Harbor Freight Tools 94187 User Manual
GAS ENGINE - 6.5 HP
Model
94187
®
ASSEMBLY AND OPERATION INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND
ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
Copyright© 2006, 2007 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form without
the express written consent of Harbor Freight Tools.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual revised 02/07.
Contents
SPECIFICATIONS ......................................................................................... 3
Save This Manual ............................................................................................... 3
SAFETY WARNINGS AND PRECAUTIONS ................................................ 3
UNPACKING ................................................................................................. 5
MOUNTING ................................................................................................... 6
OPERATION .................................................................................................6
Controls and Indicators ......................................................................................6
Pre-Operation Checks ........................................................................................ 7
TROUBLESHOOTING .................................................................................. 8
General/Basic Troubleshooting .......................................................................... 8
Engine Difficult to Start ...................................................................................... 9
Low Engine Power .............................................................................................10
Engine not Running Smoothly ............................................................................ 10
Engine Excessively Hot ...................................................................................... 11
Abnormal Engine Noise .....................................................................................12
MAINTENANCE ............................................................................................ 13
Scheduled Maintenance ..................................................................................... 13
Cleaning Air Filter ............................................................................................... 13
Cleaning and Replacing Spark Plug ..................................................................13
Changing Oil ......................................................................................................14
Cleaning the Deposit Cup ..................................................................................14
Torque Value for Major Engine Bolts .................................................................. 15
Transporting the Engine ..................................................................................... 15
Storing the Engine ............................................................................................. 15
PARTS LISTS AND ASSEMBLY DIAGRAMS .............................................. 16
Crankcase .......................................................................................................... 16
Crankcase Cover ................................................................................................17
Cylinder Head and Cover ...................................................................................18
Parts List ............................................................................................................18
Crankshaft, Piston, and Connecting Rod ........................................................... 19
Camshaft and Rocker Valve ............................................................................... 20
Carburetor .......................................................................................................... 21
Fuel Tank ............................................................................................................22
Air Cleaner .........................................................................................................23
Muffler ................................................................................................................24
Recoil Starter .....................................................................................................25
Regulator Control ............................................................................................... 26
Flywheel ............................................................................................................. 27
Ignition Coil ........................................................................................................28
Wiring Diagram ..................................................................................................29
WARRANTY ..................................................................................................29
Emission Control System Warranty .................................................................... 30
SKU 94187 For technical questions, please call 1-800-444-3353
Page 2
SPECIFICATIONS
Power Output 6.5 HP Gas Engine, EPA and CARB approved
Displacement / Stroke 196 cc; 4-stroke
Ignition Type Electronic ignition (T.C.I.)
Cooling System Forced air cooling
Idling Carburetor Adjust 1700 +/- 150 RPM
Valve clearance Cold engine – Intake: 0.15 +/- 0.02mm;
Exhaust: 0.20 +/- 0.02 mm
Distributor Timing Intake valve opening: BTDC10’;
Intake valve closing: ABDC20’
Bore and Stroke 68 x 54 mm
Spark Plug Type BP6ES, BPR6ES (NGK), or NHSPLD F6RTCU; 0.7~0.8 mm clearance
Gasoline Type Unleaded
Gasoline Tank Capacity 0.95 gallon (3.6 liters)
Drive Shaft Type Horizontal, ¾” straight, (3/16”) keyed shaft with ball bearings. Direction:
counterclockwise (facing shaft); Length: 2-1/4”; Central thread: 5/16”-24
Start Type Recoil
Speed 3600 RPM
Oil Capacity and Type 0.528 quart (0.5 liters); SAE 10W30 (in freezing weather use 5W30)
Engine Mounting Square pattern, 4 holes; 8.0-1.25 mm threads
Weight 33.8 lbs.
Overall Dimensions 12.3 (L) x 15.6 (W) x 13.2 (H) inches
Recommended Applications To drive: pump, sprayer, tiller, chipper, shredder, log splitter
Features Low oil shutdown, automatic
Longer engine life with bearing supported shaft
Meets 2005 EPA Phase II Cal. Emission Regs.
Fuel shutoff valve
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 back two pages of this manual.
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with
this manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.
SAFETY WARNINGS AND PRECAUTIONS
WARNING: When using this Gas Engine, basic safety precautions should always be followed to reduce
the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1.
2.
Keep work area clean. Cluttered areas invite injuries.
Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically
powered tools in the presence of flammable gases or liquids.
SKU 94187 For technical questions, please call 1-800-444-3353
Page 3
3.
Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
4.
5.
6.
7.
8.
9.
10.
Store idle equipment. When not in use, tools must be stored in a dry location to inhibit
rust. Always lock up tools and keep out of reach of children.
Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving
parts. Wear restrictive hair covering to contain long hair.
Use the right tool for the job. Do not attempt to force a small tool or attachment to
do the work of a larger industrial tool. There are certain applications for which this tool
was designed. It will do the job better and more safely at the rate for which it was in-
tended. Do not modify this tool and do not use this tool for a purpose for which it was
not intended.
Use eye and ear protection. Always wear ANSI approved impact safety goggles and
ear plugs.
Do not overreach. Keep proper footing and balance at all times. Do not reach over
or across running machines.
Maintain tools with care. Keep tools sharp and clean for better and safer performance.
Follow instructions for lubricating and changing accessories.
Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are
removed from the tool or machine work surface before starting.
11.
12.
13.
14.
15.
16.
Avoid unintentional starting. Be sure the power switch and gas valve are in the Off
position when not in use.
Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
Check for damaged parts. Before using this Gas Engine, any part that appears dam-
aged should be carefully checked to determine that it will operate properly and perform
its intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any part
that is damaged should be properly repaired or replaced by a qualified technician. Do
not use the Gas Engine if the switch does not turn On and Off properly.
Do not operate this Gas Engine if under the influence of alcohol or drugs. Read
warning labels if taking prescription medicine to determine if your judgment or reflexes
are impaired while taking drugs. If there is any doubt, do not operate the tool.
Maintenance. For your safety, service and maintenance should be performed regularly
by a qualified technician.
People with pacemakers should consult their physician(s) before use. Electromag-
netic fields in close proximity to heart pacemaker could cause pacemaker interference
or pacemaker failure.
Caution is necessary when near coil, spark plug cables, or distributor of running engine.
Engine should be off during distributor adjustment.
SKU 94187 For technical questions, please call 1-800-444-3353
Page 4
17.
Fire Hazard! Do not fill gas tank when the engine is running. Do not operate if
gasoline has been spilled. Clean spilled gasoline before starting the engine. Do not
operate near a pilot light or open flame.
18.
19.
20.
21.
22.
23.
Operate the engine in well ventilated areas only. Carbon Monoxide is
produced during operation and is deadly in a closed environment. Early
signs of Carbon Monoxide poisoning resemble the flu, with headaches, dizziness, or nausea. If you have these signs, the engine may not be working
properly, or is being used indoors. Get fresh air immediately.
Avoid burns from the engine. Certain parts of the engine become very hot during
use. Do not touch the engine until it cools down after use.
Install this product on a proper surface. Locate on a flat, level, and solid surface that
is capable of supporting the weight of the engine and the machinery that it is turning.
Do not operate the engine with safety guards removed. While the engine is running, do not attempt to reach around the safety guards for maintenance or any other
reason.
If the engine is installed indoors, exhaust fumes must be piped out of the building using leak-free, heat-resistant piping. Pipes and silencer should not use any
flammable materials, nor should they be installed near the same. Engine exhaust fumes
should be within legal limits.
Engine fuel and fumes are flammable, and potentially explosive. Do not smoke,
or allow sparks, flames or other sources of ignition around the engine, fuel tanks,
or batteries. Use proper fuel storage and handling procedures. Always have multiple
ABC class fire extinguishers nearby.
24.
25.
26.
Warning: The warnings, cautions, and instructions discussed in this instruction manual can-
Never store fuel or other flammable materials near the engine.
Keep hands, arms, long hair, loose clothing, and jewelry away from pulleys, belts,
and other moving parts. Be aware that when engine parts are moving fast they can-
not be seen clearly.
The 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 when it is running.
not 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.
UNPACKING
When unpacking, check to make sure the following parts are included. If any parts are
missing or broken, please call Harbor Freight Tools at the number on the cover of this manual
as soon as possible.
SKU 94187 For technical questions, please call 1-800-444-3353
Page 5
MOUNTING
1.
2.
Mount the Engine using its four mounting holes at the base (hardware not supplied).
Select a flat, smooth location able to withstand the weight, vibration, and the load device
connected to the Engine. If installed indoors, proper exhaust ventilation tubing must be
installed. If installed outdoors, a weatherproof housing is recommended.
Install the Engine load.
The Engine load must be perfectly aligned with the Engine drive shaft to prevent undue
wear on the shaft and bearings. A qualified technician should do this.
OPERATION
Controls and Indicators
Spark Plug
Fuel Tank Cap
Muffler
Muffler
Air Filter
Drive Shaft
On / Off Switch
Oil PlugDip Stick
Drain Plug
Oil Plug
Deposit Cup
Drain Plug
Throttle
Choke
Gas Valve
Starter Pull Cord
SKU 94187 For technical questions, please call 1-800-444-3353
Page 6
Pre-Operation Checks
Caution: Failure to add oil to the Engine before use will damage the Engine and void the fac-
tory warranty. Engine oil is the key factor in engine performance. Do not use Engine oil
with additives; Do not use two-stroke gasoline-oil. Using these will shorten Engine life.
See Specifications on page 2 for recommended oil type.
1.
2.
3.
Check that all installation mounting nuts and bolts are tight.
Check oil level (See illustration below, left.) If needed, add oil as specified on page 2.
Unscrew the oil Dip Stick and wipe clean. Insert the Dip Stick back into the hole without
screwing it in. Remove it again and check the oil level. Full is indicated by oil on the
Upper Level mark. Use a siphon to avoid spilling the oil. Carefully screw the plastic Dip
Stick back into the metal Engine crankcase to avoid stripping the plastic threads on the
Dip Stick.
Check Air Filter. (See illustration above, right.) Unscrew Air Filter Housing Nut and
remove the Air Filter Housing and Filter Elements. If dirty or dusty, clean (refer to the
Maintenance Section).
Caution: Never run the Engine without the Air Filter assembly. Damage will occur to En-
gine.
4.
SKU 94187 For technical questions, please call 1-800-444-3353
Remove the debris filter, clean and replace it before filling. Fill the Gas Tank (outdoors)
with up to 0.95 of a gallon of unleaded gasoline containing at least 86 octane. Do not
top-off tank. Replace Gas Cap. Clean up any spilled gas with a dry cloth.
Fire Hazard! Do not fill Gas Tank when the Engine is running, or near a pilot light or open
flame; Do not smoke. Do not operate if gasoline has been spilled. Clean spilled gasoline
before starting the engine.
Page 7
Starting the Engine
During this procedure, it may be helpful to refer to the photos of the Engine Controls on
page 5.
1.
2.
Push the Gas Valve to the open (right) position.
Close the Choke by pulling it to the left.
Note: If the Engine is already hot, it is not necessary to close the Choke.
3.
Push the Throttle Lever to the slow (right) position , then move it back
slightly.
4.
5.
Turn the On/Off Switch to the On position.
Gently pull the Starter Pull Cord until it engages. Then pull it hard and all the way out.
Slowly guide the Pull Cord back into the starter.
The Engine should start. Try again if it does not start. Refer to the Troubleshooting section if problems persist. Let the engine run for five minutes to warm up.
6.
7.
Push in the Choke Lever to the right/
Push the Throttle Lever to the fast position (left).
Throttle Setting
Stopping the Engine
Throttle Setting
1.
2.
3.
Push the Throttle Lever to the slow (right) position.
Turn the On/Off Switch to the Off position.
Push the Gas Valve to the closed (left) position.
TROUBLESHOOTING
General/Basic Troubleshooting
Symptom Probable Cause Possible Remedy
Engine will not start. 1. On/Off Switch in Off position.
2. Gas Valve in closed position.
3. Choke set to open position.
4. Gas Tank empty.
5. Spark plug dirty.
6. Technical problem.
Engine runs rough,
pinging noises.
Engine stops by itself,
but has gas.
Engine does not reach
full speed.
1. Gasoline wrong type.
2. Gasoline has water.
1. Low oil level auto shut off.
2. Technical problem.
1. Choke closed.
2. Air filters clogged.
3. Technical problem.
1. Turn to On position.
2. Push to open position.
3. Set to closed position.
4. Fill Gas Tank.
5. Remove spark plug and clean.
6. Service by qualified mechanic.
1. Replace with 89 octane gas.
2. Empty tank and replace gas.
1. Check oil level; Add if needed.
2. Service by qualified mechanic.
1. Open Choke.
2. Clean air filter elements.
3. Service by qualified mechanic.
SKU 94187 For technical questions, please call 1-800-444-3353
Page 8
Symptom Probable Cause Possible Remedy
Engine difficult to start
Engine Difficult to Start
Fuel supply blocked:
– Cylinder compression
OK
– Spark OK
Engine difficult to start
– Cylinder compression
OK
– Spark OK
– Gas supply OK
Engine difficult to start
– Cylinder Compression
OK
– Gas supply OK
– Ignition coil spark OK
Engine difficult to start
– Gas supply OK
1. Air vent in Gas Cap clogged.
2. Gas Valve plugged up
3. Main jet clog or misadjusted
4. Needle valve improperly
closed or start hole is clogged
5. Floater in fuel tank is
damaged or sticking
Fuel system problem:
1. Gas dirty, has water, or is old
2. Engine cylinder flooded
3. Gas wrong type
1. Spark plug has carbon
buildup or dirt on and around
electrodes
2. Electrodes are burned
3. Improper spark gap
1. Piston ring worn
2. Piston ring is sticking
1. Clean Gas Cap air vent
2. Unclog Gas Valve
3. Clean and/or readjust
4. Take apart needle valve and
repair, clean, and blow out
5. Repair floater
1. Drain gas and replace
2. Drain extra gas, dry spark
plug electrodes
3. Drain gas and replace
1. Remove spark plug and
clean
2. Replace spark plug
3. Adjust spark plug electrodes
1. Replace piston rings
2. Clean out carbon fouling
– Ignition system OK
3. Piston ring broken
4. Spark plug loose or without a
gasket
5. Air leakage between cylinder
block and cylinder
6. Air leakage in valve
3. Replace piston ring
4. Tighten with a gasket
5. Check cylinder gasket and
bolts
6. Check valve clearance and
thickness, repair if required
SKU 94187 For technical questions, please call 1-800-444-3353
Page 9
Symptom Probable Cause Possible Remedy
When pressing Throttle
for higher speed, engine
responds slowly; speed is
decreased; or engine stops.
Low Engine Power
Incorrect Ignition timing. Re-adjust ignition advance angle.
Fuel supply problem:
1. Fuel line is clogged or has air
1. Clean line. Bleed line of air.
2. Main jet not adjusted properly
3. Carburetor needle valve hole
and main jet clogged
4. Gas valve clogged
5. Carbon buildup in combustion
chamber.
6. Air filter is clogged.
7. Intake pipe leaking.
Low compression:
1. Piston, piston ring, or cylinder
worn.
2. Air leakage from surface
where cylinder block contacts
cylinder head.
3. Valve clearance incorrect.
4. Valve tightness poor.
Engine not Running Smoothly
Symptom Probable Cause Possible Remedy
Engine pinging. 1. Piston, ring, or cylinder worn.
2. Readjust jet.
3. Clean needle valve hole and
main jet
4. Clean or replace gas valve.
5. Clean combustion chamber.
6. Clean filter elements.
7. Repair or replace.
1. Replace damaged part.
2. Replace cylinder gaskets.
3. Adjust valve.
4. Repair or replace valve.
1. Replace worn part.
2. Piston pin and pin hole are
worn excessively.
3. Tie rod small head is worn.
4. Main crankshaft roller bearing
worn.
Abnormal combustion. 1. Engine too hot.
2. Carbon fouling in combustion
chamber.
3. Wrong gasoline type.
Spark plug not firing
correctly
1. Water in carburetor float
chamber.
2. Spark plug electrode gap
wrong.
3. Incorrect ignition timing.
4. Ignition coil malfunction.
2. Replace piston and/or pin.
3. Replace tie rod.
4. Replace roller bearing.
1. Troubleshoot overheating
(see page 11).
2. Clean chamber.
3. Drain gas from system and
replace with correct type.
1. Clean Carburetor.
2. Adjust spark plug gap.
3. Re-adjust.
4. Repair or replace coil.
SKU 94187 For technical questions, please call 1-800-444-3353
Page 10
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