5500 RATED WATTS/6500 MAX. WATTS
PORTABLE GENERATOR
98839
Set up, Operating, and Servicing Instructions
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.
CAUTION!
Only use OUTSIDE
and far away from
windows, doors, and
vents.
Your Warranty Is Voided If:
You do not put engine oil in the Engine’s crankcase prior to its first use. Before each use, check the oil level. Never run the Engine with low or no engine oil.
Running the Engine with low or no oil will permanently damage the unit.
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
Copyright© 2008 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Revised Manual 10e
SPECIFICATIONS
Electrical
Specifications
Alternator Type: 2-Pole, Single Phase
Output Frequency: 60 Hz
Output: 5,500 Rated Watts / 6,500 Max. Watts
AC Receptacles: 4 NEMA 120V, 20 Amp grounded receptacles
1 NEMA 240V 4 Prong, twist lock receptacle
DC Receptacle: 12V Terminal with Cap Screws
Circuit Breakers: 20 Amp, Qty. 2 / 25 Amp, Qty. 2
Fuse Type: F10A250V
Overload Protection: Resettable Circuit Protection for AC outlets, and Fuse for DC outlet
Engine
Specifications
13 HP / 4-Cycle / Electronic Ignition & Recoil Start
Engine Speed: 3,600 RPM
Required Fuel Type: Unleaded Gasoline
Fuel Capacity: 6.5 Gal.
Recommended Oil Type: SAE 10W-30
Automatic Low Oil Shut-Down: Yes
EPA and CARB Approved
Weight
175 Pounds
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 back two pages of this manual.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
GENERAL SAFETY RULES AND PRECAUTIONS
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1.
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2.
Do not operate power tools in explosive atmospheres, such as in
the presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
REV 09h
SKU 98839
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Page 2
3.
Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control. Provide barriers or shields as needed.
PERSONAL SAFETY
1.
Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
2.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
3.
Avoid accidental starting. Be sure the Engine Ignition (2) is in its “OFF”
position before moving the Generator and before performing any service,
maintenance, or cleaning procedures on the unit.
4.
Remove adjusting keys or wrenches before turning the Generator on. A
wrench or a key that is left attached to a rotating part of the machine may result in
personal injury.
5.
Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the power tool in unexpected situations.
6.
Use safety equipment. Always wear eye protection. Always wear
ANSI approved safety impact goggles when using this product. ANSI
approved hearing protection must also be used.
TOOL USE AND CARE
1.
Do not force the tool. Use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
2.
Do not use the Generator if the Engine’s Ignition (2) does not turn it on or off.
Any tool that cannot be controlled with its power switch is dangerous and must be
replaced.
3.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
4.
Maintain tools with care. Properly maintained tools are less likely to malfunction
and are easier to control. Do not use a damaged tool. Tag damaged tools “Do
not use” until repaired.
5.
Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
SKU 98839
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Page 3
6.
Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
7.
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 should be operated
on approved inverter type generators or pure sine wave generators.
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.
Note: When using a generator to provide home standby electricity, a transfer switch
(sold separately) is needed to prevent back feeding power into the utility line.
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.
WARNING: 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 or a qualified electrician.
*Sensitive electronic equipment includes, but is not limited to, audio/video
equipment, some television sets, computers, and printers.
AC APPLICATIONS
1.
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.
2.
If an appliance begins to operate abnormally, becomes sluggish or stops suddenly,
turn it off immediately. Disconnect the appliance, and determine whether the
problem is the appliance, or if the rated load capacity of the generator has been
exceeded.
3.
Make sure that the electrical rating of the tool or appliance does not exceed that of
the generator. Never exceed the maximum power rating of the generator. Power
levels between rated and maximum may be used for no more than 30 minutes.
4.
Substantial overloading will open 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.
SKU 98839
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Page 4
SERVICE
1.
Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
2.
When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual.
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
SPECIFIC SAFETY RULES AND PRECAUTIONS
1.
Your Warranty is voided if you do not put engine oil in the Engine’s crankcase
prior to its first use. Before each use, check the oil level. Never run the Engine
with low or no engine oil. Running the Engine with low or no oil will permanently
damage the unit.
2.
Maintain labels and nameplates on the Generator. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
3.
Make sure the Generator is located on a flat, level, sturdy surface capable of
supporting the weight of the Generator and any additional tools and equipment.
4.
Industrial applications must follow OSHA guidelines.
5.
Never stand on the Generator. Serious injury could result if the Generator is
tipped.
6.
Never leave the Generator unattended when it is running. Turn off the Engine
before leaving.
7.
Do not allow children and other unauthorized people to handle or play with
the Generator.
8.
This Generator is designed for outdoor use only. Do not operate the
Generator in a closed area or in a poorly ventilated area. When running, the Engine of this Generator produces carbon monoxide, a
colorless, odorless, toxic fume that, when inhaled, can cause serious personal injury or death. Whenever possible, use a carbon monoxide
detector (not included) to detect excessive carbon monoxide fumes in the
work area and in the surrounding area.
9.
Do not force the Generator. This tool will do the work better and safer at the speed
and capacity for which it was designed. Do not overload the generator. Know the
total running wattage necessary to power the desired items.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 5
FIRE AND EXPLOSION PRECAUTIONS
1.
Gasoline fuel and fumes are flammable, and potentially explosive. Use proper
fuel storage and handling procedures. Always have multiple ABC class fire extinguishers nearby.
2.
Keep the Generator, its Engine, and surrounding areas clean at all times.
3.
When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and
regulations. Store oil rags in a covered metal container.
4.
Never store fuel or other flammable materials near the Generator.
5.
Do not smoke, or allow sparks, flames, or other sources of ignition around
the Generator.
6.
Keep grounded conductive objects, such as tools, away from exposed, live
electrical parts and connections to avoid sparking or arcing. These events
could ignite fumes or vapors.
7.
Do not refill the Fuel Tank while the Engine is running or while the Engine is
still hot. Do not operate the Generator with known leaks in the fuel system.
8.
Use only Engine manufacturer recommended fuel and oil.
9.
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.
MECHANICAL PRECAUTIONS
1.
Prior to performing service, maintenance, or cleaning procedures, always
make sure the Engine’s Ignition (2) is in its “OFF” position. Allow the Engine
and Generator to completely cool. Then, remove the spark plug from the
Engine.
2.
Do not alter or adjust any part of the Generator or Engine that is assembled
and supplied by the manufacturer.
3.
Always follow and complete scheduled Generator and Engine maintenance.
CHEMICAL PRECAUTIONS
1.
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.
2.
Avoid body contact with fuels, oils, and lubricants used in the Generator and
Engine. If swallowed, seek medical treatment immediately. Do not induce vomiting
if fuel is swallowed. For skin contact, immediately wash with soap and water. For
eye contact, immediately flush eyes with clean water.
SKU 98839
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Page 6
NOISE PRECAUTION
Prolonged exposure to high noise levels is hazardous to hearing. Wear hearing
protection when operating or working around the Generator when it is running.
ELECTRICAL PRECAUTIONS
1.
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.
2.
The Generator must be earth-grounded in accordance with all relevant electrical codes and standards before operation.
3.
If an extension cord (not included) is used, make sure to use only UL listed
cords having the correct gauge and length. (See TABLE A, next page.)
4.
Do not attempt to connect or disconnect load connections while standing in
water, or on wet or soggy ground.
5.
Do not touch electrically energized parts of the Generator and interconnecting cables or conductors with any part of the body, or with any non-insulated
conductive object.
6.
Connect the Generator only to a load or electrical system (120 volt, 240 volt,
or 12 volt) that is compatible with the electrical characteristics and rated capacities of the Generator.
7.
Be sure the Engine’s Ignition (2) is in its “OFF” position before moving the
Generator and before performing any service, maintenance, or cleaning procedures on the unit.
8.
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.
9.
Insulate all connections and disconnected wires.
10.
Guard against electric shock. Prevent body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator enclosures.
11.
Use only Class BC or Class ABC fire extinguishers on electrical fires.
12.
Unconditioned electrical output can damage sensitive equipment. Do not use
to power sensitive electronic equipment without appropriate line conditioner (sold
separately).
SKU 98839
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Page 7
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*
(120 or 240 VOLT)
NAMEPLATE
AMPERES
EXTENSION CORD LENGTH
(at full load)
25 Feet
50 Feet
75 Feet
100 Feet
150 Feet
0 – 2.0
18
18
18
18
16
2.1 – 3.4
18
18
18
16
14
3.5 – 5.0
18
18
16
14
12
5.1 – 7.0
18
16
14
12
12
7.1 – 12.0
18
14
12
10
-
12.1 – 16.0
14
12
10
-
-
16.1 – 20.0
12
10
-
-
-
TABLE A
* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
MISC. PRECAUTIONS
1.
WARNING! People with pacemakers should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart
pacemaker could cause interference to or failure of the pacemaker.
2.
WARNING! The warnings and precautions discussed in this manual cannot cover
all possible conditions and situations that may occur. It must be understood by the
operator that common sense and caution are factors which cannot be built into this
product, but must be supplied by the operator.
SKU 98839
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Page 8
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts Lists on
pages 20 and 22 are included. If any parts are missing or broken, please call Harbor
Freight Tools at the number shown on the cover of this manual as soon as possible.
ASSEMBLY INSTRUCTIONS
CAUTION! Make sure Engine’s Ignition (2) is in its “OFF” position prior to performing any service, maintenance, or cleaning of Generator or Engine. Always
wear ANSI- approved safety impact eye goggles when assembling and using
the Generator.
To Install The Battery (not included):
NOTE: For proper operation, you must install a DC 12V, 18-35 Amp-hour Battery.
NEGATIVE BATTERY CABLE
(64)
BATTERY
(45)
Not included
BATTERY BRACKET
(47)
POSITIVE BATTERY CABLE
(63)
BATTERY GUARD PLATE (44)
(FACTORY PRE-INSTALLED)
BATTERY TRAY (48)
(FACTORY PRE-INSTALLED)
BOLT W/LOCK WASHER
(46)
FIGURE A
1.
Remove the packing from the Battery (45). Then, locate the factory pre-installed
Battery Guard Plate (44) and Battery Tray (48) beneath the Control Panel (4) of the
Generator unit. (See Figure A, previous page.)
2.
Slide the Battery (45) into the Battery Guard Plate (44), with the Battery’s terminals
facing outward and with the Battery’s negative (–) terminal facing left.
(See Figure A.)
3.
Align the two mounting holes in the Battery Bracket (46) with the two threaded mounting holes in the Battery Guard Plate (44). Then secure the Battery Bracket to the
Battery Guard Plate, using two Bolts with Lock Washers (46). (See Figure A.)
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Page 9
4.
Connect the end of the Positive Battery Cable (63) to the Battery’s positive (+) terminal. Then connect the Negative Battery Cable (64) to the Battery’s negative (–)
terminal. (See Figure A.)
INSTALLATION INSTRUCTIONS
1.
Electrical and other permits may be required for the installation of emergency or
portable power systems. Investigate the local building and electrical codes before
installing this unit.
2.
Prior to providing Generator power to tools and equipment, make sure the Generator’s rated voltage, wattage, and amperage capacity is adequate to supply all
electrical loads the unit will power. If powering exceeds the Generator’s capacity,
it may be necessary to group one or more of the tools/equipment for connection to
a separate Generator.
General Location:
1.
It is recommended to locate the Generator (outdoors only) where cooling air is
readily available. Locate the Generator so that the air inlets and outlets are not
blocked by obstructions such as bushes, trees, or snow drifts. Locating it in the path
of heavy winds or snowdrifts may require the placement of a barrier for protection.
The air inlet (on Air Filter Cover 18a), in normal weather conditions, should face
the prevailing wind direction.
2.
Locate the Generator on a concrete slab or other area where rain drainage or flood
waters can not reach it.
3.
Generator placement should allow four feet of access to all sides for maintenance
and for proper air cooling.
4.
Place the Generator as close as possible to the electrical tools and equipment being powered to reduce the length of extension cords.
SKU 98839
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Page 10
Grounding The Generator:
GROUNDING TERMINAL
(9)
#6 AWG GROUNDING WIRE
(NOT INCLUDED)
GROUNDING ROD
(NOT INCLUDED)
FIGURE B
Note: It is recommended that only a trained and licensed electrician perform this procedure.
Connect a #6 AWG grounding wire (not included) from the Grounding Terminal (9)
on the Generator 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.
(See Figure B.)
CONTROL PANEL FEATURES
1.
Engine Ignition (2): Starts and stops the Gasoline Engine. To start the Engine
using power from the Battery (45), insert the Ignition Key (65) and turn the Engine
Ignition to its “START” position. To start the Engine manually using the Starter
Rope (40A) and Starter Handle (41A), insert the Ignition Key and turn the Engine
Ignition to its “RUN” position. Then pull briskly on the Starter Handle. To stop the
Engine, turn the Engine Ignition to its “OFF” position. Always remove the Ignition
Key when the Generator is not in use. (See Figure C, next page.)
2.
Fuel Tank Cap (34): NEVER run the Engine with the Fuel Tank Cap removed.
(See Figure C.)
3.
120 Volt NEMA AC Outlets (5): The Generator is equipped with four 3-hole 120
volt AC outlets to power 120 volt tools and equipment. (See Figure C.)
REV 09h
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Page 11
(65)
(2)
(3)
(34)
(8)
(5)
(6)
(10)
(7)
FIGURE C
4.
120 Volt AC Circuit Breakers (3): Each of the four 120 Volt AC Outlets have a
Circuit Breaker to protect the Generator from overloading. Should a Circuit Breaker
“trip”, unplug all electrical loads from the Generator. Allow the Circuit Breaker to
cool down. Then, push the 120 volt Circuit Breakers. (See Figure C.)
5.
240 Volt AC Outlet (6): The Generator is equipped with one 4-blade twist lock 240
Volt AC Outlet to power 240 volt tools and equipment. (See Figure C.)
6.
240 Volt AC Circuit Breaker (3): The 240 Volt AC Outlet has two Circuit Breakers to protect the Generator from overloading. Should the Circuit Breakers “trip”,
unplug all electrical loads from the Generator. Allow the Circuit Breakers to cool
down. Then, push the 240 volt Circuit Breakers. (See Figure C.)
7.
12 VDC Terminal (7): Supplies voltage to 12 volt DC appliances such as radios,
emergency lights, etc. To power a 12 volt DC appliance, connect the positive (+)
lead from the appliance to the positive (Red +) 12 VDC Terminal on the Generator. Then connect the negative (–) lead from the appliance to the negative (Black
–) 12 VDC Terminal on the Generator. IMPORTANT: This Outlet is designed for
operating 12 volt DC appliances only. Do not attempt to charge batteries with this
Outlet. (See Figure C.)
REV 09h
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Page 12
8.
12 Volt DC Fuse (8): The 12 Volt DC Outlet has one Fuse (8) to protect the Generator from overloading. The Generator is equipped with the following size and type
of Fuse: F10A250V. Should a 12 VDC output exceed the fuse’s rating, always
check to see if the Fuse has “blown” (a melted filament within the Fuse). If necessary, unplug all electrical loads from the Generator, replace with a new Fuse, and
reattach a reduced load to the generator. (See Figure C.)
9.
Power-On Light (10): Indicates voltage is being provided by the Generator.
(See Figure C.)
PRE-START INSTRUCTIONS
To Add Engine Oil:
1.
CAUTION! Your warranty is voided if you do not put engine oil in the Engine’s
crankcase prior to its first use. Before each use, check the oil level. Never run the
Engine with low or no engine oil. Running the engine with low or no oil will permanently damage the Engine.
OIL DIPSTICK
(65A)
FUEL FILTER
(32)
FUEL TANK CAP
(34)
THIS GENERATOR
HAS AN AUTOSHUTDOWN OIL
SENSOR. IF
ENGINE STOPS OR
WILL NOT START,
CHECK OIL LEVEL.
FUEL GAUGE
(35)
FUEL TANK
(31)
FIGURE D
2.
The Engine MUST be filled with a high quality grade engine oil. If the Engine will
be run in temperatures above 32 degrees Fahrenheit, use SAE 10W-30 weight oil.
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Page 13
If the Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE
5W-30 weight oil. (See Figure D, prior page.)
3.
To do so, unscrew and remove the Oil Dipstick (65A). Pour engine oil into the oil
fill hole until the level of oil is even with the bottom edge of the oil fill hole (if you
cannot see the oil through the oil fill hole, then the oil is too low and more oil must
be added). (See Figure D.)
4.
Make sure to screw the Oil Dipstick (65A) firmly back into its Dipstick Hole.
(See Figure D.)
To Fill The Fuel Tank:
1.
Prior to first using the Generator, the Fuel Tank (31) must be filled with high octane
unleaded gasoline. (See Figure D.)
2.
To do so, remove the Fuel Tank Cap (34) and fill the Fuel Tank (31) with unleaded
gasoline. Then, replace the Fuel Tank Cap. Thereafter, check the Fuel Gauge (35)
for the amount of unleaded gasoline. When necessary, refill the Fuel Tank.
(See Figure D.)
NOTE: Periodically, make sure to check the Fuel Filter (32) for excessive dirt and debris.
If necessary, remove the Fuel Filter and clean with compressed air.
(See Figure D.)
THIS UNIT CAN POWER THE FOLLOWING ITEMS
ITEM
1 HP Air Compressor
Belt Sander
Pressure Washer
Refrigerator/Freezer
1/2 HP Sump Pump
1/2 HP Well Pump
Miter Saw
1-1/2 HP Capacitor Start &
Run Motor
Central AC-32, 000 BTU
10” Table Saw
RUNNING START-UP
WATTS
WATTS
1600
4500
1200
2400
1200
3600
700
2200
1050
2150
1000
2100
1650
3000
1400
3100
5000
1800
6500
4500
NOTE: Wattages listed above are estimates. Check nameplate wattages on all loads
before connecting to Generator.
REV 09h
SKU 98839
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Page 14
OPERATING INSTRUCTIONS
1.
Check to make sure the Engine Ignition (2) is in its “OFF” position.
(See Figure C.)
2.
CAUTION! Make sure to unplug any load from the Generator before starting to
prevent permanent damage to any appliances, tools, or equipment.
3.
CAUTION! Engine oil MUST be added to the Engine’s crankcase prior to starting and running the Engine. Failure to add oil will damage the Engine and void
its warranty. (See pages 13 and 14, and Figure D.)
4.
Before the first use, the Fuel Tank (31) must be filled with a high octane, unleaded
gasoline. (See pages 13 and 14, and Figure D.)
a. WARNING! Never fill the Fuel Tank (31) completely. Fill the Fuel Tank to 1/2”
below the bottom of the filler neck to provide space for fuel expansion. Wipe
any fuel spills from the Engine and Generator before starting the Engine.
b. WARNING! Never fill the Fuel Tank (31) when the Engine is running or hot. Do
not smoke when filling the Fuel Tank.
To Start The Engine/Generator:
ON
OFF
FUEL VALVE
(41)
CHOKE LEVER (21A)
(IN “CHOKE” POSITION)
CHOKE LEVER (21A)
(IN “RUN” POSITION)
FIGURE E
1.
Turn the Engine Fuel Valve (41) to its “OPEN” position. Then, turn the Engine
Choke Lever (21A) to its “CHOKE” position. NOTE: No choke is required if the
Engine is warm. Make sure the Engine Choke Lever is in the “RUN” position when
starting a warm Engine. (See Figure E.)
2.
To start the Engine, using the Battery (45) for cranking power, insert the Ignition Key
(65) and turn the Engine Ignition (2) to its “START” position. NOTE: To prolong
starter life, use short starting cycles (5 seconds maximum, then wait one minute
before attempting to again start). (See Figure C.)
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Page 15
3.
To start the Engine manually, using the Starter Handle (41A) and Starter Rope
(40A), insert the Ignition Key (65) and turn the Engine Ignition (2) to its “RUN” position. Grasp the Starter Handle (41A) on the Starter Rope (40A) and pull slowly
until resistance is felt. Allow the Rope to rewind slowly. Then, pull the Handle with
a rapid, full arm stroke. Allow the Rope to rewind slowly. If necessary, repeat this
procedure until the Engine starts.
4.
When the Engine starts, slowly move the Choke Lever (21A) to its “RUN” position.
(See Figure E.)
5.
IMPORTANT: Allow the Generator to run at no load for five minutes after each
start-up so that the Engine and Generator can stabilize.
To Connect Electrical Loads:
1.
Start the Engine, and allow the Engine and Generator to run and warm up for five
minutes after starting with no electrical load.
2.
WARNING! Connect 120 VAC appliances, tools, and equipment only to the
four 120 VAC Outlets (5). Connect 240 AC appliances, tools, and equipment only
to the one 240 VAC Outlet (6). Connect 12 VDC appliances, tools, and equipment
only to the 12 VDC Terminal (7). (See Figure C.)
3.
CAUTION! Never exceed the rated capacity for this Generator, as serious damage to the Generator and/or appliances, tools, and 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.
4.
Most appliances, tools, and equipment will list on the motor nameplate the starting
and running voltage and amperage requirements. Use the following formula to
convert voltage and amperage to wattage:
Volts x Amps = Watts (example: 120 volts x 3 amps = 360 watts)
5.
To determine the approximate wattage requirement for most appliances, tools, and
equipment with “inductive” type motors, multiply the wattage that was calculated by
2 times to ensure adequate Generator capacity for motor load starting current.
6.
NOTE: The starting and running wattage for “resistant” loads are the same. Example: a 100 Watt light bulb requires only 100 Watts to start. Most resistant loads
will be listed in wattage.
7.
Always power the largest electric motor first. Then, plug in other appliances, tools,
and equipment one at a time.
a. Connect “inductive” load appliances, tools, and equipment first. Inductive loads
consist of small hand tools and some small appliances. Connect the items that
require the most wattage first.
b. Connect any lights next.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 16
c. Voltage sensitive appliances, tools, and equipment should be the last to be connected to the Generator and the first to be disconnected. Plug voltage sensitive
items such as T.V.’s, VCR’s, microwaves, and cordless telephones into a UL
listed voltage surge protector (not included). Then, connect the UL Listed surge
protector into the Generator.
8.
CAUTION! 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 on this Generator.
9.
Once the Engine is running, simply connect the 120 volt appliances, tools, and
equipment into the 120 VAC Outlets (5). Connect a 240 volt appliance, tool, or
equipment into the 240 VAC Outlet (6). Or connect a 12 volt appliance, tool, or
equipment into the 12 VDC Outlet (8). (See Figure C.)
10.
IMPORTANT: If Engine speed or voltage fluctuates with a load below 250 Watts,
move the Engine Choke Lever (21A) to the “HALF-CHOKE” position.
(See Figure E.)
NOTE: Do not allow the generator to completely run out of fuel with devices attached. A generator’s output may sharply spike as it runs out of fuel, causing
damage to attached devices.
11.
When finished using the Generator, disconnect all electrical loads. Turn the Engine
Ignition (2) to its “OFF” position to stop the Engine. Then, close the Engine Fuel
Valve (41). (See Figures C and E.)
INSPECTION, MAINTENANCE, AND CLEANING
1.
WARNING! Always make sure the Engine’s Ignition (2) is in its “OFF” position
prior to performing any service, maintenance, or cleaning of the Generator or Engine. (See Figure C.)
2.
Before each use, inspect the general condition of the Generator and Engine. Check
for loose screws, misalignment or binding of moving parts, cracked or broken parts,
loose hose connections, and any other condition that may affect the safe operation of the Generator and Engine. If abnormal noise or vibration occurs, have the
problem corrected before further use.
Do not use damaged equipment.
3.
Generator maintenance:
a. Keep the Generator clean and dry at all times.
b. The Generator should not be operated or stored in locations that include excessive moisture, dust, flammable or corrosive vapors. If these substances are on
the Generator, clean with a cloth or soft brush.
c. Do not use a garden hose or anything with liquid to clean the Generator. Liquid
may enter the cooling air slots and could damage the interior workings of the
REV 10e
Generator.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 17
PLUG
(59A)
OIL DIPSTICK
(65A)
FIGURE F
4.
Engine maintenance:
a. After first 5 to 8 hours of use: Change oil. Then, change oil every 50 hours
of use. Change oil every 25 hours of use when operating the Engine under a
heavy load or in high temperatures. To change the oil, remove the Plug (59A)
and allow the old oil to drain in a proper container. Once drained, replace the
Plug. If the Engine will be run in temperatures above 32° Fahrenheit, use SAE
10W-30 weight oil. If the Engine will be run in temperatures below 32° Fahrenheit, use SAE 5W-30 weight oil. To fill the Engine crankcase with new oil,
unscrew and remove the Oil Dipstick (65A). Pour engine oil into the oil fill hole
until the level of oil is even with the bottom edge of the oil fill hole (if you cannot
see the oil through the oil fill hole, then the oil is too low and more oil must be
added). Make sure to screw the Oil Dipstick (65A) firmly back into its Dipstick
Hole. Also, make sure to dispose of the old oil according to local waste disposal
requirements.(See Figure F.)
SPARK PLUG (28A)
SPARK PLUG WIRE (36A)
FIGURE G
AIR FILTER SEPARATOR
(20A)
AIR FILTER COVER
(18A)
AIR FILTER ELEMENT
(19A)
b. After every 25 hours of use: Service the Air Filter Element (19A) and Air Filter
Separator (20A). To do so, remove the Air Filter Cover (18A). Remove the Air
Filter Element. Immerse the Air Filter Element in a mild solvent and squeeze
the Element several times to clean. Remove the Element from the solvent
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 18
and squeeze thoroughly to dry. Then, squirt several drops of a light weight oil
onto the Element. Use compressed air to clean the Air Filter Separator. Then
replace the Air Filter Separator, Air Filter Element, and Air Filter Cover. Clean
more often under dusty conditions or when airborne debris is present. Replace
Air Filter parts if necessary. (See Figure G.)
c. After every 100 hours of use: Replace the Spark Plug (28A). To do so, remove
the Spark Plug Wire (36A). Use the accessory Spark Plug Wrench Kit (86A) to
remove the old Spark Plug. Install a new Spark Plug. Then, replace the Spark
Plug Wire. (See Figure G.)
FUEL TANK CAP
(34)
FUEL FILTER
(32)
FUEL TANK
(31)
FIGURE I
d. Daily: Inspect the Fuel Filter (32): To do so, remove the Fuel Tank Cap (34).
Remove the Fuel Filter from the Fuel Tank (31). If necessary, use compressed
air to remove any dirt and debris from the Fuel Filter. Then replace the Fuel
Filter and Fuel Tank Cap. (See Figure H.)
5.
When storing the Generator, make sure to store the unit in a clean, dry, safe location out of reach of children and other unauthorized people.
6.
CAUTION! All maintenance, service, or repairs not mentioned in this manual
must only be performed by a qualified service technician.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 19
TROUBLESHOOTING
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 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 RISKS 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.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 20
PARTS LIST - GENERATOR
Part
Description
Qty
Part
Description
Qty
1
Bolt w/Lock Washer( M6*12)
4
29
Cooling Fan
1
2
Engine Ignition
1
30
Heat Insulation Board Assembly
1
3
Circuit Breaker
4
31
Fuel Tank
1
4
Control Panel
1
32
Fuel Filter
1
5
AC Outlet (120V)
4
33
Seal Ring
1
6
AC Outlet (240V)
1
34
Fuel Tank Cap
1
7
DC Terminal(12V)
2
35
Fuel Gauge
1
8
Fuse (F10A250V)
1
36
Bolt (M6*12)
2
9
Grounding Terminal
1
37
Bolt w/Lock Washer(M6*30)
4
10
Power-On Light
1
38
Spacer
4
11
Shock Absorber
4
39
Rub Washer
4
12
Bolt (M5*215)
2
40
Bushing
4
13
Lock Washer Nut (M8)
12
41
Fuel Valve
1
14
Stator Crust
1
42
Frame
1
15
Alternator Back Cover
1
43
Switch Box Cover
1
16
Automatic Voltage Regulator
1
44
Battery Guard Plate
1
17
Bolt (M5*12)
7
45
Battery(12V-17AH/20HR)
1
18
Rectifier
1
46
Bolt w/lock washer (M6*12)
2
19
Bolt (M5*20)
2
47
Battery Bracket
1
20
Cable Sheath
1
48
Battery Tray
1
21
Carbon Brush
1
58
Connection Board (Muffler)
1
22
Bolt (M10*1.25*265)
1
59
Bolt (M8*20)
4
23
Bolt(M6*180)
4
60
Bolt W/ Lock Washer (M6*12)
8
24
Bolt (M5*20)
4
63
Positive Battery Cable
1
25
Connection Board
1
64
Negative Battery Cable
1
26
Nut (M5)
4
65
Ignition Key
1
27
Stator
1
66
Carbon Canister
1
28
Rotor
1
REV 09h
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 21
NOTE: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts.
Battery(Part#45) is not included.
ASSEMBLY DIAGRAM - GENERATOR
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 22
PARTS LIST - ENGINE
Part
1A
2A
3A
4A
5A
6A
7A
8A
9A
10A
11A
12A
13A
14A
15A
16A
17A
18A
19A
20A
21A
22A
23A
24A
25A
26A
27A
28A
29A
30A
31A
32A
33A
34A
35A
36A
37A
38A
39A
40A
41A
42A
43A
Description
Muffler
Cylinder Head Bolt
Cylinder Head Cover Bolt
Cylinder Head Cover
Lock Nut
Adjusting Screw
Rocker Arm
Rocker Arm Bolt
Valve Push Rod Guiding Board
Valve Push Rod
Cylinder Head
Carburetor Shield
Carburetor Packing
Carburetor Assembly
Air Filter Case
Air Filter Seal
Bolt (M6)
Air Filter Cover
Air Filter Element
Air Filter Separator
Choke Lever
Carburetor Packing (II)
Stud Bolt (M6 x 109)
Intake Valve
Exhaust Valve
Cylinder Head Gasket
Exhaust Pipe Stud
Spark Plug
Valve Guide
Valve Spring
Rocker Shaft Circlip
Anti-Wear Valve Stem Protector
Cylinder Head Cover Packing
Governor Spring
Bolt
Spark Plug Wire
Ignition Coil
Nut (Special 14mm)
Starter Ratchet Spring
Starter Rope
Starter Handle
Starter Case Assembly
Spiral Spring
SKU 98839
Qty
1
4
4
1
2
2
3
2
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
2
1
2
2
2
2
1
1
1
1
1
1
2
1
1
1
1
Part
44A
45A
46A
47A
48A
49A
50A
51A
52A
53A
54A
55A
56A
57A
58A
59A
60A
61A
62A
63A
64A
65A
66A
67A
68A
69A
70A
71A
72A
73A
74A
75A
76A
77A
78A
79A
80A
81A
82A
83A
84A
85A
86A
Description
Starter Wheel
Circlip
Starter Ratchet
Friction Plate Screw
Cover
Starter Pulley
Cooling Fan
Flywheel Magneto
Cylinder Block
Speed Control Lever
Governor Arm
Governor Spring
Governor Support
Bolt (M6 x 15)
Oil Alert Nut
Plug (M10 x 15)
Plug Washer
Oil Alert
Bolt (M6)
Crankshaft
Crankshaft Gear
Oil Dipstick
Oil Dipstick Seal Ring
Gear Casing
Bolt (M8 x 35)
Gear Case Packing
Bearing
Camshaft Assembly
Locating Pin
Oil Seal
Connecting Rod Bolt
Connecting Rod Cap
Connecting Rod
Piston
Compression Ring (I)
Compression Ring (II)
Oil Scraper Ring
Piston Pin
Piston Pin Circlip
Starter
Gear
Fuel Pipe
Spark Plug Wrench Kit
For technical questions, please call 1-800-444-3353.
Qty
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
1
1
2
2
1
6
2
2
1
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
Page 23
SKU 98839
4A
3A
2A
1A
5A
33A
6A
7A
32A 31A
78A 79A 80A
77A
8A
9A
12A
For technical questions, please call 1-800-444-3353.
15A
14A
16A
24A
23A
22A
21A
25A
56A
74A
75A
35A
57A
34A
13A
26A
27A
28A
10A 11A
29A
30A
82A
81A
76A
17A
85A
83A
20A
38A
50A
59A
58A
19A
52A 84A 51A
54A
53A
36A
37A
55A
18A
48A
62A
39A
40A
46A
41A
68A
45A
70A 69A
65A 66A 67A
71A
64A
47A
63A
72A
43A
44A
42A
86A: Spark Plug Wrench Kit Not Shown.
61A
49A
60A
73A
ASSEMBLY DIAGRAM - ENGINE
Page 24
Limited 1 year 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 one year from the date of purchase (90 days if used by a professional
contractor or if used as rental equipment). See engine manufacturer’s warranty which covers engine. This
warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents,
repairs or alterations outside our facilities, 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 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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
Emission Control System Warranty
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 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.
Manufacturer’s Warranty Coverage
The 1995 and later 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.
SKU 98839
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.
- 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 responsibilities, you should contact the Harbor Freight
Tools Customer Service Department at 1-800-444-3353.
For technical questions, please call 1-800-444-3353.
Page 25
Emission Control System Warranty - continued
Harbor Freight Tools Emission Control Defects Warranty Provisions
1.
2.
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.
5.
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.
3.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.
4.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
damaged 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.
SKU 98839
6.
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 on page 17 of 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)Ignition System
i) Spark plug.
ii) Magneto ignition system.
4)Catalyst System (if so equipped)
i) 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.
For technical questions, please call 1-800-444-3353.
Page 26
Electrical Diagram
Please note: All electrical work should be performed
by a qualified service technician.
SKU 98839
For technical questions, please call 1-800-444-3353.
Page 27