Harbor Freight Tools 96500 User Manual
GAS ENGINE - 6.5 HP
Model
96500
®
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© 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.
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 .................................................................................. 9
General/Basic Troubleshooting .......................................................................... 9
Engine Difficult to Start ...................................................................................... 9
Low Engine Power .............................................................................................10
Engine not Running Smoothly ............................................................................ 10
Engine Excessively Hot ...................................................................................... 11
Abnormal Engine Noise .....................................................................................11
MAINTENANCE ............................................................................................ 12
Scheduled Maintenance ..................................................................................... 12
Cleaning Air Filter ............................................................................................... 12
Cleaning and Replacing Spark Plug ..................................................................12
Changing Oil ......................................................................................................13
Cleaning the Deposit Cup ..................................................................................13
Torque Value for Major Engine Bolts .................................................................. 14
Transporting the Engine ..................................................................................... 14
Storing the Engine ............................................................................................. 14
PARTS LISTS AND ASSEMBLY DIAGRAMS .............................................. 15
Parts List ............................................................................................................15
Assembly Diagram ............................................................................................. 17
WARRANTY ..................................................................................................18
Emission Control System Warranty .................................................................... 19
For technical questions, please call 1-800-444-3353.
Page 2SKU 96500
SPECIFICATIONS
Power Output 6.5 HP OHV Gas Engine, EPA and CARB approved
Displacement / Stroke 196 cc; 4-stroke
Ignition Type Electronic ignition (T.C.I.)
Start Type Recoil
Cooling System Forced air cooling
Maximum Power Output 4.8 KW @ 3600 RPM
Maximum Torque 11-N.M./2500-RPM
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 gap
Gasoline Type Unleaded
Gasoline Tank Capacity 0.95 gallon (3.6 liters)
Drive Shaft Type Horizontal, ¾” straight, keyed shaft with ball bearings. Direction:
counterclockwise (facing shaft); Length: 2-1/4”; Central thread: 5/16”-24
Speed 3600 RPM
Oil Capacity and Type 0.528 quart (0.5 liters); SAE 10W30 (in freezing weather use 5W30)
Engine Shaft Mounting Square pattern, 4 holes; 8.0-1.25 mm threads x 3-5/8” Bolt Circle
Mounting Pattern 3” x 6-3/8”
Weight 33.8 lbs.
Overall Dimensions 12-3/4” L X 14” W X 10-1/4” H
Recommended Applications To drive: pump, sprayer, tiller, chipper, shredder, log splitter
Features Low oil shutdown, automatic
Longer engine life with bearing supported shaft
Meets 2007 EPA Phase II CA. 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 ENGINE!
Keep work area clean. Dark and cluttered areas invite injuries.1.
For technical questions, please call 1-800-444-3353.
Page 3SKU 96500
2.
Observe work area conditions. Do not use the Engine in damp or wet locations. Do
not expose to rain. Keep work area well lit. Do not use powered tools in the presence
of flammable gases or liquids.
3.
4.
5.
6.
7.
8.
9.
Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords. Children must never be allowed to
operate the Engine or be in the work area when the Engine is in operation.
Store idle equipment. When not in use, the Engine must be stored in a dry location
to inhibit rust. Always lock it up 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 the Engine to do the work of
a larger industrial tool. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the rate for which it was intended.
Do not modify the Engine or use it for a purpose for which it was not intended.
Use eye and ear protection. Always wear ANSI approved impact safety goggles and
ear plugs when using the Engine.
Do not overreach. Keep proper footing and balance at all times. Do not reach over
or across running machines.
Maintain the Engine with care. Follow instructions for lubricating and changing ac-
cessories.
10.
11.
12.
13.
14.
15.
Remove adjusting keys and wrenches. Check that all keys and adjusting wrenches
are removed from the Engine before starting.
Avoid unintentional starting. Be sure the power switch and Fuel Valve are in the Off
position when not in use.
Check for damaged parts. 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 the Engine while tired or under the influence of drugs, alcohol,
or medication. 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 Engine.
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. Electro-
magnetic fields in close proximity to heart pacemaker could cause pacemaker interfer-
ence or pacemaker failure. Caution is necessary when near coil, spark plug cables, or
distributor of running engine. Engine should be off during distributor adjustment.
For technical questions, please call 1-800-444-3353.
Page 4SKU 96500
16.
Fire Hazard! Do not fill Fuel tank when the engine is running. Do not operate if
gasoline has been spilled. Clean spilled gasoline before starting the Engine and dispose of cleaning materials in a ventilated metal container. Do not operate near a pilot
light or open flame.
17.
18.
19.
20.
21.
22.
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
symptoms the engine may not be working properly, or it is being utilized with too little
ventilation in the work area. 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 completely.
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 connected machinery.
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 flam-
mable 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.
23.
24.
25.
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 ANSI-approved ear protection
when operating or working around the 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.
For technical questions, please call 1-800-444-3353.
Page 5SKU 96500
UNPACKING
When unpacking, check to make sure the all parts are included. If any parts are miss-
ing or broken, please call Harbor Freight Tools at the number on the cover of this manual as
soon as possible.
MOUNTING
1.
2.
Mount the Engine using the four mounting holes at the base (hardware not supplied).
Select a flat, level location able to withstand the weight, vibration, and the equipment
connected to the Engine. If installed indoors, proper exhaust ventilation tubing must
be installed. If installed outdoors, 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. Contact a qualified technician to connect the
Engine.
For technical questions, please call 1-800-444-3353.
Page 6SKU 96500
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