Harbor Freight Tools 61169 Product manual

REV 15a

Owner’s Manual & Safety Instructions

Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference.

Using a generator indoors CAN

Using an engine indoors

KILL YOU IN MINUTES.

CAN KILL YOU IN MINUTES.

Generator exhaust contains

Engine exhaust contains carbon monoxide. Thiscarbonis a monoxidepoison you .cannotThis seeis aorpoisonsmell. you cannot see or smell.

	NEVER use	Only use OUTSIDE
	a home or garage,	and far away from
	EVENNEVERIF doorsuse insideand	Only use OUTSIDE
		windows, doors,
	a home or garage,	and far away from
		and vents.
	windows a e open.
	EVEN IF doors and	windows, doors,
		and vents.
	windows are open.

Visit our website at: http://www.harborfreight.com Email our technical support at: [e-mail]

Email our Engine support at: [e-mail]

When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken, please call 1-888-866-5797 as soon as possible.

Copyright© 2013 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.

Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.

Table of Contents

Specifications..............................................	2
Safety	3
Setup...........................................................	7
Operation	8

Maintenances	13
Troubleshooting.........................................	17
Parts Lists and Diagrams...........................	19
Warranties..................................................	27

Specifications

			120VAC, 60Hz, 1 Phase
		Output	12VDC, 8.3A (nominal)
	Generator		2200W Running
			2500W Peak
		Receptacles	2x NEMA #5-20 (3-prong, 120VAC)
			1x 12VDC Two Pin Outlet
	Displacement		125cc
	Compression Ratio		8.5:1
	Engine Type		Horizontal Single Cylinder
			4-stroke, OHC
	Cooling System		Forced air cooled
		Type	87+ octane stabilizer treated
	Fuel		unleaded gasoline
		Capacity	1.35 Gallon
	Engine Oil	Type SAE	10W-30
		Capacity	1 Quart
	Run Time @ 50% Load		5-1/2 hr.
	with full tank
	Sound Level at 23 feet, 50% load		64 dB
	Bore x Stroke		52.4mm x 57.8mm
	Spark Plug	Type	A7RTC
		Gap	0.7 - 0.8 mm
	Valve Clearance	Intake	0.10 - 0.15 mm
		Exhaust	0.15 - 0.20 mm
	Engine Speed		5500 RPM

The emissions control system for this Engine is warranted for standards set by the

U.S. Environmental Protection Agency. For warranty information, refer to the last pages of this manual.

Page 2

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ITEM 61169

WARNING SYMBOLS AND DEFINITIONS

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that

follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Addresses practices not related to personal injury.

Symbol Definitions

Symbol	Property or Statement
RPM	Revolutions Per Minute
HP	Horsepower
AWG	American Wire Gauge
	WARNING marking concerning
	Risk of Eye Injury. Wear ANSI-approved
	safety goggles with side shields.
	Read the manual before
	set-up and/or use.

Symbol	Property or Statement
	WARNING marking concerning
	Risk of Hearing Loss.
	Wear hearing protection.
	WARNING marking concerning
	Risk of Respiratory Injury.
	Operate engine OUTSIDE and far away
	from windows, doors, and vents.
	WARNING marking concerning
	Risk of Fire while handling fuel.
	Do not smoke while handling fuel.
	WARNING marking concerning
	Risk of Fire.
	Do not refuel while operating.
	Keep flammable objects
	away from engine.

IMPORTANT SAFETY INSTRUCTIONS

WARNING! Read all instructions.

Failure to follow all instructions listed below may result in fire, serious injury and/or DEATH.

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.

SAVE THESE INSTRUCTIONS

Safety

Setup

Operation

Maintenance

ITEM 61169

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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.

2.Have multiple ABC class fire extinguishers nearby.

3.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.

4.Set up and use only on a flat, level, well ventilated surface.

5.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.

6.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.

7.Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up.

8.Use only lubricants and fuel recommended in the Specifications chart of this manual.

9.Improper connections to a building electrical system can allow electrical current from the generator

to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored. Consult

the utility company and a qualified electrician if intending to use the generator for back up power.

10.Do not operate the generator before grounding. The generator must be earth-grounded

in accordance with all relevant electrical codes and standards before operation.

Operating Precautions

1.CARBON MONOXIDE HAZARD Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage,

EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

2.Never use a generator indoors, including in garages, basements, crawl spaces and sheds. Opening doors and windows or using fans will NOT prevent carbon monoxide build up in the home.

3.When using generators, keep them outdoors and far away from open doors, windows, and vents to avoid toxic levels of carbon monoxide from building up indoors.

4.If you start to feel sick, dizzy, or weak while using a generator, get to fresh air right away. The carbon monoxide from generators can quickly lead to full incapacitation and death.

5.Keep children away from the equipment, especially while it is operating.

6.Keep all spectators at least six feet from the engine during operation.

7.Fire Hazard! Do not fill gas tank while engine is running. Do not operate if gasoline has been spilled. Clean spilled gasoline before starting engine.

Do not operate near pilot light or open flame.

8.Do not touch engine during use. Let engine cool down after use.

9.Never store fuel or other flammable materials near the engine.

10.If the plugged in product operates abnormally or unusually slow, immediately stop using the generator as a power source. 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.

11.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.

Page 4

For Generator technical questions, please call 1-888-866-5797.

ITEM 61169

Operating Precautions (cont.)

12.Do not exceed the running wattage of the generator. Make sure that the total electrical rating of the

all of the tools or appliances plugged into the generator at the same time does not exceed that of the generator. Check that the startup surge will not be beyond the limit of the generator.

13.Avoid substantially overloading which will trip the circuit breaker. Slightly overloading the generator may not trip the circuit breaker, but will lead to premature generator failure.

14.Do not attempt to connect or disconnect load connections while standing in water, or on wet or soggy ground.

15.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.

16.Connect the generator only to a load that is compatible with the electrical characteristics and running wattage of the generator.

17.Insulate all connections and disconnected wires.

18.Guard against electric shock.

Prevent body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators.

19.Only use a suitable means of transport and lifting devices with sufficient weight bearing capacity when transporting the generator.

20.Secure the generator on transport vehicles to prevent it from rolling, slipping, and tilting.

21.Industrial applications must follow OSHA requirements.

22.Do not leave the generator unattended when it is running. Turn off the generator (and remove safety keys, if available) before leaving the work area.

23.The generator can produce high noise levels. Prolonged exposure to noise levels

above 85 dBA is hazardous to hearing.

Wear ear protection when operating the generator or when working nearby while it is operating.

24.Keep access doors on enclosures locked.

25.Wear ANSI-approved safety glasses and hearing protection during use.

26.People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure. Caution is necessary when near the

engine’s magneto or recoil starter.

27.Use only accessories that are recommended by Harbor Freight Tools for your model. Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment.

28.Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Gasoline-powered engines may ignite the dust or fumes.

29.Stay alert, watch what you are doing and use common sense when operating this

generator. Do not use while tired or under the influence of drugs, alcohol or medication.

30.Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

31.Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts.

32.Do not cover the generator during operation.

33.Keep the generator and surrounding area clean at all times.

34.Use the equipment, accessories, etc.,

in accordance with these instructions and in the manner intended for the particular type of equipment, taking into account the working conditions and the work to be performed.

Use of the equipment for operations different from those intended could result in a hazardous situation.

35.Do not operate the equipment with known leaks in the engine’s fuel system.

36.WARNING: This product contains or, when used, produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.)

37.When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oil rags in a bottom-ventilated, covered, metal container.

38.Keep hands and feet away from moving parts. Do not reach over or across

equipment while operating.

39.Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation.

If damaged, have the equipment serviced before using. Many accidents are caused by poorly maintained equipment.

40.Use the correct equipment for the application. Do not modify the equipment and do not use the

equipment for a purpose for which it is not intended.

Safety

Setup

Operation

Maintenance

ITEM 61169

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Service Precautions

1.Before service, maintenance, or cleaning:

a.Unplug all devices from the generator.

b.Turn the engine switch to its “OFF” position.

c.Allow the engine to completely cool.

d.Then, remove the spark plug cap from the spark plug.

2.Keep all safety guards in place and in proper working order. Safety guards include muffler, air cleaner, mechanical guards,

and heat shields, among other guards.

3.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.

4.Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor. Only a qualified service technician may adjust parts that may increase or decrease governed engine speed.

5.Wear ANSI-approved safety goggles, heavy duty work gloves, and

dust mask/respirator during service.

6.Maintain labels and nameplates on the equipment. These carry important information.

If unreadable or missing, contact Harbor Freight Tools for a replacement.

7.Have the equipment serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the equipment is maintained. Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly.

8.Store equipment out of the reach of children.

9.Follow scheduled engine and equipment maintenance.

Refueling:

1.Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling.

2.Do not refill the fuel tank while the engine is running or hot.

3.Do not fill fuel tank to the top.

Leave a little room for the fuel to expand as needed.

4.Refuel in a well-ventilated area only.

5.Wipe up any spilled fuel and allow excess to evaporate before starting engine.

To prevent FIRE, do not start the engine while the smell of fuel hangs in the air.

SAVE THESE INSTRUCTIONS.

Page 6

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ITEM 61169

Set Up

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 local fire agencies for laws or regulations relating to fire prevention requirements.

At high altitudes, the engine’s carburetor, governor, and any other parts that control the fuel air ratio will need to be adjusted by a qualified mechanic to allow efficient high-altitude use and

to prevent damage to the engine and any other devices used with this product.

Grounding

1.The Generator must be properly grounded in accordance with all relevant electrical codes and standards before operation.

Have the unit grounded by a qualified electrician if you are not qualified to do so.

2.To ground the Generator, connect a #6 AWG grounding wire (not included) from the Grounding Terminal on the control panel to a grounding rod (not included). The grounding rod must be an earth-driven copper or brass rod (electrode) which can adequately ground the Generator.

3.Refer to local regulations for ground source information.

Components and Controls

	Fuel Cap
	Spark Plug
	Access Panel
	12VDC
	Breaker
Engine	Reset
Switch	Button
Output	12VDC
Overload	Receptacle
Oil	120VAC
Indicator
	Receptacles
Ground	Choke
	Starter
Terminal	Handle
	Exhaust

	Air Filter
	and Oil Fill	Fuel
	Access Panel	Valve
ITEM 61169	For Generator technical questions, please call 1-888-866-5797.	Page 7

Safety

Setup

Operation

Maintenance

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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.

Pre-Start Checks

Inspect Engine and Generator looking for damaged, loose, and missing parts before set up and starting. If any problems are found, do not use equipment until fixed properly.

Checking and Filling Engine Oil

NOTICE: Your Warranty is VOID if the Engine’s crankcase is not properly filled with oil before

each use. Before each use, check the oil level. Do not run the Engine with low or no Engine oil. Running the Engine with no or low Engine

oil WILL permanently damage the Engine.

1.Make sure the Engine is stopped and is level.

2.Close the Fuel Valve.

3.Remove the Access Panel on the side of the Generator.

4.Clean the top of the Dipstick and the area around it. Remove the Dipstick, turning it counterclockwise.

5.Check the oil level. The oil level should be up to the edge of the hole as shown.

6.As needed, add the appropriate type of

oil until the oil level is at the proper level.

SAE 10W 30 oil is recommended for general use.

Full level

7. Thread the Dipstick back in clockwise and replace the Access Panel.

Checking and Filling Fuel

WARNING! TO PREVENT SERIOUS INJURY FROM FIRE:

Fill the fuel tank in a well-ventilated area away from ignition sources. If the Engine is hot from use, shut the Engine off and

wait for it to cool before adding fuel. Do not smoke.

1.Clean the Fuel Cap and the area around it.

2.Unscrew and remove the Fuel Cap.

3.Remove the Strainer and remove any dirt and debris. Then replace the Strainer.

Note: Do not use gasoline containing more than 10% ethanol (E10). Do not use E85 ethanol.

Note: Do not use gasoline that has been stored in a metal fuel container or a dirty fuel container. It can cause particles to enter the carburetor, affecting Engine performance and/or causing damage.

4.If needed, fill the Fuel Tank to about 1 inch under the fill neck of the Fuel Tank with 87 octane or higher unleaded gasoline that has been treated with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for use.

5.Then replace the Fuel Cap.

6.Wipe up any spilled fuel and allow excess to evaporate before starting Engine.

To prevent FIRE, do not start the Engine while the smell of fuel hangs in the air.

Note: Fill Fuel Tank completely before first use.

Fuel Tank needs to be completely full to properly prime Carburetor.

Page 8

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ITEM 61169

Starting the Engine

Before Starting the Engine

a.Inspect the Generator and Engine.

b.Disconnect all electrical loads from the Generator.

c.Fill the Engine with the proper amount and type of both unleaded gasoline and oil.

Manual Start

1. Turn the Engine Switch on.

1

2

2. Move the Choke to the START position.

RUN START

	3	ON	OFF
3. Turn the Fuel Valve to the ON position.

Safety

Setup

Operation

Note: After unpacking, before first use,

slowly pull recoil handle 20 times to prime the Engine.

4. Grip the Starter Handle of the Engine loosely and	4
pull it slowly several times to allow the gasoline to

flow into the Engine’s carburetor. Then pull the Starter Handle gently until resistance is felt.

Allow Cable to retract fully and then pull it quickly. Repeat until the Engine starts.

Note: Do not let the Starter Handle snap back against the housing.

Hold it as it recoils so it doesn't hit the housing.

ITEM 61169

For Generator technical questions, please call 1-888-866-5797.

Maintenance

Page 9