Chicago Electric 66603 User Manual
6500 RATED WATTS/7000 MAXIMUM WATTS
PORTABLE GENERATOR
66603
SET UP, OPERATING, AND SERVICING INSTRUCTIONS
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator 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© 2007 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 10e
SPECIFICATIONS
6500 Rated Watts (Rated) / 7000 Maximum Watts (Maximum) / 60 Hz / 3600 RPM
Output Receptacles:
2 NEMA 120V, Household Receptacles, with a 20 A Circuit Breaker
1 NEMA 120V, 3-Prong Twist Lock Receptacles with a 30 A Circuit Breaker
Electrical Requirements
Engine Specications
Additional Features Locking ON/OFF with 2 Keys
Overall Dimensions 24-1/8” Long x 20-1/2” Wide x 24-1/2” High
Net Weight 205 Pounds
1 NEMA 120V/240V, 4-Prong Twist Lock Receptacles with two 30 A Circuit Breakers
Input Power: 12 VDC Battery / 7-1/4” Long x 3” Wide (not included) with an In-Line
Circuit Breaker
Voltmeters:
0 < - > 150 Volts / 50 Volt Marked Increments
0 < - > 300 Volts / 100 Volt Marked Increments w/50 Volt Hash Marks
16 HP / 4 Cycle / Air Cooled / Electric & Recoil Start / 3600 RPM
420cc Displacement / 6.6 Gallon Fuel Tank
Powered with Mid to High Octane, Unleaded Gasoline
Engine Family: 5CSG.41925C
Recommended Oil:
37 Fluid Ounces
SAE 30W (Above 32 Fahrenheit) / SAE 5W-30 (Below 32 Fahrenheit)
Recommended Spark Plug Gap: 0.028” ~ 0.031”
Estimated Run Time: 8 Hours @ 50% Load
Automatic Low Oil Shutdown
IMPORTANT! This product requires oil and fuel to be added before starting. Attempting to start
the Engine without oil WILL ruin the Engine and void the warranty.
NOTE: The Engine’s carburetor may need to be adjusted by a qualied mechanic for efcient
high-altitude use.
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.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your
invoice with this manual. Write the invoice number on the inside of the front cover. Write the
product’s serial number in the back of the manual near the assembly diagram, or write month
and year of purchase if product has no number. Keep this manual and invoice in a safe and dry
place for future reference.
REV 09l
Page 2SKU 66603 For technical questions, please call 1-800-444-3353.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, re, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. 1. Cluttered and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of 2.
ammable liquids, gases, or dust. Power tools create sparks which may ignite the dust
or fumes.
Keep bystanders, children, and visitors away while operating a power tool. 3.
Distractions can cause you to lose control. Protect others in the work area from debris
such as chips and sparks. Provide barriers or shields as needed. Children should never
be allowed in the work area.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when operating a 1.
power tool. Do not use a power tool while tired or under the inuence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may result
in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep 2.
your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or
long hair can be caught in moving parts.
Remove adjusting keys or wrenches before turning the power tool on. 3. A wrench or a
key that is left attached to a rotating part of the power tool may result in personal injury.
Do not overreach. Keep proper footing and balance at all times. 4. Proper footing and
balance enables better control of the power tool in unexpected situations.
5. Use safety equipment. Always wear eye protection. Dust mask, nonskid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
Tool Use And Care
Do not force the tool. Use the correct tool for your application. 1. The correct tool will
do the job better and safer at the rate for which it is designed. Do not force the tool and do
not use the tool for a purpose for which it is not intended.
Page 3SKU 66603 For technical questions, please call 1-800-444-3353.
Do not use the power tool if the Engine Switch does not turn it on or off. 2. Any tool
that cannot be controlled with the Engine Switch is dangerous and must be replaced.
Disconnect the Spark Plug Wire from the Engine before making any adjustments, 3.
changing accessories, or storing the tool. Such preventive safety measures reduce
the risk of starting the tool accidentally. Always disconnect the Spark Plug Wire before
performing any inspection, maintenance, or cleaning procedures.
Store idle tools out of reach of children and other untrained persons. 4. Tools are
dangerous in the hands of untrained users.
Maintain tools with care. Keep the Generator clean.5. Properly maintained tools are
less likely to malfunction and are easier to control. Do not use a damaged tool. Tag
damaged tools “Do not use” until repaired.
Check for misalignment or binding of moving parts, breakage of parts, and any 6.
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
Use only accessories that are recommended by the manufacturer for your model. 7.
Accessories that may be suitable for one tool may become hazardous when used on
another tool.
CAUTION: This generator is not intended to power sensitive electronic equipment* 8.
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.
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.
AC Applications
Before connecting an appliance or power cord to the generator: Make sure that it 1.
is in good working order. Faulty appliances or power cords can create a potential
for electrical shock.
Page 4SKU 66603 For technical questions, please call 1-800-444-3353.
If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, 2.
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 the tool or appliance does not exceed that of 3.
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 circuit breaker. Exceeding the time limit for 4.
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
Tool service must be performed only by qualied repair personnel. 1. Service or
maintenance performed by unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow 2.
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 injury.
SPECIFIC SAFETY RULES
IMPORTANT! Your Warranty is voided if:1.
You do not put engine oil in the Engine’s crankcase prior to its rst use.
Before each use, check the oil level. Never run the Engine with low or no engine
oil. Running the Engine with low or no Engine oil will permanently damage the
Engine.
Maintain labels and nameplates on the Generator. 2. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
Maintain a safe working environment. 3. Make sure there is adequate surrounding
workspace.
Avoid unintentional starting. 4. Make sure you are prepared to begin work before
turning on the Generator.
People with pacemakers should consult their physician(s) before use. 5.
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.
Page 5SKU 66603 For technical questions, please call 1-800-444-3353.
Never leave the Generator unattended when it is running. 6. Turn off the Engine
of the Generator before leaving the work area.
Always use the Generator on a at, level surface.7.
Make sure to keep hands, ngers, and feet away from all moving parts of the 8.
Generator.
Keep all safety guards of the Generator in place and in proper working order.9.
TOXIC FUMES, FIRE, AND EXPLOSION PRECAUTIONS
This Generator is designed for outdoor use only. Do not operate the 1.
Generator in a closed area or in a poorly ventilated area. When running,
the Engine of this unit produces carbon monoxide, a colorless, odorless,
toxic fume that, when inhaled, can cause serious personal injury or death.
Whenever possible, use a carbon monoxide detector (not included) to detect
excessive carbon monoxide fumes in the work area and in the surrounding area.
Gasoline fuel and fumes are ammable, and potentially explosive. 2. Use
proper fuel storage and handling procedures. Always have multiple ABC class re
extinguishers nearby.
Keep the Generator, its Engine, and surrounding areas clean at all times.3.
When spills of fuel or oil occur, they must be cleaned up immediately. 4.
Dispose of uids and cleaning materials as per any local, state, or federal codes
and regulations. Store oil rags in a covered metal container.
Never store fuel or other ammable materials near the Generator.5.
Do not smoke, or allow sparks, ames, or other sources of ignition around 6.
the Generator.
Keep grounded conductive objects, such as tools, away from exposed, live 7.
electrical parts and connections to avoid sparking or arcing. These events
could ignite fumes or vapors.
Do not rell the Fuel Tank while the Engine is running or hot. 8.
Do not operate the Generator with known leaks in the Engine’s fuel system.9.
Use only oil and fuel recommended in the “Product Specications” section 10.
of this manual.
Page 6SKU 66603 For technical questions, please call 1-800-444-3353.
MECHANICAL PRECAUTIONS
Prior to performing service, maintenance, or cleaning procedures, always 1.
make sure the Engine Switch is in its “OFF” position. Allow the Engine to
completely cool. Then, remove the Spark Plug Wire from the Spark Plug.
Do not alter or adjust any part of the Generator or its Engine that is 2.
assembled and supplied by the manufacturer or distributor.
Always follow and complete scheduled Engine maintenance.3.
CHEMICAL PRECAUTIONS
Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.1.
Avoid body contact with fuels, oils, and lubricants used in the Engine. 2. If
swallowed, seek immediate medical treatment. Do not induce vomiting if fuel is
swallowed. For skin contact, immediately wash with soap and water. For eye
contact, immediately ush eyes with clean water.
NOISE PRECAUTION
Prolonged exposure to high noise levels is hazardous to hearing. Always
wear ANSI-approved hearing protection when operating or working around the
Generator when it is running.
ELECTRICAL PRECAUTIONS
All connections and conduits from the Generator to the load must only be installed 1.
by trained and licensed electricians, and in compliance with all relevant local,
state, and federal electrical codes and standards, and other regulations where
applicable.
The Generator must be earth-grounded in accordance with all relevant electrical 2.
codes and standards before operation.
Page 7SKU 66603 For technical questions, please call 1-800-444-3353.
If an extension cord (not included) is used, make sure to use only UL® listed cords 3.
having the correct gauge and length. (See Table A.)
Do not attempt to connect or disconnect load connections while standing in water, 4.
or on wet or soggy ground.
Do not touch electrically energized parts of the Generator and interconnecting 5.
cables or conductors with any part of the body, or with any non-insulated
conductive object.
Connect the Generator only to a load or electrical system (120 volt or 240 volt) 6.
that is compatible with the electrical characteristics and rated capacities of the
Generator.
Make sure the Engine Switch is in its “OFF” position before moving the Generator 7.
and before performing any service, maintenance, or cleaning procedures on the
unit.
Keep all electrical equipment clean and dry. Replace any wiring where the 8.
insulation is cracked, cut, abraded, or otherwise degraded. Replace terminals that
are worn, discolored, or corroded. Keep terminals clean and tight.
Insulate all connections and disconnected wires.9.
Guard against electric shock. Prevent body contact with grounded surfaces such 10.
as pipes, radiators, ranges, and refrigerators.
Use only Class BC or Class ABC re extinguishers on electrical res.11.
MISC. PRECAUTION
WARNING! The warnings and precautions discussed in this manual cannot
cover all possible conditions and situations that may occur. It must be understood
by the operator that common sense and caution are factors which cannot be built
into this product, but must be supplied by the operator.
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
NAMEPLATE 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’ 50’ 75’ 100’ 150’
* Based on limiting the line voltage drop to ve volts at 150% of the rated
EXTENSION CORD LENGTH
amperes.
Page 8SKU 66603 For technical questions, please call 1-800-444-3353.
Symbology
V~
A
n0 xxxx/min.
Volts Alternating Current
Amperes
No Load Revolutions per Minute
(RPM)
UNPACKING
When unpacking, check to make sure all of the parts shown on the Parts List in this
manual are included. If any parts are missing or broken, please call Harbor Freight
Tools at the number shown on the cover (and at the bottom of each page) of this manual as soon as possible.
CONTROL PANEL FEATURES
Engine Switch (2): 1. Used to start and stop the Engine. To start, insert the Engine
Switch Key and turn to the right to its “START” position. Then immediately
release the Key. To turn off the Engine, turn the Key all the way to the left to its
“OFF” position. Always remove the Key from the Engine Switch when the unit is
not in use.
(See Figure A, above.)
Outlet Sockets (8, 10, 10B): 2. The Generator features three Outlet Sockets with
which to power tools and equipment. The type and voltage of the Outlet Sockets
are as follows:
Page 9SKU 66603 For technical questions, please call 1-800-444-3353.
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