2.5 Horsepower Gas engine generator 94678 Installation And Operation Instructions Due to continuing improvements, actual product may differ slightly from the product described herein. Distributed exclusively by Harbor Freight Tools®. 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.
Contents Unpacking................................................................................................ 2 Specifications.......................................................................................... 3 General Safety Rules............................................................................... 4 Specific Safety Rules.............................................................................. 6 Generator Control Illustrations.....................................................
Specifications Generator Type Brushless / Revolving Field / Self Exciting / Two Pole / Single Phase Wattage 1,000 / 1,050 (Continuous-Rated/Peak) Electrical Output 110/120 V~, 60 Hz about 18 V (12 V battery charging) Electrical Supply 120 V~, 3-Prong Grounded Duplex Receptacle with 10 Amp Resettable Circuit Protection 12 V Battery-charging Output* with 10 Amp Resettable Circuit Protection *Only for use with included power cord for 12 V battery charging. Voltmeter 0-300 V~ Total Weight 57 lb.
General Safety Rules WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. SAVE THESE INSTRUCTIONS Work Area 1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. 2. Do not operate equipment in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Equipment create sparks which may ignite the dust or fumes. 3.
3. Remove adjusting keys or wrenches before turning the equipment on. A wrench or a key that is left attached to a rotating part of the equipment may result in personal injury. 4. Do not overreach. Keep proper footing and balance at all times, especially when starting the equipment. 5. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.
2. When servicing a equipment, use only identical replacement parts. Follow instructions 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. 3. 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.
INSTALLATION PRECAUTIONS 1. Ensure installation meets all applicable safety, and local and national electrical codes. Have installation performed by a qualified, licensed electrician and building contractor. 2. All electrical work, including the earth-ground connection, should be completed by a licensed electrician. 3. If the generator is installed indoors, exhaust fumes must be piped out of the building using leak-free, heat-resistant piping. Use the Generator only in well ventilated outdoor areas.
6. 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. 7. Excessive buildup of unburned fuel gases in the exhaust system can create a potentially explosive condition. This buildup can occur after repeated failed start attempts, valve testing, or hot engine shutdown. If this occurs, open exhaust system drain plugs, if equipped, and allow the gases to dissipate before attempting to restart the Generator.
10. This Generator provides raw, unregulated output to the battery charging outlet. Incorporating an inline regulator is strongly recommended while charging and the charging process must be monitored at all times. The battery charging output must not be used to power any other device or charge any other type of battery without a proper regulating device. Installation Instructions 1.
Generator Control Illustrations Fuel Meter (1a) Choke Control (80) Air Filter Cover (67) transparent to show controls underneath. Oil Drain Plug (24) Fuel Valves (9a, 81) Recoil Start Handle (64) ON/OFF Switch (52a) Circuit Protectors DC (59a) AC (53a) Battery Charging Dipstick Outlet (57a) (28) AC Outlets Pilot Lamp (54a) (56a) Voltmeter (58a) Grounding Point (55a) Before setting up or using the generator, familiarize yourself with the locations of the controls and adjustments as shown above.
To Start the Engine: 1. Make sure the electrical tools/equipment that will be used are not plugged in to the Generator. 2. Turn on the Fuel Valves (9a, 81). Turn the Valve (9a) under the fuel tank to the vertical ON position and swing the Valve (81) on the carburetor behind the Air Filter right to the ON position. 3. Close the Choke Control (80), swinging it to the left. 4. Turn the ON/OFF Switch (52a) to its “ON” position. 5.
To Charge 12 V Lead-acid Type Batteries: Note: Lead-acid batteries can be hazardous. Carefully follow all instructions, safety precautions, and charging procedures as included with the battery you will recharge. Batteries contain corrosive acid that can cause blindness or severe injury; always wear splash-resistant ANSI-approved safety goggles and work gloves when handling batteries. Also, have a nearby area with water and baking soda available to allow you to wash quickly in the event of an emergency.
Inspection, Maintenance, and Cleaning (See maintenance chart on next page.) 1. WARNING! Make sure the Power Switch of the generator is in its “OFF” position, that the engine has cooled, and that all loads are unplugged from the electrical outlets before performing any inspection, maintenance, or cleaning procedures. 2. BEFORE EACH USE, inspect the general condition of the generator.
Maintenance Chart Refer to a small engine service manual for procedures not explained in this manual. If you are uncertain about your ability to successfully and safely perform any procedure below, service should be performed by a qualified mechanic. Maintenance Type Before/ After Each Use 1. Check Engine Oil Level 2. Inspect for damage 3.
Parts List - Engine Part Description Q’ty Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Crankcase Valve chamber clapboard sub-assy Stud M5 × 118 Stud M6 × 52 Oil seal (17×30×6), crankshaft Cover, oil filter Gasket Return pipe Flow guard, lower Sway bar Keeper, sway bar Oil seal, sway bar Washer, sway bar Bolt M6 × 14 Bolt M5 × 10 Crankshaft sub-assy Connecting rod Piston Piston pin Circlip, piston pin Piston ring set Set pin Ø8 ×
Assembly Diagram - Engine SKU 94678 For technical questions, please call 1-800-444-3353.
Parts List A - Generator Part 1a 2a 3a 4a 5a 6a 7a 8a 9a 10a 11a 12a 13a 14a 15a 16a 17a 18a 19a 20a 21a 22a 23a 24a 25a 26a 27a 28a 29a 30a Description Fuel Meter Fuel Tank Cap Fuel Tank Filter Flange Bolt M6 x 20 Gasket Screw Gasket Anti-vibration Gasket Fuel Tank Fuel Valve Fuel Pipe Clamp Oil Pipe Engine (See parts list on earlier page) Exhaust Pipe Gasket Exhaust Pipe Lock Nut M8 Flange Bolt M6 x 12 Muffler Gasket B Muffler Flange Bolt M6 x 12 Front Cover Gasket Flange Bolt M8 x 20 Rotor Assembly Stat
Assembly Diagram A - Generator 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. SKU 94678 For technical questions, please call 1-800-444-3353.
Emission Control System Warranty California and United States Emission Control Defects Warranty Statement The California Air Resources Board (herein CARB), the United States Environmental Protection Agency (herein EPA), and Harbor Freight Tools® (herein HFT) are pleased to explain the emission control system warranty on your 1995 and later Small Off-Road Engine (herein engine). In California, the engine must be designed, built and equipped to meet the State’s stringent anti-smog standards.
6. Warranted Parts 1) Fuel Metering System i) Carburetor and its internal parts. ii) Fuel pump (if so equipped). iii) Cold start enrichment system. 2) Air Induction System i) Intake pipe/manifold. ii) Air cleaner. 4) Catalyst System (if so equipped) i) Exhaust pipe stud. ii) Muffler. iii) Catalytic converter (if so equipped). 5) Miscellaneous items Used in Above Systems i) Vacuum, temperature and time sensitive valves and switches. ii) Hoses, belts, connectors, and assemblies.