Harbor Freight Tools Peak/7000 Product manual
Contents
1. Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 13 Calculating Total Wattage of Devices Used with the Generator Before using the Generator check that the products you want to plug into the unit are below the rated and Wattage Estimate Charts maximum wattage ratings of the Generator Use the Wattage Calculation Table below and the watts listed on your products to help calculate multiple wattage totals Note Wattages listed below are estimates for that type of equipment only Check nameplate wattages on all loads before connecting to Generator EMERGENCY To use the table 1 Add up the Running Watts for all items you Devies Running sre would like to use at any given time Watts Watts 2 Make sure that this total is under the 7 000 running wattage of the generator Radio tf 10 0 3 Find the single highest starting watts for the selected items and add to the total JOB SITE 4 Make sure that this total is under the Running Additional Device Start up 8 750 peak wattage of the generator Watts Watts 5 Plug in and turn on products from largest wattage Air Compressor 1 2 HP 7000 1000 to smallest Table Saw 10 1700 1300 Belt Sander 3 Hand Drill 1 2 i Wattage Calculation Table Halogen Wore Eight Running Watts Recipricating Saw Box Fan 20 Coffee Maker Total Running Watts must be less than 7 000 HOUSEHOLD2. SAFETY Fire Hazard Do not fill gas tank while engine is running Do not operate if gasoline has been spilled Clean spilled gasoline before starting engine Do not operate near pilot light or open flame Do not touch engine during use Let engine cool down after use Never store fuel or other flammable materials near the engine If the plugged in product operates abnormally or unusually slow immediately stop using the generator as a power source Always read and adhere to the instruction manual of the product to be powered to make sure that it can be safely and efficiently powered by a portable generator Before connecting an appliance or power cord to the generator Make sure that it is in good working order Faulty appliances or power cords can create a potential for electrical shock Do not exceed the maximum power rating of the generator Make sure that the total electrical rating of the all of the tools or appliances plugged into the generator at the same time does not exceed that of the generator Check that the startup surge will not be beyond the limit of the Generator Power levels between rated and maximum may be used for no more than 30 minutes Avoid substantially overloading which will trip the circuit breaker Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF but will shorten the service life of the genera
3. 5 AFTER STORAGE Before starting the Engine during or after storage keep in mind that untreated gasoline will deteriorate quickly Drain the fuel tank and change to fresh fuel if untreated gasoline has been sitting for a month if treated gasoline has been sitting beyond the fuel stabilizer s recommended time period or if the Engine does not start Item 68525 68530 Troubleshooting Possible Causes Probable Solutions FUEL RELATED Engine will not start l Follow all safety precautions whenever diagnosing or servicing the equipment or engine Item 68525 68530 FUEL RELATED le No fuel in tank or fuel valve closed Choke not in CHOKE position cold engine Gasoline with more than 10 ethanol used E15 E20 E85 etc Low quality or deteriorated old gasoline Carburetor not primed Dirty fuel passageways Carburetor needle stuck Fuel can be smelled in the air Too much fuel in chamber This can be caused by the carburetor needle sticking 9 Clogged Fuel Filter 1 Fill fuel tank with fresh 87 octane stabilizer treated unleaded gasoline and open fuel valve Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Move Choke to CHOKE position Clean out ethanol rich gasoline from fuel system Replace components damaged by ethanol Use fresh 87 octane stabilizer treated unleaded gasoline only Do not use gasoline with more than 10 ethanol E15 E20
4. Note Do not use gasoline containing more than 10 ethanol E10 Do not use E85 ethanol Engine Oil Change ACAUTION Oil is very hot during operation and can cause burns Wait for engine to cool before changing oil 1 Make sure the engine is stopped and is level 2 Close the Fuel Valve 3 Place a drain pan not included underneath the crankcase s drain plug 4 Remove the drain plug and if possible tilt the crankcase slightly to help drain the oil out Recycle used oil 5 Replace the drain plug and tighten it 6 Clean the top of the Dipstick and the area around it Remove the Dipstick by threading it counterclockwise and wipe it off with a clean lint free rag Full level Full level 7 Add the appropriate type of oil until the oil level is at the full level SAE 10W 30 oil is recommended for general use Air Filter Element Maintenance 1 Remove the air filter cover and the air filter elements and check for dirt Clean as described below 2 Cleaning e For paper filter elements To prevent injury from dust and debris wear ANSI approved safety goggles NIOSH approved dust mask respirator and heavy duty work gloves In a well ventilated area away from bystanders use pressurized air to blow dust out of the air filter If this does not get the filter clean replace it Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Note Do not use gasoline that has been
5. THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO PREDATOR GENERATORS 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 1 888 866 5797
6. components get very hot during use Stay clear of hot parts Do not cover the generator or its engine during operation Keep the generator its engine and surrounding area clean at all times Use the generator accessories etc in accordance with these instructions and in the manner intended for the particular type of equipment taking into account the working conditions and the work to be performed Use of the equipment for operations different from those intended could result in a hazardous situation Do not operate the generator with known leaks in the engine s fuel system WARNING This product contains or when used produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq WARNING This product contains di 2 ethylhexyl phthalate DEHP a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq 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 regulations Store oil rags in a bottom ventilated covered metal container Keep hands and feet away from moving parts Do not reach over or across generator while operating Before use check for misalignment or binding of moving parts breakage
7. fuel flow 4 Faulty magneto 4 Have qualified technician service magneto Disconnected or improperly Secure spark plug cap connected spark plug cap Engine stops when Dirty air filter Clean or replace element under heavy load Engine running cold Allow engine to warm up prior to operating equipment Engine knocks Old or low quality gasoline Fill fuel tank with fresh 87 octane stabilizer treated unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Engine overloaded Do not exceed equipment s load rating Incorrect spark timing deposit buildup Have qualified technician diagnose worn engine or other mechanical problems and service engine Engine backfires Impure or low quality gasoline Fill fuel tank with fresh 87 octane stabilizer treated unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Engine too cold Use cold weather fuel and oil additives to prevent backfiring Intake valve stuck or overheated engine Have qualified technician diagnose and service engine Incorrect timing Check engine timing Product doesn t Product not plugged in properly Turn off and unplug the product then have power plug it back in again and turn on Circuit Breaker tripped Turn off and unplug product Reset Circuit Breaker Plug in product and turn on Product needs service Have product repaired Product begins to Pro
8. goggles heavy duty work gloves and dust mask respirator during service 7 Maintain labels and nameplates on the equipment These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 9 10 Follow scheduled engine and Have the equipment serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the equipment is maintained Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly SAFETY Store equipment out of the reach of children equipment maintenance Refueling 1 Do not smoke or allow sparks flames or other sources of ignition around the equipment especially when refuelling Do not refill the fuel tank while the engine is running or hot TO PREVENT FUEL LEAKAGE AND FIRE HAZARD Do not overfill with fuel Fill with fuel according to the Fuel Level information below the Specification chart for your model Do not fill fuel tank to the top Leave a little room for the fuel to expand as needed Refuel in a well ventilated area only Wipe up any spilled fuel and allow excess to evaporate before starting engine To prevent FIRE do not start the engine while the smell of fuel hangs in the air SAVE THESE INSTRUCTIONS PREDATOR GENERATORS Item 68525 68530 For Generator
9. stored ina metal fuel container or a dirty fuel container It can cause particles to enter the carburetor effecting engine performance and or causing damage 3 If needed fill the Fuel Tank to about 1 inch under the fill neck with 87 octane or higher unleaded gasoline that has been treated with a fuel stabilizer additive Follow fuel stabilizer manufacturer s recommendations for use 4 Replace the Fuel Cap 5 Wipe up any spilled fuel and allow excess to evaporate before starting engine To prevent FIRE do not start the engine while the smell of fuel hangs in the air Note Do not thread the dipstick in when checking the oil level The SAE Viscosity Grade chart shows other viscosities to use in different average temperatures SAE Viscosity oe 1 a Average outdoor temperature 8 Thread the dipstick back in clockwise CAUTION Do not run the engine with too little oil The engine will be permanently damaged e For foam filter elements Wash the element in warm water and mild detergent several times Rinse Squeeze out excess water and allow it to dry completely Soak the filter in lightweight oil briefly then squeeze out the excess oil 3 Install the cleaned filter Secure the Air Cleaner Cover before use Page 17 MAINTENANCE 2 Z m Z gt Z O m Spark Plug Maintenance 1 Disconnect spark plug cap from end of plug Clean out debris from around spark plug 2 Using a spa
10. technical questions please call 1 888 866 5797 Page 5 wn gt mn m lt Functional Description Specifications eee Output 120 240VAC 60Hz p 7 000 Running Watts 8750 Peak Watts Battery needed for electric start 12V lead acid 9Ah not included Generator Two 3 Prong duplex NEMA 5 15 120V One 3 Prong NEMA L5 20 twistlock 120V One 4 Prong NEMA L14 30 twistlock 120V 240V One DC Outlet 12VDC Displacement Engine Type Horizontal Single Cylinder 4 stroke OHV Electrical Receptacle Cooling System Forced air cooled Fuel 87 octane stabilizer treated unleaded gasoline Capacity 6 6 Gallons 25L Engine Type SAE 10W 30 above 32 F Engine Oil YP 5W 30 at 32 F or below Capacity 1 16 Quart 1 1L Run Time 50 load 12 hr Operational Volume 76 dB Available accessories Wheel kit sold separately Item 68525 The emission control system for this Generator s Engine is warranted for standards set by the U S Environmental Protection Agency and by the California Air Resources Board also known as CARB For warranty information refer to the last pages of this manual Item 68530 The emission control system for this Generator s Engine is warranted for standards set by the U S Environmental Protection Agency For warranty information refer to the last pages of this manual Components and Controls Fuel Cap DC Receptacle DC Circuit Breaker Fuel Valve AC Circuit Breakers Choke A
11. C Receptacles Air Filter Frame Ground Terminal Starter Power Switch Handle Low Oil Indicator Page 6 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Components and Controls cont The following are descriptions of the controls on the power panel Your generator has sockets to power your products with circuit breakers to protect the voltage flow fe N START ae O 1 Engine Switch Used to start and stop the Engine 2 AC Receptacles The Generator contains several AC Receptacles to power tools and equipment a 3 Prong duplex 120 volt receptacle NEMA 5 15 b 3 Prong twistlock 120 volt receptacle NEMA L5 20 c 4 Prong twistlock 120 240 volt receptacle NEMA L14 30 AWARNING Connect tools and equipment only to the Receptacle 120 volt or 240 volt that is compatible with the electrical characteristics and rated capacities of the tools and equipment being used Item 68525 68530 wi ON AL oFF Circuit Breakers The circuit breaker protects the Generator from overloading The rating of the breaker and the load it protects are marked near the breaker Should any of the Circuit Breakers trip the Generator will stop the electricity output If this happens unplug all loads from the Generator Allow the Generator to cool down Then press the tripped Circuit Breaker restart the Engine and re attach loads 12 VDC Receptacle 12 VDC Recepta
12. Cup 12 Reassemble the air cleaner and reattach all hoses to it 13 Wipe up any spilled fuel and allow excess to evaporate s Seal before starting engine To prevent FIRE do not start the engine while the smell of fuel hangs in the air High Altitude Kit Parts List A Bolt Part Description _ Main Jet 3000 6000 ft 1a 2a Main Jet 6000 8000 ft 1 3a_ BoltSeal tt om Solenoid Seal BA p Screws 4a Fuel Cup Seal 5a Solenoid Seal Both altitude kits are included with this item 1a 2a 3a 4a 5a Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 9 e m S e zZ Operating Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product Inspect tool before use looking for damaged loose and missing parts If any problems are found do not use tool until repaired Generator Pre Start Checks Inspect engine and equipment looking for damaged loose and missing parts before set up and starting If any problems are found do not use equipment until fixed properly Checking and Filling Engine Oil CAUTION Your Warranty is VOID if the engine s crankcase is not properly filled with oil before each use Before each use check the oil level Do not run the engine with low or no engine oil Running the engine with no or low e
13. E85 etc Use fresh 87 octane stabilizer treated unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc 5 Pull on Starter Handle to prime 6 Clean out passageways using fuel additive 9 Heavy deposits may require further cleaning Gently tap side of carburetor float chamber with screwdriver handle Turn Choke to RUN position Remove spark plug and pull the start handle several times to air out the chamber Reinstall spark plug and set Choke to CHOKE position Replace Fuel Filter IGNITION SPARK RELATED Spark plug cap not connected securely Spark plug electrode wet or dirty Incorrect spark plug gap Spark plug cap broken Circuit breaker tripped electric start models only Incorrect spark timing or faulty ignition system IGNITION SPARK RELATED 1 Connect spark plug cap properly 2 Clean spark plug Correct spark plug gap Replace spark plug cap Reset circuit breaker Check wiring and starter motor if breaker continues to trip Have qualified technician diagnose repair ignition system COMPRESSION RELATED f Cylinder not lubricated Problem after long storage periods Loose or broken spark plug Hissing noise will occur when trying to start Loose cylinder head or damaged head gasket Hissing noise will occur when trying to start Engine valves or tappets mis adjusted or st
14. Generator s wattage capacity to the appliance tool or equipment Use the DC12V Receptacle to power 12VDC equipment WARNING Do not charge batteries without a proper charge controller Do not overcharge a Connect the items that require the most wattage first b Connect inductive load appliances tools and equipment next Inductive loads are small hand tools and some small appliances c Connect any lights next d Voltage sensitive appliances tools and equipment should be the last to be connected to the Generator Plug voltage sensitive items such as TVs DVD players microwaves and cordless telephones into a UL Listed voltage surge protector not included Then connect the surge protector into the Generator IMPORTANT Failure to connect and operate appliances tools and equipment in this sequence can cause damage to the Generator appliances tools and equipment and will void the Warranty of this Generator Note If Engine speed or voltage fluctuates with a load below the Generator s running watts move the Engine Choke Lever to the HALF CHOKE position Z O E lt of Lu A O IF ANY CIRCUIT BREAKERS TRIP CHECK THE FOLLOWING Evenly distributed 1 Make sure that ALL circuit breakers are reset over outlets before starting the generator again Adjust the plugs so the loads are shared across outlet circuits To achieve rated output from the generator distribute loads over outlets
15. Largest Additional Start up Watts ooo gr Total Startup Watts needed for all loads Additional m must be less than 8 750 Device Start up A Example gt ae Rinting Computer w Monitor uipmeni z z P TT PE Electric Clothes Dryer O lets Mete Beate 2 000 tO E aia 400 0 700 Electric Range z Laun Mower 1 200 1 200 7 200 Electric Water Heater Kand Drill 600 600 600 Light Bulb 100 watts Microwave 1000 watts Sump Pump 1 2 HP Total Running Watts 4 200 must be less than 7 000 Washing Machine Largest Additional Start up Watts 7 200 Well Pump 1 2 HP Total Startup Watts needed for all loads 5 400 must be less than 8 750 A generator that is rated more than the minimum required peak watts will last much longer than a generator that only supplies the exact watts needed To Calculate Wattage Volts and amps can be multiplied together to get watts volts x amps watts To Calculate Additional Start Up Watts HEATING amp COOLING If They Are Not Listed Additional For equipment with a motor Use the rated watts Device Watt Start up amount as an estimate of additional Start up Watts a Watts For most lights or heaters Furnace Fan 1 2HP 900 1400 there are no additional start up watts Space Heater 1800 0 Window AC 10 000 BTU 1200 6o Page 14 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Stopping the Engine in an Emergency 1 T
16. Owner s Manual amp Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference REVSA 8750 WATT PORTABLE GENERATOR 7000 RUNNING WATTS 8750 PEAK WATTS A DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell ITEM 68525 68530 Only use OUT and far away from Visit our website at http www harborfreight com EVEN IF doors and windows doors Email our technical support at and vents productsupport harborfreight com Email our Engine support at predator harborfreight com NEVER use inside a home or garage windows are open When unpacking make sure that the product is intact and undamaged If any parts are missing or broken please call 1 888 866 5797 as soon as possible Copyright 2011 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this m
17. and are not available individually as replacement parts Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 21 MAINTENANCE Assembly Diagram Note Parts 169 173 are only on Item 68525 EPA Carb version A ANAD Dh ANLAN Ny Alina 2 mar m Z gt Z 2 m Page 22 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Limited 90 Day Warranty Harbor Freight Tools 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 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear 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 th
18. andle the a Breaking in the engine will help to ensure wattage needed to power your products proper equipment and engine operation b The operational break in period will last 2 Start the Engine and allow the Engine and about 3 hours of use During this period Generator to run and warm up for five minutes after starting with no electrical load Do not apply a heavy load to the equipment c The maintenance break in period will last 3 Plug in products about 20 hours of use After this period e Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the SERVICE section 4 When finished using the Generator disconnect all electrical loads Z O E lt ad Lu A O Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 11 Starting the Engine 1 To start a cold engine move the Choke to the CHOKE position To restart a warm engine leave the Choke in the RUN position 2 Open the Fuel Valve 3 For MANUAL START For ELECTRIC START A Turn the Engine Switch to ON Turn the Engine Switch to START START B Grip the Starter Handle of the Engine loosely and pull it slowly several times to allow the gasoline to flow into the Engine s carburetor Then pull the Starter Handle gently until resistance is felt Allow Cable to retract fully and then pull it quickly Repeat until the engine starts Note Do not let th
19. anual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included Table of Contents DOSY E A E E EN E E EE 2 Mamina e picna R 16 SUP stele Aa 6 Parts List and Diagram 21 SPeECIICATIONS sena ee a RE 6 Warranty EEEN 23 Operations mende a aE a E 10 wn gt mn m lt PREDATOR GENERATORS WARNING SYMBOLS AND DEFINITIONS A DANGER AWARNING ACAUTION This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death CAUTION Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Addresses practices not related to personal injury IMPORTANT SAFETY INSTRUCTIONS INSTRUCTIONS PERTAINING TO A RISK OF FIRE ELECTRIC SHOCK OR INJURY TO PERSONS WARNING When using tools basic precautions should always be followed including the following Set up Precautions 1 Gasoline fuel and fumes are flammable and potentially explosive Use proper fuel storage and handling procedures Do not store fuel or other flammabl
20. blem with appliance Immediately unplug appliance Have operate abnormally appliance repaired by a qualified technician or replace appliance Rated load capacity exceeded Lower the number of items plugged into the generator to stay within the rated capacity or use a more powerful generator 2 m gt Z O m Follow all safety precautions whenever diagnosing or servicing the equipment or engine Page 20 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Parts List and Diagram Parts List Part Description Qty 6 Std i a 8 Pn ey 7 9 Plug Spark dt Part Description _ Qty 60 Starter Assy Recoil 1 66 Carburetor Assy 1 68 Gasket Carburetor _ __ 1 69 Plate Carburetor Insulator 1 80 Flywheel Sub 1 86 Coil Sub Charge 1 89 Spring Throttle Valve Returning 1 Nut 1 Muffler Ass 9 9 0 10 10 10 0 0 0 0 0 0 i 1 1 i 1 1 1 Gasket Exhaust Outlet 1 Cover Muffler Side 9 1 1 1 1 1 1 1 1 7 0 1 2 3 4 5 6 r 8 9 10 11 12 13 14 15 16 17 18 1 Record Product s Serial Number Here Part Description _ Qty The following parts are only on Item 68525 EPA CARB version 171 Clamp 1 173 Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only
21. cle provides a power source for 12 volt DC items SAFETY t Grounding Terminal Prior to each use set up the ground wire not included connection to the Grounding Terminal to properly ground the Generator See Set up instructions to properly ground the Generator For Generator technical questions please call 1 888 866 5797 Page 7 Initial Tool Set Up Assembly Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product AWARNING TO PREVENT SERIOUS INJURY Operate only with proper spark arrestor installed Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements At high altitudes the engine s carburetor governor and any other parts that control the fuel air ratio will need to be adjusted by a qualified mechanic to allow efficient high altitude use and to prevent damage to the engine and any other devices used with this product Battery Setup Instructions All Generators can be started using the recoil method This generator requires installation of a battery to operate the electric start feature Connect the battery to the generator engine 1 Place a fully charged lead acid 12 V 9 Ah battery not included in the battery hold
22. e Starter Handle snap back against the engine Hold it as it recoils so it doesn t hit the engine Note To prolong starter life use short starting cycles 5 seconds maximum Then wait one minute before attempting to start again e U m S e zZ 4 Allow the Engine to run for several seconds Then if the Choke lever is in the CHOKE position move the Choke Lever very slowly to its RUN position Note Moving the Choke Lever too fast could stall the engine IMPORTANT Allow the engine to run at no load for five minutes with no load after each start up so that the engine can stabilize Page 12 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Connecting Electrical Loads Familiarize yourself with the engine controls power panel and how to start the engine before using the generator Calculate the wattage of the products you will use with the generator and verify that the generator can handle the total load Awarninc Connect only properly wired plugs to the generator A plug that is spliced onto a different cord may be hazardous Only a qualified electrician should wire a plug onto a cord Less than 7 000 CAUTION Never exceed the rated capacity for this Generator as serious damage to the Generator and Must b e or appliances tools and equipment could result from ree than an overload Starting and running wattage requirements should always be calculated when matching this
23. e materials nearby Have multiple ABC class fire extinguishers nearby Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrestor may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements Set up and use only on a flat level well ventilated surface Page 2 For Generator technical questions please call 1 888 866 5797 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 Connections for standby power to a building electrical system must be made by a qualified electrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes Wear ANSl approved safety goggles heavy duty work gloves and dust mask respirator during set up Use only lubricants and fuel recommended in this manual Item 68525 68530 Set up Precautions cont 9 Improper connections to a building electrical system can allow electrical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause fires when util
24. ed due to failure to follow the maintenance and operating instructions set forth in the Owner s Manual including but not limited to a Use of parts which are not authorized by HFT b Improper installation adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty center c Failure to follow recommendations on fuel use contained in the Owner s Manual d Improper or inadequate maintenance of any warranted parts e Repairs performed outside of the authorized warranty service dealers f Alterations by changing adding to or removing parts from the engine Service and Maintenance Component parts which are not scheduled for replacement as required maintenance or are scheduled only for regular inspection to the effect of repair or replace as necessary are warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part Any replacement part provided it is equivalent in durability and performance may be used in performance of maintenance or repairs The owner is responsible for commissioning a qualified technician mechanic to perform all required maintenance as outlined in the Inspection Cleaning and Maintenance section in this manual Warranted Parts 1 Fuel Metering System i Carburetor and its internal parts ii Air fuel ratio feedback a
25. emove air cleaner cover D b Remove the foam filter and deflecting plate V D 4 Place a bowl under the fuel cup to catch any spilled fuel 5 Unthread the screws holding the solenoid in place Air Cleaner CAUTION Carburetor bowl may have gas in it which Housing will leak upon removing the solenoid bolt 6 Disconnect the solenoid and solenoid seal from the bolt 7 Unthread the bolt holding the fuel cup 8 Remove the bolt Bolt Seal fuel cup Fuel Cup Seal and Main Jet from the body of the carburetor assembly A carburetor screwdriver not included is needed to remove and install the Main Jet Note The mixing tube is held in place by the Main Jet and might fall out when it is removed If it falls out replace it in the same orientation before replacing the Main Jet Carburetor Assembly 9 Replace the Main Jet with the replacement Main Jet needed for your altitude range part 1a or 2a Note The Fuel Cup Seal and Bolt Seal may be damaged during removal and should be replaced with the new ones from the kit Fuel Cup Seal 10 Replace the Fuel Cup Seal 4a fuel cup Bolt Seal 3a and bolt Tighten in place CAUTION Do not cross thread bolt when tightening Finger tighten first and then use a wrench to make sure the bolt is properly threaded Mixing Tube might remain inside carburetor Main Jet 11 Replace the solenoid and Solenoid Seal 5a and tighten in place with screws uel
26. er on the generator 2 Bolt in place using the hardware included with the battery Positive Negative Connector Connector 3 Attach the positive red cable connector from the engine to the Positive Terminal on the battery Connect cable securely to prevent disconnection and short circuits 4 Attach the negative black cable connector to the negative battery terminal Grounding The Generator must be properly grounded before use Have the unit grounded by a qualified electrician if you are not qualified to do so To ground the Generator connect a 6 AWG grounding wire not included from the Grounding Terminal on the Control 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 CAUTION This generator is not intended to power sensitive electronic equipment without the addition of an appropriate line conditioner and surge protector both not included Sensitive electronic equipment includes but is not limited to audio video equipment some television sets computers and printers Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual Note Wheel Kit item 68531 so
27. es you should contact the Harbor Freight Tools Customer Service Department at 1 888 866 5797 Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 23 MAINTENANCE Harbor Freight Tools Emission Control Defects Warranty Provisions 1 Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two 2 years after the date of delivery to the first retail purchaser No Charge Repair or Replacement Repair or replacement of any warranted part will be performed at no charge to the owner if the work is performed through a warranty station authorized by HFT For emissions warranty service contact the HFT Customer Service Department at 1 888 866 5797 Consequential Damages Coverage Coverage under this warranty shall also extend to the failure of any engine components caused by the failure of any warranted part while it is still covered under this warranty Coverage Exclusions Warranty claims shall be filed in accordance with the provisions of the HFT warranty policy explained in the box at the top of the previous page HFT shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconvenience Warranty coverage shall also be excluded for any part which fails malfunctions or is damag
28. ied technician service the equipment instead Cleaning Maintenance and Lubrication Note This maintenance schedule is intended solely as a general guide If performance decreases or if equipment operates unusually check systems immediately The maintenance needs of each piece of equipment will differ depending on factors such as duty cycle temperature air quality fuel quality and other factors Note The following procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the engine and equipment e e hr 4 use hr a use EEE GA E E ce ar a Ge E A E A E enearo a T SOY S Uw Cd Ow dT CSS A A a Ser A eA Ea a Check and clean spark plug Check adjust idle speed Check adjust valve clearance Clean fuel tank strainer and carburetor Clean carbon build up from combustion chamber Replace fuel line if necessary a ee e e Service more frequently when used in dusty areas These items should be serviced by a qualified technician Page 16 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 Checking and Filling Fuel AWaARNING TO PREVENT SERIOUS INJURY FROM FIRE Fill the fuel tank in a well ventilated area away from ignition sources If the engine is hot from use shut the engine off and wait for it to cool before adding fuel Do not smoke 1 Clean the Fuel Cap and the area around it 2 Unscrew and remove the Fuel Cap
29. is 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 Emission Control System Warranty For Item 68525 EPA CARB version California and United States Emission Control Defects Warranty Statement The California Air Resources Board herein CARB the United States Environmental Protection Agency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 2014 2015 Small Off Road Engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti smog standards Elsewhere within the United States new off road spark ignition engines certified for model year 2014 2015 must meet similar standards set forth by the EPA HFT must warrant the emission control system on your engine fo
30. ity power is restored Consult the utility company and a qualified electrician if intending to use the generator for back up power Operating Precautions 1 CARBON MONOXIDE HAZARD Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents 2 Never use a generator indoors including in garages basements crawlspaces and sheds Opening doors and windows or using fans will NOT prevent carbon monoxide build up in the home 3 When using generators keep them outdoors and far away from open doors windows and vents to avoid toxic levels of carbon monoxide from building up indoors 4 Ifyou start to feel sick dizzy or weak while using a generator get to fresh air right away The carbon monoxide from generators can quickly lead to full incapacitation and death 5 Keep children away from the equipment especially while it is operating 6 Keep all spectators at least six feet from the Engine during operation Item 68525 68530 10 10 11 12 13 14 15 For Generator technical questions please call 1 888 866 5797 Do not operate the Generator before grounding The Generator must be earth grounded in accordance with all relevant electrical codes and standards before operation
31. l stabilizer additive Follow fuel stabilizer manufacturer s recommendations for use Note Do not use gasoline containing more than 10 ethanol E10 Do not use E85 ethanol Note Do not use gasoline that has been stored in a metal fuel container or a dirty fuel container It can cause particles to enter the carburetor effecting engine performance and or causing damage 4 Then replace the Fuel Cap 5 Wipe up any spilled fuel and allow excess to evaporate before starting engine To prevent FIRE do not start the engine while the smell of fuel hangs in the air Item 68525 68530 Using the Generator Before Starting the Generator Engine Note Do not allow generator to run out of fuel with loads attached Before starting the engine A a Follow the Set Up Instructions 5 Turn off the Engine to prepare the Generator b Unplug all loads from the Generator 6 Allow the Generator and its Engine to c Inspect the Generator and engine completely cool Then store the unit in a d Fill the engine with the proper clean dry safe location out of reach of amount and type of both children and other unauthorized people Stabilize Meoted tueland oll IMPORTANT After starting the engine allow it to run at no load for five minutes with no load after Basic Generator Use Procedure See each start up so that the engine can stabilize following pages for specific instructions 7 Break in Period 1 Check that the generator can h
32. ld separately can be used with this generator Page 8 For Generator technical questions please call 1 888 866 5797 Item 68525 68530 High Altitude Operation Above 3000 feet AAWARNING TO PREVENT SERIOUS INJURY FROM FIRE Follow instructions in a well ventilated area away from ignition sources If the engine is hot from use shut the engine off and wait for it to cool before proceeding Do not smoke NOTICE Warranty void if necessary adjustments are not made for high altitude use At high altitudes the engine s carburetor governor and any other parts that control the fuel air ratio will need to be adjusted by a qualified mechanic to allow efficient high altitude use and to prevent damage to the engine and any other devices used with this product The fuel system on this engine may be influenced by operation at higher altitudes Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 ft above sea level At elevations above 8000 ft the engine may experience decreased performance even with the proper main jet Operating this engine without the proper altitude kit installed may increase the engine s emissions and decrease fuel economy and performance The kit should be installed by a qualified mechanic 1 Turn off the engine Nuts 2 Close the fuel valve Deflecting Plate 3 Move the air cleaner housing aside to allow access to the carburetor AN Foam Filter a Loosen the knob and r
33. nd control system iii Cold start enrichment system iv Fuel Tank 2 Air Induction System i Controlled hot air intake system ii Intake manifold iii Air filter 3 Ignition System i Spark Plugs ii Magneto or electronic ignition system iii Spark advance retard system 4 Exhaust Gas Recirculation EGR System if so equipped i EGR valve body and carburetor spacer ii EGR rate feedback and control system 5 Air Injection System i Air pump or pulse valve ii Valves affecting distribution of flow iii Distribution manifold 6 Catalyst or Thermal Reactor System if so equipped i Catalytic converter ii Thermal reactor iii Exhaust manifold 7 Particulate Controls Traps filters precipitators and any other device used to capture particulate emissions 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 BUYER THAT HE OR SHE IS QUALIFIED TO 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
34. ngine oil WILL permanently damage the engine 1 Make sure the engine is stopped and is level 2 Close the Fuel Valve 3 Clean the top of the Dipstick and the area around it Remove the Dipstick by threading it counterclockwise and wipe it off with a clean lint free rag Full level Full level 4 Reinsert the Dipstick without threading it in and remove it to check the oil level The oil level should be up to the full level as shown above 5 Ifthe oil level is at or below the low mark add the appropriate type of oil until the oil level is at the proper level SAE 10W 30 oil is recommended for general use The SAE Viscosity Grade chart on page 17 in the Service section shows other viscosities to use in different average temperatures Page 10 For Generator technical questions please call 1 888 866 5797 6 Thread the dipstick back in clockwise CAUTION Do not run the engine with too little oil The engine will be permanently damaged Awarnine TO PREVENT SERIOUS INJURY FROM FIRE Fill the fuel tank in a well ventilated area Checking and Filling Fuel away from ignition sources If the engine is hot from use shut the engine off and wait for it to cool before adding fuel Do not smoke 1 Clean the Fuel Cap and the area around it Unscrew and remove the Fuel Cap 3 If needed fill the Fuel Tank to about 1 inch under the fill neck with 87 octane or higher unleaded gasoline that has been treated with a fue
35. o stop the engine in an emergency turn the Engine Switch off OFF NOTICE Generator shut off under load may damage the generator and attached equipment Stopping the Engine Under Normal Conditions 1 Before turning off the Engine turn off all electrical loads then unplug them N 2 Turn the Engine Switch off Lo bo forr Z O E lt o Lu ou O 3 Close the Fuel Valve Item 68525 68530 For Generator technical questions please call 1 888 866 5797 Page 15 2 Z m Z gt Z O m User Maintenance Instructions Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the generator to its OFF position wait for the engine to cool and disconnect the spark plug cap before performing any inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE Do not use damaged equipment If abnormal noise vibration or excess smoking occurs have the problem corrected before further use Follow all service instructions in this manual The engine may fail critically if not serviced properly performed by a qualified technician for safety If you have any doubts about your ability to safely Many maintenance procedures including any not detailed in this manual will need to be service the equipment or engine have a qualif
36. 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 equipment Use the correct generator for the application Do not modify the generator or its engine and do not use the generator for a purpose for which it is not intended Item 68525 68530 Service Precautions 1 Before service maintenance or cleaning a Unplug all devices from the generator b Turn the engine switch to its OFF position c Allow the engine to completely cool d Then remove the spark plug cap from the spark plug 2 Keep all safety guards in place and in proper working order Safety guards include muffler air cleaner mechanical guards and heat shields among other guards 3 Make sure the Engine Switch is in its OFF position before moving the Generator and before performing any service maintenance or cleaning procedures on the unit 4 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 5 Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor Only a qualified service technician may adjust parts that may increase or decrease governed engine speed 6 Wear ANSI approved safety
37. oth item numbers Manufacturer s Warranty Coverage The 2014 2015 engines are warranted for two 2 years If any emission related part on your engine is defective the part will be repaired or replaced by HFT Harbor Freight Tools Emission Control Defects Warranty Coverage Engines are warranted for a period of two 2 years relative to emission control parts defects subject to the provisions set forth below If any emission related part on your engine is defective the part will be repaired or replaced by HFT Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual HFT recommends that you retain all receipts covering maintenance on your engine but HFT cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that HFT may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications e You are responsible for shipping your engine to a HFT warranty station as soon as a problem exists Contact the HFT Customer Service department at the number below to make shipping arrangements The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibiliti
38. r the periods of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor or fuel injection system and the ignition system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists HFT will repair your engine at no cost to you including diagnosis parts and labor For Item 68530 EPA version United States Emission Control Defects Warranty Statement The United States Environmental Protection Agency herein EPA and Harbor Freight Tools herein HFT are pleased to explain the emission control system warranty on your 2014 2015 Small Off Road Engine herein engine Within the United States new off road spark ignition engines certified for model year 2014 2015 must be designed built and equipped to meet the stringent anti smog standards set forth by the EPA HFT must warrant the emission control system on your engine for the periods of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor or fuel injection system and the ignition system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists HFT will repair your engine at no cost to you including diagnosis parts and labor For b
39. rk plug wrench remove the spark plug 3 Inspect the spark plug If the electrode is oily clean it using a clean dry rag If the electrode has deposits on it polish it using emery paper If the white insulator is cracked or chipped the spark plug needs to be replaced e Cylinder Assembly NOTICE Using an incorrect spark plug may damage the engine See the Specifications chart for your Generator for the type and gap required Storage When the equipment is to remain idle for longer than 20 days prepare the Engine for storage as follows 1 CLEANING Wait for Engine to cool then clean Engine with dry cloth NOTICE Do not clean using water The water will gradually enter the Engine and cause rust damage Apply a thin coat of rust preventive oil to all metal parts 2 FUEL To protect the fuel tank during storage fill the tank with gasoline that has been treated with a fuel stabilizer additive Follow fuel stabilizer manufacturer s recommendations for use Refer to Checking and Filling Fuel on page Checking and Filling Fuel on page 10 A WARNING TO PREVENT SERIOUS INJURY FROM FIRE Fill tank in a well ventilated area away from ignition sources If the engine is hot from use shut the engine off and wait for it to cool before adding fuel Do not smoke 3 LUBRICATION a Change engine oil b Clean out area around spark plug Remove spark plug and pour one tablespoon of engine oil into cylinder th
40. rough spark plug hole Page 18 Spark Plug For Generator technical questions please call 1 888 866 5797 4 When installing a new spark plug adjust the plug s gap to the specification on the Specifications chart Do not pry against the electrode the spark plug can be damaged 5 Install the new spark plug or the cleaned spark plug into the engine Gasket style Finger tighten until the gasket contacts the cylinder head then about 1 2 2 3 turn more Non gasket style Finger tighten until the plug contacts the head then about 1 16 turn more NOTICE Tighten the spark plug properly If loose the spark plug will cause the engine to overheat If overtightened the threads in the engine block will be damaged 6 Apply dielectric spark plug boot protector not included to the end of the spark plug and reattach the wire securely c Replace spark plug but leave spark plug cap disconnected d Pull Starter Handle to distribute oil in cylinder Stop after one or two revolutions when you feel the piston start the compression stroke when you start to feel resistance 4 STORAGE AREA Cover and store in a dry level well ventilated area out of reach of children Storage area should also be away from ignition sources such as water heaters clothes dryers and furnaces NOTICE During extended storage periods the Engine must be started every 3 months and allowed to run for 15 20 minutes or the Warranty is VOID
41. s hearing protection and NIOSH approved dust mask respirator during use People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure Caution is necessary when near the engine s magneto or recoil starter Use only accessories that are recommended by Harbor Freight Tools for your model Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment Do not operate in explosive atmospheres such as in the presence of flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes 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 Page 4 29 30 31 32 33 34 35 36 37 38 39 40 41 For Generator technical questions please call 1 888 866 5797 Stay alert watch what you are doing and use common sense when operating this piece of equipment Do not use this piece of equipment while tired or under the influence of drugs alcohol or medication Dress properly Do not wear loose clothing or jewelry Keep hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Parts especially exhaust system
42. tor Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground 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 Page 3 16 wn gt mn m lt 21 22 23 24 25 26 27 28 Connect the Generator only to a load or electrical system 120 volt or 240 volt that is compatible with the electrical characteristics and rated capacities of the Generator Insulate all connections and disconnected wires Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerators Only use a suitable means of transport and lifting devices with sufficient weight bearing capacity when transporting the generator Secure the Generator on transport vehicles to prevent the tool from rolling slipping and tilting Industrial applications must follow OSHA requirements Do not leave the Generator unattended when it is running Turn off the Generator and remove safety keys if available before leaving the work area The Generator engine can produce high noise levels Prolonged exposure to noise levels above 85 dBA is hazardous to hearing Always wear ear protection when operating or working around the gas engine while it is operating Wear ANSI approved safety glasse
43. uck COMPRESSION RELATED 1 Tighten head If that does not remedy Have qualified technician diagnose Pour tablespoon of oil into spark plug hole Crank engine a few times and try to start again Tighten spark plug If that does not work replace spark plug If problem persists may have head gasket problem see 3 problem replace head gasket repair ignition system MAINTENANCE For Generator technical questions please call 1 888 866 5797 Page 19 Troubleshooting cont Possible Causes Probable Solutions Engine misfires Spark plug cap loose 1 Check wire connections Incorrect spark plug gap or Re gap or replace spark plug damaged spark plug Defective spark plug cap Replace spark plug cap 4 Old or low quality gasoline 4 Use only fresh 87 octane stabilizer treated unleaded gasoline Do not use gasoline with more than Incorrect compression 10 ethanol E15 E20 E85 etc Diagnose and repair compression Use Engine will not start COMPRESSION RELATED section Engine stops Low oil shutdown Fill engine oil to proper level Check suddenly engine oil before EVERY use Fuel tank empty or full of impure or low Fill fuel tank with fresh 87 octane stabilizer quality gasoline treated unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Defective fuel tank cap creating Test replace fuel tank cap vacuum preventing proper
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