  
 
Electrical Safety  
4.  
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.  
5.  
6.  
Do not expose power tools to rain or wet conditions. Water entering a power tool  
will increase the risk of electric shock.  
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.  
7.  
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.  
8.  
9.  
Do not abuse the Power Cord. Never use the Power Cord to carry the tools or  
pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp  
edges, or moving parts. Replace damaged Power Cords immediately. Damaged  
Power Cords increase the risk of electric shock.  
When operating a power tool outside, use an outdoor extension cord marked  
“W-A” orW”. 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  
power tool. Do not use a power tool while tired or under the influence of drugs,  
alcohol, or medication. A moment of inattention while operating power tools 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 Power Switch is off before plugging in.  
Carrying power tools with your finger on the Power Switch, or plugging in power tools  
with the Power Switch on, invites accidents.  
13. Remove adjusting keys or wrenches before turning the power tool on. A wrench  
or a key that is left attached to a rotating part of the power tool may result in personal  
injury.  
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SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
14. Do not overreach. Keep proper footing and balance at all times. Proper footing  
and balance enables better control of the power tool in unexpected situations.  
15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety  
shoes, hard hat, or hearing protection must be used for appropriate conditions.  
Tool Use and Care  
16. Use clamps (not included) or other practical ways to secure and support the  
workpiece to a stable platform. Holding the work by hand or against your body is  
unstable and may lead to loss of control.  
17. Do not force the tool. Use the correct tool for your application. The correct tool  
will do the job better and safer at the rate for which it is designed.  
18. Do not use the power tool if the Power Switch does not turn it on or off. Any tool  
that cannot be controlled with the Power Switch is dangerous and must be replaced.  
19. Disconnect the Power Cord Plug from the power source before making any  
adjustments, changing accessories, or storing the tool. Such preventive safety  
measures reduce the risk of starting the tool accidentally.  
20. Store idle tools out of reach of children and other untrained persons. Tools are  
dangerous in the hands of untrained users.  
21. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained  
tools with a sharp cutting edge are less likely to bind and are easier to control. Do not  
use a damaged tool. Tag damaged tools “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 tool’s operation. If damaged, have the tool  
serviced before using. Many accidents are caused by poorly maintained tools.  
23. Use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one tool may become hazardous when  
used on another tool.  
Service  
24. Motor 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 tool, use only identical replacement parts. Follow instructions  
in the “Inspection, Maintenance, And Cleaningsection of this manual. Use of  
unauthorized parts or failure to follow maintenance instructions may create a risk of  
electric shock or injury.  
SPECIFIC SAFETY RULES FOR THIS PRODUCT  
1.  
Maintain labels and nameplates on the Motor. These carry important information. If  
unreadable or missing, contact Harbor Freight Tools for a replacement.  
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SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
2.  
3.  
Always wear ANSI approved safety impact eye goggles and heavy work gloves  
when setting up and using the Motor. Using personal safety devices reduce the risk  
for injury. Safety impact eye goggles and heavy work gloves are available from Harbor  
Freight Tools.  
Maintain a safe working environment. Keep the work area well lit. Make sure there  
is adequate surrounding workspace. Always keep the work area free of obstructions,  
grease, oil, trash, and other debris. Do not use install the motor in areas near  
flammable chemicals, dusts, and vapors. Do not use this product in a damp or wet  
location.  
4.  
5.  
6.  
Avoid unintentional starting. Make sure you are prepared to begin work before  
turning on the Motor.  
Do not force the Motor. This tool will do the work better and safer at the speed and  
capacity for which it was designed.  
Always unplug the Motor from its electrical outlet (or turn off the circuit breaker  
and tag) before performing any inspection, maintenance, or cleaning  
procedures.  
7.  
When installing motor, observe all national and local codes. Make sure to install,  
protect, and fuse according to the latest issue of the National Electric Code, NEMA  
Standard Publication No. MG2, and local codes. Ground frames in accordance with  
NEC Article 430. For general grounding information, refer to NEC Article 250.  
8.  
9.  
Install guards when appropriate. Make sure all moving parts, including the shaft  
and any attached accessories, are permanently guarded to prevent clothing and body  
parts from being caught.  
Disconnect power before working on motor driven equipment.  
10. Before each use, check all nuts, bolts, and screws for tightness. Vibration during  
operation may cause these to loosen.  
11. Keep extension cord off the ground and away from water.  
12. Always connect the Line Cord to a Ground Fault Circuit Interrupter (GFCI) protected  
electrical outlet.  
(1)  
13. Do not allow children to play with, or touch this product.  
14. Keep the motor dry; never submerge in water. Keep the motor a safe distance from all  
flammable objects.  
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.  
Page 5  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
GROUNDING  
WARNING!  
Improperly connecting the grounding wire can result in the risk of electric shock.  
Check with a qualified electrician if you are in doubt as to whether the outlet is  
properly grounded. Do not modify the power cord plug provided with the tool or  
product. Never remove the grounding prong from the plug. Do not use the tool if  
the power cord or plug is damaged. If damaged, have it repaired by a service  
facility before use. If the plug will not fit the outlet, have a proper outlet installed by  
a qualified electrician.  
Grounded Tools: Tools with Three Prong Plugs  
1.  
Tools marked with “Grounding Required” have a three wire cord and three prong  
grounding plug. The plug must be connected to a properly grounded outlet. If the tool  
should electrically malfunction or break down, grounding provides a low resistance  
path to carry electricity away from the user, reducing the risk of electric shock. (See  
Figure A.)  
2.  
3.  
The grounding prong in the plug is connected through the green wire inside the cord to  
the grounding system in the tool.The green wire in the cord must be the only wire  
connected to the tool’s grounding system and must never be attached to an electrically  
“live” terminal. (See Figure A.)  
Your tool must be plugged into an appropriate outlet, properly installed and grounded  
in accordance with all codes and ordinances. The plug and outlet should look like  
those in the following illustration. (See Figure A.)  
Figure B  
Figure A  
Double Insulated Tools: Tools with Two Prong Plugs  
4.  
Tools marked “Double Insulated” do not require grounding. They have a special double  
insulation system which satisfies OSHA requirements and complies with the  
applicable standards of Underwriters Laboratories, Inc., the Canadian Standard  
Association, and the National Electrical Code. (See Figure B.)  
5.  
Double insulated tools may be used in either of the 120 volt outlets shown in the  
following illustration. (See Figure B.)  
Page 6  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
EXTENSION CORDS  
1.  
2.  
Grounded tools require a three wire extension cord. Double Insulated tools can use  
either a two or three wire extension cord.  
As the distance from the supply outlet increases, you must use a heavier gauge  
extension cord. Using extension cords with inadequately sized wire causes a serious  
drop in voltage, resulting in loss of power and possible tool damage. (See Table A.)  
3.  
The smaller the gauge number of the wire, the greater the capacity of the cord. For  
example, a 14 gauge cord can carry a higher current than a 16 gauge cord. (See Table  
A.)  
4.  
5.  
6.  
7.  
When using more than one extension cord to make up the total length, make sure  
each cord contains at least the minimum wire size required. (See Table A.)  
If you are using one extension cord for more than one tool, add the nameplate  
amperes and use the sum to determine the required minimum cord size. (See Table A.)  
If you are using an extension cord outdoors, make sure it is marked with the suffix “W-  
A” (“W” in Canada) to indicate it is acceptable for outdoor use.  
Make sure your extension cord is properly wired and in good electrical condition.  
Always replace a damaged extension cord or have it repaired by a qualified  
electrician before using it.  
8.  
Protect your extension cords from sharp objects, excessive heat, and damp or wet  
areas.  
Table A  
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*  
(120 VOLT)  
NAMEPLATE  
AMPERES  
EXTENSION CORD LENGTH  
(At Full Load)  
25  
Feet  
18  
18  
18  
18  
16  
14  
12  
50  
Feet  
18  
18  
18  
16  
14  
12  
10  
75  
Feet  
18  
18  
16  
14  
12  
10  
-
100  
150  
Feet  
16  
14  
12  
12  
-
Feet  
18  
16  
14  
12  
10  
-
0 – 2.0  
2.1 – 3.4  
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.  
Page 7  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
SYMBOLOGY  
Table B  
UNPACKING  
When unpacking, check to make sure that all the parts are included. If any parts are miss-  
ing or broken, please call Harbor Freight Tools at the number on the cover of this manual as  
soon as possible.  
INSTALLATION  
WARNING: Electrical shock hazard. The wiring of the motor to the facility power circuit  
must be done by a qualified electrician.  
General  
1.  
The ambient air temperature where the motor is to be installed cannot exceed 104° F.  
If it does, cooling must be provided to ensure the temperature stays below the limit.  
2.  
3.  
Do not block motor air vents.  
This motor should be installed indoors in a clean, dry, and noncorrosive environment  
where no flammable liquids or gases are present.  
4.  
5.  
6.  
When mounting the motor for use, make sure all mounting hardware is securely  
fastened. Make sure all hardware (not supplied) is securely fastened.  
When mounting a pulley (not included) to the drive shaft, make sure it is properly  
aligned or motor life will be significantly shortened.  
Never operate motor without installing a safety guard (not supplied), with at least a two  
inch clearance, around all pulleys and belts driven by this motor.  
Page 8  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
Motor Wire Connections  
The table below, and the photo on the next page, indicate the proper wiring connections for  
the motor internal wires and the external power connections (neutral power wire is usually  
white; hot power wire is usually black, ground wire (green) is for earth ground).  
1.  
2.  
Remove Connection Cover to expose the terminal strip (see photo below).  
Verify that there is no power to the circuit to be connected. Check fuse box and turn off  
circuit breaker.  
3.  
Using approved National Electrical Code electrical standards, make the connections  
as described in the table below for 115 VAC operation only.  
Reverse the blue and black leads for clockwise rotation. Note: As there are tap  
connections under the electrical block, do not reverse the line conductors. The facility  
power circuit, and connecting wires, must be rated at least 20 amps of current. Use  
wire lugs (not included) to connect the wires to the Motor terminal strip.The motor can  
be connected by an appropriate size line cord (not included) or hard wired through  
conduit.  
4.  
Replace motor Connection Cover.  
Caution: Always connect the green grounding wire to the green motor chassis screw.  
Failure to connect this wire properly can create a severe safety hazard.  
Counterclockwise  
Clockwise  
Wired from factory  
for counterclockwise  
rotation  
Line In (Hot)  
Line In (Neutral)  
(1)  
Connection  
Cover  
GroundWire (green)  
Page 9  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
OPERATING INSTRUCTIONS  
Before initial operation, verify that:  
1.  
2.  
The Motor is dry.  
The voltage and frequency stamped on motor and control nameplates correspond with  
that of the input power line.  
3.  
4.  
5.  
All connections to the motor are correct.  
The rotor turns freely when disconnected from the load.  
The motor is detached from the load for the initial start. Operate the motor without a  
load for about one hour to test for any localized heating in bearings and windings.  
6.  
7.  
The voltage is correct and balanced at the motor terminals, and no-load current draw  
(in amps) is correct.  
The motor comes up to its operational speed and is not being overloaded.  
INSPECTION, MAINTENANCE, AND CLEANING  
WARNING! Make sure the Power Switch of the Motor is in itsOFFposition and that  
the tool is unplugged or disconnected from its electrical outlet before performing any  
inspection, maintenance, or cleaning procedures.  
1.  
Before each use, inspect the general condition of the Motor. 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.  
2.  
3.  
4.  
Maintenance and repairs should only be done by a qualified technician.  
Periodically recheck all nuts, bolts, and screws for tightness.  
Store in a clean and dry location.  
Lubrication  
Note: If lubrication instructions are shown on motor, they will supersede this general  
instruction. Lubrication should be completed by a qualified technician.  
1.  
2.  
3.  
The Motor is properly lubricated at the time of manufacture. It is not necessary to  
lubricate at time of installation unless the motor has been in storage for a period of 12  
months or longer.  
Re-oil sleeve bearings with drops of 5W20 viscosity motor oil every 2000 hours of  
normal service. Direct drive operation (no pulleys) requires lubrication every 3000  
hours of normal service.  
Sealed ball bearings require no attention during the life of the bearing.  
Page 10  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 
WIRING DIAGRAMS  
92103/92104  
92105  
REV 03/05  
Page 11  
SKU 92103/104/105  
For technical questions, please call 1-800-444-3353  
 

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