Harbor Freight Tools 69672 User's Manual
Contents
1. HALF CHOKE position 2 lt nc n Oo IF ANY CIRCUIT BREAKERS TRIP CHECK THE FOLLOWING Evenly distributed over outlets 1 Make sure that ALL circuit breakers are reset before starting the generator again 2 Adjust the plugs so the loads are shared across outlet circuits To achieve rated output from the generator distribute loads over outlets For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 11 NOILVasadO Calculating Total Wattage of Devices Used with the Generator Before using the Generator check that the products Wattage Estimate Charts you want to plug into the unit are below the rated and maximum wattage ratings of the Generator Use the Note Wattages listed below are estimates for that Wattage Calculation Table below and the watts listed type of equipment only Check nameplate wattages on all loads before connecting to Generator on your products to help calculate multiple wattage totals EMERGENCY To use the table EMERGENCY 1 Add up the Running Watts for all items you Running Aen Device Start up would like to use at any given time Watts Watts 2 Make sure that this total is under the 5 500 rated wattage of the generator Radio 10 o 3 Find the single highest starting watts for the selected items and add to the total 4 Make sure2. 87 octane unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Carburetor not primed Pull on Starter Handle to prime 6 Dirty fuel passageways 6 Clean out passageways using fuel additive Heavy deposits may require further cleaning Carburetor needle stuck Fuel Gently tap side of carburetor float can be smelled in the air chamber with screwdriver handle Too much fuel in chamber This can be Turn Choke to RUN position Remove spark caused by the carburetor needle sticking plug and pull the start handle several times to air out the chamber Reinstall spark plug and set Choke to CHOKE position 9 Clogged Fuel Filter 9 Replace Fuel Filter IGNITION SPARK RELATED IGNITION SPARK RELATED 1 Spark plug cap not connected securely 1 Connect spark plug cap properly 2 Spark plug electrode wet or dirty 2 Clean spark plug Incorrect spark plug gap Correct spark plug gap Spark plug cap broken Replace spark plug cap Circuit breaker tripped electric Reset circuit breaker Check wiring and start models only starter motor if breaker continues to trip Incorrect spark timing or Have qualified technician diagnose faulty ignition system repair ignition system COMPRESSION RELATED COMPRESSION RELATED 1 Oylinder not lubricated Problem after long 1 Pour tablespoon of oil into spark storage periods plug hole Crank engine a few times and try to start aga
3. 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 5 Turn off the Engine Allow the Generator and its Engine to completely cool Then store the unit in a clean dry safe location out of reach of children and other unauthorized people 2 lt nc Lu ou Oo IMPORTANT After starting the engine allow it to run at no load for five minutes with no load after each start up so that the engine can stabilize 6 Break in Period a Breaking in the engine will help to ensure proper equipment and engine operation b The operational break in period will last about 3 hours of use During this period Do not apply a heavy load to the equipment c The maintenance break in period will last about 20 hours of use After this period Change the engine oil Under normal operating conditions subsequent maintenance follows the schedule explained in the SERVICE section For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 9 NOILVHJdO Starting
4. 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 69674 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 1995 and later 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 1997 and later must meet similar 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 s
5. 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 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 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 Wheel Kit item 68531 sold separately can be used with this generator 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 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 mis
6. flammable liquids gases or dust Gasoline powered engines may ignite the dust or fumes 28 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 29 30 31 32 33 34 35 36 3T 38 39 40 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 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 This product contains or when used produces a chemical known to the State of California to ca
7. monoxide build up in the home 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 If you 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 Keep children away from the equipment especially while it is operating Keep all spectators at least six feet from the Engine during operation 10 10 11 12 13 14 15 Do not operate the Generator before grounding The Generator must be earth grounded in accordance with all relevant electrical codes and standards before operation 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 or
8. 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 Asthe 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 Youare responsible for shipping your engine to a HFT warranty station as soon as a problem exists Contact the HFT Customer Service depart ment 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 For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 23 MAINTENANCE If you have any questions regarding your warranty
9. 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 Turn the Engine Switch to ON 4 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 the Starter Handle snap back against the engine Hold it as it recoils so it doesn t hit the engine 5 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 For Generator technical questions please call 1 800 444 3353 Page 10 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 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 pl
10. when you feel the piston start the compression stroke when you start to feel resistance BATTERY Disconnect battery cables if equipped Recharge batteries monthly while in storage 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 6 AFTER STORAGE Before starting the engine 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 For Generator technical questions please call 1 800 444 3353 Page 16 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Troubleshooting Engine will not start FUEL RELATED FUEL RELATED 1 No fuel in tank or fuel valve closed Fill fuel tank and open fuel valve 2 Choke not in CHOKE position cold engine 2 Move Choke to CHOKE position 3 Gasoline with more than 1096 ethanol used 3 Clean out ethanol rich gasoline from fuel E15 E20 E85 etc system Replace components damaged by ethanol Use fresh 87 octane unleaded gasoline only Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Low quality or deteriorated old gasoline Use fresh
11. Engine overloaded Incorrect spark timing deposit buildup worn engine or other mechanical problems Impure or low quality gasoline Engine too cold Intake valve stuck or overheated engine Incorrect timing Product not plugged in properly Circuit Breaker tripped Product needs service Problem with appliance Rated load capacity exceeded 1 2 3 Check wire connections Re gap or replace spark plug Replace spark plug cap 4 Use only fresh 87 octane unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Diagnose and repair compression Use Engine will not start COMPRESSION RELATED section Fill engine oil to proper level Check engine oil before EVERY use Fill fuel tank with fresh 87 octane unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Test replace fuel tank cap 4 Have qualified technician service magneto Secure spark plug cap Clean or replace element Allow engine to warm up prior to operating equipment Fill fuel tank with fresh 87 octane unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 etc Do not exceed equipment s load rating Have qualified technician diagnose and service engine Fill fuel tank with fresh 87 octane unleaded gasoline Do not use gasoline with more than 10 ethanol E15 E20 E85 e
12. Ignition System i Spark plug ii Magneto ignition system 4 Catalyst System if so equipped i X Exhaust pipe stud ii Muffler iii Catalytic converter if so equipped 5 Miscellaneous Items Used in Above Systems i Vacuum temperature and time sensitive valves and switches ii Hoses belts connectors and assemblies PREDATOR GENERATORS 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
13. L RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Parts List Part Descripton Bolt Flange UJ o 2 Q lt 3 ES Q Z 2 Q 7 L Bolt Flange M6x12 D t Set Piston Piston O V o a 2 Connecting Rod Ass Pi Q her xt i n Crankshaft Ass Camshaft Assy ing 6202 43 Ball Bearing 6207 1 a a f be t tato lve Washer Drain Plug M12 Alert Unit Oil n Pi ran t ei lan Ulo co m o zz 2 gt o 6 7 8 9 43 Part Description Qty 52 5 54 5 6 57 58 59 61 62 63 64 65 67 70 71 72 73 4 5 6 77 78 79 86 FlangeM5x10 1 3 3 52 53 54 EE 58 59 60 61 62 63 64_ 65 66 67 68 69 70 O 7i 72 EC NIS 78 79 80 MAINTENANCE For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 AONVNALNIVIN Parts List cont Part Description Grommet Crankcase S 7 Grommet n n Seal Protector Muffler Protector Comp Muffler Inner MufflerAssy 0 N t M 00 Bolt F
14. 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 Sea Ses 1246242 eee eee btt 0t 0t ere eee e s X Peter ete tate teeta ee ee eee hee ee eee ome ee ee ee OOG60000000000000000Q 6 LJ s 6202020 id JOVO 644 4 C 090 2 4066 6 620626 LJ 2C 94999 6500 WATT PORTABLE GENERATOR 5500 RATED WATTS 6500 MAX WATTS 420cc Air Cooled OHV Gas Engine e 12 Hour Run Time at 50 Capacity Low Oil Indicator Low Oil Shutdown e Heavy Duty 1 1 4 Steel Roll Cage UL Listed Circuit Breaker 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 69672 69674 NEVER use inside Only use OUTSIDE a home or garage and far away from ES 5 EVEN IF doors and windows doors Visit our website at http www harborfreight com windows are open Email our technical support at tech harborfrei
15. all applicable laws and electrical codes relating to fire prevention requirements 7 Wear ANSI approved safety goggles heavy duty 4 Setup and use only on a flat level work gloves and dust mask respirator during set up well ventilated surface 8 Useonly lubricants and fuel recommended in this manual For Generator technical questions please call 1 800 444 3353 Page 2 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 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 utility power is restored Consult the utility company and a qualified electrician if intending to use the generator for back up power Operating Precautions 1 Item 69672 69674 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 e NEVER use inside a home or garage EVEN IF doors and windows are open Bj Only use OUTSIDE and far away from windows doors and vents Never use a generator indoors including in garages basements crawlspaces and sheds Opening doors and windows or using fans will NOT prevent carbon
16. carbon build up from combustion chamber Replace fuel line if necessary Service more frequently when used in dusty areas These items should be serviced by a qualified technician For Generator technical questions please call 1 800 444 3353 Page 14 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 A WARNING TO PREVENT SERIOUS INJURY FROM FIRE Fill the fuel tank in a well ventilated area away from ignition sources If the engine is Checking and Filling Fuel 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 3 If needed fill the Fuel Tank with 87 octane or higher unleaded gasoline Engine Oil Change CAUTION 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 Air Filter Element Maintenance 1 Remove the air filter cover and the air filter elemen
17. der 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 generator 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 For Generator technical questions please call 1 800 444 3353 For Engine technical questions please call 1 800 520 0882 Page 3 SAFETY ALAAVS Operating Precautions cont 16 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 17 Insulate all connections and disconnected wires 18 Guard agains
18. em 69674 EPA CARB version A AN s Lae 86 Item 69672 69674 For Generator technical questions please call 1 800 444 3353 For Engine technical questions please call 1 800 520 0882 Assembly Diagram cont MAINTENANCE Page 22 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 this 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
19. ght com Email our Engine support at predator harborfreight com When unpacking make sure that the product is intact and undamaged If any generator parts are missing or broken please call 1 800 444 3353 as soon as possible If any engine parts are missing or broken AWARNING please call 1 800 520 0882 as soon as possible Copyright 2012 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 manual 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 ALAAVS Table of Contents SIME EIL 2 Maintenant noncer 14 SOlUpi E E A A T 6 Parts List and 19 Specifications 6 Warranty 23 Operationer e tero e irte ens 8 PREDATOR GENERATORS WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol Itis used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a hazardous situatio
20. hat may room for the fuel to expand as needed increase or decrease governed engine speed 5 Refuel in a well ventilated area only 6 Wear ANSI approved safety goggles heavy duty work gloves and dust mask respirator during service 6 Wipe up any spilled fuel and allow excess to evaporate before starting engine 7 Maintain labels and nameplates on the To prevent FIRE do not start the engine equipment These carry important information while the smell of fuel hangs in the air If unreadable or missing contact Harbor Freight Tools for a replacement SAVE TH ES E INSTRUCTIONS PREDATOR GENERATORS For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 5 0135 Functional Description Specifications 120 240V 60Hz Pared OU 5 500 Watts 6 500 max Generator Two 3 Prong duplex NEMA 5 20 120V Electrical Receptacle One 4 Prong NEMA L14 30 twistlock 120V 240V One DC Outlet 12VDC Displacement Enaine Horizontal Single Cylinder 4 stroke OHV 9 EPA phase III compliant Cooling System Forced air cooled Fuel 87 octane unleaded gasoline eng Capacity 6 1 Gallons 23L 10W 30 above 32 F Engine Oil Type SAE 5w 30 at 32 F or below Capacity 1 16 Quart 1 1L Run Time 60 load Operational Volume 74 dB Available accessories Wheel kit sold separately Item 69674 The emission control system for this Ge
21. in Loose or broken spark plug Hissing noise 2 Tighten spark plug If that does not work will occur when trying to start replace spark plug If problem persists may have head gasket problem see 3 Loose cylinder head or damaged Tighten head If that does not remedy head gasket Hissing noise will problem replace head gasket occur when trying to start Engine valves or tappets Have qualified technician diagnose mis adjusted or stuck repair ignition system Follow all safety precautions whenever diagnosing or servicing the equipment or engine MAINTENANCE For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 17 AONVNALNIVIN Troubleshooting cont Engine stops suddenly Engine stops when under heavy load Engine knocks Engine backfires Product doesn t have power Product begins to operate abnormally Spark plug cap loose Incorrect spark plug gap or damaged spark plug Defective spark plug cap 4 Old or low quality gasoline Incorrect compression Low oil shutdown Fuel tank empty or full of impure or low quality gasoline Defective fuel tank cap creating vacuum preventing proper fuel flow 4 Faulty magneto Disconnected or improperly connected spark plug cap Dirty air filter Engine running cold Old or low quality gasoline
22. l 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 15 MAINTENANCE AONVNALNIVIN Spark Plug Maintenance 1 Disconnect spark plug cap from end of plug Clean out debris from around spark plug 2 Using a spark plug wrench remove the spark plug Spark Plug 3 Inspect the spark plug y LS 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 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 AA WARNING TO PREVENT SERIOUS INJURY FROM FIRE Drain 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 draining fuel Do not smoke a Place a funnel leading to a proper gasoline container below the carburetor Air Filter Assembly b Remo
23. lange 8x32 1 01 Fuel Tank A 2 2 2 2 e co co co co co Qo oo e Meter Comp Fuel Tube Fuel elo 109 A 2 25 2 2 3l op TO ES eo he Ed olt Fla ay Co uffler Rubber Fuel Cushion Rubber Fuel Tank Mounting Pipe CCCs pg o o rush As ousing olt Fla olt Fla Bracket Carbon Alternator B Brush Assy 4 Washer 1 NINININ gt gt Co ge D SSy Sy Rr ge ge 1 Record Product s Serial Number 3 N 125 126 127 128 129 30 131 132 133 134 135 Part Description N 136 137 138 139 141 Pipe Clip 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 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 and are not available individually as replacement parts For Generator technical questions please call 1 800 444 3353 Page 20 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Assembly Diagram MAINTENANCE For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 21 ite N Note Parts 114 117 and 141 143 are only on It
24. 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 l Many maintenance procedures including any not detailed in this manual will need to be service the equipment or engine have a qualified 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 Procedure Before juin r Every 3 mo or Every 6 mo or Meets Each Use y 50 hr of use 100 hr of use ry hr of use hr of use Brush off outside of engine Check engine oil level ine oi Check air cleaner 1 Check adjust idle speed Check adjust valve clearance Clean fuel tank strainer and carburetor Clean
25. n which if not avoided will result in death or serious injury AWARN NG Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided ACAUTION could result in minor or moderate injury NOTICE CAUTION 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 Addresses practices not related to personal injury Set up Precautions 1 Gasoline fuel and fumes are flammable and 5 All connections and conduits from the Generator potentially explosive Use proper fuel storage to the load must only be installed by trained and and handling procedures Do not store fuel licensed electricians and in compliance with all or other flammable materials nearby relevant local state and federal electrical codes and standards and other regulations where applicable 2 Have multiple ABC class fire extinguishers nearby 6 Connections for standby power to a building 3 Operation of this equipment may create sparks electrical system must be made by a qualified that can start fires around dry vegetation A spark electrician The connection must isolate the arrestor may be required The operator should generator power from utility power and must comply contact local fire agencies for laws or regulations with
26. ne and re attach loads 1 Engine Switch Used to enable disable Generator operation 2 AC Receptacles The Generator contains several AC receptacles to power tools and equipment 4 DC Receptacle 12 VDC Receptacle set provides a power source for 12 volt DC items 0 5 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 SETUP a 3 Prong duplex 120 volt receptacle NEMA 725 20 4 Prong twistlock 120 240 volt receptacle NEMA 1 14 30 Awarninc 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 For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 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 Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual AWARNING TO PREVENT SERIOUS INJURY Operate only with proper spark arrestor installed Operation of this equipment may
27. nerator 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 69672 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 Fuel Valve DC Circuit Breaker AC Circuit Breakers AC Receptacles Choke Air Filter Frame Starter Handle Ground Terminal Power Switch Low Oil Indicator For Generator technical questions please call 1 800 444 3353 Page 6 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Components and Controls cont The following are descriptions of the controls re AK on the power panel Your generator has sockets to power your products with circuit 3 Circuit Breakers The circuit breaker protects the breakers to protect the voltage flow 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 C J cool down Then press the tripped Circuit Breaker restart the Engi
28. plained in this gt manual or any procedures that you are uncertain m d Then remove the spark plug a Lu about your ability to perform safely or correctly LL cap from the spark plug lt 2 Keep all safety guards in place and 9 Store equipment out of the reach of children o proper working order Safety guards include 10 Follow scheduled engine and muffler air cleaner mechanical guards equipment maintenance and heat shields among other guards 3 Make sure the Engine Switch is in its OFF Refueling position before moving the Generator and 1 Do not smoke or allow sparks flames before performing any service maintenance or other sources of ignition around the or cleaning procedures on the unit equipment especially when refuelling 4 Keep all electrical equipment clean and dry 2 Replace any wiring where the insulation is cracked cut abraded or otherwise degraded Replace terminals that are worn discolored or 3 TO PREVENT FUEL LEAKAGE AND FIRE corroded Keep terminals clean and tight HAZARD Do not overfill with fuel Fill with fuel according to the Fuel Level information below the Specification chart for your model Do not refill the fuel tank while the engine is running or hot 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 4 Do not fill fuel tank to the top Leave little service technician may adjust parts t
29. ps watts 1000 1000 To Calculate Additional Start Up Watts HEATING amp COOLING If They Are Not Listed Runnin Additional Device Wate Start up amount as an estimate of additional Start up Watts Watts For equipment with a motor Use the rated watts For most lights or heaters Furnace Fan 1 2HP 900 1400 there are no additional start up watts Space Heater 41800 0o Window AC 10 000 BTU 1200 600 For Generator technical questions please call 1 800 444 3353 Page 12 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Stopping the Engine in an Emergency 1 To stop the engine in an emergency turn the Engine Switch off NOTICE Generator shut off under load may damage b OFF 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 95 2 Turn the Engine Switch off 2 lt nc Lu n Oo 3 Close the Fuel Valve For Generator technical questions please call 1 800 444 3353 Item 69672 69674 For Engine technical questions please call 1 800 520 0882 Page 13 AONVNALNIVIN User Maintenance Instructions 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
30. rights and responsibilities you should contact the Harbor Freight Tools Customer Service Department at 1 800 444 3353 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 1 800 444 3353 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 War ranty coverage shall also be excluded for any part which fails malfunctions or is damaged due to failure to follow the maintenance and operating instructions set forth in the Owner
31. 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 Fuel pump if so equipped iii Cold start enrichment system 2 Air Induction System i Intake pipe manifold ii Air cleaner 3
32. sing 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 engine 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 For Generator technical questions please call 1 800 444 3353 Page 8 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 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 15 in the User Maintenance Instructions section shows other viscosities to use in different average tempera
33. t electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerators 19 Only use a suitable means of transport and lifting devices with sufficient weight bearing capacity when transporting the generator 20 Secure the Generator on transport vehicles to prevent the tool from rolling slipping and tilting 21 Industrial applications must follow OSHA requirements 22 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 23 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 24 Wear ANSI approved safety glasses hearing protection and NIOSH approved dust mask respirator during use 25 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 26 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 27 Do not operate in explosive atmospheres such as in the presence of
34. tc Use cold weather fuel and oil additives to prevent backfiring Have qualified technician diagnose and service engine Check engine timing Turn off and unplug the product then plug it back in again and turn on Turn off and unplug product Reset Circuit Breaker Plug in product and turn on Have product repaired Immediately unplug appliance Have appliance repaired by a qualified technician or replace appliance Lower the number of items plugged into the generator to stay within the rated capacity or use a more powerful generator Follow all safety precautions whenever diagnosing or servicing the equipment or engine Page 18 For Generator technical questions please call 1 800 444 3353 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Parts List and Diagram 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 AL
35. that this total is under the 6 500 Running Additional Start up maximum rated wattage of the generator Watts Watts 5 Plugin and turn on products from largest wattage Air Compressor 1 2 HP 1000 to smallest Table Saw 10 1700 Belt Sander 3 1200 Hand Drill 1 2 600 i Wattage Calculation Table Halogen Work Light 1008 Recipricating Saw 900 Running Watts RECREATION Running Additional Device Watts Start up ed 1 TEE EE T must be less than 5 500 Largest Additional Start up Watts must be less than 6 500 Example ES Running Computer w Monitor TZ ZO Electric Clothes Dryer Television 400 0 400 Electric Range Laun Mower 1 200 1 200 7 200 Electric Water Heater aud Drill 600 600 600 Light Bulb 100 watts Microwave 1000 watts Sump Pump 1 2 HP Total Running Watts must be less than 5 500 Washing Machine Largest Additional Start up Watts 7 200 Total Startup Watts needed for all loads Well Pump 1 2 HP must be less than 6 500 2 400 LAWN amp GARDEN Runnin Additional Device Wate Start up generator that only supplies the exact watts needed Watts Hedge Trimmer To Calculate Wattage 1200 1200 Volts and amps can be multiplied together to get watts volts x 1200 1200 A generator that is rated more than the minimum required peak watts will last much longer than a am
36. ts and check for dirt Clean or replace as described below 2 Cleaning 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 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 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 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 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 Grades 20 0 20 40 60 80 Average outdoor temperature 100 F 8 Thread the dipstick back in clockwise CAUTION Do not run the engine with too little oil The engine will be permanently damaged 3 Install the new filter or the cleaned filter Secure the Air Cleaner Cover before use For Generator technical questions please cal
37. tures 6 Thread the dipstick back in clockwise CAUTION Do not run the engine with too little oil The engine will be permanently damaged Using the Generator Before Starting the Generator Engine Before starting the engine A a Follow the Set Up Instructions to prepare the Generator b Unplug all loads from the Generator c Inspect the Generator and engine d Fill the engine with the proper amount and type of both fuel and oil Basic Generator Use Procedure See following pages for specific instructions 1 Check that the generator can handle the wattage needed to power your products 2 Start the Engine and allow the Engine and Generator to run and warm up for five minutes after starting with no electrical load 3 Plug in products 4 When finished using the Generator disconnect all electrical loads Note Do not allow generator to run out of fuel with loads attached Checking and Filling Fuel AwWarninc 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 Unscrew and remove the Fuel Cap 3 If needed fill the Fuel Tank to about 1 inch under the fill neck of the Fuel Tank with 87 octane or higher unleaded gasoline Note Do not use gasoline containing more than 10 ethanol
38. ug that is spliced onto a different cord may be hazardous Only a qualified electrician should wire a plug onto a cord CAUTION Never exceed the rated capacity for this Generator as serious damage to the Generator and or appliances tools and 5 500 equipment could result from an overload Starting and running wattage requirements should always be calculated when matching this Generator s wattage capacity to the appliance tool or equipment 6 500 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 TV s 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 rated watts move the Engine Choke Lever to the
39. use 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 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 For Generator technical questions please call 1 800 444 3353 Page 4 For Engine technical questions please call 1 800 520 0882 Item 69672 69674 Service Precautions 1 Before service maintenance or cleaning 8 Have the equipment serviced by a qualified repair person using only identical replacement parts a Unplug all devices from the generator pM j This will ensure that the safety of the equipment b Turn the engine switch to its OFF position is maintained Do not attempt any service or c Allow the engine to completely cool maintenance procedures not ex
40. ve the drain bolt from the bottom of the carburetor bowl and allow Cylinder the fuel to drain Assembly If present on your model remove the small sediment cup next to the bowl and allow the fuel to drain from there as well Drain Plug c Open the fuel valve After all fuel has drained reinstall the drain bolt and sediment cup if equipped Tighten securely 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 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 through spark plug hole 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
41. ystem 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 69672 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 1997 and later Small Off Road Engine herein engine Within the United States new off road spark ignition en gines certified for model year 1997 and later 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 Both Items Manufacturer s Warranty Coverage The 1995 and later engines are warranted for two 2 years If any emission related part
Download Pdf Manuals
Related Search