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Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the products serial number in the
back of the manual near the assembly diagram (or month and year of purchaseifproducthasnonumber).
Keep this manual and the receipt in a safe and dry place for future reference.
REV 15a
Generator
exhaust
contains
Engine
exhaust
contains
carbon monoxide.
carbon
monoxide.
This see
is aorpoison
This is a poison you cannot
smell.
you cannot see or smell.
windows, doors,
and vents.
Table of Contents
Specifications.............................................. 2
Safety 3
Setup........................................................... 7
Operationr 8
Maintenances 13
Troubleshooting.......................................... 17
Parts Lists and Diagrams........................... 19
Warranties.................................................. 27
Specifications
Generator
Output
Receptacles
Displacement
Compression Ratio
Engine Type
Cooling System
Fuel
Type
Capacity
Type SAE
Engine Oil
Capacity
Run Time @ 50% Load
with full tank
Sound Level at 23 feet, 50% load
Bore x Stroke
Type
SparkPlug
Gap
Intake
Valve Clearance
Exhaust
Engine Speed
The emissions control system for this Engine is warranted for standards set by the
U.S.EnvironmentalProtectionAgency. Forwarranty information, refer to the last pages of thismanual.
Page 2
ITEM 61169
Safety
RPM
HP
AWG
Property or Statement
Revolutions Per Minute
Horsepower
American Wire Gauge
WARNING marking concerning
RiskofEye Injury. Wear ANSI-approved
safety goggles with side shields.
Read the manual before
set-up and/oruse.
Symbol
Property or Statement
WARNING marking concerning
RiskofHearing Loss.
Wearhearing protection.
WARNING marking concerning
Risk of Respiratory Injury.
OperateengineOUTSIDE and far away
from windows, doors, and vents.
WARNING marking concerning
RiskofFire while handling fuel.
Donotsmoke while handling fuel.
WARNING marking concerning
RiskofFire.
Do not refuel while operating.
Keepflammable objects
away from engine.
Operation
Symbol
Setup
Symbol Definitions
ITEM 61169
Maintenance
Page 3
Setup Precautions
1. Gasoline fuel and fumes are flammable, and
potentially explosive. Use proper fuel storage
and handling procedures. Do not store fuel
or other flammable materials nearby.
Safety
Setup
Operating Precautions
CARBON MONOXIDE HAZARD
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains
carbonmonoxide. This is a poison
youcannot see or smell.
1.
Operation
Maintenance
Page 4
ITEM 61169
Safety
ITEM 61169
Setup
Operation
Page 5
Maintenance
Service Precautions
1. Before service, maintenance, orcleaning:
a. Unplug all devices from the generator.
b. Turn the engine switch to its OFFposition.
Safety
Setup
Operation
Maintenance
Page 6
ITEM 61169
Set Up
Safety
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.
TO PREVENT SERIOUS INJURY AND FIRE: Operate only with proper spark arrestor installed.
Operation of this equipment may create sparks that can start fires around dry vegetation.
A spark arrestor may be required.
The operator should contact localfireagencies for laws or regulations relating to fire
preventionrequirements.
At high altitudes, the engines carburetor, governor, and any other parts that control thefuelairratio
will need to be adjusted by a qualified mechanic to allow efficient high-altitude use and
toprevent damage to the engine and any other devices used with this product.
Setup
Grounding
Spark Plug
AccessPanel
Output
Overload
Oil
Indicator
Ground
Terminal
12VDC
Receptacle
120VAC
Receptacles
Choke
Starter
Handle
Exhaust
Air Filter
and OilFill
AccessPanel
ITEM 61169
Fuel
Valve
Page 7
Maintenance
Engine
Switch
12VDC
Breaker
Reset
Button
Operation
Fuel Cap
Operation
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.
Safety
Pre-Start Checks
Inspect Engine and Generator looking for damaged, loose, and missing parts before set up and starting.
Ifany problems are found, do not use equipment until fixedproperly.
Checking and Filling Engine Oil
NOTICE: Your Warranty is VOID if the Engines
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 Engineoil.
Running the Engine with no or low Engine
oil WILL permanently damage the Engine.
Setup
Operation
Full level
Maintenance
ITEM 61169
Safety
Manual Start
Setup
2
2. Move the Choke to the STARTposition.
ON
START
Operation
RUN
OFF
Maintenance
Note: Do not let the Starter Handle snap back against thehousing.
Hold it as it recoils so it doesn't hit the housing.
ITEM 61169
Page 9
Safety
Move Slowly
RUN
START
Setup
PUT
OUT
AD
RLO
OVE
LOW
OIL
Break-in Period:
a. Breaking-in the Engine will help to ensure proper equipment and Engine operation.
Operation
Maintenance
+Positive
Negative
Page 10
Terminal
12VDC
Terminal
Reset Button
ITEM 61169
Safety
Power draw can be calculated by multiplying volts and amps. The resulting number is wattage.
Never exceed the running wattage for the Generator or any outlet amperage rating.
Refer to appliance/tool owners manuals to determine the wattage of electrical load devices.
Long power cords and extension cords draw additional power. Keep cord length at a minimum.
Wattage Estimates
Running
Watts
600
500
400
400
200
380
350
500
50
750
Start-up
Watts
900
800
600
700
Operation
Setup
OVERLOAD Light
Note: The OVERLOAD light may turn on for a few seconds as a large device starts up.
This is normal for loads approaching the capacity of this Generator.
1. The total combined load through the
outlet on the Generator must not exceed
the running power of the unit.
2. If theOVERLOADlight turns on and theGenerator
stops producing power, it has been overloaded.
PUT
OUT
AD
RLO
OVE
LOW
OIL
Maintenance
ITEM 61169
Page 11
Safety
EMERGENCY
SHUT OFF
Setup
Under normal conditions, use the following procedure to shut off the Generator:
1
1. Unplug all electrical load devices
from the Generator.
Unplug Loads
2
Operation
Maintenance
ON
OFF
NOTICE
Drain fuel at end of season or warranty is void.
See Storage on page 16 for complete storage instructions.
Page 12
ITEM 61169
Maintenance
Safety
WARNING
Follow all service instructions in this manual. The engine may fail critically if not serviced properly.
Many maintenance procedures, including any not detailed in this manual, will need to be performed
by a qualified technician for safety. If you have any doubts about your ability to safely service the
equipment or engine, have a qualified technician service the equipment instead.
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.
Before
Each Use
Procedure
Monthly or
Every 3 mo. or Every 6 mo. or
every 20
50 hr. of use 100 hr. of use
hr. of use
Yearly or
every 300
hr. of use
Setup
Every
2Years
**
**
Operation
**
Maintenance
ITEM 61169
Page 13
Safety
Setup
Operation
Maintenance
Page 14
Full level
ITEM 61169
Safety
3. Cleaning:
For paper filter elements:
To prevent injury from dust and debris,
wear ANSI-approved safety goggles,
NIOSHapproved dust mask/respirator, and
heavy-duty work gloves. In a wellventilated
area away from bystanders, use pressurized
air to blow dust out of the air filter.
Ifthisdoesnot get the filter clean, replace it.
Setup
SparkPlug Maintenance
NOTICE: Use only A7RTC type sparkplug. Using
an incorrect sparkplug may damage theengine.
5. When installing a new sparkplug,
adjusttheplugsgap to the specification on the
Specifications chart. Do not pry against the
electrode, the sparkplug can bedamaged.
Operation
ITEM 61169
Maintenance
Non-gasket-style:
Finger-tighten until the plug
contactsthecylinderhead,
thentighten about 1/16 turnmore.
Page 15
Storage
When the equipment is to remain idle for longer than
20 days, prepare the Engine for storage as follows:
Safety
1. CLEANING:
Wait for Engine to cool, then clean Engine with
drycloth. NOTICE: Do not cleanusingwater.
Thewater will gradually enter the Engine
and cause rust damage. Apply a thin coat
of rust preventive oil to all metal parts.
2. FUEL:
To protect the fuel tank during storage, fill the
tank with gasoline that has been treated with
a fuel stabilizer additive. Follow fuel stabilizer
manufacturers recommendations for use.
Refer to Checking and Filling Fuel on page
Checking and Filling Fuel on page 8.
Setup
Operation
Maintenance
Page 16
ITEM 61169
Troubleshooting
FUEL RELATED:
1. Fill fuel tank with fresh 87+ octane
stabilizer-treated unleadedgasoline and
open fuel valve.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Clean sparkplug.
4. Sparkplugcap broken.
4. Replace sparkplugcap.
COMPRESSION RELATED:
COMPRESSION RELATED:
2. Tighten sparkplug.
If that does not work, replace sparkplug.
Ifproblem persists, may have
head gasket problem, see #3.
3. Tighten head.
If that does not remedy problem,
replace headgasket.
Operation
Follow all safety precautions whenever diagnosing or servicing the generator or engine.
ITEM 61169
Safety
Probable Solutions
Setup
Possible Causes
Maintenance
Problem
Page 17
Problem
Engine misfires
Possible Causes
Probable Solutions
1. Check wire connections.
3. Defective sparkplugcap.
3. Replace sparkplugcap.
5. Incorrect compression.
4. Faulty magneto.
5. Disconnected or improperly
connected sparkplugcap.
5. Secure sparkplugcap.
Engine knocks
2. Engine overloaded.
4. Incorrect timing.
Safety
1. Sparkplugcap loose.
Engine stops
suddenly
Setup
Operation
Engine backfires
Maintenance
Attached device
begins to operate
abnormally
Follow all safety precautions whenever diagnosing or servicing the generator or engine.
Page 18
ITEM 61169
Qty
Safety
1a
2a
3a
4a
5a
6a
7a
8a
9a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
1
1
1
1
1
2
2
4
2
1
1
1
1
1
2
1
1
1
1
6
2
1
2
Setup
Part
Operation
Description
Crankshaft Asm.
Piston Pin Clip
Piston Pin
Piston
Piston Spacer Ring
Spacer Rails
Second Piston Ring
Top Piston Ring
Semicircle Key
Qty
1
2
1
1
1
2
1
1
1
Maintenance
ITEM 61169
Page 19
Safety
1c
2c
3c
4c
5c
6c
7c
8c
9c
10c
11c
12c
13c
14c
15c
16c
17c
18c
Description
Qty
1
1
1
1
4
1
2
1
2
1
1
4
4
1
1
2
2
1
Setup
Part
Maintenance
1d
2d
3d
4d
5d
6d
7d
8d
9d
10d
11d
12d
13d
14d
15d
16d
17d
18d
19d
20d
21d
Description
Qty
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
2
1
1
2
1
1
Page 20
ITEM 61169
Description
Bolt M612
Oil Pump Gear Cap
Nut M6
Chain 6.3544
Gear
Bolt
Oil Pump Asm.
Qty
2
1
1
1
1
2
1
Safety
Part
Setup
Carburetor Gasket A
Carburetor Asm.
Carburetor Gasket B
Air Cleaner Gasket
Air Cleaner Asm.
Fan Volute Bushing
Bolt M520
Air Cleaner Bushing
Nut M6
Clip 11
Clip 10
Rubber Tube
Rubber Tube
Rubber Tube
Oil Separator Asm.
Spacer
Carburetor Asm.
Qty
Operation
1f
2f
3f
4f
5f
6f
7f
8f
9f
10f
11f
12f
13f
14f
15f
16f
17f
1
1
1
1
1
1
1
2
2
1
5
1
1
1
1
4
1
Maintenance
Part
ITEM 61169
Page 21
Safety
1g
2g
3g
4g
5g
6g
7g
8g
9g
10g
11g
12g
13g
Description
Bolt M612
Recoil Starter
Fan Cover
Bolt M520
Fan Cover Bushing
Screw ST4.816-F.H
Recoil Cage
Cooling Fan
Shroud B
Shroud
Bolt M512
Shroud Bushing
Nut M5
Qty
5
1
1
4
4
4
1
1
1
1
4
4
2
Setup
Part
1h
2h
3h
4h
5h
6h
7h
Description
Gasket
Elbow
Nut M6
Gasket
Muffler Asm.
Bolt M680
Bolt M650
Qty
1
1
2
1
1
1
2
Maintenance
Page 22
ITEM 61169
Description
Nut M121.25
Stator
Rotor
Bolt M540
Bolt M515
Trigger
Rubber Block
Bolt M625
Spark Plug
Ignition Asm.
Ignition Cap
Qty
1
1
1
2
2
1
1
1
1
1
1
Safety
Part
Setup
Qty
Operation
1j
2j
3j
4j
5j
6j
7j
8j
9j
10j
11j
12j
13j
14j
15j
16j
17j
18j
19j
20j
21j
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Maintenance
Part
ITEM 61169
Page 23
Safety
Setup
1k
2k
3k
4k
5k
6k
7k
8k
9k
10k
11k
12k
13k
14k
15k
16k
17k
18k
19k
Description
Screw M612
Side Cover
Screw M620
Lift Cover
Protector Asm.
Protector Asm. Seal
Top Cover
Right Cover
Bolt ST4.213
Nut M8
Cover Plate
Bolt M812
Rear Damping Pad
Front Damping Pad
Chassis Asm.
Bolt M616
Foot
Screw M516
Nut M5
Qty
5
1
2
1
1
1
1
1
1
8
1
4
2
2
1
4
4
2
2
Part
1m
2m
3m
4m
5m
6m
7m
Description
Governor Arm
Stepper Motor Stand
Bolt M416
Bolt M410
Bolt M46
Stepper Motor Asm.
Governor Spring
Qty
1
1
2
1
1
1
1
Maintenance
Page 24
ITEM 61169
Description
Inverter Asm.
U Rack
Screw M612
Bolt M613
U Rack
Rubber Foot
Qty
1
1
2
2
1
2
Safety
Part
Setup
Box
Screw M516
Screw M520
Rectifier Bridge KBPC 3502
Screw M510
Nut M4
Screw M516
Screw ST4.213
Screw M612
Ignition Controller
AC Outlet
Engine Switch
Panel Asm.
DC Outlet
Screw M412
Nut M5
Qty
Operation
1p
2p
3p
4p
5p
6p
7p
8p
9p
10
11
12
13
14
15
16
1
1
1
1
4
2
8
4
4
1
1
1
1
1
2
1
Maintenance
Part
ITEM 61169
Page 25
Wiring Diagram
DC coil
Safety
R
O
BL
PI
BU
Step motor
Main
coil
Setup
Control
coil
BU
BU
BU
FUSE
BL
BL
BL
BL
BL
BL
BL
BL
BL
BL
BL
R
BL
BU
O
BL
Inverter
Spring coil
BL
Operation
Y/G
BL
BR
OUTPUT
GR
BU
Y/G
O
OVERLOAD
W
R
P
LOW OIL
BL
Ignition coil
High
voltage
coil
BU
BL
R
O
W
BL
BU
Oil sensor
Spark
plug
BU
Engine
switch
BL
Black
BR
Brown
BU
Blue
Red
Green
White
Yellow
Orange
Purple
GR
Gray
Y/G Yellow/Green
PI
Pink
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTSTHERETO.
Record Products Serial Number Here:
Note: If product has no serial number,
record month and year of purchase instead.
Page 26
ITEM 61169
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 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.
Setup
Safety
Warranties
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
ITEM 61169
Page 27
Maintenance
Operation
6. Warranted Parts
1)
2)
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 Owners 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 fueluse
contained in the Owners Manual
d) Improper or inadequate maintenance of any warranted parts
e) Repairs performed outside of
theauthorizedwarranty servicedealers
f) Alterations by changing, adding to or
removing parts from theengine.
3)
4)
5)