Harbor Freight Tools 96156 User Manual 2
5.5 HP Lawn Mower enGIne
96156
InstaLLatIon, oPeratInG, and servIcInG
InstructIons
using an engine indoors can KILL You In
MInutes.
engine exhaust contains carbon monoxide.
this is a poison you cannot see or smell.
never use inside
a home or garage,
even IF doors and
windows are open.
distributed exclusively by Harbor Freight tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
visit our website at: http://www.harborfreight.com
only use outsIde
and far away from
windows, doors, and
vents.
read this material before using this product.
Failure to do so can result in serious injury.
save tHIs ManuaL.
Copyright© 2008 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
installation and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual revised 10f
contents
Parts LIst ......................................16
IMPortant saFetY
InForMatIon .................................3
sPecIFIcatIons ...............................6
unPacKInG .......................................6
InstaLLatIon ...................................6
oPeratInG InstructIons ...........8
enGIne controLs .............................. 8
startInG tHe enGIne ........................ 8
cHecKInG and FILLInG enGIne
oIL ...................................................8
cHecKInG and FILLInG FueL .......9
start Procedure ........................ 9
BreaK-In PerIod .........................10
servIcInG .......................................11
MaIntenance Procedures ...........11
enGIne oIL cHanGe .....................11
aIr FILter eLeMent
MaIntenance .............................11
sParK PLuG MaIntenance ....... 12
asseMBLY dIaGraM .....................17
LIMIted 90 daY warrantY .........18
eMIssIon controL sYsteM
warrantY ...................................18
cLeanInG, MaIntenance, and
LuBrIcatIon scHeduLe ............... 12
aFter InItIaL 20 oPeratIon
Hour PerIod: ............................12
everY 25 oPeratIon Hours
tHereaFter: .............................. 12
everY 50 oPeratIon Hours: ...12
everY 100 oPeratIon Hours: . 12
everY 300 oPeratIon Hours: . 12
storaGe .............................................13
trouBLesHootInG ........................... 14
Page 2 For technical questions, please call 1-800-444-3353. SKU 96156
save tHIs ManuaL
Keep this manual for the safety warnings
and precautions, installation, 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.
IMPortant saFetY
InForMatIon
In this manual, on the labeling, and
all other information provided with
this product:
cautIon, without the
safety alert symbol, is
used to address practices not
related to personal injury.
warnInG! read all instructions.
Failure to follow all instructions
listed below may result in re,
serious injury and/or deatH. The
warnings and precautions discussed
in this manual cannot cover all
possible conditions and situations that
may occur. It must be understood
by the operator that common sense
and caution are factors which cannot
be built into this product, but must be
supplied by the operator.
save tHese InstructIons
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.
danGer indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
warnInG indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
cautIon, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
notIce is used to
address practices not
related to personal injury.
InstaLLatIon PrecautIons
Gasoline fuel and fumes are ammable, 1.
and potentially explosive. Use proper
fuel storage and handling procedures.
Do not store fuel or other ammable
materials nearby.
Have multiple ABC class re 2.
extinguishers nearby.
Operation of this engine may create 3.
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.
Install only to a lawn mower and only in 4.
an upright position.
Wear ANSI-approved safety goggles, 5.
heavy-duty work gloves, and dust mask/
respirator during installation.
Use only oil and fuel recommended 6.
in the “Specications” section of this
manual.
Page 3For technical questions, please call 1-800-444-3353.SKU 96156
Follow lawn mower manufacturer’s 7.
installation procedures for attaching the
engine to the mower and connecting the
output shaft.
oPeratInG PrecautIons
1. carBon MonoxIde
Hazard
using an engine indoors
can KILL You In MInutes.
Engine 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.
Keep children away from the engine, 2.
especially while it is operating.
Do not leave the engine unattended 3.
when it is running. Turn off the engine
before leaving the work area.
6.
Use only accessories that are
recommended by Harbor Freight Tools
for your model. Accessories that may
be suitable for one engine may become
hazardous when used on another
engine.
7.
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.
Stay alert, watch what you are doing and 8.
use common sense when operating this
engine. Do not use this engine while
tired or under the inuence of drugs,
alcohol or medication.
Do not overreach. Keep proper 9.
footing and balance at all times. This
enables better control of the engine in
unexpected situations.
Dress properly. Do not wear loose 10.
clothing or jewelry. Keep hair, clothing
and gloves away from moving parts.
Loose clothes, jewelry or long hair can
be caught in moving parts.
Parts, especially exhaust system 11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine during 12.
operation.
Keep the engine and surrounding area 13.
clean at all times.
Wear ANSI-approved safety goggles and 4.
hearing protection during use.
People with pacemakers should 5.
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.
Page 4 For technical questions, please call 1-800-444-3353. SKU 96156
Use the engine, accessories, etc., in 14.
accordance with these instructions and
in the manner intended for the particular
engine, taking into account the working
conditions and the work to be performed.
Use of the engine for operations different
from those intended could result in a
hazardous situation.
Do not operate the engine with known 15.
leaks in the fuel system.
This product contains or, when used, 16.
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.)
17.
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 bottomventilated, covered, metal container.
Keep hands and feet away from moving 18.
parts. Do not reach over or across
engine while operating.
Before use, check for misalignment 19.
or binding of moving parts, breakage
of parts, and any other condition that
may affect the engine’s operation. If
damaged, have the engine serviced
before using. Many accidents are
caused by poorly maintained engines.
Use the correct engine for the 20.
application. Do not modify the engine
and do not use the engine for a purpose
for which it is not intended. Install on
Lawn mower only.
Follow lawn mower manufacturer’s 21.
operation precautions.
servIce PrecautIons
Before service, maintenance, or 1.
cleaning:
close the engine’s fuel valve.a.
allow the engine to completely cool.b.
then, remove the spark plug wire(s) c.
from the spark plug(s).
Keep all safety guards in place and in 2.
proper working order. Safety guards
include mufer, air cleaner, mechanical
guards, and heat shields, among other
guards.
do not alter or adjust any part of 3.
the engine that is sealed by the
manufacturer or distributor.
Wear ANSI-approved safety goggles, 4.
heavy-duty work gloves, and dust mask/
respirator during service.
Maintain labels and nameplates on 5.
the engine. These carry important
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
Have the engine serviced by a qualied 6.
repair person using only identical
replacement parts. This will ensure that
the safety of the engine 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.
tHe enGIne BraKe Is For
eMerGencY sHutoFF; do not
rePLace tHe BraKe sPrInG wItH
a weaKer sPrInG.
Store engine out of the reach of children.7.
Follow scheduled maintenance.8.
Refueling Precautions:9.
Do not smoke, or allow sparks, ames, a.
or other sources of ignition around the
engine, especially when refuelling.
Do not rell the fuel tank while the b.
engine is running or hot.
Do not ll fuel tank to the top. Leave c.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.
d.
save tHese
InstructIons.
Page 5For technical questions, please call 1-800-444-3353.SKU 96156
sPecIFIcatIons
InstaLLatIon
Engine Rating 5.5 Horsepower
Fuel
Engine Oil
Run Time @ 50% Load 3.5 Hours with full tank
Sound Level 77 dB
Engine Type
Bore x Stroke 68 mm x 45 mm
Compression Ratio 8:1
Displacement 163cc
Rotation viewed from PTO
(power takeoff - the output shaft)
Shaft Size/Type
Spark Plug
Valve
Clearance
Speed 3250 RPM
Type
Capacity 0.45 Gallons
Type
Capacity 18.6 oz.
Type
Gap 0.028”-0.031”
Intake 0.1 mm
Exhaust 0.15 mm
89+ octane unleaded gasoline
10W-30
(Detergent or non-detergent)
4 Stroke, OHV
(1P68FV / 7CLGS.16368V)
Counterclockwise
7/8” x 3-1/8”, 3/16” keyway,
end tapped 3/8”-24
F6TC resistive
(NGK® BP-6HS, Champion® RL86C)
The emission control system for this
engine is warranted for standards set by the
U.S. Environmental Protection Agency. For
warranty information, refer to the last pages of
this manual.
At high altitudes, the engine’s carburetor
and any other parts that control the fuel-air
ratio will need to be adjusted by a qualied
mechanic to allow efcient high-altitude use
and to prevent damage to the engine and any
other devices used with this product.
read the entIre IMPortant
saFetY InForMatIon
section at the beginning of this
manual including all text under
subheadings therein before
installation or use of this product.
to Prevent
serIous InjurY
FroM accIdentaL startInG:
close the engine’s fuel valve,
wait for the engine to cool, and
disconnect the spark plug wire(s)
before installing or making any
adjustments to the engine.
to Prevent
serIous InjurY:
operate only with proper spark
arrestor installed.
operation of this engine 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.
IMPortant: 1. If you have any doubts
about your ability to perform the following
procedures, have a qualied service
technician perform the installation.
Install this engine on a lawn mower only.2.
unPacKInG
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon as
possible.
Page 6 For technical questions, please call 1-800-444-3353. SKU 96156
Figure a - Mounting Hole Locations (Bottom view)
3. Set the Engine upright on the mower,
and align the four 3/8” diameter coarse
threaded engine mounting holes with
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