Chicago Electric 65414 User Manual

3000 RATED Watts/3500 MAX. watts

portable generator

certified for all states except california

Model 65414

Set up, Operating, and Servicing Instructions

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

Read this material before using this product. Failure to do so can result in serious injury. Save this manual.

Copyright© 2009 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.

For technical questions or replacement parts, please call 1-800-444-3353.

Manual Revised 09j

Contents

Important SAFETY Information 3

Extension Cords 7

Basic Specifications 8

Functions 8

Unpacking 8 CONTROLS 9

Operating Instructions 10

Starting the Engine 10

Checking and Filling Engine Oil 10

Checking and Filling Fuel 11 Start Procedure 11 Break-in Period 12

Equipment Operation 12 Control Panel Features 13

Technical Specifications 14

Servicing 14

Maintenance Procedures 14 Engine Oil Change 14

Air Filter Element Maintenance 14

Spark Plug Maintenance 15

Cleaning, Maintenance, and Lubrication Schedule 16

After Initial 20

Operation Hour Period: 16

Every 25 Operation

Hours Thereafter: 16

Every 50 Operation

Hours: 16

Every 100 Operation

Hours: 16

Every 300 Operation

Hours: 16 Storage 16 Engine Troubleshooting 18

Equipment

Troubleshooting 20

Main Parts List 21

Diagram 22

Parts List and Diagram A - Crankcase Assembly 23

Parts List and Diagram B - Cylinder Head Assembly 24

Parts List and Diagram C - Crankshaft, Piston, Connecting Rod,

Camshaft and Flywheel Assemblies 25

Parts List and Diagram

D - Recoil Starter and Ignition Coil Assembly 26

Parts List and Diagram E - Air Cleaner and Muffler

Assembly 27

Parts List and Diagram F - Fuel Supply System 27

Parts List and Diagram G -

Starter and Generator Assembly 28

Wiring Diagram 29

Limited 1 year / 90 Day warranty 30

Emission Control System Warranty 30

Page 2

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SKU 65414

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.

Important SAFETY

Information

In this manual, on the labeling, and all other information provided with this product:

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.

DANGER indicates a hazardous

situation which, if not avoided, will result in death or serious injury.

WARNING indicates a

hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety

alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert

symbol, is used to address practices not related to personal injury.

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.

SAVE THESE INSTRUCTIONS

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.

2.Have multiple ABC class fire extinguishers nearby.

3.Operation of this equipment may create sparks that can start fires around dry vegetation.

SKU 65414

For technical questions, please call 1-800-444-3353.

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A spark arrestor may be required. The operator should contact local fire agencies for laws or

regulations relating to fire prevention requirements.

4.Set up and use only on a flat, level, well-ventilated surface.

5.Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up and use.

6.Use only oil and fuel recommended in the “Specifications” section of this manual.

Operating precautions

1. 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.

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.

2.Keep children away from the equipment, especially while it is operating.

3.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.

4.Wear ANSI-approved safety goggles and hearing protection during use.

5.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.

6.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.

7.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.

8.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.

9.Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations.

10.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.

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SKU 65414

11.Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts.

12.Do not cover the engine or equipment during operation.

13.Keep the equipment, engine, and surrounding area clean at all times.

14.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.

15.Do not operate the equipment with known leaks in the engine’s fuel system.

16.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.)

17.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 bottomventilated, covered, metal container.

18.Keep hands and feet away from moving parts. Do not reach over or across equipment while operating.

19.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.

20.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.

21.CAUTION: This generator is not intended to power sensitive electronic equipment* without the addition of an appropriate line conditioner and surge protector (both not included). Sensitive electronic equipment should be operated on approved inverter type generators or pure sine wave generators.

If the plugged in product operates abnormally or unusually slow, immediately stop using the generator as a power source. Always read and adhere to the instruction manual of the

product to be powered, to make sure that it can be safely and efficiently powered by a portable generator.

Note: When using a generator to provide home standby electricity, a transfer switch (sold separately) is needed to prevent back feeding power into the utility line.

Connections for standby power to a building electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes.

WARNING: Improper connections to a building electrical system can allow electrical current from the generator to backfeed into the utility lines. Such

backfeed may electrocute utility company workers or others who contact the

lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored. Consult the utility company or a qualified electrician.

*Sensitive electronic equipment includes, but is not limited to, audio/ video equipment, some television sets, computers, and printers.

SKU 65414

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AC APPLICATIONS

1.Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock.

2.If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.

Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded.

3.Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

4.Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF, but will shorten the service life of the generator.

Service precautions

1.Before service, maintenance, or cleaning:

a.Turn the engine switch to its “OFF” position.

b.Allow the engine to completely cool.

c.Then, remove the spark plug wire(s) from the spark plug(s).

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.

7.Store equipment out of the reach of children.

8.Follow scheduled engine and equipment maintenance.

9.Refueling Precautions:

a.Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling.

b.Do not refill the fuel tank while the engine is running or hot.

c.Do not fill fuel tank to the top. Leave a little room for the fuel to expand as needed.

d.Refuel in a well-ventilated area only.

Save these instructions.

Page 6

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SKU 65414

Extension Cords

1.Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord.

2.As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage.

(See Table A.)

3.The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Table A.)

4.When using more than one extension cord to make up the total length, make sure each cord contains at least the minimum wire size required.

(See Table A.)

5.If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum cord size.

(See Table A.)

6.If you are using an extension cord outdoors, make sure it is marked with the suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

7.Make sure the extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified electrician before using it.

8.Protect the extension cords from sharp objects, excessive heat, and damp or wet areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)

	NAMEPLATE				EXTENSION CORD LENGTH
	AMPERES
	(at full load)
				25 Feet	50 Feet	75 Feet	100 Feet	150 Feet
	0 – 2.0			18	18	18	18	16
	2.1	– 3.4		18	18	18	16	14
	3.5	– 5.0		18	18	16	14	12
5.1		– 7.0		18	16	14	12	12
	7.1 – 12.0			18	14	12	10	-
	12.1	– 16.0		14	12	10	-	-
16.1		– 20.0		12	10	-	-	-
	TABLE A			* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
SKU 65414			For technical questions, please call 1-800-444-3353.					Page 7

Basic Specifications

		Type	91+ octane premium
	Fuel		unleaded gasoline
		Capacity	4 Gallons
		Type	SAE 10W-30 above 32°F
	Engine		SAE 5W-30 at 32°F or below
	Oil	Capacity	2/3 Quart; Low Oil Shutdown
			Sensor
	Spark Plug Gap		0.030”
	Run Time @ 50%		9 Hours with full tank
	Load
	Engine Type		6.5 HP Four-stroke Overhead
			Valve Design
	Ignition		Recoil Start with Electronic
			Ignition
			One 20A duplex NEMA
			120V~receptacle
	Electrical Plugs		One 25A NEMA 120V 3 prong
			twist lock receptacle
			One T-Type 12V outlet

Note: Additional specifications found in the Technical Engine Specifications chart in this manual.

The emission control system for this Generator’s Engine is warranted for standards set by the U.S. Environmental Protection Agency. For warranty information, refer to the last pages of this manual.

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.

Functions

This unit can power items such as the following:

ITEM	RUNNING	START-UP
	WATTS	WATTS
Belt Sander	1200	2400
Refrigerator/Freezer	700	2200
1/2 HP Sump Pump	1050	2150
1/2 HP Well Pump	1000	2100
Miter Saw	1650	3000
1-1/2 HP Capacitor Start	1400	3100
& Run Motor

Note: The above wattages are estimates.

Check nameplate wattages on all loads before connecting to generator.

Unpacking

When unpacking, check to make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at 1-800-444-

3353 as soon as possible.

REMOVE THESE BOLTS AND BRACKETS BEFORE USE!

There are two metal brackets that secure the generator to the bottom of the crate. These brackets hold the generator in place during shipment to prevent damage. They must be removed before use. See the photo above.

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SKU 65414

CONTROLS

Power Indicator Light	AC Circuit
Engine Power Switch	Breaker Switch

MAIN BREAKER

120V AC OUTLETS ONLY

20A RESET

120 V~ Duplex	AC Reset	Ground Wire	12 VDC Outlet
Receptacle	Switch	Connection
		120 V~
Plug for up		Twist Lock Receptacle
			DC Circuit
to 15A

Breaker Switch

	Plug for up	120V Duplex
	to 20A
		Receptacle
		for 15A or 20A
		plugs

Note: Be sure to use the proper plug for the amps needed.

Figure 1

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Operating Instructions

Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

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.

Starting the Engine

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.

Before starting, first familiarize yourself with proper shut down and emergency shut down procedures.

Checking and Filling Engine Oil

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. Check the oil level with the engine stopped and in a level position.

1.Wipe dipstick exterior with a clean cloth. Remove the dipstick and wipe it off with a clean rag. Pour engine oil into the oil fill hole until the level of oil is even with the bottom edge of the oil fill hole (if you cannot see the oil through the oil fill hole, then the oil is too low and more oil must be added).

2.Reinsert the dipstick into the oil filler neck, but do not screw in, then remove it to check the oil level. The oil level should reach the upper limit

(H) mark on the dipstick (bottom edge of the oil fill hole).

3.If the oil level is not to the upper limit mark (bottom edge of the oil fill hole), add the appropriate type of oil until the oil level reaches the upper limit mark.

THIS GENERATOR HAS AN AUTO-SHUTDOWN OIL SENSOR. IF ENGINE STOPS OR WILL NOT START, CHECK OIL LEVEL.

	Engine Oil	SAE 10W-30 above 32°F
		SAE 5W-30 at 32°F or below

4.Replace the Oil Dipstick.

The Oil Sensor will automatically shut down the engine before the oil level falls below the safe/low limit.

To avoid nuisance tripping of the

Oil Sensor and damage to property, check that the oil level is at the

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For technical questions, please call 1-800-444-3353.

SKU 65414