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 KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
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NEVER use inside |
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Only use OUTSIDE |
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and far away from |
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a home or garage, |
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windows, doors, |
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EVEN IF doors and |
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and vents. |
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windows are open. |
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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© 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.
SAFETY
Table of Contents
..........................................................Safety |
2 |
...............................................Maintenance |
16 |
Setup........................................................... |
6 |
Parts List and Diagram............................... |
21 |
Specifications.............................................. |
6 |
Warranty..................................................... |
23 |
Operation................................................... |
10 |
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SETUP
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.
OPERATION
MAINTENANCE
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 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 this manual.
Page 2 |
For Generator technical questions, please call 1-888-866-5797. |
Item 68525 68530 |
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 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, 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.
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. Always read and adhere to the instruction manual of the product
to be powered, to make sure that it can be safely and efficiently powered by a portable generator.
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.
SAFETY
SETUP
OPERATION
MAINTENANCE
Item 68525 68530 |
For Generator technical questions, please call 1-888-866-5797. |
Page 3 |
SAFETY
SETUP
OPERATION
MAINTENANCE
16.Connect the Generator only to a load or electrical system (120 volt or 240 volt) that is compatible with the electrical characteristics 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 sufficient 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.
25.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.
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 flammable 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.
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 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 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.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.WARNING: This product contains di (2-ethylhexyl) phthalate (DEHP), 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.)
38.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.
39.Keep hands and feet away from moving parts. Do not reach over or across generator while operating.
40.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.
41.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 Generator technical questions, please call 1-888-866-5797. |
Item 68525 68530 |
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.
8.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.
9.Store equipment out of the reach of children.
10.Follow scheduled engine and equipment maintenance.
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 qualified service technician may adjust parts that may increase or decrease governed engine speed.
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.TO PREVENT FUEL LEAKAGE AND FIRE HAZARD, Do not overfill with fuel. Fill with fuel according to the Fuel Level information below the Specification chart for your model.
4.Do not fill 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.Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during service. 6. Wipe up any spilled fuel and allow excess
7.Maintain labels and nameplates on the equipment. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
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.
SAFETY
SETUP
OPERATION
MAINTENANCE
Item 68525 68530 |
For Generator technical questions, please call 1-888-866-5797. |
Page 5 |
Functional Description
Specifications
SAFETY
SETUP
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Output |
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120/240VAC, 60Hz |
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7,000 Running Watts (8750 Peak Watts) |
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Battery needed for electric start |
12V, lead acid, 9Ah |
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Generator |
(not included) |
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Two 3-Prong, duplex NEMA #5-15 120V |
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Electrical Receptacle |
One 3-Prong, NEMA #L5-20 twistlock 120V |
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One 4-Prong, NEMA #L14-30 twistlock 120V/240V |
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One DC Outlet 12VDC |
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Displacement |
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420cc |
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Engine Type |
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Horizontal Single Cylinder 4 stroke OHV |
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Cooling System |
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Forced air cooled |
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Fuel |
Type |
87+ octane stabilizer treated unleaded gasoline |
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Engine |
Capacity |
6.6 Gallons (25L) |
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Type SAE |
10W-30 above 32° F |
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Engine Oil |
5W-30 at 32° F or below |
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Capacity |
1.16 Quart (1.1L) |
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Run Time @ 50% load |
12 hr. |
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Operational Volume |
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76 dB |
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Available accessories |
Wheel kit (sold separately) |
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OPERATION
MAINTENANCE
Item 68525 - 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 68530 - 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.
Components and Controls
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Fuel Cap |
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DC Receptacle |
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DC Circuit Breaker |
Fuel Valve |
AC Circuit Breakers |
Choke |
AC Receptacles |
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Air Filter
Frame
Ground Terminal
Starter |
Power Switch |
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Low Oil Indicator |
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Handle |
Page 6 |
For Generator technical questions, please call 1-888-866-5797. |
Item 68525 68530 |
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 flow.
START
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)
b.3-Prong, twistlock,
120 volt receptacle (NEMA #L5-20)
c.4-Prong, twistlock, 120/240 volt receptacle (NEMA #L14-30)
ON
OFF
3.Circuit Breakers: The circuit breaker protects the 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.
4.12 VDC Receptacle: 12 VDC Receptacle provides a 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.
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.
SAFETY
SETUP
OPERATION
MAINTENANCE
Item 68525 68530 |
For Generator technical questions, please call 1-888-866-5797. |
Page 7 |
SAFETY
SETUP
OPERATION
MAINTENANCE
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.
TO PREVENT SERIOUS INJURY:
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 fuelair 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.
Battery Setup Instructions
All Generators can be started using the recoil method. This generator requires installation of a battery to operate the electric start feature. Connect the battery to the generator engine:
1. Place a fully charged, lead-acid 12 V, 9 Ah battery (not included) in the battery holder on the generator.
2. |
Bolt in place using the hardware included with the battery. |
Positive |
Negative |
3. |
Attach the positive (red) cable connector from the engine to the Positive Terminal |
Connector |
Connector |
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on the battery. Connect cable securely to prevent disconnection and short circuits. |
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4. |
Attach the negative (black) cable connector to the negative battery terminal. |
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Grounding |
Battery |
Hardware |
The Generator must be properly grounded before use. Have the unit grounded by a qualified electrician if you are not qualified to do so.
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) 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.
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: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual.
Note: Wheel Kit, item # 68531 (sold separately) can be used with this generator.
Page 8 |
For Generator technical questions, please call 1-888-866-5797. |
Item 68525 68530 |
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