Page 1
GENERATOR SET
16 HP - 7000/7500 WATTS
95960
SET UP, OPERATING, AND SERVICING INSTRUCTIONS
DANGER
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.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Only use OUTSIDE and
far away from windows,
doors, and vents.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright© 2007 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.
Manual Revised 08i
Page 2
SPECIFICATIONS
7000 Watts (Rated) / 7500 Watts (Maximum) / 60 Hz / 3600 RPM
Output Receptacles:
20 A / 120 V~ / 3-Prong / (Qty. 1 Duplex) with a 20 A Circuit Breaker
30 A / 120 V~ / 3-Prong Twist Lock / (Qty. 1) with a 30 A Circuit Breaker
Electrical Requirements
Engine Specications
Additional Features Locking ON/OFF with 2 Keys
Overall Dimensions 24-1/8” Long x 20-1/2” Wide x 24-1/2” High
Net Weight 188 Pounds
30 A / 240/120 V~ / 4-Blade Twist Lock / (Qty. 1) with two 30 A Circuit Breakers
Input Power: 12 VDC Battery / 7-1/4” Long x 3” Wide (not included) with an In-Line
Circuit Breaker
Voltmeters:
0 < - > 150 Volts / 50 Volt Marked Increments
0 < - > 300 Volts / 100 Volt Marked Increments w/50 Volt Hash Marks
16 HP / 4 Cycle / Air Cooled / Electric & Recoil Start / 3600 RPM
420cc Displacement / 6.6 Gallon Fuel Tank
Powered with Mid to High Octane, Unleaded Gasoline
Engine Family: 5CSG.41925C
Recommended Oil:
37 Fluid Ounces
SAE 30W (Above 32 Fahrenheit) / SAE 5W-30 (Below 32 Fahrenheit)
Recommended Spark Plug Gap: 0.028” ~ 0.031”
Estimated Run Time: 8 Hours @ 50% Load
Automatic Low Oil Shutdown
IMPORTANT! This product requires oil and fuel to be added before starting. Attempt-
ing to start the Engine without oil WILL ruin the Engine and void the warranty.
NOTE: The Engine’s carburetor may need to be adjusted by a qualied mechanic for
efcient high-altitude use.
The emission control system for this Generator’s Engine is warranted for standards
set by the U.S. Environmental Protection Agency and by the California Air Resources
Board (also known as CARB). For warranty information, refer to the last pages of this
manual
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. Write the product’s serial number in the back of the manual near the assembly diagram, or write month and year of purchase if product has no number. Keep
this manual and invoice in a safe and dry place for future reference.
Page 2SKU 95960 For technical questions, please call 1-800-444-3353.
Page 3
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, re, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. 1. Cluttered and dark areas invite acci-
dents.
Do not operate power tools in explosive atmospheres, such as in the pres-2.
ence of ammable liquids, gases, or dust. Power tools create sparks which
may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool. 3.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed. Children
should never be allowed in the work area.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when operat-1.
ing a power tool. Do not use a power tool while tired or under the inuence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. 2.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
Remove adjusting keys or wrenches before turning the power tool on. 3. A
wrench or a key that is left attached to a rotating part of the power tool may result
in personal injury.
Do not overreach. Keep proper footing and balance at all times. 4. Proper foot-
ing and balance enables better control of the power tool in unexpected situations.
5. Use safety equipment. Always wear eye protection. Dust mask, non-
skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.
Page 3SKU 95960 For technical questions, please call 1-800-444-3353.
Page 4
Tool Use And Care
Do not force the tool. Use the correct tool for your application. 1. The correct
tool will do the job better and safer at the rate for which it is designed. Do not force
the tool and do not use the tool for a purpose for which it is not intended.
Do not use the power tool if the Engine Switch does not turn it on or off. 2. Any
tool that cannot be controlled with the Engine Switch is dangerous and must be
replaced.
Disconnect the Spark Plug Wire from the Engine before making any adjust-3.
ments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally. Always disconnect the
Spark Plug Wire before performing any inspection, maintenance, or cleaning
procedures.
Store idle tools out of reach of children and other untrained persons. 4. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Keep the Generator clean.5. 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.
Check for misalignment or binding of moving parts, breakage of parts, and 6.
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.
Use only accessories that are recommended by the manufacturer for your 7.
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
Tool service must be performed only by qualied repair personnel. 1. Service or
maintenance performed by unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instruc-2.
tions 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 injury.
SPECIFIC SAFETY RULES
IMPORTANT! Your Warranty is voided if:1.
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Page 5
You do not put engine oil in the Engine’s crankcase prior to its rst use. Be-
fore each use, check the oil level. Never run the Engine with low or no engine oil.
Running the Engine with low or no Engine oil will permanently damage the Engine.
Maintain labels and nameplates on the Generator. 2. These carry important infor-
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.
Maintain a safe working environment. 3. Make sure there is adequate surrounding
workspace.
Avoid unintentional starting. 4. Make sure you are prepared to begin work before
turning on the Generator.
People with pacemakers should consult their physician(s) before use. 5. Elec-
tromagnetic elds 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.
Never leave the Generator unattended when it is running. 6. Turn off the Engine
of the Generator before leaving the work area.
Always use the Generator on a at, level surface.7.
Make sure to keep hands, ngers, and feet away from all moving parts of the 8.
Generator.
Keep all safety guards of the Generator in place and in proper working order.9.
TOXIC FUMES, FIRE, AND EXPLOSION PRECAUTIONS
This Generator is designed for outdoor use only. Do not operate the Genera-1.
tor in a closed area or in a poorly ventilated area. When running, the Engine
of this unit 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 car-
bon monoxide fumes in the work area and in the surrounding area.
Gasoline fuel and fumes are ammable, and potentially explosive. 2. Use
proper fuel storage and handling procedures. Always have multiple ABC class re
extinguishers nearby.
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. 4. Dis-
pose of uids and cleaning materials as per any local, state, or federal codes and
regulations. Store oil rags in a covered metal container.
Never store fuel or other ammable materials near the Generator.5.
Page 5SKU 95960 For technical questions, please call 1-800-444-3353.
Page 6
Do not smoke, or allow sparks, ames, or other sources of ignition around 6.
the Generator.
Keep grounded conductive objects, such as tools, away from exposed, live 7.
electrical parts and connections to avoid sparking or arcing. These events
could ignite fumes or vapors.
Do not rell the Fuel Tank while the Engine is running or hot. 8.
Do not operate the Generator with known leaks in the Engine’s fuel system.9.
Use only oil and fuel recommended in the “Product Specications” section 10.
of this manual.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always 1.
make sure the Engine Switch is in its “OFF” position. Allow the Engine to
completely cool. Then, remove the Spark Plug Wire from the Spark Plug.
Do not alter or adjust any part of the Generator or its Engine that is assem-2.
bled and supplied by the manufacturer or distributor.
Always follow and complete scheduled Engine maintenance.3.
CHEMICAL PRECAUTIONS
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.1.
Avoid body contact with fuels, oils, and lubricants used in the Engine. 2. If
swallowed, seek immediate medical treatment. Do not induce vomiting if fuel is
swallowed. For skin contact, immediately wash with soap and water. For eye con-
tact, immediately ush eyes with clean water.
NOISE PRECAUTION
Prolonged exposure to high noise levels is hazardous to hearing. 1. Always
wear ANSI-approved hearing protection when operating or working around the
Generator when it is running.
ELECTRICAL PRECAUTIONS
All connections and conduits from the Generator to the load must only be installed 1.
by trained and licensed electricians, and in compliance with all relevant local, state,
Page 6SKU 95960 For technical questions, please call 1-800-444-3353.
Page 7
and federal electrical codes and standards, and other regulations where applica-
ble.
The Generator must be earth-grounded in accordance with all relevant electrical 2.
codes and standards before operation.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE AMPERES
(at full load)
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
25’ 50’ 75’ 100’ 150’
* Based on limiting the line voltage drop to ve volts at 150% of the rated
EXTENSION CORD LENGTH
amperes.
If an extension cord (not included) is used, make sure to use only UL® listed cords 3.
having the correct gauge and length. (See Table A.)
Do not attempt to connect or disconnect load connections while standing in water, 4.
or on wet or soggy ground.
Do not touch electrically energized parts of the Generator and interconnecting 5.
cables or conductors with any part of the body, or with any non-insulated conduc-
tive object.
Connect the Generator only to a load or electrical system (120 volt or 240 volt) that 6.
is compatible with the electrical characteristics and rated capacities of the Genera-
tor.
Make sure the Engine Switch is in its “OFF” position before moving the Generator 7.
and before performing any service, maintenance, or cleaning procedures on the
unit.
Keep all electrical equipment clean and dry. Replace any wiring where the insula-8.
tion is cracked, cut, abraded, or otherwise degraded. Replace terminals that are
worn, discolored, or corroded. Keep terminals clean and tight.
Insulate all connections and disconnected wires.9.
Guard against electric shock. Prevent body contact with grounded surfaces such 10.
as pipes, radiators, ranges, and refrigerators.
Use only Class BC or Class ABC re extinguishers on electrical res.11.
Page 7SKU 95960 For technical questions, please call 1-800-444-3353.
Page 8
MISC. PRECAUTION
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.
Symbology
V~
A
n0 xxxx/min.
Volts Alternating Current
Amperes
No Load Revolutions per Minute
(RPM)
UNPACKING
When unpacking, check to make sure all of the parts shown on the Parts List in this
manual are included. If any parts are missing or broken, please call Harbor Freight
Tools at the number shown on the cover (and at the bottom of each page) of this manual as soon as possible.
CONTROL PANEL FEATURES
7 7
VOLTMETER VOLTMETER
2
3
FIGURE A
10B
5 5
10
5
9
8
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Page 9
Engine Switch (2): 1. Used to start and stop the Engine. To start, insert the En-
gine Switch Key and turn to the right to its “START” position. Then immediately
release the Key. To turn off the Engine, turn the Key all the way to the left to its
“OFF” position. Always remove the Key from the Engine Switch when the unit is
not in use.
(See Figure A, previous page.)
Outlet Sockets (8, 10, 10B): 2. The Generator features three Outlet Sockets with
which to power tools and equipment. The type and voltage of the Outlet Sockets
are as follows:
3-Prong, 120 volt Outlet Socket (8)a.
3-Prong, Twistlock, 120 volt Outlet Socket (10)b.
4-Prong, Twistlock, 240/120 volt Outlet Socket (10B)c.
WARNING! Connect tools and equipment only to the Outlet Socket (120 volt or
240 volt) that is compatible with the electrical characteristics and rated capacities
of the tools and equipment being used. (See Figure A.)
Circuit Breakers (3, 5): 3. The Generator features ve Circuit Breakers to protect
the unit from overloading.
Onea. Circuit Breaker controls the 3-Prong, 120 volt Outlet Socket (8).
Oneb. Circuit Breaker controls the 3-Prong, Twistlock, 120 volt Outlet Socket (10).
Twoc. Circuit Breakers control the 4-Prong, Twistlock, 240/120 volt Outlet Socket
(10B).
Oned. In-Line Circuit Breaker to protect the Engine’s Starter (83A).
Should any of the four Circuit Breakers “trip”, the Engine will automatically shut
down. In this event, unplug all loads from the Generator. Allow the Generator to
cool down. Then, press the tripped Circuit Breaker and restart the Engine. (See
Figure A.)
Voltmeters (7): 4. The Generator features two Voltmeters which provide readings
of voltage output depending on which of the three Outlet Sockets (8, 10, 10B) are
being used. (See Figure A.)
Grounding Terminal (9): 5. Prior to each use, always connect a ground wire (not
included) to the Grounding Terminal to properly ground the Generator.
(See Figure C, page 11.)
BATTERY INSTALLATION
1. The Engine of the Generator may be started manually or electrically.
To use the Engine’s electric start capability, a Battery (45, not included) must rst 2.
be installed. The type and size Battery required is: 12 volt DC, 7-1/4” long by 3”
wide. (See Figure B, next page.)
Page 9SKU 95960 For technical questions, please call 1-800-444-3353.
Page 10
Locate the factory pre-installed Battery Guard Plate (44) and Battery Tray (48) be-3.
neath the Control Panel of the Generator. (See Figure B.)
Slide the Battery into the Battery Guard Plate (44) with the Battery’s terminals fac-4.
ing outward and with the Battery’s negative (--) terminal facing left. (See Figure
B.)
Align the two mounting holes in the Battery Bracket (47) with the two threaded 5.
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 B.)
FIGURE B
NEGATIVE BATTERY CABLE
12 VDC BATTERY
(NOT INCLUDED)
BATTERY GUARD PLATE (44)
BATTERY BRACKET (47)
POSITIVE BATTERY CABLE
BATTERY TRAY (48)
BOLT WITH LOCK WASHER (46)
Connect the Engine’s Positive Battery Cable (RED +) to the Battery’s positive (+) 6.
terminal. Then connect the Engine’s Negative Battery Cable (BLACK --) to the
Battery’s negative (--) terminal. (See Figure B.)
TO ATTACH THE WHEEL ASSEMBLY
With additional assistance, and a proper lifting device, raise the left side of the 1.
Generator about 6 to 8 inches off the oor surface.
Attach the two Axle Brackets (53) to the lower Frame (42), using two Bolts (52) and 2.
two Lock Washer Nuts (13) for each Axle Bracket.
(See Assy. Diagram.)
Slide the Axle (49) through the two Axle Brackets (53). 3. (See Assy. Diagram.)
Insert one Wheel (50) onto each end of the Axle (49). 4. (See Assy. Diagram.)
Page 10SKU 95960 For technical questions, please call 1-800-444-3353.
Page 11
Secure the Axle (49) and Wheels (50) in place, using four Pins (51). 5.
(See Assy. Diagram.)
INSTALLATION INSTRUCTIONS
IMPORTANT: 1. Electrical and other permits may be required for the installation of
emergency or portable power systems. Make sure to investigate the local building
and electrical codes before installing this unit.
Locate the Generator (outdoors only) where cooling air is readily available. Locate 2.
the Generator so that the air inlets and outlets are not blocked by obstructions
such as bushes, trees, walls, snow drifts, etc. Locating the Generator in the path
of heavy winds may require the placement of a barrier for protection. The air inlet,
in normal weather conditions, should face the prevailing wind direction.
Locate the Generator on a concrete slab or other area where rain drainage or ood 3.
waters can not reach it.
Generator placement should allow four feet of access to all sides for maintenance 4.
and proper air cooling.
Place the Generator as close as possible to the electrical tools and equipment be-5.
ing powered to reduce the length of extension cords.
To ground the Generator, connect a #6 AWG grounding wire (not included) from 6.
the Grounding Terminal (9) 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. (See Figure C.)
FIGURE C
GROUNDING TERMINAL (9)
#6 AWG GROUNDING WIRE
(NOT INCLUDED)
GROUNDING ROD
CONCRETE SLAB
(NOT INCLUDED)
PRE-START INSTRUCTIONS
IMPORTANT: Your Warranty is voided if you do not put engine oil in the 1.
Engine’s crankcase prior to its rst use. Before each use, check the oil level.
Never run the Engine with low or no engine oil. Running the Engine with no or low
engine oil WILL permanently damage the Engine.
Page 11SKU 95960 For technical questions, please call 1-800-444-3353.
Page 12
The Engine MUST be lled with a high quality engine oil. If the Engine will be 2.
run in temperatures above 32 degrees Fahrenheit, use SAE 30 weight oil. If the
Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE 5W-30
weight oil.
To add engine oil, unscrew and remove the Oil Dipstick (65A). Pour engine oil into 3.
the Dipstick Hole until the level of oil is even with the top edge of the Dipstick Hole.
Then, make sure to screw the Oil Dipstick back into its Dipstick Hole.
(See Figure D.)
FUEL TANK (31)
FUEL TANK
GAUGE
FUEL FILTER (32)
FUEL TANK CAP (34)
FIGURE E
4. To ll the Fuel Tank (31), unscrew and remove the Fuel Tank Cap (34). Fill the
Fuel Tank with mid-to-high octane unleaded gasoline. Then replace the Fuel
Tank Cap. Thereafter, check the Fuel Tank Gauge for the amount of unleaded
gasoline. When necessary, rell the Fuel Tank. (See Figure E.)
Periodically, check the Fuel Filter (32) for excessive dirt and debris. If necessary, 5.
remove the Fuel Filter and clean with compressed air. (See Figure E.)
FUEL VALVE (41)
CHOKE LEVER (21A)
FIGURE F
REV 07h
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Page 13
OPERATING INSTRUCTIONS
Check to make sure the Engine Switch (2) is in its 1. “OFF” position.
(See Figure A.)
IMPORTANT: 2. Make sure to unplug any load from the Generator before starting to
prevent permanent damage to any appliances, tools, or equipment.
Turn the Engine Fuel Valve (41) to its3. “OPEN” position. Then turn the Engine
Choke Lever (21A) to its “CHOKE” position. No choke is required if the Engine is
warm. Make sure the Choke Lever is in the “RUN” position when starting a warm
Engine. (See Figure F.)
To start the Engine, using the Battery (45) for cranking power, insert the Engine 4.
Switch Key into the Engine Switch (2). Then turn the Key to the “START” position.
NOTE: To prolong Starter life, use short starting cycles (5 seconds maximum).
Then wait one minute before attempting to start again. (See Figure A.)
To start the Engine manually, using the Starter Handle (41A), insert the Engine 5.
Switch Key and turn the Key to its “RUN” position. Grasp the Starter Handle, and
pull slowly until resistance is felt. Allow the Starter Rope to rewind slowly. Then,
pull the Starter Handle with a rapid, full arm stroke. Allow the Rope to rewind
slowly. If necessary, repeat this procedure until the Engine starts.
When the Engine starts, slowly move the Choke Lever (21A) to its 6. “RUN” position.
(See Figure F.)
IMPORTANT: 7. Allow the Generator to run at no load for ve minutes after each
start-up so that the Engine and Generator can stabilize.
TO CONNECT ELECTRICAL LOADS
Start the Engine, and allow the Engine and Generator to run and warm up for ve 1.
minutes after starting with no electrical load.
2. WARNING! Connect 120 VAC appliances, tools, and equipment only to the two
120 VAC Outlet Sockets (8, 10). Connect 240 VAC appliances, tools, and equipment only to the one 240 VAC Outlet Socket (10B). (See Figure A.)
3. CAUTION! Never exceed the rated capacity for this Generator, as serious dam-
age 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.
Most appliances, tools, and equipment will list on the motor nameplate the start-4.
ing and running voltage and amperage requirements. Use the following formula to
convert voltage and amperage to wattage:
Page 13SKU 95960 For technical questions, please call 1-800-444-3353.
Page 14
Volts x Amps = Watts (example: 120 Volts x 3 Amps = 360 Watts)a.
To determine the approximate wattage requirement for most appliances, tools, b.
and equipment with “inductive” type motors, multiply the wattage that was calculated by 2 times to assure adequate Generator capacity.
The starting and running wattage for “resistant” loads are the same. Example: a c.
100 watt light bulb requires only 100 watts to turn on. Most resistant loads will be
listed in wattage.
Always power the largest electric motor rst. The, plug in other appliances, tools, 5.
and equipment.
Connect “inductive” load appliances, tools, and equipment rst. Inductive loads a.
consist of small hand tools and some small appliances. Connect the items that
require the most wattage rst.
Connect any lights next.b.
Voltage sensitive appliances, tools, and equipment should be the last to be con-c.
nected to the Generator. 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 surge protector into the Generator.
IMPORTANT!6. 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.
Once the Engine is running, simply connect the 120 VAC appliances, tools, and 7.
equipment into the 120 VAC Outlet Sockets (8, 10). Also, connect a 240 VAC appliance, tool, or equipment into the 240 VAC Outlet Socket (10B). (See Figure A.)
NOTE: 8. If Engine speed or voltage uctuates with a load below 250 watts, move
the Engine Choke Lever (21A) to the “HALF-CHOKE” position. (See Figure F.)
When nished using the Generator, disconnect all electrical loads. Turn the En-9.
gine Switch (2) to its “OFF” position to stop the Engine. Then, close the Engine
Fuel Valve (41). (See Figures A and F.)
Allow the Generator and its Engine to completely cool. Then store the unit in a 10.
clean, dry, safe location out of reach of children and other unauthorized people.
INSPECTION, MAINTENANCE, AND CLEANING
1. WARNING! Always make sure the Engine Switch (2) is in its ‘OFF” position and
the Spark Plug Wire is removed from the Spark Plug (28A) prior to performing any
inspection, maintenance, or cleaning procedures.
Before each use: 2. Inspect the general condition of the Generator and its Engine.
Check for loose screws, misalignment or binding of moving parts, cracked or
Page 14SKU 95960 For technical questions, please call 1-800-444-3353.
Page 15
broken parts, loose hose connections, and any other condition that may affect the
safe operation of the unit. If abnormal noise or vibration occurs, have the problem
corrected before further use.
GENERATOR MAINTENANCE
Keep the Generator clean and dry at all times.1.
The Generator should not be operated or stored in locations that include exces-2.
sive moisture, dust, ammable or corrosive vapors. If these substances are on the
Generator, clean with a soft cloth or brush.
Do not use a garden hose or anything with liquid to clean the Generator. Liquid 3.
may enter the cooling air slots and could damage the interior workings of the Generator.
ENGINE MAINTENANCE
After the rst 5 to 8 hours of use: 1. Change the oil. Then, change the oil every
50 hours of use. Change the oil every 25 hours of use when operating the Engine
under a heavy load or in high temperatures.
FIGURE G
PLUG (59A)
OIL DIPSTICK (65A)
2. To change the oil, remove the Plug (59A) and allow the old oil to drain in a proper
container. Once drained, replace the Plug. (See Figure G.)
NOTE: 3. If the Engine will be run in temperatures above 32 degrees Fahrenheit,
use SAE 30 weight oil. If the Engine will be run in temperatures below 32 degrees
Fahrenheit, use SAE 5W-30 weight oil.
To add engine oil, unscrew and remove the Oil Dipstick (65A). Pour engine oil into 4.
the Dipstick Hole until the level of oil is even with the top edge of the Dipstick Hole.
Then, make sure to screw the Oil Dipstick back into its Dipstick Hole.
(See Figure G.)
Page 15SKU 95960 For technical questions, please call 1-800-444-3353.
Page 16
AIR CLEANER SEPARATOR (20A)
FIGURE H
AIR CLEANER COVER (18A)
AIR CLEANER ELEMENT (19A)
5. After every 25 hours of use: Service the Air Cleaner Element (19A) and Air
Cleaner Separator (20A). (See Figure H.)
To do so, remove the Air Cleaner Cover (18A). Remove the Air Cleaner Element 6.
(19A). Immerse the Air Cleaner Element in a mild solvent and squeeze the Element several times to clean. Remove the Element from the solvent and squeeze
thoroughly to dry. Then, squirt several drops of a light weight oil into the Element
and squeeze the Element so oil reaches all parts of the Element. (See Figure H.)
Use compressed air to clean the Air Element Separator (20A). Then replace the 7.
Air Element Separator, Air Cleaner Element, and Air Cleaner Cover (18A).
(See Figure H.)
Clean more often under dusty conditions or when airborne debris is present. Re-8.
place Air Cleaner parts if necessary. (See Figure H.)
0.028” - 0.031”
SPARK PLUG (28A)
9. After every 100 hours of use: Clean and re-gap the Spark Plug (28A).
(See Figure I.)
To do so, use a 13/16” spark plug wrench (not included) to remove the Spark Plug.10.
Use a ne-grade sandpaper to clean off carbon build-up from the electrodes of the 11.
Spark Plug (28A). Clean with compressed air to remove residue. (See Figure I.)
FIGURE I
Page 16SKU 95960 For technical questions, please call 1-800-444-3353.
Page 17
Measure the electrode gap with a suitable gauge. The gap should be 12. 0.028” to
0.031”. If necessary, correct the gap by carefully bending the side of the electrode.
(See Figure I.)
Reinstall the Spark Plug (28A) carefully to avoid cross-threading. 13. (See Figure I.)
Daily: 14. Inspect the Fuel Filter (32).
FUEL TANK (31)
FUEL TANK
GAUGE
FUEL FILTER (32)
FUEL TANK CAP (34)
FIGURE J
15. To do so, remove the Fuel Tank Cap (34) from the Fuel Tank (31).
(See Figure J.)
If necessary, use compressed air to remove any dirt and debris from the Fuel Filter 16.
(32). Then replace the Fuel Filter and Fuel Tank Cap (34). (See Figure J.)
When storing the Generator for extended periods: Before storing, drain all fuel
out of the Engine’s Fuel Tank (31). If this is not followed, old fuel in the Fuel Tank
may clog the Carburetor of the Engine and prevent it from starting until cleaned
out. Then make sure to store the unit in a clean, dry, safe location out of
reach of children and other unauthorized people.
PLEASE READ THE FOLLOWING
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 PARTS THERETO.
Page 17SKU 95960 For technical questions, please call 1-800-444-3353.
Page 18
TROUBLESHOOTING
Page 18SKU 95960 For technical questions, please call 1-800-444-3353.
Page 19
PARTS LIST - GENERATOR
Part Description Qty.
1 Bolt w/Lock Washer (M6x12) 4
2 Engine Switch 1
3 Circuit Breaker (30 Amp) 1
4 Control Panel 1
5 Circuit Breaker (20 Amp) 4
6 Bolt (M5x12) 2
7 Voltmeter 2
8 Outlet Socket (120V) 2
9 Grounding Terminal 1
10 Outlet Socket (120V) 1
10B Outlet Socket (240V/120V) 1
11 Shock Absorber 4
12 Bolt (M5x215) 2
13 Lock Washer Nut (M8) 12
14 Stator Cover 1
15 Alternator Back Cover 1
16 Automatic Voltage Regulator 1
17 Bolt (M5x12) 7
18 Rectier 1
19 Bolt (M5x20) 2
20 Cable Sheath 1
21 Carbon Brush 1
22 Bolt (M10x1.25x265) 1
23 Bolt (M6x180) 4
24 Bolt (M5x20) 4
25 Connection Board 1
26 Nut (M5) 4
27 Stator 1
28 Rotor 1
29 Cooling Fan 1
30 Heat Insulation Board Assy. 1
31 Fuel Tank 1
32 Fuel Filter 1
33 Seal Ring 1
34 Fuel Tank Cap 1
37 Lock Washer Bolt (M6x30) 4
Part Description Qty.
38 Spacer 4
39 Rub Washer 4
40 Bushing 4
41 Fuel Valve 1
42 Frame 1
43 Switch Box Cover 1
44 Battery Guard Plate 1
45 Battery (Not Included) 1
46 Bolt w/Lock Washer (M6x12) 2
47 Battery Bracket 1
48 Battery Tray 1
49 Axle 1
50 Wheel 2
51 Pin 4
52 Bolt (M8x20) 8
53 Axle Bracket 2
54 Shock Absorbing Foot 2
55 Bolt (M8x25) 2
56 Bracket 2
57 Nut (M8) 2
58 Connection Board (Mufer) 1
59 Bolt (M8x20) 4
60 Bolt w/Lock Washer (M6x12) 8
61 Handle 2
62 Bolt (M8x45) 2
63 Pin (8x45) 2
64 Bolt (M6x45) 4
65 Link 2
66 Washer (M6) 4
67 Lock Washer 4
68 Nut (M6) 4
69 Nut (M8) 2
70 Pin (2x20) 2
Some parts are listed and shown for illustration purposes only, and are not
NOTE:
available individually as replacement parts.
Page 19SKU 95960 For technical questions, please call 1-800-444-3353.
Page 20
ASSEMBLY DIAGRAM - GENERATOR
Page 20SKU 95960 For technical questions, please call 1-800-444-3353.
Page 21
PARTS LIST - ENGINE
Part Description Qty.
1A Mufer 1
2A Cylinder Head Bolt 4
3A Cylinder Head Cover Bolt 4
4A Cylinder Head Cover 1
5A Lock Nut 2
6A Adjusting Screw 2
7A Rocker Arm 3
8A Rocker Arm Bolt 2
9A Valve Push Rod Guide Board 1
10A Valve Push Rod 2
11A Cylinder Head 1
12A Carburetor Shield 1
13A Carburetor Packing 1
14A Carburetor Assy. 1
15A Air Cleaner Case 1
16A Air Cleaner Seal 1
17A Bolt (M6) 4
18A Air Cleaner Cover 1
19A Air Cleaner Element 1
20A Air Cleaner Separator 1
21A Choke Lever 1
22A Carburetor Packing (II) 1
23A Stud Bolt (M6x109) 2
24A Intake Valve 1
25A Exhaust Valve 1
26A Cylinder Head Gasket 1
27A Exhaust Pipe Stud 2
28A Spark Plug 1
29A Valve Guide 2
30A Valve Spring 2
31A Rocker Shaft Circlip 2
32A Anti-Wear Valve Stem Protector 2
33A Cylinder Head Cover Packing 1
34A Governor Spring 1
35A Bolt 1
36A High Tension Line 1
37A Ignition Coil 1
38A Nut (Special 14mm) 1
Part Description Qty.
39A Starter Ratchet Spring 2
40A Starter Rope 1
41A Starter Handle 1
42A Recoil Starter 1
43A Spiral Spring 1
44A Starter Wheel 1
45A Circlip 1
46A Starter Ratchet 2
47A Friction Plate Screw 1
48A Cover 1
49A Starter Pulley 1
50A Cooling Fan 1
51A Flywheel Magneto 1
52A Cylinder Block 1
53A Speed Control Lever 1
54A Governor Arm 1
55A Governor Spring 1
56A Governor Support 1
57A Bolt (M6x15) 2
58A Oil Alert Nut 1
59A Plug (M10x15) 2
60A Plug Washer 2
61A Oil Alert 1
62A Bolt (M6) 2
63A Crankshaft 1
64A Crankshaft Gear 1
65A Oil Dipstick 2
66A Oil Dipstick Seal Ring 2
68A Bolt (M8x35) 1
69A Gear Case Packing 6
70A Bearing 2
71A Camshaft Assy. 1
72A Locating Pin 4
73A Oil Seal 2
74A Connecting Rod Bolt 2
75A Connecting Rod Cap 1
76A Connecting Rod 1
77A Piston 1
Page 21SKU 95960 For technical questions, please call 1-800-444-3353.
Page 22
PARTS LIST - ENGINE (CONT.)
Part Description Qty.
78A Compression Ring (I) 1
79A Compression Ring (II) 1
80A Oil Scraper Ring 1
81A Piston Pin 1
82A Piston Pin Circlip 1
Part Description Qty.
83A Starter 1
84A Gear 1
85A Fuel Pipe 1
NOTE: Some parts are listed and shown for illustration purposes only, and are not
available individually as replacement parts.
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Page 22SKU 95960 For technical questions, please call 1-800-444-3353.
Page 23
ASSEMBLY DIAGRAM -ENGINE
Page 23SKU 95960 For technical questions, please call 1-800-444-3353.
Page 24
WIRING DIAGRAM
REV 08g
Page 24SKU 95960 For technical questions, please call 1-800-444-3353.
Page 25
LIMITED 1 YEAR / 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 for a period
of ninety days from date of purchase that the engine/motor, the belts (if so equipped),
and the blades (if so equipped) are free of defects in materials and workmanship. Harbor Freight Tools also warrants to the original purchaser, for a period of one year from
date of purchase, that all other parts and components of the product are free from
defects in materials and workmanship (90 days if used by a professional contractor or
if used as rental equipment). 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 veries 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 specic 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 certied 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.
Page 25SKU 95960 For technical questions, please call 1-800-444-3353.
Page 26
EMISSION CONTROL SYSTEM WARRANTY (CONT.)
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 Responsibilities1.
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 modications.
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 reason-
able 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.
Harbor Freight Tools Emission Control Defects Warranty Provisions
1. Length of Coverage2.
HFT warrants to a rst 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 rst retail
purchaser.
2. No Charge Repair or Replacement3.
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 Coverage4.
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 Exclusions5.
Warranty claims shall be led 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:
Use of parts which are not authorized by HFTa)
Improper installation, adjustment or repair of the engine or of any warranted part unless performed by an authorized war-b)
ranty center
Failure to follow recommendations on fuel use contained in the Owner’s Manualc)
Improper or inadequate maintenance of any warranted partsd)
Repairs performed outside of the authorized warranty service dealerse)
Alterations by changing, adding to or removing parts from the engine.f)
5. Service and Maintenance6.
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 rst 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 qualied technician/mechanic to perform all required maintenance, as
outlined in the Inspection, Cleaning, and Maintenance section in this manual.
Page 26SKU 95960 For technical questions, please call 1-800-444-3353.
Page 27
EMISSION CONTROL SYSTEM WARRANTY (CONT.)
6. Warranted Parts7.
1) Fuel Metering System
Carburetor and its internal parts.i)
Fuel pump (if so equipped).ii)
Cold start enrichment system.iii)
2) Air Induction System
Intake pipe/manifold.i)
Air cleaner.ii)
3) Ignition System
Spark plug.i)
Magneto ignition system.ii)
4) Catalyst System (if so equipped)
Exhaust pipe stud.i)
Mufer.ii)
Catalytic converter (if so equipped).iii)
5) Miscellaneous Items Used in Above Systems
Vacuum, temperature and time sensitive valves and switches.i)
Hoses, belts, connectors, and assemblies.ii)
Page 27SKU 95960 For technical questions, please call 1-800-444-3353.
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