PREDATOR 59205 6500 Watt Gas Powered Portable Generator with CO SECURE Technology Owner’s Manual
- June 3, 2024
- Predator
Table of Contents
59205 6500 Watt Gas Powered Portable Generator with CO SECURE Technology
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 (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.
22h
Visit our website at: http://www.harborfreight.com Email our technical support
at: productsupport@harborfreight.com
Email our engine support at: predator@harborfreight.com
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a poison you cannot see or
smell.
Do not use in trailers, truck beds, or tents.
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.
DANGER
Use at least 20 feet away from people, animals, and structures with exhaust
pointed away.
20
20 20
20 20
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© 2022 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.
Table of Contents
Safety ………………………………………………… 2 Setup …………………………………………………. 7 Specifications ……………………………………… 7 Operation…………………………………………… 11
Maintenance ………………………………………. 17 Parts List and Diagram ………………………… 24 Warranty ……………………………………………. 28
SAFETY
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.
SETUp
OpERATION
IMpORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during
installation and maintenance of the Generator and any batteries.
Set up precautions
1. This unit is to be installed so that access is restricted to only
qualified service personnel who have been instructed of the reasons for the
restrictions applied to the location and about any precautions that must be
taken. Access shall be through the use of a special tool, or lock and key, or
other means of security and shall be controlled by the authority responsible
for the location.
2. 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.
3. Have multiple ABC class fire extinguishers nearby.
4. 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.
5. Set up and use only on a flat, level, well-ventilated surface.
6. 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.
7. 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.
8. A transfer switch should be installed by a licensed electrician in
compliance with all applicable laws and electrical codes.
9. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust
mask/respirator during set up.
10. Use only lubricants and fuel recommended in this manual.
Page 2
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ITEM 59205
MAINTENANCE
SAFETY
SETUp
Set up precautions (continued)
11. 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.
12. Do not operate the Generator before grounding. The Generator must be
earth-grounded in accordance with all relevant electrical codes and standards
before operation.
13. Install carbon monoxide alarm(s) with battery backup in nearby buildings
according to manufacturer’s instructions.
Operating precautions
CARBON MONOXIDE HAZARD
NOTE: Yellow light flashes once after
Using a generator indoors CAN KILL
starting to indicate passing self-check
YOU IN MINUTES.
and is functioning normally.
Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
Carbon Monoxide sensor must only be serviced by qualified technician to restore it to original settings. Do not modify or tamper with the
Carbon Monoxide sensor. Not following these
instructions can result in death or serious injury
due to Carbon Monoxide sensor malfunction.
NEVER use inside a home or garage, EVEN IF doors and windows are open.
3. 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.
4. 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.
Only use OUTSIDE and far away from windows, doors, and vents.
2. CARBON MONOXIDE SHUTOFF
DANGER! TO pREVENT SERIOUS INJURY AND DEATH FROM CARBON MONOXIDE INHALATION:
The Carbon Monoxide sensor is an additional layer of protection only. Do not
use the Generator in any area or situation that will allow carbon monoxide to
accumulate.
· FLASHING RED LIGHT: Dangerous levels of carbon monoxide gas have built up
and generator will shutoff. Leave immediately until area has aired out. Move
Generator to well-ventilated area before operation.
· FLASHING YELLOW LIGHT: Carbon monoxide sensor malfunction. Sensor needs
service. Do not use the Generator until the sensor is working properly. For
technical questions, please call
1-888-866-5797.
5. 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.
6. Keep children away from the equipment, especially while it is operating.
7. Keep all spectators at least six feet from the Engine during operation.
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. 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.
11. 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.
OpERATION
MAINTENANCE
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Page 3
SAFETY
SETUp
12. 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.
13. 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.
14. 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.
15. Do not attempt to connect or disconnect load connections while standing
in water, or on wet or soggy ground.
16. 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.
17. 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.
18. GFCI pRECAUTIONS Test Ground Fault Circuit Interrupter (GFCI) receptacles
before each use as follows: a. Disconnect all devices from the Generator. b.
Start the engine. c. Press Test button on receptacle to trip the GFCI device.
d. The Reset button should extend, cutting off electricity to the receptacle.
e. If above test fails, do not use receptacle until it is repaired or
replaced. f. Press Reset button in for use.
The Generator must be grounded before use. An ungrounded Generator has an
increased risk of electric shock. Refer to Grounding on page 9.
19. Insulate all connections and disconnected wires.
20. Guard against electric shock. Prevent body contact with grounded surfaces
such as pipes, radiators, ranges, and refrigerators.
21. Only use a suitable means of transport and lifting devices with
sufficient weight bearing capacity when transporting the Generator.
22. Secure the Generator on transport vehicles to prevent the tool from
rolling, slipping, and tilting.
23. Industrial applications must follow OSHA requirements.
24. 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.
25. 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.
26. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved
dust mask/respirator during use.
27. 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.
28. 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.
29. 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.
30. 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.
31. 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.
32. 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.
33. Parts, especially exhaust system components, get very hot during use.
Stay clear of hot parts.
34. Do not cover the Generator or its engine during operation.
35. Keep the Generator, its engine, and surrounding area clean at all times.
36. Do not smoke, or allow sparks, flames, or other sources of ignition
around the equipment, especially when refuelling.
OpERATION
MAINTENANCE
Page 4
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ITEM 59205
SAFETY
37. 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.
38. Do not operate the Generator with known leaks in the engine’s fuel
system.
39. 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.
40. Keep hands and feet away from moving parts. Do not reach over or across
Generator while operating.
41. 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.
42. 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.
43. Extension Cord – Make sure your extension cord is in good condition. When
using an extension cord, be sure to use one heavy enough to carry the current
your product will draw. An undersized extension cord will cause a drop in line
voltage resulting in loss of power and overheating.
The following table shows the correct cord size to use depending on cord
length and nameplate ampere rating. If in doubt, use the next heavier gauge.
The smaller the gauge number, the heavier the cord.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS
CURRENT (AMpS)
Load @ 120V
(WATTS)
Load @ 240V
(WATTS)
0 ~ 50 ft
50 ~ 75 ft
75 ~ 100 ft
2
240
480
18 AWG
4
480
960
18 AWG
16 AWG
6
720
1440
18 AWG
16 AWG
14 AWG
8
960
1920
16 AWG
12 AWG
10
1200
2400
16 AWG
14 AWG
12 AWG
15
1800
3600
14 AWG
12 AWG
10 AWG
20
2400
4800
12 AWG
10 AWG
25
3000
6000
12 AWG
10 AWG
8 AWG
30
3600
7200
10 AWG
8 AWG
35
4200
8400
8 AWG
6 AWG
40
4800
9600
6 AWG
SETUp
OpERATION
MAINTENANCE
ITEM 59205
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Page 5
SAFETY
SETUp
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.
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.
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 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.
GFCI protection:
This Generator is equipped with two 3-Prong, duplex 120V ground fault circuit
interrupter (GFCI) receptacles. These outlets provide additional protection
from the risk of electric shock. Should replacement of the receptacles become
necessary, use only identical replacement parts that include GFCI protection.
Refueling:
1. Do not refill the fuel tank while the engine is running or hot.
2. Do not smoke, or allow sparks, flames, or other sources of ignition around
the equipment, especially when refuelling.
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. 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 INSTRUCTIONS.
OpERATION
MAINTENANCE
Page 6
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ITEM 59205
SAFETY
SETUp
Functional Description
Specifications
Generator Engine
Output
Electrical Receptacle
Displacement Engine Type Cooling System
Fuel
Type Recommended fill level
Engine Oil
Type SAE Capacity
Spark Plug
Type Gap
Valve Clearance
Intake Exhaust
Run Time @ 50% load
Available accessories
120/240VAC, 60Hz 46A at 120V; 23A at 240V 5,500 Running Watts (6,500 Max.
Starting Watts)
Two 3-Prong, duplex NEMA #5-20 120V GFCI One 4-Prong, NEMA #L14-30 twistlock
120V/240V One DC Outlet 12VDC
302cc
Horizontal Single Cylinder 4 stroke OHV
Forced air cooled
87+ octane stabilizer treated unleaded gasoline
8 Gallons
10W30 above 32°F 5W30 at 32°F or below
1 Quart NHSP® / Torch® F7TC
0.028″0.031″
0.004″0.006″
0.006″0.008″
Up to 14.5 hr.
Wheel kit (sold separately)
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.
Components and Controls
Fuel Gauge
AC Circuit Breaker (L14-30R) (5-20R)
OpERATION
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Page 7
SAFETY
SETUp
Components and Controls (continued)
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.
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. Then, turn the tripped Circuit Breaker to ON and re-attach loads
gradually. Note: For the push-type Circuit Breakers, allow a few minutes for
cool-down before resetting.
2. AC Receptacles: The Generator contains several AC Receptacles to power tools and equipment.
RESET TEST
a. 3-prong, duplex 120 volt GFCI receptacle (NEMA #5-20)
TEST RESET
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. Refer to Grounding on page 9 for instructions on grounding the
Generator.
b. 4-prong, twistlock, 120/240 volt receptacle (NEMA #L14-30)
WARNING! TO pREVENT SERIOUS INJURY: 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.
OpERATION
MAINTENANCE
Page 8
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ITEM 59205
SAFETY
SETUp
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.
Note: For additional information regarding the parts listed in the following
pages, refer to the Assembly Diagram near the end of this manual.
NOTICE: 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.
Wheel Kit, #64788 (sold separately) can be used with this Generator.
Grounding
The Generator must be properly grounded in accordance with all relevant
electrical codes and standards before operation. In many locations, local code
will not require this generator to be grounded when used with cord and plug
equipment plugged directly into the receptacles on the generator. However,
your local regulations may require the generator to be grounded. Contact a
licensed electrician or consult local authorities regarding local grounding
requirements. If grounding is required, have the unit grounded by a qualified
electrician if you are not qualified to do so. General grounding instructions
are as follows: Use one of the following as the grounding electrode:
pipe or conduit, minimum ¾ in. diameter, minimum 8 ft. long. If steel, it must
have anti-corrosion coating.
Rod, stainless steel or copper- or zinc-coated steel, minimum 5/8 in.
diameter, minimum 8 ft. long.
1. Drive electrode at least 8 ft. vertically into the ground. a. If rock
layer prevents vertical entry, drive at an angle not exceeding 45 degrees from
vertical. b. If rock layer prevents angle entry, bury electrode in horizontal
trench at least 30 in. deep.
2. The upper end of electrode must be protected if above ground level.
3. Connect a #6 AWG grounding wire (not included) from the Grounding Terminal
on the Generator Control Panel to the buried electrode.
For additional information on grounding methods, please see the National
Electrical Code. NOTICE: There is a permanent conductor between the portable
generator stator winding (Neutral Conductor) and the frame.
OpERATION
MAINTENANCE
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Page 9
High Altitude Operation Above 3000 feet
SAFETY
SETUp
WARNING! TO pREVENT SERIOUS INJURY FROM FIRE: Follow instructions 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 proceeding. Do not smoke.
NOTICE: Warranty void if necessary adjustments are not made for high altitude
use.
At high altitudes, the engine’s carburetor, governor, and any other parts that
control the fuel-air 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. The fuel system on this engine may be
influenced by operation at higher altitudes. Proper operation can be ensured
by installing an altitude kit at altitudes higher than 3000 ft. above sea
level. At elevations above 8000 ft, the engine may experience decreased
performance, even with the proper main jet. Operating this engine without the
proper altitude kit installed may increase the engine’s emissions and decrease
fuel economy and performance. The kit should be installed by a qualified
mechanic.
Note: Not all Generator models have a Solenoid. Skip those steps if a Solenoid is not present.
1. Turn off the engine. 2. Close the fuel valve.
Nuts Deflecting plate
3. Move the air cleaner housing aside to allow access to the carburetor: a. Loosen the knob and remove air cleaner cover.
Foam Filter
b. Remove the foam filter and deflecting plate.
c. Remove the nuts to allow the air cleaner housing to be moved aside.
4. Place a bowl under the fuel cup to catch any spilled fuel. 5. Unthread the screws holding the solenoid in place.
Air Cleaner Housing
CAUTION! Carburetor bowl may have gas in it which will leak upon removing the
solenoid/bolt.
6. Disconnect the solenoid and solenoid seal from the bolt.
Air Cleaner Cover
7. Unthread the bolt holding the fuel cup.
8. Remove the bolt, Bolt Seal, fuel cup, Fuel Cup Seal and Main Jet from the body of the carburetor assembly. A carburetor screwdriver (not included) is needed to remove and install the Main Jet.
Note: The mixing tube is held in place by the Main Jet and might fall out when it is removed. If it falls out, replace it in the same orientation before replacing the Main Jet.
Carburetor Assembly
9. Replace the Main Jet with the replacement Main Jet needed for your altitude range (part 1a or 2a).
Fuel Cup Seal
Note: The Fuel Cup Seal and Bolt Seal may be damaged during removal and should
be replaced with the new ones from the kit.
10. Replace the Fuel Cup Seal (4a), fuel cup, Bolt Seal (3a), and bolt.
Tighten in place.
NOTICE: Do not cross thread bolt when tightening. Finger tighten first and
then use a wrench to make sure the bolt is properly threaded.
11. Replace the solenoid and Solenoid Seal (5a), and tighten in place with
screws.
12. Reassemble the air cleaner and reattach all hoses to it.
Mixing Tube (might remain inside carburetor) Main Jet
Fuel Cup
Bolt Seal
13. 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.
Bolt Solenoid Seal
High Altitude Kit parts List – A
part
Description
Qty
1a Main Jet 3000-6000 ft. 1
2a Main Jet 6000-8000 ft. 1
3a Bolt Seal
1
4a Fuel Cup Seal
1
5a Solenoid Seal
1
Not present on some Generators
Solenoid Screws
Page 10
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ITEM 59205
OpERATION
MAINTENANCE
SAFETY
SETUp
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
1. 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 fixed properly.
2. Brush off outside of Engine.
3. Remove the air filter cover and the air filter elements and check for
dirt. Clean as needed and replace them.
4. Install carbon monoxide alarm(s) with battery backup in all nearby
buildings according to alarm manufacturers instructions.
Checking and Filling Engine Oil
NOTICE: Your Warranty is VOID if the engine’s crankcase is not properly filled
with oil before each use. Before each use, check the oil level. Engine will
not start with low or no engine oil.
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
Full level
NOTICE: Do not run the engine with too little oil. Engine will shut off if
engine oil level is too low.
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, fill the Fuel Tank to about 1 inch under the fill neck with 87
octane or higher unleaded gasoline that has been treated with a fuel
stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for
use.
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.
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 18 in the Service
section shows other viscosities to use in different average temperatures.)
6. Thread the dipstick back in clockwise.
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SAFETY
SETUp
Using the Generator
Before Starting the Generator Engine
Before starting 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 stabilizer-treated fuel and oil.
Basic Generator Use procedure – See following pages for specific 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 up
for five minutes after starting with no electrical load.
3. With the engine running, test GFCI receptacles before each use as follows:
a. Press Test button on receptacle to trip the GFCI device. b. The Reset
button should extend, cutting off electricity to the receptacle. c. If above
test fails, do not use receptacle until it is repaired or replaced. d. Press
Reset button in for use.
4. Plug in products.
5. When finished using the Generator, disconnect all electrical loads.
Note: Do not allow Generator to run out of fuel with loads attached.
6. Turn off the Engine.
7. 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 five
minutes with no load after each start-up so that the engine can stabilize.
8. 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.
Reset
Button
RESET
TEST
TEST RESET
Test Button
120 Volt GFCI Receptacle
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ITEM 59205
Starting the Engine
1. To start a cold engine, move the Choke to the START position. To restart a
warm engine, leave the Choke in the RUN position.
SAFETY
2. Open the Fuel Valve.
SETUp
OpERATION
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 flow 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.
Note: If engine does not start, check engine oil level. Engine will not start
with low or no engine oil.
5. Allow the Engine to run for several seconds. Then, if the Choke Lever is
in the START 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 five minutes with no load
after each start-up so that the engine can stabilize.
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MAINTENANCE
CARBON MONOXIDE SHUTOFF
SAFETY
DANGER! TO pREVENT SERIOUS INJURY AND DEATH FROM CARBON MONOXIDE INHALATION: The Carbon Monoxide sensor is an additional layer of protection only. Do not use the Generator in any area or situation that will allow carbon monoxide to accumulate.
· FLASHING RED LIGHT: Dangerous levels of carbon monoxide gas have built up. Leave immediately until area has aired out. Move Generator to well-ventilated area before operation.
· FLASHING YELLOW LIGHT: Carbon monoxide sensor malfunction. Sensor needs service. Call 1-888-866-5797 as soon as possible. Do not use the Generator until the sensor is working properly. NOTE: Yellow light flashes once after starting to indicate passing selfcheck and is functioning normally.
Carbon Monoxide sensor must only be serviced by qualified technician to restore it to original settings. Do not modify or tamper with the Carbon Monoxide sensor. Not following these instructions can result in death or serious injury due to Carbon Monoxide sensor malfunction.
Connecting Electrical Loads
SETUp
OpERATION
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.
WARNING! Connect only properly wired plugs to the Generator. A plug that is
spliced onto a different cord may be hazardous. Only a qualified electrician
should wire a plug onto a cord.
NOTICE: 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.
1,040000 201,0200
LSatragretuspt AWdaTdtoittstiaonlneRaeuldSnentdainrftgo-
urWpaalWltltaostatdss4,2105,20,40000
Must be less than
5,500
Must be less than
6,500
Use the DC12V Receptacle to power 12VDC equipment. CAUTION! Do not charge
batteries without a proper charge controller. Do not overcharge.
a. Connect the items that require the most wattage first.
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 TVs, 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 fluctuates with a load below the Generator’s running watts, move the Choke Lever to the halfway 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:
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SAFETY
SETUp
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.
Wattage Estimate Charts
Note: Wattages listed below are estimates for that type of equipment only.
Check nameplate wattages on all loads before connecting to Generator.
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 running 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 max. starting wattage of the
Generator.
5. Plug in and turn on products from largest wattage to smallest.
Wattage Calculation Table
Equipment
Running Watts
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) Television (400 + 0) Lawn Mower (1,200 +
1,200) Hand Drill (600 + 600)
Running Watts
2,000 400 1,200 600
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)
4,200 1,200 5,400
A generator that is rated more than the minimum required max. starting 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.
EMERGENCY
Device
Refrigerator/Freezer Radio
Running Watts
700 100
Additional Start-up Watts 1500 0
JOB SITE
Device
Air Compressor – 1/2 HP Table Saw – 10 Belt Sander – 3 Hand Drill – 1/2
Halogen Work Light Recipricating Saw
Running Watts
1000 1700 1200 600 1000 900
Additional Start-up Watts 1000 1300 1200 600 0 900
Device
AM/FM Radio Electric Grill Inflator Pump CD/DVD Player Box Fan – 20 Coffee
Maker
RECREATION
Running Watts
100 1700
50 100 200 600
Additional Start-up Watts 0 0 100 0 200 0
HOUSEHOLD
Device
Computer w/ Monitor Electric Clothes Dryer Electric Range Electric Water
Heater Light Bulb – 100 watts Microwave – 1000 watts Sump Pump – 1/2 HP
Television Washing Machine Well Pump – 1/2 HP
Running Watts
800 5500 2100 2000 100 1000 1000 400 1100 1000
Additional Start-up Watts 0 500 0 0 0 200 1100 0 1100 1000
LAWN & GARDEN
Device
Hedge Trimmer Pressure Washer Lawn Mower Edger
Running Watts
400 1200 1200 1000
Additional Start-up Watts 400 1200 1200 1000
HEATING & COOLING
Device
Central AC – 10,000 BTU Furnace Fan – 1/2 HP Space Heater Window AC – 10,000
BTU
Running Watts
1500 900 1800 1200
Additional Start-up Watts 1500 1400 0 600
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SAFETY
SETUp
Stopping the Engine in an Emergency
1. To stop the engine in an emergency, turn the Engine Switch off.
NOTICE: Generator shut-off under load may damage the Generator and attached
equipment.
START
I O
OFF
Stopping the Engine Under Normal Conditions
1. Before turning off the Engine,
turn off all electrical loads,
RESET
then unplug them.
TEST
TEST RESET
2. Turn the Engine Switch off.
I O OFF
3. Close the Fuel Valve.
OpERATION
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ITEM 59205
SAFETY
SETUp
User-Maintenance Instructions
procedures not specifically explained in this manual must be performed only by
a qualified 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 qualified technician for safety. If you have any
doubts about your ability to safely service the equipment or engine, have a
qualified technician service the equipment instead.
Cleaning, Maintenance, and Lubrication
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 Change
engine oil Clean/replace air cleaner Clean Spark Arrestor 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 Every 6 mo. or 50 hr. of use 100 hr. of use
Yearly or every 300 hr. of use
**
*Service more frequently when used in dusty areas. **These items should be serviced by a qualified technician.
Every 2 Years
page
11 11 11 18 18 19 19
**
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SAFETY
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.
Note: Do not use gasoline containing more than 10% ethanol (E10). Do not use
E85 ethanol.
Engine Oil Change
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.
3. If needed, fill the Fuel Tank to about 1 inch under the fill neck with 87
octane or higher unleaded gasoline that has been treated with a fuel
stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for
use.
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.
CAUTION! Oil is very hot during operation and can Note: Do not thread the dipstick in cause burns. Wait for engine to cool before changing oil. when checking the oil level.
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.
The SAE Viscosity Grade chart shows other viscosities to use in different
average temperatures.
SAE Viscosity Grades
30
10W-30
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.
5W-30
-20 0 20 40 60 80 100°F
Average outdoor temperature
8. Thread the dipstick back in clockwise.
Full level
Full level
NOTICE: Do not run the engine with too little oil. Engine will not start with low or no engine oil.
SETUp
OpERATION
MAINTENANCE
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.
Air Filter Element Maintenance
1. Remove the air filter cover and the air filter elements and check for
dirt. Clean as described below.
2. Cleaning:
· For “paper” filter elements: To prevent injury from dust and debris, wear
ANSI-approved safety goggles, NIOSH-approved dust mask/respirator, and heavy-
duty work gloves. In a well-ventilated area away from bystanders, use
pressurized air to blow dust out of the air filter. If this does not get the
filter clean, replace it.
· For foam filter elements: Wash the element in warm water and mild detergent
several times. Rinse. Squeeze out excess water and allow it to dry completely.
Soak the filter in lightweight oil briefly, then squeeze out the excess oil.
3. Install the cleaned filter. Secure the Air Cleaner Cover before use.
Page 18
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ITEM 59205
SAFETY
SETUp
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 the spark plug.
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
Cylinder
it using emery paper.
Assembly
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 Specifications chart for your Generator for the type and gap required.
4. When installing a new spark plug, adjust the plug’s gap to the
specification on the Specifications 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.
Spark Arrestor Maintenance
1. Wait for Engine exhaust and Muffler to cool completely.
2. Remove Spark Arrestor from end of exhaust.
3. Brush all carbon off Spark Arrestor using a stiff brush (sold separately).
4. WARNING! TO pREVENT SERIOUS INJURY FROM ACCIDENTAL BRUSH FIRE, secure Spark Arrestor back in place immediately after cleaning and before further operation.
Long-Term 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: Gasoline Treatment/Draining the Fuel Tank
To protect the fuel tank during storage, fill the tank with fresh gasoline
that has been treated with a fuel stabilizer additive. Follow fuel stabilizer
manufacturer’s recommendations for use. Refer to Checking and Filling Fuel
Checking and Filling Fuel on page 11.
Aged gasoline that has not been treated with stabilizer ahead of time must be
safely drained away and not run through the engine.
WARNING! TO pREVENT SERIOUS INJURY FROM FIRE: Fill 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.
Draining the Carburetor
After closing the Fuel Valve, place an appropriate container under the
Carburetor and carefully remove the Drain Bolt from the bottom of the
Carburetor Bowl, allowing the fuel to drain completely. Replace the Drain Bolt
after draining.
WARNING! To prevent serious injury and fire, close the Fuel Valve before
draining the Carburetor.
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).
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4. 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. Avoid direct exposure to
rain and sunlight.
NOTICE: During extended storage periods the Engine must be started every 3
months and allowed to run for 1520 minutes or the Warranty is VOID.
5. AFTER STORAGE: Before starting the Engine during or 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.
SAFETY
SETUp
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ITEM 59205
SAFETY
SETUp
Troubleshooting
problem
Engine will not start
possible Causes
probable Solutions
FUEL RELATED:
FUEL RELATED:
1. No fuel in tank or fuel valve closed.
1. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline and open fuel valve. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
2. Choke not in START position, cold engine.
2. Move Choke to START position.
3. Gasoline with more than 10% ethanol used. (E15, E20, E85, etc.)
3. Clean out ethanol rich gasoline from fuel system. Replace components damaged by ethanol. Use fresh 87+ octane stabilizer treated unleaded gasoline only. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
4. Low quality or deteriorated, old gasoline.
4. Use fresh 87+ octane stabilizer treated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
5. Carburetor not primed.
5. Pull on Starter Handle to prime.
6. Dirty fuel passageways.
6. Clean out passageways using fuel additive. Heavy deposits may require further cleaning.
7. Carburetor needle stuck. Fuel can be smelled in the air.
7. Gently tap side of carburetor float chamber with screwdriver handle.
8. Too much fuel in chamber. This can be caused by the carburetor needle sticking.
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 START position.
9. Clogged Fuel Filter.
9. Replace Fuel Filter.
IGNITION (SPARK) RELATED:
IGNITION (SPARK) RELATED:
1. Power Switch at OFF position.
1. Turn Power Switch to ON.
2. Spark plug cap not connected securely.
2. Connect spark plug cap properly.
3. Spark plug electrode wet or dirty.
3. Clean spark plug.
4. Incorrect spark plug gap.
4. Correct spark plug gap.
5. Spark plug cap broken.
5. Replace spark plug cap.
6. Circuit breaker tripped (electric start models only).
6. Reset circuit breaker. Check wiring and starter motor if breaker continues to trip.
7. Incorrect spark timing or faulty ignition system. 7. Have qualified technician diagnose/ repair ignition system.
COMPRESSION RELATED:
COMPRESSION RELATED:
1. Cylinder not lubricated. Problem after long storage periods.
1. Pour tablespoon of oil into spark plug hole. Crank engine a few times and try to start again.
2. Loose or broken spark plug. (Hissing noise will occur when trying to start.)
2. Tighten spark plug. If that does not work, replace spark plug. If problem persists, may have head gasket problem, see #3.
3. Loose cylinder head or damaged head gasket. (Hissing noise will occur when trying to start.)
3. Tighten head. If that does not remedy problem, replace head gasket.
4. Engine valves or tappets mis-adjusted or stuck.
4. Have qualified technician diagnose/ repair ignition system.
OIL RELATED:
OIL RELATED:
1. Low engine oil.
1. Fill engine oil to proper level. Check engine oil before EVERY use.
2. Engine mounted on slope, triggering low oil shutdown.
2. Operate engine on level surface. Check engine oil level.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
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Page 21
SAFETY
SETUp
Troubleshooting (continued)
problem
Engine stops when under heavy load Engine misfires
Engine stops suddenly
Engine knocks Engine backfires
possible Causes
probable Solutions
1. Dirty air filter.
1. Clean or replace element.
2. Engine running cold.
2. Allow engine to warm up prior to operating equipment.
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.
1. Check wire connections. 2. Re-gap or replace spark plug.
3. Replace spark plug cap. 4. Use only fresh 87+ octane stabilizer treated
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. Carbon Monoxide level high. Red light on Carbon Monoxide Sensor
illuminates.
2. CO Sensor Alarm flashes yellow continually shortly after starting.
3. CO Sensor Alarm flashes yellow continually after longer period of
operation.
4. Low oil shutdown.
5. Fuel tank empty or full of impure or low quality gasoline.
6. Defective fuel tank cap creating vacuum, preventing proper fuel flow.
7. Faulty magneto. 8. Disconnected or improperly
connected spark plug cap.
1. Leave area immediately and allow area to ventilate thoroughly. Only
operate generator outside.
2. Carbon monoxide sensor malfunction. Sensor needs service. Call
1-888-866-5797 as soon as possible. Do
not use the Generator until the sensor is working properly.
3. Make sure to operate generator within rated ambient temperature; maintain
minimum 5 ft. clearance from all sides.
4. Fill engine oil to proper level. Check engine oil before EVERY use.
5. Fill fuel tank with fresh 87+ octane stabilizer treated unleaded gasoline.
Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.).
6. Test/replace fuel tank cap.
7. Have qualified technician service magneto. 8. Secure spark plug cap.
1. Old or low quality gasoline.
2. Engine overloaded. 3. Incorrect spark timing, deposit buildup, worn
engine, or other mechanical problems.
1. Fill fuel tank with fresh 87+ octane stabilizer treated 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 qualified technician diagnose and service engine.
1. Impure or low quality gasoline.
2. Engine too cold. 3. Intake valve stuck or overheated engine. 4. Incorrect
timing.
1. Fill fuel tank with fresh 87+ octane stabilizer treated 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 backfiring.
3. Have qualified technician diagnose and service engine.
4. Check engine timing.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
OpERATION
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ITEM 59205
SAFETY
Troubleshooting (continued)
problem
Product doesn’t have power.
possible Causes
1. Product not plugged in properly.
2. Circuit Breaker tripped.
3. GFCI activated.
Product begins to operate abnormally.
4. Product needs service. 1. Problem with appliance.
2. Rated load capacity exceeded.
probable Solutions
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. Turn off and unplug product. Test GFCI receptacle. If functioning properly
reset GFCI, plug in product and turn on.
4. Have product repaired.
1. Immediately unplug appliance. Have appliance repaired by a qualified
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.
Follow all safety precautions whenever diagnosing or servicing the equipment or engine.
pLEASE READ THE FOLLOWING CAREFULLY
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.
SETUp
OpERATION
MAINTENANCE
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. Specify UPC 193175459732 when
ordering parts.
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Page 23
SAFETY
SETUp
parts List and Diagram
parts List
part
Description
Qty
1 Hex Bolt With Flange
15
2 Flat Washer
4
3 Power Socket Combination
1
4 Tarpaulin
1
5 Panel Output Indicator Light
1
6 Start Control Switch
1
7 Tarpaulin
3
8 Co Indicator Light
1
9 Overcurrent Protector
1
10 Overcurrent Protector
2
11 Power Socket Combination
2
12 Nut With Flange
12
13 Power Socket Combination
1
14 Overcurrent Protector-
1
Two Pole Breaker
15 Earth Terminal Combination
1
16 Components Of Control Panel
1
17 Panel Bed
1
18 Caulking
1
19 CO Module
1
20 Flat Washer
6
21 Components Of Frame
1
22 Frame Girder
1
23 Hex Bolt With Flange
6
24 Nut With Flange
4
25 Frame Shock Absorbing Seat
1
26 Nut With Flange
4
27 Nut With Flange
6
29 Nut
2
30 Elastic Washer
1
31 Lock Washer
1
32 Frame Shock Absorbing Seat
4
33 Hex Bolt With Flange
1
34 Components Of Motor
1
35 Carbon Brush Combination
1
36 Motor Terminal Plate
1
37 Flat Washer
1
38 Rear Motor Support
1
39 Hex Bolt With Flange
4
40 Hex Bolt With Flange
2
41 Hex Bolt
1
42 Voltage Regulator
1
43 Hex Bolt With Flange
6
44 Rear Motor End Cover
1
45 Hex Bolt With Flange
7
46 Muffler Bracket
1
47 Rubber Strip For Muffler Guard Shield 1
48 Muffler Guard Shield
1
49 Muffler
1
50 Muffler Tail Cover
1
51 Spark Collector
1
52 Muffler Guard Shield
1
53 Muffler Gasket
1
54 Hex Bolt With Flange
2
55 Tank Damping Cushion
4
56 Liner Tube Of Tank Damping Cushion 4
57 Flat Washer
4
part
Description
Qty
58 Hex Bolt With Flange
4
59 Components Of Oil Level
1
60 Cross Recessed Countersunk
2
Head Screw
61 Engine Block
1
62 Tank Cover
1
63 Filter Screen Combination
1
64 Tank
1
65 Components Of Oil Switch
1
66 Oil Tube
1
67 Clip Combination
2
68 Cross Recessed Pan Head Screw
2
69 Clip Combination
1
75 Canister Pipe
1
76 Clip Combination
1
77 Air Filter Bracket
1
78 Motor Limit Stop
1
79 Motor Fan Housing
1
80 Hex Bolt With Flange
1
81 Outlet Pipe
1
82 Nut
2
83 Outlet Gasket
1
84 Cylinder Head Cover
1
85 Breather Tube
1
86 Engine Oil Strainer
1
87 Packing, Breather Chamber
1
88 Cap,Breather Chamber
1
89 Hex Bolt With Flange
2
90 Gasket For Cylinder Head Cover
1
91 Hex Bolt With Flange
4
92 Stud
2
93 Cylinder Head
1
94 Spark Plug
1
95 Gasket For Cylinder Head
1
96 Location Pin
2
97 Stud
2
98 Air Deflector
1
99 Carburetor Gasket
1
100 Heat Insulating Pad For Carburetor
1
101 Carburetor Gasket
1
102 Carburetor
1
103 Carburetor Gasket
1
104 Air Filter
1
105 Throttle Return Spring
1
106 Throttle Rod
1
108 Valve Rocker Shaft
2
107 Valve Rocker Combination
2
109 Valve Adjustment Cap
2
110 Retainer, Valve Spring
2
111 Inner Spring Of Valve
2
112 Valve Oil Seal
1
113 Push Rod
2
114 Lifter, Valve
2
115 Valve Kit
1
116 Piston Ring Combination
1
117 Piston
1
118 Piston Pin
1
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ITEM 59205
SAFETY
parts List (continued)
part
Description
Qty
part
Description
Qty
119 Steel Cable Baffle Ring
3
138 Engine Oil Protector
1
120 Connecting Rod
1
139 Cable Cleat
1
121 Hex Bolt With Flange
7
140 Hex Bolt With Flange
10
122 Oil Seal
2
141 Coil Assy.,Ignntion
1
123 Crankcase Cover
1
142 Hex Bolt With Flange
2
124 Oil Rule Combination
1
143 Flywheel Comp
1
125 Crankcase Cover Gasket
1
144 Impeller
1
126 Location Pin
2
145 Starting Disc
1
127 Bearing
1
146 Nut With Flange
1
128 Camshaft Assy
1
147 Manual Starting Assembly
1
129 Crankshaft
1
148 Manual Starting Components
1
130 Oil Level Sensor
1
149 Speed Regulating Arm
1
131 Components Of Governor Gear
1
150 Pin Clip
1
132 Crankcase Body
1
151 Flat Washer
5
133 Sealing Plug Screw
2
152 Speed Regulating Bracket
1
134 Flat Washer
2
153 Governing Spring
1
135 Seat, Valve Spring
1
154 Throttle Handle Combination
1
136 Valve Locker
4
155 Location Wire Nail
1
137 Location Wire Nail
1
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Assembly Diagram 1
SAFETY
SETUp
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ITEM 59205
Assembly Diagram 2
SAFETY
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SAFETY
Warranties
Limited 90 Day Warranty (Retail)
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, EXCEPT FOR
THE EMISSIONS CONTROL SYSTEM WARRANTY BELOW.
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 verifies
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 specific legal rights and you may also have other
rights which vary from state to state.
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ITEM 59205
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SETUp
Emissions Control System Warranty
Harbor Freight Tools (HFT) is pleased to explain the emissions control system
warranty on your Small Off-Road Engine produced after January 1, [Model Year]
(engine), in addition to the Retail Warranty above. HFT warrants that the
emissions control system on your engine is designed, built, and equipped so
that it conforms to the United States Environmental Protections Agency’s (EPA)
emissions requirements in effect at the time of manufacture. HFT also warrants
that the emissions control system on your engine will be free from defects in
material and workmanship for two (2) years, provided there has been no
improper maintenance, misuse, or abuse of your engine.
Your emissions 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 emissions-related assemblies.
WHAT WE WILL DO
Where a warrantable condition exists, HFT will repair or replace, at our
option, any emissions-related part on your engine if it becomes defective,
malfunctions, or otherwise fails to conform with this warranty under normal
use and service during the two (2) year term of this warranty at no cost to
you, including diagnosis, parts and labor. This warranty applies to the
original purchaser and any subsequent owner within the two year warranty
period.
WHAT IS COVERED?
The following parts are examples of components of the emissions control system and are covered by this two (2) year warranty. For a full list of emissions control components covered by this warranty, please see 40 CFR §1068, Appendix I.
1. Fuel Metering System a. Carburetor and its internal parts. b. Fuel pump (if so equipped). c. Cold start enrichment system.
4. Catalyst System (if so equipped) a. Exhaust pipe stud. b. Muffler. c. Catalytic converter (if so equipped).
2. Air Induction System a. Intake pipe/manifold. b. Air cleaner.
3. Ignition System a. Spark plug. b. Magneto ignition system.
5. Miscellaneous Items Used in Above Systems a. Vacuum, temperature and time sensitive valves and switches. b. Hoses, belts, connectors, and assemblies.
This warranty does not cover normal maintenance services or replacement of maintenance items such as filters, oils, or spark plugs.
WHAT YOU MUST DO TO OBTAIN WARRANTY SERVICE
As the engine owner, you are responsible for the performance of the required
maintenance listed in your Owner’s Manual. HFT may deny you warranty coverage
if your engine or a part has failed due to abuse (including failure to follow
the fuel use instructions contained in this manual), neglect, improper
maintenance, or unapproved modifications.
In order to obtain warranty repair or replacement, you may either (a) contact
HFT product support at 1-888-866-5797
or productsupport@harborfreight.com; or (b) bring the to your nearest Harbor
Freight Tools retail store. When going to the retail store or contacting
product support, you must indicate the specific emissions control part or
defect that you are claiming and the date this was originally purchased. The
nearest Harbor Freight Tools retail store can be found on the internet at
http://www.harborfreight.com.
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MAINTENANCE
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Page 30
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ITEM 59205
ITEM 59205
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Page 31
MAINTENANCE
OpERATION
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SAFETY
26677 Agoura Road· Calabasas, CA 91302 · 1-888-866-5797
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