Harbor Freight 5 Hp 173Cc Ohv Vertical Shaft Gas Engine Carb Product Manual
2015-05-27
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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 near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. REV 15a 173cc Vertical Engine Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Visit our website at: http://www.harborfreight.com Email our technical support at: predator@harborfreight.com ITEM 69731 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© 2012 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 Specifications.............................................. 2 Maintenance............................................... 12 Safety.......................................................... 3 Warranties.................................................. 17 Set Up......................................................... 7 Parts Lists and Diagrams........................... 18 Operation..................................................... 9 Specifications Engine Type Cooling System Type Fuel Capacity Type SAE Engine Oil Capacity Run Time @ 50% Load with full tank Sound Level Bore x Stroke Displacement Compression Ratio Rotation viewed from PTO (power takeoff - the output shaft) Mounting Base Pattern Shaft dia. Keyway Shaft End Tapped Type Spark Plug Valve Clearance Speed Page 2 Gap Intake Exhaust Idle Vertical Single Cylinder 4 stroke OHV EPA phase III and CARB compliant Forced air cooled 87+ octane stabilizer treated unleaded gasoline 0.3 gallon (1.1 liter) 10W-30 above 32° F 5W30 at 32° F or below 0.6 Quart 40 minutes 104 dB 70 mm x 45 mm 173cc 8.5:1 Counterclockwise 8" (203mm); 3/8"-24 UNF tapped hole; 2 x 8.7mm through-hole 7/8″ x 3.16″ 3/16″ (4.76 mm) 3/8″ - 24 NGK® BP-6ES/BPR6ES DENSO®: W16EPR-U/W16EP-U CHAMPION®: RN9YC4 NHSP®: F7TC/F7RTC TORCH®: F7TC/F7RTC 0.7 - 0.8 mm 0.10 - 0.15 mm 0.15 - 0.20 mm 1,800 ± 50 RPM For technical questions, please call 1-888-866-5797. Item 69731 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. Safety 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. Symbol Definitions Symbol RPM HP Property or Statement Revolutions Per Minute Horsepower WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields. Read the manual before set-up and/or use. WARNING marking concerning Risk of Hearing Loss. Wear hearing protection. Symbol Property or Statement WARNING marking concerning Risk of Respiratory Injury. Operate engine OUTSIDE and far away from windows, doors, and vents. WARNING marking concerning Risk of Fire while handling fuel. Do not smoke while handling fuel. WARNING marking concerning Risk of Fire. Do not refuel while operating. Keep flammable objects away from engine. WARNING! Read all instructions. Failure to follow all instructions listed below may result in fire, serious injury and/or DEATH. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Operation Setup Safety Warnings Set up Precautions 1. 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. 4. Set up and use only on a flat, level, well‑ventilated surface. 2. Have multiple ABC class fire extinguishers nearby. 6. Use only lubricants and fuel recommended in the Specifications chart of this manual. 3. 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. Item 69731 5. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up. For technical questions, please call 1-888-866-5797. Page 3 Maintenance SAVE THESE INSTRUCTIONS Operating Precautions CARBON MONOXIDE HAZARD Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. 1. Safety NEVER use inside a home or garage, EVEN IF doors and windows are open. 12. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved dust mask/ respirator under a full face shield along with steel-toed work boots during use. 13. 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. 14. 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. Setup 15. 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. Only use OUTSIDE and far away from windows, doors, and vents. 2. Keep children away from the equipment, especially while it is operating. 16. 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. Operation 3. Keep all spectators at least six feet from the Engine during operation. 17. Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations. 4. 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. 18. Use this equipment with both hands only. Using equipment with only one hand can easily result in loss of control. 5. Do not touch engine during use. Let engine cool down after use. 6. Never store fuel or other flammable materials near the engine. 7. Only use a suitable means of transport and lifting devices with sufficient weight bearing capacity when transporting the Engine. 19. 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. 20. Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts. 21. Do not cover the engine or equipment during operation. Maintenance 8. Secure the Engine on transport vehicles to prevent the tool from rolling, slipping, and tilting. 22. Keep the equipment, engine, and surrounding area clean at all times. 9. Industrial applications must follow OSHA requirements. 23. Use the equipment, 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. 10. Do not leave the equipment unattended when it is running. Turn off the equipment (and remove safety keys, if available) before leaving the work area. 11. 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. Page 4 24. Do not operate the equipment with known leaks in the engine’s fuel system. For technical questions, please call 1-888-866-5797. Item 69731 26. 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. 27. Keep hands and feet away from moving parts. Do not reach over or across equipment while operating. 28. Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation. If damaged, have the equipment serviced before using. Many accidents are caused by poorly maintained equipment. 29. Use the correct equipment for the application. Do not modify the equipment and do not use the equipment for a purpose for which it is not intended. 30. Follow equipment manufacturer’s operation precautions. Safety 25. WARNING: This product contains or, when used, produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.) a. Release the brake handle, stopping the engine. b. Allow the engine to completely cool. c. 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. 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. 4. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during service. 5. Maintain labels and nameplates on the equipment. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 6. 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. THE ENGINE BRAKE IS FOR EMERGENCY SHUTOFF; DO NOT REPLACE THE BRAKE SPRING WITH A WEAKER SPRING. 7. Store equipment out of the reach of children. 8. Follow scheduled engine and equipment maintenance. Refueling: 1. Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling. Operation 1. Before service, maintenance, or cleaning: Setup Service Precautions 2. Do not refill the fuel tank while the engine is running or hot. 3. Do not fill fuel tank to the top. Leave a little room for the fuel to expand as needed. 4. Refuel in a well-ventilated area only. 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. Maintenance SAVE THESE INSTRUCTIONS. Item 69731 For technical questions, please call 1-888-866-5797. Page 5 Engine Components Fuel Cap Safety Priming Bulb Setup Starter Handle Dipstick Muffler Operation Air Filter Brake Arm Throttle Maintenance XXXXXXXXXX Serial Number Location (Write on front cover of manual.) Page 6 For technical questions, please call 1-888-866-5797. Item 69731 Set Up Safety 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. 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. WARNING! DO NOT INSTALL THIS ENGINE ON A VEHICLE. NOT FOR HIGHWAY USE. FOLLOW ALL APPLICABLE LAWS FOR INSTALLATION AND USE. High Altitude Operation Above 3000 feet NOTICE Warranty void if necessary adjustments are not made for high altitude use. At high altitudes, the engine’s carburetor, governor (if so equipped), 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. Setup Note: The Fuel Cup Seal and Bolt Seal may be damaged during removal and should be replaced with the new ones from the kit. 7. Replace the Fuel Cup Seal (4a), fuel cup, Bolt Seal (3a), and bolt. Tighten in place. CAUTION: Do not cross thread bolt when tightening. Finger tighten first and then use a wrench to make sure the bolt is properly threaded. 8. 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. Carburetor Assembly Operation 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. Fuel Cup Seal Mixing Tube (might remain inside carburetor) 1. Turn off the engine. Main Jet 2. Close the fuel valve. 3. Place a bowl under the fuel cup to catch any spilled fuel. Fuel Cup CAUTION! Carburetor bowl may have gas in it which will leak upon removing the bolt. Maintenance Bolt Seal 4. Unthread the bolt holding the fuel cup. 5. 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. 6. Replace the Main Jet with the replacement Main Jet needed for your altitude range (part 1a or 2a). Item 69731 Bolt High Altitude Kit Parts List - A Part 1a 2a 3a 4a Description Main Jet 3000-6000 ft. Main Jet 6000-8000 ft. Bolt Seal Fuel Cup Seal For technical questions, please call 1-888-866-5797. Qty 1 1 1 2 Page 7 Installation 1. IMPORTANT: If you have any doubts about your ability to perform the following procedures, have a qualified service technician perform the installation. Safety 2. Install this engine on a lawn mower only. Do not use to power a vehicle. 3. Mounting hole locations: a 6. Insert the mower’s brake cable sheath through the hole in the Brake bracket. Secure the mower brake cable to the brake arm. Adjust the brake cable sheath to remove all slack and secure it in place using the adjusting nuts on the cable sheath, as shown in the illustration below. THE ENGINE BRAKE IS FOR EMERGENCY SHUTOFF; DO NOT REPLACE THE BRAKE SPRING WITH A WEAKER SPRING. If operating the engine brake is too difficult, a qualified technician must install a different brake handle on the mower. Note: The brake cable on some mowers may need to be adjusted in a different manner. Install according to mower manufacturer’s instructions. Brake Arm b Setup Brake Cable b a. one 3/8 in. x 24 threaded; 1 in. deep b. two Ø0.34 in. / 8.7mm unthreaded (use 5/16 in. / 8mm diameter hardware) Throttle Control Operation 4. Set the Engine upright on the mower, and align at least three engine mounting holes with mower mounting holes. Throttle Cable NOTE: Depending on the mower, it may be necessary to drill mounting holes or make a mounting plate to align with the engine mounting holes. Only a qualified technician should attempt these solutions. Bracket and Bolt 5. Use hardened, stainless steel Bolts, Lock Washers, and Washers (not included) of appropriate length and diameter to secure the Engine to the mower. Make sure the hardware will not contact moving parts during operation. Brake Cable Bracket 7. Attach the end of the mower’s Throttle Cable to the Throttle Control. Use the Bracket and Bolt to secure its sheath in place as shown above. 8. Refer to the mower’s service manual for instructions on how to properly attach a belt drive pulley, chain drive gear, etc. onto the output shaft of the Engine. Maintenance Page 8 For technical questions, please call 1-888-866-5797. Item 69731 Operation 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. Safety Pre-Start Checks 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. Checking and Filling Engine Oil Checking and Filling Fuel CAUTION! 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. Do not run the engine with low or no engine oil. Running the engine with no or low engine oil WILL permanently damage the engine. 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. 2. 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. 1. Clean the Fuel Cap and the area around it. 2. Unscrew and remove the Fuel Cap. Setup 1. Make sure the engine is stopped and is level. 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. 3. 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, the top of the crosshatched area on the dipstick as shown above. 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. Operation Full level 4. If the oil level is below the full level add the appropriate type of oil until the oil level is at the correct level. SAE 10W‑30 oil is recommended for general use. (The SAE Viscosity Grade chart on page 13 in the Maintenance section shows other viscosities to use in different average temperatures.) 5. Thread the Dipstick back in clockwise. Item 69731 For technical questions, please call 1-888-866-5797. Maintenance CAUTION! Do not run the engine with too little oil. The engine will be permanently damaged. Page 9 Starting the Engine Before Starting the Engine: Safety a. Follow the Set Up Instructions in the equipment manual to prepare the equipment. b. Inspect the equipment and engine. c. Fill the engine with the proper amount and type of both fuel and oil. d. Read the Equipment Operation section in the equipment manual. e. Move the mower to a location that is flat, level, and free from loose objects (such as rocks or sticks). The mower may be difficult to start on grass. Setup 1. Press the Priming Bulb 2-3 times to prime the engine. Operation 2. Adjust the Mower’s Throttle control to full throttle. 1 2 Note: Location, operation, and design of the Throttle control will vary from manufacturer to manufacturer. 3 Maintenance 3. Hold the mower’s brake handle closed. Page 10 For technical questions, please call 1-888-866-5797. Item 69731 Note: Do not let the Starter Handle snap back against the engine. Hold it as it recoils so it doesn't hit the engine. 5. Allow the Engine to run for several seconds. Then, the Mower’s Throttle control can be adjusted as desired for operation. Safety 4. Grip the Starter Handle of the Engine loosely and pull it gently until resistance is felt. Allow Cable to retract fully and then pull it quickly. Repeat until the engine starts. 4 5 Setup IMPORTANT: Allow the engine to run at no load for a minute or two after each start‑up so that the engine can stabilize. 6. 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: Operation • Change the engine oil. Under normal operating conditions subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section. Stopping the Engine Maintenance To stop the engine, release the brake handle. Item 69731 For technical questions, please call 1-888-866-5797. Page 11 Maintenance WARNING Safety TO PREVENT SERIOUS INJURY FROM ACCIDENTAL STARTING: Release the brake handle, 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 Schedule Setup 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. Before Each Use Procedure Monthly or Every 3 mo. or Every 6 mo. or every 20 50 hr. of use 100 hr. of use hr. of use Yearly or every 300 hr. of use Every 2 Years Brush off outside of engine Check engine oil level Check air cleaner Check deposit cup Change engine oil Operation * Clean/replace air cleaner 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 ** ** *Service more frequently when used in dusty areas. **These items should be serviced by a qualified technician. Maintenance Page 12 For technical questions, please call 1-888-866-5797. Item 69731 Checking and Filling Fuel Safety 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. Full level 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. Engine Oil Change CAUTION! Oil is very hot during operation and can cause burns. Wait for engine to cool before changing oil. 1. Make sure the engine is stopped. 2. Clean the top of the Dipstick and the area around it. Remove the Dipstick by threading it counterclockwise. 6. 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, the top of the crosshatched area on the dipstick as shown above. 7. Thread the dipstick back in clockwise. CAUTION! Do not run the engine with too little oil. The engine will be permanently damaged. 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. • 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. Tilt the engine over a suitable oil container far enough to allow all the oil to drain out. Recycle used oil. 4. Wipe off the dipstick with a clean lint free rag. 5. Add the appropriate type of oil until the oil level is at the full level. SAE 10W‑30 oil is recommended for general use. The SAE Viscosity Grade chart shows other viscosities to use in different average temperatures. Setup 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. 3. Install the cleaned filter. Secure the Air Cleaner Cover before use. Operation 2. Unscrew and remove the Fuel Cap. Spark Plug Maintenance SAE Viscosity Grade 30 Maintenance Spark Plug Cap 10W-30 1. Disconnect spark plug cap from end of plug. Clean out debris from around spark plug. 5W-30 -20 0 20 40 60 80 Average outdoor temperature Item 69731 100°F 2. Using a spark plug wrench, remove the spark plug. For technical questions, please call 1-888-866-5797. Page 13 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 it using emery paper. If the white insulator is cracked or chipped, the spark plug needs to be replaced. Safety Recommended Spark Plugs Brand NGK® NHSP® / TORCH® DENSO® CHAMPION® Plug BP-6ES/BPR6ES F7TC/F7RTC W16EPR-U/W16EP-U RN9YC4 NOTICE: Using an incorrect spark plug may damage the engine. 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. Storage Setup 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: Operation To protect the fuel tank during storage, fill the tank with gasoline that has been treated with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations for use. Refer to Checking and Filling Fuel on page Checking and Filling Fuel chart on page 9. 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. a. Place a funnel leading to a proper gasoline container below the carburetor. c. After all fuel has drained, reinstall the drain bolt. Tighten securely. 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). 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. NOTICE: During extended storage periods the Engine must be started every 3 months and allowed to run for 15 – 20 minutes or the Warranty is VOID. Maintenance 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. Drain Plug b. Remove the drain bolt from the bottom of the carburetor bowl and allow the fuel to drain. Page 14 For technical questions, please call 1-888-866-5797. Item 69731 Troubleshooting Engine misfires MOWER ENGINE SPECIFIC: 1. Brake Handle not held or brake cable not connected properly. 1. Make sure brake handle is held down and brake cable is properly adjusted. 2. Mower on top of grass. 2. Start mower atop clear area free of loose objects and grass. FUEL RELATED: FUEL RELATED: 1. No fuel in tank. 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. Low quality or deteriorated, old gasoline. 2. Use fresh 87+ octane stabilizer-treated unleaded gasoline.. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 3. Carburetor not primed. 3. Press priming bulb before starting cold engine. 4. Dirty fuel passageways. 4. Clean out passageways using fuel additive. Heavy deposits may require further cleaning. 5. Carburetor needle stuck. Fuel can be smelled in the air. 5. Gently tap side of carburetor float chamber with screwdriver handle. 6. Too much fuel in chamber. This can be caused by the carburetor needle sticking. 6. Turn Throttle to full position. Remove spark plug and pull the start handle several times to air out the chamber. Reinstall spark plug and attempt to restart. IGNITION (SPARK) RELATED: IGNITION (SPARK) RELATED: 1. Spark plug cap not connected securely. 1. Connect spark plug cap properly. 2. Spark plug electrode wet or dirty. 2. Clean spark plug. 3. Incorrect spark plug gap. 3. Correct spark plug gap. 4. Spark plug cap broken. 4. Replace spark plug cap. 5. Incorrect spark timing or faulty ignition system. 5. 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. 1. Spark plug cap loose. 1. Check wire connections. 2. Incorrect spark plug gap or damaged spark plug. 2. Re-gap or replace spark plug. 3. Defective spark plug cap. 3. Replace spark plug cap. 4. Old or low quality gasoline. 4. Use only fresh 87+ octane stabilizer-treated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 5. Incorrect compression. 5. Diagnose and repair compression. (Use Engine will not start: COMPRESSION RELATED section.) Follow all safety precautions whenever diagnosing or servicing the equipment or engine. Item 69731 For technical questions, please call 1-888-866-5797. Page 15 Setup MOWER ENGINE SPECIFIC: Safety Probable Solutions Operation Engine will not start Possible Causes Maintenance Problem Problem Engine stops suddenly Possible Causes Probable Solutions 1. Fill engine oil to proper level. Check engine oil before EVERY use. 2. Fuel tank empty or full of impure or low quality gasoline. 2. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 3. Defective fuel tank cap creating vacuum, preventing proper fuel flow. 3. Test/replace fuel tank cap. 4. Faulty magneto. 4. Have qualified technician service magneto. 5. Disconnected or improperly connected spark plug cap. 5. Secure spark plug cap. Engine stops when under heavy load 1. Dirty air filter 1. Clean or replace element. 2. Engine running cold. 2. Allow engine to warm up prior to operating equipment. Engine knocks 1. Old or low quality gasoline. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Engine overloaded. 2. Do not exceed equipment’s load rating. 3. Incorrect spark timing, deposit buildup, worn engine, or other mechanical problems. 3. Have qualified technician diagnose and service engine. 1. Impure or low quality gasoline. 1. Fill fuel tank with fresh 87+ octane stabilizertreated unleaded gasoline. Do not use gasoline with more than 10% ethanol (E15, E20, E85, etc.). 2. Engine too cold. 2. Use cold weather fuel and oil additives to prevent backfiring. 3. Intake valve stuck or overheated engine. 3. Have qualified technician diagnose and service engine. 4. Incorrect timing. 4. Check engine timing. Safety 1. Low oil shutdown. Setup Engine backfires Follow all safety precautions whenever diagnosing or servicing the equipment or engine. Operation Warranties Limited 90 Day Warranty Maintenance 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. 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. Page 16 For technical questions, please call 1-888-866-5797. Item 69731 Emission Control System Warranty Where a warrantable condition exists, HFT will repair your engine at no cost to you including diagnosis, parts and labor. Manufacturer’s Warranty Coverage The 2014-2015 engines are warranted for two (2) years. If any emission-related part on your engine is defective, the part will be repaired or replaced by HFT. Harbor Freight Tools Emission Control Defects Warranty Coverage Engines are warranted for a period of two (2) years relative to emission control parts defects, subject to the provisions set forth below. If any emission related part on your engine is defective, the part will be repaired or replaced by HFT. Owner’s Warranty Responsibilities • As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. HFT recommends that you retain all receipts covering maintenance on your engine, but HFT cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. • As the engine owner, you should, however, be aware that HFT may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. • You are responsible for shipping your engine to a HFT warranty station as soon as a problem exists. Contact the HFT Customer Service department at the number below to make shipping arrangements. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact the Harbor Freight Tools Customer Service Department at 1-888-866-5797. Harbor Freight Tools Emission Control Defects Warranty Provisions 1. Length of Coverage HFT warrants to a first retail purchaser and each subsequent 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. 2. 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 1-888-866-5797. Item 69731 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 alternative 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: a) Use of parts which are not authorized by HFT b) Improper installation, adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty center c) Failure to follow recommendations on fuel use contained in the Owner’s Manual d) Improper or inadequate maintenance of any warranted parts e) Repairs performed outside of the authorized warranty service dealers f) Alterations by changing, adding to or removing parts from the engine. 5. Service and Maintenance Component parts which are not scheduled for replacement 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 replacement 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 maintenance, as outlined in the Inspection, Cleaning, and Maintenance section in this manual. 6. Warranted Parts 1) Fuel Metering System i) Carburetor and its internal parts. ii) Air/fuel ratio feedback and control system. iii) Cold start enrichment system. iv) Fuel Tank. 2) Air Induction System i) Controlled hot air intake system. ii) Intake manifold. iii) Air filter. 3) Ignition System i) Spark Plugs. ii) Magneto or electronic ignition system. iii) Spark advance/retard system. 4) Exhaust Gas Recirculation (EGR) System (if so equipped) i) EGR valve body, and carburetor spacer. ii) EGR rate feedback and control system. 5) Air Injection System i) Air pump or pulse valve. ii) Valves affecting distribution of flow. iii) Distribution manifold. 6) Catalyst or Thermal Reactor System (if so equipped) i) Catalytic converter. ii) Thermal reactor. iii) Exhaust manifold. 7) Particulate Controls Traps, filters, precipitators, and any other device used to capture particulate emissions. For technical questions, please call 1-888-866-5797. Page 17 Safety 4. Coverage Exclusions Setup Your emission 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 emission-related assemblies. 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. Operation 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 2014-2015 Small OffRoad Engine (herein engine). In California, the engine must be designed, built and equipped to meet the State’s stringent antismog standards. Elsewhere within the United States, new offroad, spark-ignition engines certified for model year 2014-2015, must meet similar standards set forth by the EPA. HFT must warrant the emission control system on your engine for the periods of time described below, provided there has been no abuse, neglect or improper maintenance of your engine. 3. Consequential Damages Coverage Maintenance California and United States Emission Control Defects Warranty Statement Parts Lists and Diagrams PLEASE READ THE FOLLOWING CAREFULLY Safety 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. Parts List Part Setup Operation Maintenance 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 Description Cover, Cylinder Head Gasket, Cylinder Head Head Sub., Cylinder Gasket, Cylinder Head Bolt Plug, Spark Bolt, Cylinder Head Bracket, Muffler Shield Bolt Stud Pin Crankcase Sub. Shield, Crankcase Side Dipstick Sub., Oil Bolt Bolt Bracket, Fuel Tank Right Seal, Oil Bolt Bolt Plate, Breather Cover Gasket, Breather Breather Screen, Breather Shield, Crankcase Rear Bearing Bracket, Fuel Tank Left Bolt Arm, Governor Washer Seal, Oil Pin Gasket, Crankcase Pin Washer Block, Returning Oil Qty 1 1 1 1 4 1 4 1 1 2 2 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Part 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Description Bolt Plate, Governor Spindle Seal, Oil Bolt Gear Asm, Governor Cover, Crankcase Ring, Primary Ring, Secondary Ring Set, Oil Piston Clip, Piston Pin Pin, Piston Rod, Connecting Crankshaft Asm. Nut, Valve Lock Nut, Valve Adjusting Seat, Valve Spring Rocker, Valve Spring, Valve Guide, Seal Bolt, Valve Adjusting Valve, Intake Plate Sub., Lifter Stopper Lifter, Valve Tappet, Valve Camshaft Asm. Valve, Exhaust Starter Asm, Recoil Housing, Engine Shroud Nut Stud Stud Gasket, Insulator Plate Plate, Carb. Insulator Gasket, Carburetor Qty 1 1 1 6 1 1 1 1 1 1 2 1 1 1 2 2 2 2 2 1 2 1 1 2 2 1 1 1 1 1 3 2 1 1 1 2 Part 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 Description Gasket, Carb. Insulator Carburetor Asm. Gasket, Air Cleaner Valve, Enrichment Gasket, Air Cleaner Tube, Breather Nut Case, Air Cleaner Element, Air Cleaner Cover, Air Cleaner Case Cover, Muffler Outer Muffler Asm. Gasket, Exhaust Outlet Nut Strainer, Fuel Clamp Tube, Fuel Clamp Bolt Tank Asm, Fuel Nut, Flywheel Flywheel Subassembly Bolt Coil, Ignition Brake Asm. Bolt Bolt Rod, Governor Spring, Throttle Returning Control Asm, Throttle Bolt Support Sub., Governor Bolt, Governor Support Nut Spring, Governor Clip Qty 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 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. Page 18 For technical questions, please call 1-888-866-5797. Item 69731 Assembly Diagram 67 67 Safety 67 65 66 68 68 93 99 69 64 94 98 97 20 20 21 19 15 16 15 13 92 22 23 24 25 17 91 18 45 28 29 30 32 31 12 44 43 47 53 10 6 1 7 5 7 53 10 3 2 52 54 70 71 51 72 55 52 61 63 60 61 41 60 33 34 54 76 35 37 38 34 78 80 36 81 82 77 42 75 39 40 40 Item 69731 107 103 57 73 74 72 106 102 56 57 59 51 7 55 105 108 49 46 58 9 11 50 62 Operation 48 11 4 40 40 For technical questions, please call 1-888-866-5797. Maintenance 85 8 5 104 101 7 5 100 26 47 84 5 90 27 14 83 87 88 89 86 86 91 Setup 95 96 79 79 40 40 Page 19 Mounting Hole Diagram Note: Not to scale. A Ø8 in. / 203mm 6*Ø0.35 in. / 9mm Ø0.24 in. / 6mm 3.27 in. / 83mm A Ø0.34 in. / 8.7mm A-A 2:1 Ø1 in. / 25.4mm Ø0.24 in. / 6mm 0.98 in. / 25mm Ø0.34 in. / 8.7mm 3.94 in. / 100mm 3.85 in. / 97.7mm 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797 www.harborfreight.com 3/8 in. x 24 1.1 in. / 28mm
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