Page 1
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.
6500 WAT T
PORTABLE
GENERATOR
5500 RATED WATTS
6500 MAX WATTS
• 420ccAirCooledOHVGasEngine
• 12HourRunTimeat50%Capacity
• LowOilIndicator/LowOilShutdown
• HeavyDuty1-1/4"SteelRollCage
• ULListedCircuitBreaker
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.
ITEM 68526 / 68529
Visit our website at: http://www.harborfreight.com
Email our technical support at: tech@harborfreight.com
Email our Engine support at: predator@harborfreight.com
When unpacking, make sure that the product is intact and undamaged.
If any generator parts are missing or broken, please call 1-800-444-
3353 as soon as possible. If any engine parts are missing or broken,
please call 1-800-520-0882 as soon as possible.
Copyright© 2011 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.
Page 2
Table of Contents
Safety ......................................................... 2
Setup .......................................................... 6
Specications ............................................. 6
SAFETY OPERATION MAINTENANCESETUP
Operation .................................................... 9
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Maintenance .............................................. 15
Parts List and Diagram .............................. 20
Warranty .................................................... 23
WARNING SYMBOLS AND DEFINITIONS
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.
IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS PERTAINING TO A RISK OF FIRE,
ELECTRIC SHOCK, OR INJURY TO PERSONS
WARNING – When using tools, basic precautions should always be followed, including the following:
Set up Precautions
1. Gasoline fuel and fumes are ammable, and
potentially explosive. Use proper fuel storage
and handling procedures. Do not store fuel
or other ammable materials nearby.
2. Have multiple ABC class re extinguishers nearby.
3. Operation of this equipment may create sparks
that can start res around dry vegetation. A spark
arrestor may be required. The operator should
contact local re agencies for laws or regulations
relating to re prevention requirements.
4. Set up and use only on a at, 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 qualied
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 this manual.
Page 2
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 3
Set up Precautions (cont.)
9. Improper connections to a building electrical
system can allow electrical current from the
generator to backfeed into the utility lines.
Such backfeed may electrocute utility company
workers or others who contact the lines during a
power outage, and the generator may explode,
burn, or cause res when utility power is restored.
Consult the utility company and a qualied electrician
if intending to use the generator for back up power.
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.
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.
SAFETYOPERATIONMAINTENANCE SETUP
7. Fire Hazard! Do not ll 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 ame.
8. Do not touch engine during use. Let
engine cool down after use.
9. Never store fuel or other ammable
materials near the engine.
10. 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 efciently powered by a portable generator.
Only use OUTSIDE and far away from windows,
doors, and vents.
2. Never use a generator indoors, including in
garages, basements, crawlspaces 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.
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.
12. Do not exceed the maximum power rating of the
generator. Make sure that the total electrical rating
of the all of the tools or appliances plugged into
the generator at the same time does not exceed
that of the generator. Check that the startup surge
will not be beyond the limit of the Generator.
Power levels between rated and maximum
may be used for no more than 30 minutes.
13. Avoid substantially overloading which will trip the
circuit breaker. Exceeding the time limit for maximum
power operation or slightly overloading the generator
may not switch the circuit breaker or circuit protector
OFF, but will shorten the service life of the generator.
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.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 3
Page 4
Operating Precautions (cont.)
16. Connect the Generator only to a load or
electrical system (120 volt or 240 volt) that is
compatible with the electrical characteristics
SAFETY OPERATION MAINTENANCESETUP
and rated capacities 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 sufcient weight bearing
capacity when transporting the generator.
20. Secure the Generator on transport vehicles to
prevent the tool from rolling, slipping, and tilting.
21. Industrial applications must follow
OSHA requirements.
22. Do not leave the Generator unattended when it is
running. Turn off the Generator (and remove safety
keys, if available) before leaving the work area.
23. The Generator engine can produce high noise
levels. Prolonged exposure to noise levels
above 85 dBA is hazardous to hearing. Always
wear ear protection when operating or working
around the gas engine while it is operating.
24. Wear ANSI-approved safety glasses,
hearing protection, and NIOSH-approved
dust mask/respirator during use.
29. Stay alert, watch what you are doing and
use common sense when operating this
piece of equipment. Do not use this piece of
equipment while tired or under the inuence
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 or its
engine during operation.
33. Keep the generator, its engine, and
surrounding area clean at all times.
34. Use the generator, accessories, etc., in accordance
with these instructions and in the manner intended for
the particular type of equipment, taking into account
the working conditions and the work to be performed.
Use of the equipment for operations different from
those intended could result in a hazardous situation.
35. Do not operate the generator with known
leaks in the engine’s fuel system.
36. 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.)
25. People with pacemakers should consult their
physician(s) before use. Electromagnetic 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.
26. Use only accessories that are recommended
by Harbor Freight Tools for your model.
Accessories that may be suitable for one
piece of equipment may become hazardous
when used on another piece of equipment.
27. Do not operate in explosive atmospheres,
such as in the presence of ammable
liquids, gases, or dust. Gasoline-powered
engines may ignite the dust or fumes.
28. Keep grounded conductive objects, such as
tools, away from exposed, live electrical parts
and connections to avoid sparking or arcing.
These events could ignite fumes or vapors.
37. When spills of fuel or oil occur, they must be
cleaned up immediately. Dispose of uids 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 generator while operating.
39. Before use, check for misalignment or binding
of moving parts, breakage of parts, and any
other condition that may affect the generator’s
operation. If damaged, have the generator
serviced before using. Many accidents are
caused by poorly maintained equipment.
40. Use the correct generator for the application. Do not
modify the generator or its engine, and do not use the
generator for a purpose for which it is not intended.
Page 4
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 5
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
mufer, air cleaner, mechanical guards,
and heat shields, among other guards.
3. Make sure the Engine Switch is in its “OFF”
position before moving the Generator and
before performing any service, maintenance,
or cleaning procedures on the unit.
4. 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.
5. Do not alter or adjust any part of the
equipment or its engine that is sealed by the
manufacturer or distributor. Only a qualied
service technician may adjust parts that may
increase or decrease governed engine speed.
6. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during service.
7. Maintain labels and nameplates on the
equipment. These carry important information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
8. Have the equipment serviced by a qualied 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.
9. Store equipment out of the reach of children.
10. Follow scheduled engine and
equipment maintenance.
Refueling:
1. Do not smoke, or allow sparks, ames,
or other sources of ignition around the
equipment, especially when refuelling.
2. Do not rell the fuel tank while the
engine is running or hot.
3. TO PREVENT FUEL LEAKAGE AND FIRE
HAZARD, Do not overll with fuel. Fill with
fuel according to the Fuel Level information
below the Specication chart for your model.
4. Do not ll fuel tank to the top. Leave a little
room for the fuel to expand as needed.
5. Refuel in a well-ventilated area only.
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.
SAVE THESE
SAFETYOPERATIONMAINTENANCE SETUP
Item 68526 / 68529
INSTRUCTIONS.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 5
Page 6
Functional Description
Specications
SAFETY OPERATION MAINTENANCESETUP
Rated Output
Generator
Electrical Receptacle
Displacement 420cc
Engine Type Horizontal Single Cylinder 4 stroke OHV
Cooling System Forced air cooled
Fuel
Engine
Engine Oil
Run Time @ 50% load 12 hr.
Operational Volume 74 dB
Available accessories Wheel kit (sold separately)
Item 68526 - 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.
Item 68529 - The emission control system for this Generator’s Engine is warranted for standards set by the U.S.
Environmental Protection Agency. For warranty information, refer to the last pages of this manual.
Type 87+ octane unleaded gasoline
Capacity 6.6 Gallons (25L)
Type SAE
Capacity 1.16 Quart (1.1L)
120/240V~, 60Hz
5,500 Watts (6,500 max)
Two 3-Prong, duplex NEMA #5-15 120V
One 4-Prong, NEMA #L14-30 twistlock 120V/240V
One DC Outlet 12VDC
10W-30 above 32° F
5W-30 at 32° F or below
Components and Controls
Fuel Cap
Fuel Valve
Choke
Air Filter
Frame
Starter
Handle
DC Receptacle
DC Circuit Breaker
AC Circuit Breakers
AC Receptacles
Ground Terminal
Power Switch
Low Oil Indicator
Page 6
Wheel Kit sold separately
(Item 68531)
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 7
Components and Controls (cont.)
The following are descriptions of the controls
on the power panel. Your generator has
sockets to power your products with circuit
breakers to protect the voltage ow.
I
O
1.
Engine Switch: Used to start and stop the Engine.
2. AC Receptacles: The Generator contains several
AC receptacles to power tools and equipment.
a.
3-Prong, duplex
120 volt receptacle
(NEMA #5-15)
ON
OFF
Circuit Breakers: The circuit breaker protects the
3.
Generator from overloading. The rating of the breaker
and the load it protects are marked near the breaker.
Should any of the Circuit Breakers trip, the Generator
will stop the electricity output. If this happens, unplug
all loads from the Generator. Allow the Generator to
cool down. Then, press the tripped Circuit Breaker,
restart the Engine, and re-attach loads.
DC Receptacle: 12 VDC Receptacle set provides a
4.
power source for 12 volt DC items.
5.
Grounding Terminal: Prior to each use, set
up the ground wire (not included) connection
to the Grounding Terminal to properly ground
the Generator. See Set up instructions
to properly ground the Generator.
SAFETYOPERATIONMAINTENANCE SETUP
4-Prong, twistlock,
120/240 volt receptacle
(NEMA #L14-30)
WARNING! Connect tools and equipment
only to the Receptacle (120 volt or 240 volt)
that is compatible with the electrical
characteristics and rated capacities of the
tools and equipment being used.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 7
Page 8
Initial Tool Set Up/Assembly
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
SAFETY OPERATION MAINTENANCESETUP
Note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
TO PREVENT SERIOUS INJURY:
Operate only with proper spark arrestor installed.
Operation of this equipment may create sparks that can start res around dry vegetation.
A spark arrestor may be required.
The operator should contact local re agencies for laws or
regulations relating to re prevention requirements.
CAUTION: This generator is not intended to power sensitive electronic equipment without the addition of an
appropriate line conditioner and surge protector (both not included). Sensitive electronic equipment includes,
but is not limited to, audio/video equipment, some television sets, computers, and printers. Sensitive
electronic equipment should be operated on approved inverter type generators or pure sine wave generators.
Note: Wheel Kit, item # 68531 (sold separately) can be used with this generator.
Grounding
The Generator must be properly grounded before
use. Have the unit grounded by a qualied
electrician if you are not qualied to do so.
To ground the Generator, connect a #6 AWG
grounding wire (not included) from the Grounding
High Altitude Operation
The fuel system on this generator may be inuenced
by operation at higher altitudes. Proper operation
can be ensured by installing an altitude kit when
required. See the table at right to determine when
an altitude kit is required. Operating this generator
without the proper altitude kit installed may increase
the engine’s emissions and decrease fuel economy
and performance. Kits should be installed by a
qualied mechanic. The kits may be requested
from Customer service. See parts list for details.
Terminal on the Control Panel to a grounding rod
(not included) that has been driven at least 24
inches deep into the earth. The grounding rod must
be an earth-driven copper or brass rod (electrode)
which can adequately ground the Generator.
Altitude Range* Kit Part Number
Up to 3000 ft No modication needed
3000-6000 ft #174
6000-8000 ft** #175
* Elevation above sea level
** At elevations above 8000 ft, the engine
may experience decreased performance
Page 8
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 9
Operating Instructions
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
Inspect tool before use, looking for damaged, loose, and missing parts.
If any problems are found, do not use tool until repaired.
Generator Pre-Start Checks
Inspect engine and equipment, looking for
damaged, loose, and missing parts before set
up and starting. If any problems are found,
do not use equipment until xed properly.
6. Thread the dipstick back in clockwise.
SAFETYOPERATIONMAINTENANCE SETUP
CAUTION! Do not run the engine with too little oil.
The engine will be permanently damaged.
Checking and Filling Engine Oil
CAUTION! Your Warranty is VOID if the engine’s
crankcase is not properly lled with oil before
each use. Before each use, check the oil level.
Do not run the engine with low or no engine oil.
Running the engine with no or low engine oil
WILL permanently damage the engine.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Full level
4.
Reinsert the Dipstick without threading it in and
remove it to check the oil level. The oil level
should be up to the full level as shown above.
5. If the oil level is at or below the low mark add the
appropriate type of oil until the oil level is at the
proper level. SAE 10W-30 oil is recommended
for general use. (The SAE Viscosity Grade
chart on page 16 in the User-Maintenance
Instructions section shows other viscosities
to use in different average temperatures.)
Full level
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. If needed, ll the Fuel Tank to about 1 inch
under the ll neck of the Fuel Tank with
87 octane or higher unleaded gasoline.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
Note: Do not use gasoline that has been stored in a
metal fuel container or a dirty fuel container. It can
cause particles to enter the carburetor, effecting
engine performance and/or causing damage.
4. Then replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess
to evaporate before starting engine.
To prevent FIRE, do not start the engine
while the smell of fuel hangs in the air.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 9
Page 10
Using the Generator
Before Starting the Generator Engine
Before starting the engine:
SAFETY OPERATION MAINTENANCESETUP
Basic Generator Use Procedure - See following pages for specic instructions
1. Check that the generator can handle the wattage needed to power your products.
2. Start the Engine, and allow the Engine and Generator to run and warm
3. Plug in products.
4. When nished using the Generator, disconnect all electrical loads.
Note: Do not allow generator to run out of fuel with loads attached.
5. Turn off the Engine.
a. Follow the Set Up Instructions to prepare the Generator.
b. Unplug all loads from the Generator.
c. Inspect the Generator and engine.
d. Fill the engine with the proper amount and type of both fuel and oil.
up for ve minutes after starting with no electrical load.
Allow the Generator and its Engine to completely cool. Then store the unit in a clean,
dry, safe location out of reach of children and other unauthorized people.
IMPORTANT: After starting the engine, allow it to run at no load for ve minutes
with no load after each start-up so that the engine can stabilize.
6. Break-in Period:
a. Breaking-in the engine will help to ensure proper equipment and engine operation.
b. The operational break-in period will last about 3 hours of use. During this period:
• Do not apply a heavy load to the equipment.
c. The maintenance break-in period will last about 20 hours of use. After this period:
• Change the engine oil.
Under normal operating conditions subsequent maintenance follows
the schedule explained in the SERVICE section.
Page 10
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 11
Starting the Engine
1. To start a cold engine, move the Choke to the
CHOKE position.
To restart a warm engine, leave the Choke in the
RUN position.
2. Open the Fuel Valve.
SAFETYOPERATIONMAINTENANCE SETUP
3. Turn the Engine Switch to ON.
4. Grip the Starter Handle of the Engine loosely and pull it
slowly several times to allow the gasoline to ow into the
Engine’s carburetor. Then pull the Starter Handle gently
until resistance is felt. Allow Cable to retract fully and
then pull it quickly. Repeat until the engine starts.
Note: Do not let the Starter Handle snap back against
the engine. Hold it as it recoils so it doesn’t
hit the engine.
I
ON
O
5. Allow the Engine to run for several seconds.
Then, if the Choke lever is in the CHOKE position,
move the Choke Lever very slowly to its RUN position.
NOTE: Moving the Choke Lever too fast could stall the engine.
IMPORTANT: Allow the engine to run at no load for ve minutes with no
load after each start-up so that the engine can stabilize.
For Pump technical questions, please call 1-800-444-3353.
Item 68526 / 68529
For Engine technical questions, please call 1-800-520-0882.
Page 11
Page 12
Connecting Electrical Loads
Familiarize yourself with the engine controls, power panel and how to start the engine before using the generator.
Calculate the wattage of the products you will use with the generator and verify that the generator can handle the
total load.
SAFETY OPERATION MAINTENANCESETUP
WARNING! Connect only properly wired plugs to the generator.
A plug that is spliced onto a different cord may be hazardous.
Only a qualied electrician should wire a plug onto a cord.
CAUTION Never exceed the rated capacity for this Generator, as
serious damage to the Generator and/or appliances, tools, and
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.
Use the DC12V Receptacle to power 12VDC equipment.
WARNING! Do not charge batteries without a proper charge controller. Do not overcharge.
a. Connect the items that require the most wattage rst.
b. Connect “inductive” load appliances, tools, and equipment next. Inductive
loads are small hand tools and some small appliances.
c. Connect any lights next.
d. Voltage sensitive appliances, tools, and equipment should be the last to be connected to the Generator.
Plug voltage sensitive items such as TV’s, DVD players, microwaves, and cordless telephones into a UL®
Listed voltage surge protector (not included). Then, connect the surge protector into the Generator.
IMPORTANT! Failure to connect and operate appliances, tools, and equipment in this sequence can cause
damage to the Generator, appliances, tools, and equipment and will void the Warranty of this Generator.
NOTE: If Engine speed or voltage uctuates with a load below the Generator’s rated watts, move the Engine Choke
Lever to the “HALF-CHOKE” position.
IF ANY CIRCUIT BREAKERS TRIP CHECK THE FOLLOWING:
1. Make sure that ALL circuit breakers are reset
before starting the generator again.
2. Adjust the plugs so the loads are
shared across outlet circuits.
To achieve rated output from the generator,
distribute loads over outlets.
Evenly distributed
over outlets:
Page 12
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 13
Calculating Total Wattage of Devices Used with the Generator
Before using the Generator, check that the products
you want to plug into the unit are below the rated and
maximum wattage ratings of the Generator. Use the
Wattage Calculation Table below, and the watts listed
on your products, to help calculate multiple
wattage totals.
To use the table:
1. Add up the Running Watts for all items you
would like to use at any given time
2. Make sure that this total is under the
5,500 rated wattage of the generator.
3. Find the single highest starting watts for
the selected items and add to the total.
4. Make sure that this total is under the 6,500
maximum rated wattage of the generator.
5. Plug in and turn on products from largest wattage
to smallest.
Wattage Calculation Table
Running
Watts
4,200
1,200
5,400
Running
Watts
Equipment
Total Running Watts
(must be less than 5,500)
Largest Additional Start-up Watts
Total Startup Watts needed for all loads
(must be less than 6,500)
Example
Equipment
Electric Water Heater (2,000 + 0) 2,000
Television (400 + 0) 400
Lawn Mower (1,200 + 1,200) 1,200
Hand Drill (600 + 600) 600
Total Running Watts
(must be less than 5,500)
Largest Additional Start-up Watts
Total Startup Watts needed for all loads
(must be less than 6,500)
A generator that is rated more than the minimum
required peak watts will last much longer than a
generator that only supplies the exact watts needed.
To Calculate Wattage
Volts and amps can be multiplied together to get watts (volts x
amps = watts).
To Calculate Additional Start-Up Watts
(If They Are Not Listed)
For equipment with a motor: Use the rated watts
amount as an estimate of additional Start-up Watts.
For most lights or heaters:
there are no additional start-up watts.
Note: Wattages listed below are estimates for that
type of equipment only. Check nameplate wattages
Wattage Estimate Charts
on all loads before connecting to Generator.
EMERGENCY
Device
Refrigerator/Freezer 700 1500
Radio 100 0
JOB SITE
Device
Air Compressor - 1/2 HP 1000 1000
Table Saw - 10" 1700 1300
Belt Sander - 3" 1200 1200
Hand Drill - 1/2" 600 600
Halogen Work Light 1000 0
Recipricating Saw 900 900
RECREATION
Device
AM/FM Radio 100 0
Electric Grill 1700 0
Inator Pump 50 100
CD/DVD Player 100 0
Box Fan - 20" 200 200
Coffee Maker 600 0
HOUSEHOLD
Device
Computer w/ Monitor 800 0
Electric Clothes Dryer 5500 500
Electric Range 2100 0
Electric Water Heater 2000 0
Light Bulb - 100 watts 100 0
Microwave - 1000 watts 1000 200
Sump Pump - 1/2 HP 1000 1100
Television 400 0
Washing Machine 1100 1100
Well Pump - 1/2 HP 1000 1000
LAWN & GARDEN
Device
Hedge Trimmer 400 400
Pressure Washer 1200 1200
Lawn Mower 1200 1200
Edger 1000 1000
HEATING & COOLING
Device
Central AC - 10,000 BTU 1500 1500
Furnace Fan - 1/2 HP 900 1400
Space Heater 1800 0
Window AC - 10,000 BTU 1200 600
Running
Watts
Running
Watts
Running
Watts
Running
Watts
Running
Watts
Running
Watts
Additional
Start-up
Watts
Additional
Start-up
Watts
Additional
Start-up
Watts
Additional
Start-up
Watts
Additional
Start-up
Watts
Additional
Start-up
Watts
SAFETYOPERATIONMAINTENANCE SETUP
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 13
Page 14
Stopping the Engine in an Emergency
1. To stop the engine in an emergency,
SAFETY OPERATION MAINTENANCESETUP
turn the Engine Switch off.
I
NOTICE: Generator shut-off under load may damage
the generator and attached equipment.
Stopping the Engine Under Normal Conditions
1. Before turning off the Engine,
turn off all electrical loads,
then unplug them.
2. Turn the Engine Switch off.
O
O
OFF
I
OFF
3. Close the Fuel Valve.
Page 14
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 15
User-Maintenance Instructions
Procedures not specically explained in this manual must
be performed only by a qualied technician.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch of the generator to its “OFF” position, wait for the engine to cool, and disconnect
the spark plug cap before performing any inspection, maintenance, or cleaning procedures.
TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE:
Do not use damaged equipment. If abnormal noise, vibration, or excess
smoking occurs, have the problem corrected before further use.
Follow all service instructions in this manual. The engine may fail critically if not serviced properly.
Many maintenance procedures, including any not detailed in this manual, will need to be
performed by a qualied technician for safety. If you have any doubts about your ability to safely
service the equipment or engine, have a qualied technician service the equipment instead.
Cleaning, Maintenance, and Lubrication
SAFETYOPERATIONMAINTENANCE SETUP
Note: This maintenance schedule is intended solely as a general guide. If performance decreases or if
equipment operates unusually, check systems immediately. The maintenance needs of each piece of equipment
will differ depending on factors such as duty cycle, temperature, air quality, fuel quality, and other factors.
Note: The following procedures are in addition to the regular checks and maintenance
explained as part of the regular operation of the engine and equipment.
Procedure
Brush off outside of engine
Check engine oil level
Check air cleaner
Check deposit cup
Change engine oil
Clean/replace air cleaner
Check and clean spark plug
1. Check/adjust idle speed
2. Check/adjust valve clearance
3. Clean fuel tank, strainer
and carburetor
4. Clean carbon build-up from
combustion chamber
Replace fuel line if necessary
Before
Each Use
Monthly or
every 20
hr. of use
Every 3 mo. or
50 hr. of use
*
Every 6 mo. or
100 hr. of use
Yearly or
every 300
hr. of use
** **
Every
2 Years
**
*Service more frequently when used in dusty areas.
**These items should be serviced by a qualied technician.
For Pump technical questions, please call 1-800-444-3353.
Item 68526 / 68529
For Engine technical questions, please call 1-800-520-0882.
Page 15
Page 16
Checking and Filling Fuel
WARNING! TO PREVENT SERIOUS
INJURY FROM FIRE:
Fill the fuel tank in a well-ventilated area
SAFETY OPERATION MAINTENANCESETUP
Do not smoke.
1. Clean the Fuel Cap and the area around it.
2. Unscrew and remove the Fuel Cap.
3. If needed, ll the Fuel Tank with 87 octane
or higher unleaded gasoline.
away from ignition sources. If the engine is
hot from use, shut the engine off and wait
for it to cool before adding fuel.
Engine Oil Change
CAUTION! Oil is very hot during operation and can
cause burns. Wait for engine to cool before changing oil.
1. Make sure the engine is stopped and is level.
2. Close the Fuel Valve.
3. Place a drain pan (not included) underneath
the crankcase’s drain plug.
4. Remove the drain plug and, if possible,
tilt the crankcase slightly to help drain
the oil out. Recycle used oil.
Note: Do not use gasoline containing more than
10% ethanol (E10). Do not use E85 ethanol.
Note: Do not use gasoline that has been stored in a
metal fuel container or a dirty fuel container. It can
cause particles to enter the carburetor, effecting
engine performance and/or causing damage.
4. Replace the Fuel Cap.
5. Wipe up any spilled fuel and allow excess
to evaporate before starting engine.
To prevent FIRE, do not start the engine
while the smell of fuel hangs in the air.
Full level
7.
Add the appropriate type of oil until the
oil level is at the full level. SAE 10W-30
oil is recommended for general use.
Note: Do not thread the dipstick in
when checking the oil level.
Full level
5. Replace the drain plug and tighten it.
6. Clean the top of the Dipstick and the area around it.
Remove the Dipstick by threading it counterclockwise,
and wipe it off with a clean lint free rag.
Air Filter Element Maintenance
1. Remove the air lter cover and the
air lter elements and check for dirt.
Clean or replace as described below.
2. Cleaning: Wash the element in warm water and mild
detergent several times. Rinse. Squeeze out excess
water and allow it to dry completely. Soak the lter in
lightweight oil briey, then squeeze out the excess oil.
The SAE Viscosity Grade chart shows other
viscosities to use in different average temperatures.
SAE Viscosity Grades
30
10W-30
5W-30
-20 0 20 40 60 80 100°F
Average outdoor temperature
8. Thread the dipstick back in clockwise.
CAUTION! Do not run the engine with too little
oil. The engine will be permanently damaged.
3. Install the new lter or the cleaned lter.
Secure the Air Cleaner Cover before use.
Page 16
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 17
Spark Plug Maintenance
1. Disconnect spark plug cap from end of plug.
Clean out debris from around spark plug.
2. Using a spark plug
wrench, remove
Spark Plug
the spark plug.
3. Inspect the spark plug:
If the electrode is
oily, clean it using a
clean, dry rag. If the
electrode has deposits
on it, polish it using
Cylinder
Assembly
emery paper. If the white insulator is cracked or
chipped, the spark plug needs to be replaced.
NOTICE: Using an incorrect spark plug may
damage the engine. See the Specications chart
for your Generator for the type and gap required.
Storage
When the equipment is to remain idle for longer than
20 days, prepare the engine for storage as follows:
1. CLEANING:
Wait for engine to cool, then clean engine with
dry cloth. NOTICE: Do not clean using water.
The water will gradually enter the engine and cause
rust damage.
Apply a thin coat of rust preventive
oil to all metal parts.
2. FUEL:
WARNING! TO PREVENT SERIOUS
INJURY FROM FIRE:
Drain the fuel tank in a well-ventilated area
away from ignition sources. If the engine is
hot from use, shut the engine off and wait
for it to cool before draining fuel.
Do not smoke.
a. Place a funnel leading to a proper gasoline
container below the carburetor.
b. Remove the
drain bolt from
the bottom of
the carburetor
bowl and allow
the fuel to drain.
Cylinder
Assembly
If present on
your model,
remove the small sediment cup next to the bowl
and allow the fuel to drain from there as well.
c. Open the fuel valve. After all fuel has
drained, reinstall the drain bolt and sediment
cup (if equipped). Tighten securely.
Air Filter Assembly
Drain Plug
4. When installing a new spark plug, adjust
the plug’s gap to the specication on the
Specications chart. Do not pry against the
electrode, the spark plug can be damaged.
5. Install the new spark plug or the cleaned spark plug
into the engine. Gasket-style: Finger-tighten until the
gasket contacts the cylinder head, then about 1/2-2/3
turn more.
Non-gasket-style: Finger-tighten until the plug
contacts the head, then about 1/16 turn more.
NOTICE: Tighten the spark plug properly. If
loose, the spark plug will cause the engine
to overheat. If overtightened, the threads
in the engine block will be damaged.
6. Apply dielectric spark plug boot protector
(not included) to the end of the spark
plug and reattach the wire securely.
3. LUBRICATION:
a. Change engine oil.
b. Clean out area around spark plug.
Remove spark plug and pour one tablespoon of
engine oil into cylinder through spark plug hole.
c. Replace spark plug, but leave spark
plug cap disconnected.
d. Pull Starter Handle to distribute oil in cylinder.
Stop after one or two revolutions when you
feel the piston start the compression stroke
(when you start to feel resistance).
4. BATTERY:
Disconnect battery cables (if equipped).
Recharge batteries monthly while in storage.
5. STORAGE AREA:
Cover and store in a dry, level, well-ventilated
area out of reach of children. Storage area
should also be away from ignition sources, such
as water heaters, clothes dryers, and furnaces.
6. AFTER STORAGE:
Before starting the engine after storage, keep
in mind that untreated gasoline will deteriorate
quickly. Drain the fuel tank and change to fresh
fuel if untreated gasoline has been sitting for
a month, if treated gasoline has been sitting
beyond the fuel stabilizer’s recommended
time period, or if the engine does not start.
SAFETYOPERATIONMAINTENANCE SETUP
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 17
Page 18
Troubleshooting
Problem Possible Causes Probable Solutions
Engine will not start FUEL RELATED:
SAFETY OPERATION MAINTENANCESETUP
1. No fuel in tank or fuel valve closed.
2. Choke not in CHOKE position, cold engine.
3. Gasoline with more than 10% ethanol used.
(E15, E20, E85, etc.)
4. Low quality or deteriorated, old gasoline.
5. Carburetor not primed.
6. Dirty fuel passageways.
7. Carburetor needle stuck. Fuel
can be smelled in the air.
8. Too much fuel in chamber. This can be
caused by the carburetor needle sticking.
9. Clogged Fuel Filter.
IGNITION (SPARK) RELATED:
1. Spark plug cap not connected securely.
2. Spark plug electrode wet or dirty.
3. Incorrect spark plug gap.
4. Spark plug cap broken.
5. Circuit breaker tripped (electric
start models only).
6. Incorrect spark timing or
faulty ignition system.
COMPRESSION RELATED:
1. Cylinder not lubricated. Problem after long
storage periods.
2. Loose or broken spark plug. (Hissing noise
will occur when trying to start.)
3. Loose cylinder head or damaged
head gasket. (Hissing noise will
occur when trying to start.)
4. Engine valves or tappets
mis-adjusted or stuck.
FUEL RELATED:
1. Fill fuel tank and open fuel valve.
2. Move Choke to CHOKE position.
3. Clean out ethanol rich gasoline from fuel
system. Replace components damaged
by ethanol. Use fresh 87+ octane
unleaded gasoline only.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
4. Use fresh 87+ octane unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Pull on Starter Handle to prime.
6. Clean out passageways using fuel additive.
Heavy deposits may require further cleaning.
7. Gently tap side of carburetor oat
chamber with screwdriver handle.
8. Turn Choke to RUN position. Remove spark
plug and pull the start handle several times
to air out the chamber. Reinstall spark
plug and set Choke to CHOKE position.
9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
1. Connect spark plug cap properly.
2. Clean spark plug.
3. Correct spark plug gap.
4. Replace spark plug cap.
5. Reset circuit breaker. Check wiring and
starter motor if breaker continues to trip.
6. Have qualied technician diagnose/
repair ignition system.
COMPRESSION RELATED:
1. Pour tablespoon of oil into spark
plug hole. Crank engine a few
times and try to start again.
2. Tighten spark plug. If that does not work,
replace spark plug. If problem persists,
may have head gasket problem, see #3.
3. Tighten head. If that does not remedy
problem, replace head gasket.
4. Have qualied technician diagnose/
repair ignition system.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Page 18
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 19
Troubleshooting (cont.)
Problem Possible Causes Probable Solutions
Engine misres 1. Spark plug cap loose.
2. Incorrect spark plug gap or
damaged spark plug.
3. Defective spark plug cap.
4. Old or low quality gasoline.
5. Incorrect compression.
Engine stops
suddenly
Engine stops when
under heavy load
Engine knocks 1. Old or low quality gasoline.
Engine backres 1. Impure or low quality gasoline.
Product doesn’t
have power.
Product begins to
operate abnormally.
1. Low oil shutdown.
2. Fuel tank empty or full of impure or low
quality gasoline.
3. Defective fuel tank cap creating
vacuum, preventing proper fuel ow.
4. Faulty magneto.
5. Disconnected or improperly
connected spark plug cap.
1. Dirty air lter.
2. Engine running cold.
2. Engine overloaded.
3. Incorrect spark timing, deposit buildup,
worn engine, or other mechanical problems.
2. Engine too cold.
3. Intake valve stuck or overheated engine.
4. Incorrect timing.
1. Product not plugged in properly.
2. Circuit Breaker tripped.
3. Product needs service.
1. Problem with appliance.
2. Rated load capacity exceeded.
1. Check wire connections.
2. Re-gap or replace spark plug.
3. Replace spark plug cap.
4. Use only fresh 87+ octane unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
5. Diagnose and repair compression.
(Use Engine will not start:
COMPRESSION RELATED section.)
1. Fill engine oil to proper level. Check
engine oil before EVERY use.
2. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
3. Test/replace fuel tank cap.
4. Have qualied technician service magneto.
5. Secure spark plug cap.
1. Clean or replace element.
2. Allow engine to warm up prior
to operating equipment.
1. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Do not exceed equipment’s load rating.
3. Have qualied technician diagnose
and service engine.
1. Fill fuel tank with fresh 87+ octane
unleaded gasoline.
Do not use gasoline with more than
10% ethanol (E15, E20, E85, etc.).
2. Use cold weather fuel and oil
additives to prevent backring.
3. Have qualied technician diagnose
and service engine.
4. Check engine timing.
1. Turn off and unplug the product, then
plug it back in again and turn on.
2. Turn off and unplug product, Reset Circuit
Breaker. Plug in product and turn on.
3. Have product repaired.
1. Immediately unplug appliance. Have
appliance repaired by a qualied
technician, or replace appliance.
2. Lower the number of items plugged into the
generator to stay within the rated capacity,
or use a more powerful generator.
SAFETYOPERATIONMAINTENANCE SETUP
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 19
Page 20
Parts List and Diagram
PLEASE READ THE FOLLOWING CAREFULLY
SAFETY OPERATION MAINTENANCESETUP
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.
Parts List
Part Description Qty
1 Gasket, Cylinder Head 1
2 Cover Subassembly, Cylinder Head 1
3 Gasket, Cylinder Head Cover 1
4 Tube, Breather 1
5 Bolt Subasm., Cylinder Head Cover 1
6 Stud 2
7 Stud 2
8 Pin 2
9 Plug, Spark 1
10 Head Subassembly, Cylinder 1
11 Crankcase Subassembly. 1
12 Seal, Oil 1
13 Sensor, Engine Oil 1
14 Bearing 1
15 Plug, Rubber 1
16 Protector, Oil 1
17 Bolt 1
18 Flat Washer 2
19 Bolt, Drain Plug 2
20 Clip 1
21 Arm, Governor 1
22 Seal, Oil 1
23 Pin 1
24 Flat Washer 1
25 Bolt 2
26 Cover, Crankcase 1
27 Gasket, Crankcase 1
28 Bearing 1
29 Dipstick Subassembly, Oil 1
30 Pin 2
31 Bolt 7
32 Bearing 1
33 Gear Assy, Governor 1
34 Seal, Oil 1
35 Crankshaft Assy. 1
36 Shaft Assy, Balancing 1
37 Ring Set, Oil 1
38 Clip, Piston Pin 2
39 Piston 1
40 Pin, Piston 1
41 Rod, Connecting 1
42 Primary Ring 1
43 Secondary Ring 1
Part Description Qty
44 Camshaft Assy. 1
45 Valve, Exhaust 1
46 Valve, Intake 1
47 Seat, Valve Spring 1
48 Exhaust Valve Retainer 1
49 Rotator, Valve 1
50 Guide, Seal 1
51 Tappet, Valve 2
52 Lifter Subassembly, Valve 2
53 Plate Subassembly, Lifter Stopper 1
54 Bolt, Valve Adjusting 2
55 Rocker, Valve 2
56 Valve Adjusting Nut 2
57 Nut, Valve Lock 2
58 Spring, Valve 2
59 Retainer, Valve Spring 1
60 Starter Assy, Recoil 1
61 Bolt 3
62 Shroud 1
63 Shroud, Cylinder Body 1
64 Bolt 1
65 Bolt 5
66 Carburetor Assy. 1
67 Gasket, Air Cleaner 2
68 Gasket, Carburetor 1
69 Plate, Carburetor Insulator 1
70 Gasket, Inlet 1
71 Clip 2
72 Sleeve, Breather Tube Fixing 1
73 Control Assy, Choke 1
74 Valve, One Way 1
75 Cleaner, Air 1
76 Nut 2
77 Nut, Flywheel 1
78 Pulley,Starter 1
79 Impeller 1
80 Flywheel Subassembly 1
81 Bolt 2
82 Coil, Ignition 1
83 Bolt 2
84 Control Assy, Throttle 1
85 Spring, Throttle Valve Returning 1
86 Rod, Governor 1
Page 20
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 21
Parts List (cont.)
Part Description Qty
87 Spring, Governor 1
88 Support Subassembly, Governor 1
89 Nut 1
90 Bolt, Governor Support 1
91 Collar 1
92 Mufer Assy. 1
93 Cover, Mufer Inner 1
94 Cushion, Mufer Insulator Rubber 3
95 Bracket,Mufer 1
96 Bolt 4
97 Cover, Mufer Side 1
98 Bolt 7
99 Cover, Mufer Outer 1
100 Gasket, Exhaust Outlet 2
101 Nut 2
102 Pipe, Exhaust 1
103 Bolt 2
104 Tank, Fuel 1
105 Sleeve, Fuel Tank Rubber 4
106 Bush 4
107 Washer 4
108 Bolt 4
109 Cover, Fuel Tank 1
110 Fuel Strainer 1
111 Screw 2
112 Leveler Assy, Oil 1
113 Cock Assy, Fuel 1
114 Collar 2
115 Tube, Fuel 1
116 Frame Assy, Engine 1
117 Nut 4
118 Cushion, Engine Frame 2
119 Cushion, Engine Frame Rear 2
120 Nut 4
121 Brace 1
122 Bolt 2
123 Socket Subassembly, Power Supply 2
124 Protector, Overcurrent 2
125 Terminal Subassembly, Grounding 1
126 Socket Subassembly, DC 1
127 Switch Subassembly 1
128 Socket Subassembly, Power Supply 1
Part Description Qty
129 Protector, Overcurrent 2
130 Protector, Overcurrent 1
131 Seat, Panel 1
132 Panel Subassembly, Control 1
133 Motor Assy. 1
134 Bracket, Motor 1
135 Stator Bolt 4
136 Washer 1
137 Rotor Bolt 1
138 Regulator, Voltage 1
139 Bolt 2
140 Brush Subassembly, Carbon 1
141 Bolt 1
142 Cover, Motor Tail 1
143 Bolt 2
144 Block, Terminal 1
145 Bolt 2
146 Band 2
147 Bolt 2
148 Stator Bolt 2
149 Washer 2
150 Stator Nut 2
151 Bolt 1
152 Stopper, Motor Right Cover 1
153 Shroud, Motor 1
154 Bolt 1
155 Bolt, Cylinder Head 4
156 Valve, One Way 1
157 Clamp 1
158 Hose, Fuel Steam Rubber 1
159 Clamp 1
The following parts are only on Item
68526 (EPA/CARB version)
160 Bolt 2
161 Collector, Fuel Steam 1
162 Clamp 1
163 Hose, Air Cleaner Rubber 1
164 Clamp 1
Accessories not included (provided on request)*
174 High Altitude Kit 3000-6000 ft *
175 High Altitude Kit 6000-8000 ft *
SAFETYOPERATIONMAINTENANCE SETUP
Record Product's Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and
are not available individually as replacement parts.
For Pump technical questions, please call 1-800-444-3353.
Item 68526 / 68529
For Engine technical questions, please call 1-800-520-0882.
Page 21
Page 22
Assembly Diagram
Note: Parts 160 - 164 are only on
Item 68526 (EPA/Carb version)
SAFETY OPERATION MAINTENANCESETUP
132
128
131
129
124
130
135
137
138
146
147
143
143
145
139
140
139
141
146
147
142
116
119
117
120
118
117
120
119
117
120
160
97
120
117
120
118
122
121
113
114
164
115
114
163
162
79
80
81
16
15
18
19
13
25
96
100
92
25
103
103
12
11
18
19
96
96
96
95
94
93
101
102
81
82
41
100
122
77
78
38
51
46
45
7
101
52
8
8
1
7
155
155
155
9
2
2
65
65
65
65
65
62
63
75
38
40
39
37
43
42
155
71
71
51
52
6
6
70
10
59
58
48
4
4
3
3
74
68
69
50
54
58
55
47
49
56
57
64
76
76
67
66
53
54
55
56
57
73
72
107
105
106
108
105
107
106
108
123
123
124
125
126
127
133
150
149
148
136
135
135
144
145
134
151
148
135
29
31
31
31
34
31
31
109
110
111
156
111
106
107
108
105
157
112
108
106
107
89
90
88
87
154
86
85
116
23
35
36
44
30
27
30
153
98
83
84
91
83
152
150
149
33
32
28
26
31
31
105
24
104
159
158
161160
17
20
21
22
14
98
98
98
98
99
98
98
61
61
61
60
67
Page 22
5
5
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Page 23
Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must 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.
Emission Control System Warranty
For Item 68526 (EPA/CARB version)
California and United States Emission Control Defects Warranty Statement
The California Air Resources Board (herein CARB), the United States Environmental Protection Agency (herein EPA), and Harbor Freight Tools
(herein HFT) are pleased to explain the emission control system warranty on your 1995 and later Small Off-Road Engine (herein engine). In California,
the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards. Elsewhere within the United States, new off-road,
spark-ignition engines 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.
SAFETYOPERATIONMAINTENANCE SETUP
For Item 68529 (EPA version)
United States Emission Control Defects Warranty Statement
The United States Environmental Protection Agency (herein EPA) and Harbor Freight Tools (herein HFT) are pleased to explain the emission
control system warranty on your 1997 and later Small Off-Road Engine (herein engine). Within the United States, new off-road, spark-ignition en-
gines certied for model year 1997 and later, must be designed, built and equipped to meet the stringent anti-smog standards set forth by the EPA.
HFT must warrant the emission control system on your engine for the periods of time described below, provided there has been no abuse, neglect
or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor or fuel-injection system, and the ignition system. Also included may be
hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, HFT will repair your engine at no cost to you including diagnosis, parts and labor.
For Both Item Numbers
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.
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 modications.
• You are responsible for shipping your engine to a HFT warranty station as soon as a problem exists. Contact the HFT Customer Service depart-
ment at the number below to make shipping arrangements. The warranty repairs should be completed in a reasonable amount of time, not to
exceed 30 days.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
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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 Coverage
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 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 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:
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.
5. 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 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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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