Harbor Freight Tools Portable Generator 94191 User Manual

GAS ENGINE GENERATOR  
13 HP  
Model 94191  
ASSEMbly ANd OPERATION INSTRucTIONS  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
cAuTION!  
your Warranty Is Voided If:  
you do not put engine oil in the Engine’s crankcase prior to its first use.  
Before each use, check the oil level. Never run the Engine with low or no engine oil.  
Running the Engine with low or no oil will permanently damage the unit.  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
TO PREVENT SERIOuS INjuRy, REAd ANd uNdERSTANd  
All WARNINGS ANd INSTRucTIONS bEfORE uSE.  
Copyright© 2006 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.  
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3.  
1.  
Keep bystanders, children, and visitors away while operating a power tool.  
Distractions can cause you to lose control. Provide barriers or shields as needed.  
PERSONAl SAfETy  
Stay alert. Watch what you are doing, and use common sense when operat-  
ing a power tool. do not use a power tool while tired or under the influence  
of drugs, alcohol, or medication. A moment of inattention while operating power  
tools may result in serious personal injury.  
2.  
3.  
4.  
dress properly. do not wear loose clothing or jewelry. contain long hair.  
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,  
jewelry, or long hair can be caught in moving parts.  
Avoid accidental starting. be sure the Engine Ignition (2) is in itsOffposi-  
tion before moving the Generator and before performing any service, mainte-  
nance, or cleaning procedures on the unit.  
Remove adjusting keys or wrenches before turning the Generator on. A  
wrench or a key that is left attached to a rotating part of the machine may result in  
personal injury.  
5.  
6.  
do not overreach. Keep proper footing and balance at all times. Proper footing  
and balance enables better control of the power tool in unexpected situations.  
use safety equipment. Always wear eye protection. Always wear  
ANSI approved safety impact goggles when using this product. ANSI  
approved hearing protection must also be used.  
TOOl uSE ANd cARE  
1.  
2.  
do not force the tool. use the correct tool for your application. The correct  
tool will do the job better and safer at the rate for which it is designed.  
do not use the Generator if the Engine’s Ignition (2) does not turn it on or off.  
Any tool that cannot be controlled with its power switch is dangerous and must be  
replaced.  
3.  
4.  
Store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
Maintain tools with care. Properly maintained tools are less likely to malfunction  
and are easier to control. Do not use a damaged tool. Tag damaged tools do not  
use” until repaired.  
5.  
check for misalignment or binding of moving parts, breakage of parts, and any  
other condition that may affect the tool’s operation. If damaged, have the tool  
serviced before using. Many accidents are caused by poorly maintained tools.  
SKU 94191  
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6.  
use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one tool may become hazardous  
when used on another tool.  
SERVIcE  
1.  
2.  
Tool service must be performed only by qualified repair personnel. Service or  
maintenance performed by unqualified personnel could result in a risk of injury.  
When servicing a tool, use only identical replacement parts. follow instruc-  
tions in the “Inspection, Maintenance, And Cleaning” section of this manual.  
Use of unauthorized parts or failure to follow maintenance instructions may create  
a risk of electric shock or injury.  
SPEcIfIc SAfETy RulES ANd PREcAuTIONS  
1.  
yourWarranty is voided if you do not put engine oil in the Engine’s crankcase  
prior to its first use. Before each use, check the oil level. Never run the Engine  
with low or no engine oil. Running the Engine with low or no oil will permanently  
damage the unit.  
2.  
3.  
Maintain labels and nameplates on the Generator. These carry important infor-  
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.  
Make sure the Generator is located on a flat, level, sturdy surface capable of  
supporting the weight of the Generator and any additional tools and equip-  
ment.  
4.  
5.  
Industrial applications must follow OSHA guidelines.  
Never stand on the Generator. Serious injury could result if the Generator is  
tipped.  
6.  
7.  
8.  
Never leave the Generator unattended when it is running. Turn off the Engine  
before leaving.  
do not allow children and other unauthorized people to handle or play with  
the Generator.  
This Generator is designed for outdoor use only. Do not operate the  
Generator in a closed area or in a poorly ventilated area. When running,  
the Engine of this Generator produces carbon monoxide, a color-  
less, odorless, toxic fume that, when inhaled, can cause serious  
personal injury or death. Whenever possible, use a carbon monoxide detec-  
tor (not included) to detect excessive carbon monoxide fumes in the work  
area and in the surrounding area.  
SKU 94191  
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9.  
1.  
do not force the Generator. This tool will do the work better and safer at the speed  
and capacity for which it was designed. Do not overload the generator. Know the  
total running wattage necessary to power the desired items.  
fIRE ANd EXPlOSION PREcAuTIONS  
Gasoline fuel and fumes are flammable, and potentially explosive. Use proper  
fuel storage and handling procedures. Always have multiple ABC class fire extin-  
guishers nearby.  
2.  
3.  
Keep the Generator, its Engine, and surrounding areas clean at all times.  
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 regula-  
tions. Store oil rags in a covered metal container.  
4.  
5.  
Never store fuel or other flammable materials near the Generator.  
do not smoke, or allow sparks, flames, or other sources of ignition around  
the Generator.  
6.  
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.  
7.  
8.  
do not refill the fuel Tank while the Engine is running or while the Engine is  
still hot. Do not operate the Generator with known leaks in the fuel system.  
use only Engine manufacturer recommended fuel and oil.  
MEcHANIcAl PREcAuTIONS  
1.  
Prior to performing service, maintenance, or cleaning procedures, always  
make sure the Engine’s Ignition (2) is in its “Off” position. Allow the Engine  
and Generator to completely cool. Then, remove the spark plug from the  
Engine.  
2.  
3.  
do not alter or adjust any part of the Generator or Engine that is assembled  
and supplied by the manufacturer.  
Always follow and complete scheduled Generator and Engine maintenance.  
cHEMIcAl PREcAuTIONS  
1.  
2.  
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.  
Avoid body contact with fuels, oils, and lubricants used in the Generator and  
Engine. If swallowed, seek medical treatment immediately. Do not induce vomiting  
SKU 94191  
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if fuel is swallowed. For skin contact, immediately wash with soap and water. For  
eye contact, immediately flush eyes with clean water.  
NOISE PREcAuTIONS  
Prolonged exposure to high noise levels is hazardous to hearing. Always wear  
ANSI approved hearing protection when operating or working around the Generator  
when it is running.  
ElEcTRIcAl PREcAuTIONS  
1.  
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.  
2.  
3.  
4.  
5.  
The Generator must be earth-grounded in accordance with all relevant electri-  
cal codes and standards before operation.  
If an extension cord (not included) is used, make sure to use only ul listed  
cords having the correct gauge and length. (See figure A, next page.)  
do not attempt to connect or disconnect load connections while standing in  
water, or on wet or soggy ground.  
do not touch electrically energized parts of the Generator and interconnect-  
ing cables or conductors with any part of the body, or with any non-insulated  
conductive object.  
6.  
7.  
8.  
connect the Generator only to a load or electrical system (120 volt, 240 volt,  
or 12 volt) that is compatible with the electrical characteristics and rated ca-  
pacities of the Generator.  
be sure the Engine’s Ignition (2) is in its “Off” position before moving the  
Generator and before performing any service, maintenance, or cleaning pro-  
cedures on the unit.  
Keep all electrical equipment clean and dry. Replace any wiring where the in-  
sulation is cracked, cut, abraded, or otherwise degraded. Replace terminals that  
are worn, discolored, or corroded. Keep terminals clean and tight.  
9.  
Insulate all connections and disconnected wires.  
10.  
Guard against electric shock. Prevent body contact with grounded surfaces such  
as pipes, radiators, ranges, and refrigerator enclosures.  
11.  
12.  
use only class bc or class Abc fire extinguishers on electrical fires.  
unconditioned electrical output can damage sensitive equipment. Do not use  
to power sensitive electronic equipment without appropriate line conditioner (sold  
separately).  
07k  
SKU 94191  
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REcOMMENdEd MINIMuM WIRE GAuGE fOR EXTENSION cORdS*  
(120 OR 240 VOlT)  
NAMEPlATE  
AMPERES  
(at full load)  
EXTENSION cORd lENGTH  
25 feet  
50 feet  
75 feet 100 feet 150 feet  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* based on limiting the line voltage drop to five volts at 150% of the rated amperes.  
TAblE A  
MISc. PREcAuTIONS  
1.  
2.  
WARNING! People with pacemakers should consult their physician(s) before using  
this product. Operation of electrical equipment in close proximity to a heart pace-  
maker could cause interference to or failure of the pacemaker.  
WARNING! 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.  
SKU 94191  
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uNPAcKING  
When unpacking, check to make sure all the parts shown on the Parts lists on  
pages 20 and 22 are included. If any parts are missing or broken, please call Harbor  
Freight Tools at the number shown on the cover of this manual as soon as possible.  
ASSEMbly INSTRucTIONS  
cAuTION! Make sure Engine’s Ignition (2) is in its “Offposition prior to performing  
any service, maintenance, or cleaning of Generator or Engine. Always wear ANSI-  
approved safety impact eye goggles when assembling and using the Generator.  
To Install The battery (not included):  
NOTE: for proper operation, you must install a dc 12V, 18-35 Amp-hour battery.  
NEGATIVE bATTERy cAblE  
(64)  
bATTERy  
(45)  
Not included  
POSITIVE bATTERy cAblE  
(63)  
bATTERy GuARd PlATE (44)  
(fAcTORy PRE-INSTAllEd)  
bATTERy bRAcKET  
(47)  
bATTERy TRAy (48)  
(fAcTORy PRE-INSTAllEd)  
bOlT W/lOcK WASHER  
(46)  
fIGuRE b  
1.  
2.  
3.  
4.  
Remove the packing from the Battery (45). Then, locate the factory pre-installed  
Battery Guard Plate (44) and Battery Tray (48) beneath the Control Panel (4) of the  
Generator unit. (See figure b, previous page.)  
Slide the Battery (45) into the Battery Guard Plate (44), with the Battery’s terminals  
facing outward and with the Battery’s negative (--) terminal facing left.  
(See figure b.)  
Align the two mounting holes in the Battery Bracket (46) with the two threaded mount-  
ing holes in the Battery Guard Plate (44). Then secure the Battery Bracket to the  
Battery Guard Plate, using two Bolts with Lock Washers (46). (See figure b.)  
Connect the end of the Positive Battery Cable (63) to the Battery’s positive (+) ter-  
minal. Then connect the Negative Battery Cable (64) to the Battery’s negative (–)  
terminal. (See figure b.)  
REV 07h  
SKU 94191  
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INSTAllATION INSTRucTIONS  
1.  
2.  
Electrical and other permits may be required for the installation of emergency or  
portable power systems. Investigate the local building and electrical codes before  
installing this unit.  
Prior to providing Generator power to tools and equipment, make sure the Gen-  
erator’s rated voltage, wattage, and amperage capacity is adequate to supply all  
electrical loads the unit will power. If powering exceeds the Generator’s capacity,  
it may be necessary to group one or more of the tools/equipment for connection to  
a separate Generator.  
General location:  
1.  
It is recommended to locate the Generator (outdoors only) where cooling air is  
readily available. Locate the Generator so that the air inlets and outlets are not  
blocked by obstructions such as bushes, trees, or snow drifts. Locating it in the path  
of heavy winds or snowdrifts may require the placement of a barrier for protection.  
The air inlet (on Air Filter Cover 18a), in normal weather conditions, should face  
the prevailing wind direction.  
2.  
3.  
4.  
Locate the Generator on a concrete slab or other area where rain drainage or flood  
waters can not reach it.  
Generator placement should allow four feet of access to all sides for maintenance  
and for proper air cooling.  
Place the Generator as close as possible to the electrical tools and equipment be-  
ing powered to reduce the length of extension cords.  
SKU 94191  
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Grounding The Generator:  
GROuNdING TERMINAl  
(9)  
#6 AWG GROuNdING WIRE  
(NOT INcludEd)  
GROuNdING ROd  
(NOT INcludEd)  
fIGuRE c  
Note: It is recommended that only a trained and licensed electrician perform this proce-  
dure.  
Connect a #6 AWG grounding wire (not included) from the Grounding Terminal (9)  
on the Generator to a grounding rod (not included) that has been driven at least 24  
inches deep into the earth. The grounding rod must be an earth-driven copper or  
brass rod (electrode) which can adequately ground the Generator.  
(See figure c.)  
cONTROl PANEl fEATuRES  
1.  
Engine Ignition (2): Starts and stops the Gasoline Engine. To start the Engine  
using power from the Battery (45), insert the Ignition Key (65) and turn the Engine  
Ignition to its “STARTposition. To start the Engine manually using the Starter Rope  
(40A) and Starter Handle (41A), insert the Ignition Key and turn the Engine Ignition  
to its “RuN” position. Then pull briskly on the Starter Handle. To stop the Engine,  
turn the Engine Ignition to its “Offposition. Always remove the Ignition Key  
when the Generator is not in use. (See figure d, next page.)  
2.  
3.  
fuel Tank cap (34): NEVER run the Engine with the Fuel Tank Cap removed.  
(See figure d.)  
120 Volt Ac Outlets (5): The Generator is equipped with two 3-hole 120 volt AC  
outlets to power 120 volt tools and equipment. (See figure d.)  
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(2)  
(65)  
(3)  
(34)  
(10)  
(8)  
(6)  
(5)  
(7)  
fIGuRE d  
4.  
120 Volt Ac circuit breakers (3): Each of the two 120 Volt AC Outlets have a  
Circuit Breaker to protect the Generator from overloading. Should a Circuit Breaker  
“trip”, unplug all electrical loads from the Generator. Allow the Circuit Breaker to  
cool down. Then, push the 120 volt Circuit Breakers. (See figure d.)  
5.  
6.  
240Volt Ac Outlet (6): The Generator is equipped with one 4-blade twist lock 240  
Volt AC Outlet to power 240 volt tools and equipment. (See figure d.)  
240 Volt Ac circuit breaker (3): The 240 Volt AC Outlet has two Circuit Break-  
ers to protect the Generator from overloading. Should the Circuit Breakers “trip”,  
unplug all electrical loads from the Generator. Allow the Circuit Breakers to cool  
down. Then, push the 240 volt Circuit Breakers. (See figure d.)  
7.  
12V dc Terminal (7): Supplies voltage to 12 volt DC appliances such as radios,  
emergency lights, etc. To power a 12 volt DC appliance, connect the positive (+)  
lead from the appliance to the positive (Red +) 12V DC Terminal on the Genera-  
tor. Then connect the negative (--) lead from the appliance to the negative (black  
--) 12V DC Terminal on the Generator. IMPORTANT: This Outlet is designed for  
operating 12 volt DC appliances only. Do not attempt to charge batteries with this  
Outlet. (See figure d.)  
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8.  
9.  
12Volt dc fuse (8): The 12Volt DC Outlet has one Fuse (8) to protect the Genera-  
tor from overloading. The Generator is equipped with the following size and type of  
Fuse: f10A250V. Should a 12 VDC output exceed the fuse’s rating, always check  
to see if the Fuse has “blown” (a melted filament within the Fuse). If necessary,  
unplug all electrical loads from the Generator, replace with a new Fuse, and reat-  
tach a reduced load to the generator. (See figure d.)  
Power-On light (10): Indicates voltage is being provided by the Generator.  
(See figure d.)  
PRE-START INSTRucTIONS  
To Add Engine Oil:  
1. cAuTION! Your warranty is voided if you do not put engine oil in the Engine’s  
crankcase prior to its first use. Before each use, check the oil level. Never run the  
Engine with low or no engine oil. Running the engine with low or no oil will perma-  
nently damage the Engine.  
OIl dIPSTIcK  
(65A)  
fuEl TANK cAP  
fuEl fIlTER  
(34)  
(32)  
fuEl GAuGE  
(35)  
fuEl TANK  
(31)  
fIGuRE E  
2.  
The Engine MuST be filled with a high quality grade engine oil. If the Engine will  
be run in temperatures above 32 degrees Fahrenheit, use SAE 30 weight oil. If the  
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Engine will be run in temperatures below 32 degrees Fahrenheit, use SAE 5W-30  
weight oil. (See figure E, prior page.)  
3.  
4.  
To do so, unscrew and remove the Oil Dipstick (65A). Pour engine oil into the Dip-  
stick Hole until the level of oil is even with top edge of the Dipstick Hole.  
(See figure E.)  
Make sure to screw the Oil Dipstick (65A) firmly back into its Dipstick Hole.  
(See figure E.)  
To fill The fuel Tank:  
1.  
Prior to first using the Generator, the Fuel Tank (31) must be filled with high octane  
unleaded gasoline. (See figure E.)  
2.  
To do so, remove the Fuel Tank Cap (34) and fill the Fuel Tank (31) with unleaded  
gasoline. Then, replace the Fuel Tank Cap. Thereafter, check the Fuel Gauge (35)  
for the amount of unleaded gasoline. When necessary, refill the Fuel Tank.  
(See figure E.)  
3.  
NOTE: Periodically, make sure to check the Fuel Filter (32) for excessive dirt and  
debris. If necessary, remove the Fuel Filter and clean with compressed air.  
(See figure E.)  
OPERATING INSTRucTIONS  
1.  
2.  
3.  
Check to make sure the Engine Ignition (2) is in its “Offposition.  
(See figure d.)  
cAuTION! Make sure to unplug any load from the Generator before starting to  
prevent permanent damage to any appliances, tools, or equipment.  
cAuTION! Engine oil MuST be added to the Engine’s crankcase prior to start-  
ing and running the Engine. Failure to add oil will damage the Engine and void  
its warranty. (See pages 12 and 13, and figure E.)  
4.  
Before the first use, the Fuel Tank (31) must be filled with a high octane, unleaded  
gasoline. (See pages 12 and 13, and figure E.)  
a. WARNING! Never fill the Fuel Tank (31) completely. Fill the Fuel Tank to 1/2”  
below the bottom of the filler neck to provide space for fuel expansion. Wipe any  
fuel spills from the Engine and Generator before starting the Engine.  
b. WARNING! Never fill the Fuel Tank (31) when the Engine is running or hot. Do  
not smoke when filling the Fuel Tank.  
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To Start The Engine/Generator:  
ON  
Off  
cHOKE lEVER (21A)  
fuEl VAlVE  
cHOKE lEVER (21A)  
(IN “RuN” POSITION)  
(IN “cHOKE” POSITION)  
(41)  
fIGuRE f  
Turn the Engine FuelValve (41) to its “OPEN” position. Then, turn the Engine Choke  
Lever (21A) to its “cHOKE” position. NOTE: No choke is required if the Engine is  
warm. Make sure the Engine Choke Lever is in the “RuN” position when starting  
a warm Engine. (See figure f.)  
1.  
2.  
3.  
To start the Engine, using the Battery (45) for cranking power, insert the Ignition Key  
(65) and turn the Engine Ignition (2) to its “START” position. NOTE: To prolong  
starter life, use short starting cycles (5 seconds maximum, then wait one minute  
before attempting to again start). (See figure d.)  
To start the Engine manually, using the Starter Handle (41A) and Starter Rope  
(40A), insert the Ignition Key (65) and turn the Engine Ignition (2) to its “RuN” po-  
sition. Grasp the Starter Handle (41A) on the Starter Rope (40A) and pull slowly  
until resistance is felt. Allow the Rope to rewind slowly. Then, pull the Handle with  
a rapid, full arm stroke. Allow the Rope to rewind slowly. If necessary, repeat this  
procedure until the Engine starts.  
4.  
5.  
When the Engine starts, slowly move the Choke Lever (21A) to its “RuN” position.  
(See figure f.)  
IMPORTANT: Allow the Generator to run at no load for five minutes after each  
start-up so that the Engine and Generator can stabilize.  
To connect Electrical loads:  
1.  
Start the Engine, and allow the Engine and Generator to run and warm up for five  
minutes after starting with no electrical load.  
2.  
WARNING! Connect 120V AC appliances, tools, and equipment only to the  
two 120V AC Outlets (5). Connect 240 AC appliances, tools, and equipment only  
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to the one 240V AC Outlet (6). Connect 12V DC appliances, tools, and equipment  
only to the 12V DC Terminal (7). (See figure d.)  
3.  
4.  
cAuTION! 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.  
Most appliances, tools, and equipment will list on the motor nameplate the start-  
ing and running voltage and amperage requirements. Use the following formula to  
convert voltage and amperage to wattage:  
Volts x Amps = Watts (example: 120 volts x 3 amps = 360 watts)  
5.  
6.  
7.  
To determine the approximate wattage requirement for most appliances, tools, and  
equipment with “inductive” type motors, multiply the wattage that was calculated by  
2 times to ensure adequate Generator capacity for motor load starting current.  
NOTE: The starting and running wattage for “resistant” loads are the same. Ex-  
ample: a 100 Watt light bulb requires only 100 Watts to start. Most resistant loads  
will be listed in wattage.  
Always power the largest electric motor first. Then, plug in other appliances, tools,  
and equipment one at a time.  
a. Connect “inductive” load appliances, tools, and equipment first. Inductive loads  
consist of small hand tools and some small appliances. Connect the items that  
require the most wattage first.  
b. Connect any lights next.  
c. Voltage sensitive appliances, tools, and equipment should be the last to be con-  
nected to the Generator and the first to be disconnected. Plug voltage sensitive  
items such as T.V.’s, VCR’s, microwaves, and cordless telephones into a UL  
listed voltage surge protector (not included). Then, connect the UL Listed surge  
protector into the Generator.  
8.  
9.  
cAuTION! Failure to connect and operate appliances, tools, and equipment in  
this sequence can cause damage to the Generator, appliances, tools, and equip-  
ment and will void the warranty on this Generator.  
Once the Engine is running, simply connect the 120 volt appliances, tools, and  
equipment into the 120V AC Outlets (5). Connect a 240 volt appliance, tool, or  
equipment into the 240V AC Outlet (6). Or connect a 12 volt appliance, tool, or  
equipment into the 12V DC Outlet (8). (See figure d.)  
10.  
IMPORTANT: If Engine speed or voltage fluctuates with a load below 250 Watts,  
move the Engine Choke Lever (21A) to the “HAlf-cHOKE” position.  
(See figure f.)  
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11.  
When finished using the Generator, disconnect all electrical loads. Turn the Engine  
Ignition (2) to its “Offposition to stop the Engine. Then, close the Engine Fuel  
Valve (41). (See figures d and f.)  
INSPEcTION, MAINTENANcE, ANd clEANING  
1.  
2.  
WARNING! Always make sure the Engine’s Ignition (2) is in its “Offposi-  
tion prior to performing any service, maintenance, or cleaning of the Generator or  
Engine. (See figure d.)  
before each use, inspect the general condition of the Generator and Engine. Check  
for loose screws, misalignment or binding of moving parts, cracked or broken parts,  
loose hose connections, and any other condition that may affect the safe opera-  
tion of the Generator and Engine. If abnormal noise or vibration occurs, have the  
problem corrected before further use.  
do not use damaged equipment.  
3.  
Generator maintenance:  
a. Keep the Generator clean and dry at all times.  
b. The Generator should not be operated or stored in locations that include exces-  
sive moisture, dust, flammable or corrosive vapors. If these substances are on  
the Generator, clean with a cloth or soft brush.  
c. Do not use a garden hose or anything with liquid to clean the Generator. Liquid  
may enter the cooling air slots and could damage the interior workings of the  
Generator.  
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PluG  
(59A)  
OIl dIPSTIcK  
(65A)  
fIGuRE G  
4.  
Engine maintenance:  
a. After first 5 to 8 hours of use: Change oil. Then, change oil every 50 hours  
of use. Change oil every 25 hours of use when operating the Engine under a  
heavy load or in high temperatures. To change the oil, remove the Plug (59A)  
and allow the old oil to drain in a proper container. Once drained, replace the  
Plug. If the Engine will be run in temperatures above 32° Fahrenheit, use SAE  
30 weight oil. If the Engine will be run in temperatures below 32° Fahrenheit,  
use SAE 5W-30 weight oil. To ll the Engine crankcase with new oil, unscrew  
and remove the Oil Dipstick (65A). Pour engine oil into the Dipstick Hole until the  
level of oil is even with the top edge of the Dipstick Hole. Make sure to screw the  
Oil Dipstick (65A) firmly back into its Dipstick Hole. Also, make sure to dispose  
of the old oil according to local waste disposal requirements.  
(See figure G.)  
SPARK PluG (28A)  
SPARK PluG WIRE (36A)  
fIGuRE H  
AIR fIlTER SEPARATOR  
(20A)  
AIR fIlTER cOVER  
AIR fIlTER ElEMENT  
(18A)  
(19A)  
b. After every 25 hours of use: Service the Air Filter Element (19A) and Air Filter  
Separator (20A). To do so, remove the Air Filter Cover (18A). Remove the Air  
Filter Element. Immerse the Air Filter Element in a mild solvent and squeeze  
the Element several times to clean. Remove the Element from the solvent and  
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squeeze thoroughly to dry. Then, squirt several drops of a light weight oil onto  
the Element. Use compressed air to clean the Air Filter Separator. Then replace  
the Air Filter Separator, Air Filter Element, and Air Filter Cover. Clean more often  
under dusty conditions or when airborne debris is present. Replace Air Filter  
parts if necessary. (See figure H.)  
c. After every 100 hours of use: Replace the Spark Plug (28A). To do so, remove  
the Spark Plug Wire (36A). Use the accessory Spark Plug Wrench Kit (86A) to  
remove the old Spark Plug. Install a new Spark Plug. Then, replace the Spark  
Plug Wire. (See figure H.)  
fuEl TANK cAP  
(34)  
fuEl fIlTER  
(32)  
fuEl TANK  
(31)  
fIGuRE I  
d. daily: Inspect the fuel filter (32): To do so, remove the Fuel Tank Cap (34).  
Remove the Fuel Filter from the Fuel Tank (31). If necessary, use compressed  
air to remove any dirt and debris from the Fuel Filter. Then replace the Fuel  
Filter and Fuel Tank Cap. (See figure I.)  
5.  
6.  
When storing the Generator, make sure to store the unit in a clean, dry, safe loca-  
tion out of reach of children and other unauthorized people.  
cAuTION! All maintenance, service, or repairs not mentioned in this  
manual must only be performed by a qualified service technician.  
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TROublESHOOTING  
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 ORWARRANTY OF ANY KINDTOTHE BUYERTHAT 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 RISKS 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.  
SKU 94191  
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SKU 94191  
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ASSEMbly dIAGRAM - GENERATOR  
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PARTS lIST - ENGINE  
Part  
1A  
2A  
3A  
4A  
5A  
6A  
7A  
8A  
9A  
description  
Qty.  
1
4
4
1
2
2
3
2
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
2
1
2
2
2
2
1
1
1
1
1
1
2
1
1
1
1
Part  
description  
Qty.  
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
1
1
2
2
1
6
2
2
1
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
Muffler  
44A Starter Wheel  
45A Circlip  
Cylinder Head Bolt  
Cylinder Head Cover Bolt  
Cylinder Head Cover  
Lock Nut  
Adjusting Screw  
Rocker Arm  
46A Starter Ratchet  
47A Friction Plate Screw  
48A Cover  
49A Starter Pulley  
50A Cooling Fan  
51A Flywheel Magneto  
52A Cylinder Block  
53A Speed Control Lever  
54A Governor Arm  
55A Governor Spring  
56A Governor Support  
57A Bolt (M6 x 15)  
58A Oil Alert Nut  
59A Plug (M10 x 15)  
60A Plug Washer  
61A Oil Alert  
Rocker Arm Bolt  
Valve Push Rod Guiding Board  
10A Valve Push Rod  
11A Cylinder Head  
12A Carburetor Shield  
13A Carburetor Packing  
14A Carburetor Assembly  
15A Air Filter Case  
16A Air Filter Seal  
17A Bolt (M6)  
18A Air Filter Cover  
19A Air Filter Element  
20A Air Filter Separator  
21A Choke Lever  
22A Carburetor Packing (II)  
23A Stud Bolt (M6 x 109)  
24A Intake Valve  
62A Bolt (M6)  
63A Crankshaft  
64A Crankshaft Gear  
65A Oil Dipstick  
66A Oil Dipstick Seal Ring  
67A Gear Casing  
68A Bolt (M8 x 35)  
69A Gear Case Packing  
70A Bearing  
71A Camshaft Assembly  
72A Locating Pin  
73A Oil Seal  
74A Connecting Rod Bolt  
75A Connecting Rod Cap  
76A Connecting Rod  
77A Piston  
78A Compression Ring (I)  
79A Compression Ring (II)  
80A Oil Scraper Ring  
81A Piston Pin  
25A Exhaust Valve  
26A Cylinder Head Gasket  
27A Exhaust Pipe Stud  
28A Spark Plug  
29A Valve Guide  
30A Valve Spring  
31A Rocker Shaft Circlip  
32A Anti-Wear Valve Stem Protector  
33A Cylinder Head Cover Packing  
34A Governor Spring  
35A Bolt  
36A Spark Plug Wire  
37A Ignition Coil  
38A Nut (Special 14mm)  
39A Starter Ratchet Spring  
40A Starter Rope  
82A Piston Pin Circlip  
83A Starter  
84A Gear  
85A Fuel Pipe  
86A Spark Plug Wrench Kit  
41A Starter Handle  
42A Starter Case Assembly  
43A Spiral Spring  
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ASSEMbly dIAGRAM - ENGINE  
SKU 94191  
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lIMITEd 1yEAR WARRANTy  
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and du-  
rability standards, and warrants to the original purchaser that this product is free from defects in materials  
and workmanship for the period of one year from the date of purchase (90 days if used by a professional  
contractor or if used as rental equipment). See engine manufacturer’s warranty which covers engine. This  
warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents,  
repairs or alterations outside our facilities, 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 WAR-  
RANTIES OF MERCHANTABILITY AND FITNESS.  
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 merchan-  
dise. 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.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
Emission control System Warranty  
california and united States Emission  
control defects Warranty Statement  
Harbor freight Tools Emission control  
defects Warranty coverage  
The California Air Resources Board (herein CARB), the Engines are warranted for a period of two (2) years relative  
United States Environmental Protection Agency (herein to emission control parts defects, subject to the provisions  
EPA), and Harbor Freight Tools® (herein HFT) are pleased set forth below. If any emission related part on your engine  
to explain the emission control system warranty on your is defective, the part will be repaired or replaced by HFT.  
1995 and later Small Off-Road Engine (herein engine). In  
Owner’s Warranty Responsibilities  
California, the engine must be designed, built and equipped  
- As the engine owner, you are responsible for the per-  
to meet the State’s stringent anti-smog standards. Else-  
formance of the required maintenance listed in your  
where within the United States, new off-road, spark-ignition  
Owner’s Manual. HFT recommends that you retain  
engines certified for model year 1997 and later, must meet  
all receipts covering maintenance on your engine,  
similar standards set forth by the EPA. HFT must warrant  
but HFT cannot deny warranty solely for the lack of  
the emission control system on your engine for the periods  
receipts or for your failure to ensure the performance  
of time described below, provided there has been no abuse,  
of all scheduled maintenance.  
neglect or improper maintenance of your engine.  
- As the engine owner, you should, however, be aware  
Your emission control system may include parts such as the  
that HFT may deny you warranty coverage if your  
carburetor or fuel-injection system, and the ignition system.  
engine or a part has failed due to abuse, neglect,  
Also included may be hoses, belts, connectors and other  
improper maintenance, or unapproved modifications.  
emission-related assemblies.  
- You are responsible for shipping your engine to a HFT  
Where a warrantable condition exists, HFT will repair your  
warranty station as soon as a problem exists. Contact  
engine at no cost to you including diagnosis, parts and  
the HFT Customer Service department at the number  
labor.  
below to make shipping arrangements. The warranty  
repairs should be completed in a reasonable amount  
of time, not to exceed 30 days.  
Manufacturer’s Warranty coverage  
The 1995 and later engines are warranted for two (2) years.  
If you have any questions regarding your warranty rights  
If any emission-related part on your engine is defective, the  
and responsibilities, you should contact the Harbor Freight  
part will be repaired or replaced by HFT.  
Tools Customer Service Department at 1-800-444-3353.  
SKU 94191  
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Emission control System Warranty - continued  
Harbor freight Tools Emission control defects Warranty Provisions  
1.  
2.  
length of coverage  
5.  
Service and Maintenance  
HFT warrants to a first retail purchaser and each sub-  
sequent purchaser that the engine is free from defects  
in materials and workmanship that cause the failure of  
warranted parts for a period of two (2) years after the  
date of delivery to the first retail purchaser.  
Component parts which are not scheduled for replace-  
ment as required maintenance or are scheduled only  
for regular inspection to the effect of “repair or replace  
as necessary” are warranted for the warranty period.  
Any warranted part which is scheduled for replace-  
ment as required maintenance is warranted for the  
period of time up to the first scheduled replacement  
point for that part. Any replacement part, provided it  
is equivalent in durability and performance, may be  
used in performance of maintenance or repairs. The  
owner is responsible for commissioning a qualified  
technician/mechanic to perform all required mainte-  
nance, as outlined in the Inspection, cleaning, and  
Maintenance section on page 17 of this manual.  
No charge Repair or Replacement  
Repair or replacement of any warranted part will be  
performed at no charge to the owner if the work is  
performed through a warranty station authorized by  
HFT. For emissions warranty service, contact the HFT  
Customer Service Department at 1-800-444-3353.  
3.  
4.  
consequential damages coverage  
Coverage under this warranty shall also extend to  
the failure of any engine components caused by the  
failure of any warranted part while it is still covered  
under this warranty.  
6.  
Warranted Parts  
1) fuel Metering System  
i) Carburetor and its internal parts.  
ii) Fuel pump (if so equipped).  
iii) Cold start enrichment system.  
coverage Exclusions  
2) Air Induction System  
i) Intake pipe/manifold.  
ii) Air cleaner.  
Warranty claims shall be filed in accordance with the  
provisions of the HFT warranty policy explained in the  
box at the top of the previous page. HFT shall not be  
liable for any loss of use of the engine, for any alter-  
native usage, for any damage to goods, loss of time,  
or inconvenience. Warranty coverage shall also be  
excluded for any part which fails, malfunctions, or is  
damaged due to failure to follow the maintenance and  
operating instructions set forth in the Owner’s Manual  
including, but not limited to:  
3) Ignition System  
i) Spark plug.  
ii) Magneto ignition system.  
4) catalyst System (if so equipped)  
i) Exhaust pipe stud.  
ii) Muffler.  
iii) Catalytic converter (if so equipped).  
(a) use of parts which are not authorized by HFT  
5) Miscellaneous items used in Above Systems  
(b) improper installation, adjustment or repair of the  
engine or of any warranted part unless performed  
by an authorized warranty center  
i) Vacuum, temperature and time sensitive  
valves and switches.  
ii) Hoses, belts, connectors, and assemblies.  
(c) failure to follow recommendations on fuel use  
contained in the Owner’s Manual  
(d) improper or inadequate maintenance of any war-  
ranted parts  
(e) repairs performed outside of the authorized war-  
ranty service dealers  
(f) alterations by changing, adding to or removing  
parts from the engine.  
SKU 94191  
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Electrical diagram  
Please note: All electrical work should be performed by  
a qualified service technician.  
REV 07c, 07h  
Page 26  
SKU 94191  
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