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.
Visit our website at: http://www.harborfreight.com
Only use OUTSIDE
and far away from
windows, doors, and
vents.
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
EVERY 300 OPERATION
HOURS: .................................... 16
STORAGE ........................................16
ENGINE TROUBLESHOOTING .......18
EQUIPMENT
TROUBLESHOOTING .................. 20
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
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 For technical questions, please call 1-800-444-3353. 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 re,
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
Gasoline fuel and fumes are 1.
ammable, and potentially explosive.
Use proper fuel storage and handling
procedures. Do not store fuel or
other ammable materials nearby.
Have multiple ABC class re 2.
extinguishers nearby.
Operation of this equipment may 3.
create sparks that can start res
around dry vegetation.
Page 3For technical questions, please call 1-800-444-3353.SKU 65414
A spark arrestor may be required.
The operator should contact
local re agencies for laws or
regulations relating to re prevention
requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.
Wear ANSI-approved safety goggles, 5.
heavy-duty work gloves, and dust
mask/respirator during set up and
use.
Use only oil and fuel recommended 6.
in the “Specications” 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.
Keep children away from the equipment, 2.
especially while it is operating.
Do not leave the equipment unattended 3.
when it is running. Turn off the
equipment (and remove safety keys, if
available) before leaving the work area.
Wear ANSI-approved safety goggles and 4.
hearing protection during use.
People with pacemakers should 5.
consult their physician(s) before use.
Electromagnetic elds 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.
Use only accessories that are 6.
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.
Do not operate in explosive 7.
atmospheres, such as in the presence
of ammable liquids, gases, or dust.
Gasoline-powered engines may ignite
the dust or fumes.
Stay alert, watch what you are doing 8.
and use common sense when operating
this piece of equipment. Do not use
this piece of equipment while tired or
under the inuence of drugs, alcohol or
medication.
NEVER use inside a home or garage,
EVEN IF doors and windows are
open.
Only use OUTSIDE and far away
Do not overreach. Keep proper footing 9.
and balance at all times. This enables
better control of the equipment in
unexpected situations.
Dress properly. Do not wear loose 10.
clothing or jewelry. Keep hair, clothing
and gloves away from moving parts.
Loose clothes, jewelry or long hair can
be caught in moving parts.
from windows, doors, and vents.
Page 4 For technical questions, please call 1-800-444-3353. SKU 65414
Parts, especially exhaust system 11.
components, get very hot during use.
Stay clear of hot parts.
Do not cover the engine or equipment 12.
during operation.
Keep the equipment, engine, and 13.
surrounding area clean at all times.
Use the equipment, accessories, etc., in 14.
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.
Do not operate the equipment with 15.
known leaks in the engine’s fuel system.
equipment and do not use the equipment
for a purpose for which it is not intended.
CAUTION:21. 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 efciently powered
by a portable generator.
This product contains or, when used, 16.
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.)
When spills of fuel or oil occur, they must 17.
be cleaned up immediately. Dispose
of uids and cleaning materials as per
any local, state, or federal codes and
regulations. Store oil rags in a bottomventilated, covered, metal container.
Keep hands and feet away from moving 18.
parts. Do not reach over or across
equipment while operating.
Before use, check for misalignment 19.
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.
Use the correct equipment for the 20.
application. Do not modify the
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 qualied 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
res when utility power is restored.
Consult the utility company or a qualied
electrician.
*Sensitive electronic equipment
includes, but is not limited to, audio/
video equipment, some television
sets, computers, and printers.
Page 5For technical questions, please call 1-800-444-3353.SKU 65414
AC APPLICATIONS
Before connecting an appliance or 1.
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.
Do not alter or adjust any part of the 3.
equipment or its engine that is sealed
by the manufacturer or distributor.
Only a qualied service technician
may adjust parts that may increase or
decrease governed engine speed.
If an appliance begins to operate 2.
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.
Make sure that the electrical rating of 3.
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.
Substantial overloading will open the 4.
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.
W4. ear ANSI-approved safety goggles,
heavy-duty work gloves, and dust mask/
respirator during service.
Maintain labels and nameplates on 5.
the equipment. These carry important
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
Have the equipment serviced by a 6.
qualied 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.
Store equipment out of the reach of 7.
children.
Follow scheduled engine and equipment 8.
maintenance.
Refueling Precautions:9.
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its “OFF” a.
position.
Allow the engine to completely cool.b.
Then, remove the spark plug wire(s) c.
from the spark plug(s).
Keep all safety guards in place and in 2.
proper working order. Safety guards
include mufer, air cleaner, mechanical
guards, and heat shields, among other
guards.
Do not smoke, or allow sparks, ames, a.
or other sources of ignition around the
equipment, especially when refuelling.
Do not rell the fuel tank while the b.
engine is running or hot.
Do not ll fuel tank to the top. Leave c.
a little room for the fuel to expand as
needed.
Refuel in a well-ventilated area only.d.
SAVE THESE
INSTRUCTIONS.
Page 6 For technical questions, please call 1-800-444-3353. SKU 65414
Extension Cords
Grounded1. tools require a three wire
extension cord. Double Insulated
tools can use either a two or three
wire extension cord.
If you are using one extension cord 5.
for more than one tool, add the
nameplate amperes and use the sum
to determine the required minimum
cord size.
(See Table A.)
As the distance from the supply 2.
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.)
The smaller the gauge number of the 3.
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.)
When using more than one extension 4.
cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(See Table A.)
If you are using an extension cord 6.
outdoors, make sure it is marked with
the sufx “W-A” (“W” in Canada) to
indicate it is acceptable for outdoor
use.
Make sure the extension cord is 7.
properly wired and in good electrical
condition. Always replace a damaged
extension cord or have it repaired by
a qualied electrician before using it.
Protect the extension cords from 8.
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)
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
25 Feet 50 Feet 75 Feet 100 Feet 150 Feet
* Based on limiting the line voltage drop to ve volts at 150% of the rated amperes.
Page 7For technical questions, please call 1-800-444-3353.SKU 65414
BASIC SPECIFICATIONS
Functions
Fuel
Engine
Oil
Spark Plug Gap 0.030”
Run Time @ 50%
Load
Engine Type
Ignition
Electrical Plugs
Type
Capacity 4 Gallons
Type
Capacity
91+ octane premium
unleaded gasoline
SAE 10W-30 above 32°F
SAE 5W-30 at 32°F or below
2/3 Quart; Low Oil Shutdown
Sensor
9 Hours with full tank
6.5 HP Four-stroke Overhead
Valve Design
Recoil Start with Electronic
Ignition
One 20A duplex NEMA
120V~receptacle
One 25A NEMA 120V 3 prong
twist lock receptacle
One T-Type 12V outlet
Note: Additional specications found
in the TECHNICAL ENGINE
SPECIFICATIONS chart in this
manual.
This unit can power items such as the
following:
ITEM RUNNING
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
& Run Motor
1400 3100
START-UP
WATTS
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 1-800-4443353 as soon as possible.
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 qualied
mechanic to allow efcient high-altitude
use and to prevent damage to the engine
and any other devices used with this
product.
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.
Page 8 For technical questions, please call 1-800-444-3353. SKU 65414
Engine Power Switch
120V AC OUTLETS ONLY
CONTROLS
Power Indicator Light AC Circuit
Breaker Switch
MAIN BREAKER
20A
RESET
120 V~ Duplex
Receptacle
Plug for up
to 15A
Plug for up
to 20A
AC Reset
Switch
120V Duplex
Receptacle
for 15A or 20A
plugs
Ground Wire
Connection
Twist Lock Receptacle
Note: Be sure to use the proper plug for the amps needed.
Figure 1
12 VDC Outlet
120 V~
DC Circuit
Breaker Switch
Page 9For technical questions, please call 1-800-444-3353.SKU 65414
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 res around dry
vegetation.
A spark arrestor may be
required.
The operator should contact
local re agencies for laws or
regulations relating to re
prevention requirements.
Starting the Engine
low engine oil WILL permanently
damage the engine. Check the oil
level with the engine stopped and
in a level position.
Wipe dipstick exterior with a clean 1.
cloth. Remove the dipstick and wipe
it off with a clean rag. Pour engine oil
into the oil ll hole until the level of oil
is even with the bottom edge of the
oil ll hole (if you cannot see the oil
through the oil ll hole, then the oil is
too low and more oil must be added).
Reinsert the dipstick into the oil 2.
ller 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 ll hole).
If the oil level is not to the upper limit 3.
mark (bottom edge of the oil ll hole),
add the appropriate type of oil until
the oil level reaches the upper limit
mark.
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 xed properly.
Before starting, rst 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
lled 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
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
Replace the Oil Dipstick.4.
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
Page 10 For technical questions, please call 1-800-444-3353. SKU 65414
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