Harbor Freight Tools 65414 User Manual
3000 RUNNING WATTS/3500 STARTUP WATTS
PORTABLE GENERATOR
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.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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© 2008 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.
Revised 09g
CONTENTS
IMPORTANT SAFETY
INFORMATION ............................ 3
EXTENSION CORDS .........................7
BASIC SPECIFICATIONS ............. 8
UNPACKING .................................. 8
OPERATING INSTRUCTIONS ...... 8
STARTING THE ENGINE ...................9
CHECKING AND FILLING
ENGINE OIL ............................... 9
CHECKING AND FILLING FUEL ..9
START PROCEDURE ...................9
BREAK-IN PERIOD ....................10
EQUIPMENT OPERATION ...............10
CONTROL PANEL FEATURES ....... 11
CONTROL PANEL CHART ..............13
TECHNICAL SPECIFICATIONS .. 14
STORAGE ........................................17
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 ASSEMBLY ..........27
SERVICING .................................. 15
MAINTENANCE PROCEDURES .....15
ENGINE OIL CHANGE ...............15
AIR FILTER ELEMENT
MAINTENANCE .......................15
SPARK PLUG MAINTENANCE ..16
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
PARTS LIST AND DIAGRAM F -
FUEL SUPPLY SYSTEM ............... 28
PARTS LIST AND DIAGRAM G -
STARTER AND GENERATOR
ASSEMBLY ....................................29
WIRING DIAGRAM ...........................30
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 31
EMISSION CONTROL SYSTEM
WARRANTY .............................. 31
Page 2For 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.
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
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.
Gasoline fuel and fumes are amma-1.
ble, and potentially explosive. Use
proper fuel storage and handling procedures. Do not store fuel or other
ammable materials nearby.
Have multiple ABC class re extin-2.
guishers nearby.
Operation of this equipment may cre-3.
ate 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 relat-
ing to re prevention requirements.
Set up and use only on a at, level, 4.
well-ventilated surface.
Page 3For technical questions, please call 1-800-444-3353.SKU 65414
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
Wear ANSI-approved safety goggles 4.
and 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.
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.
Keep children away from the equip-2.
ment, especially while it is operating.
Do not leave the equipment unat-3.
tended when it is running. Turn off
the equipment (and remove safety
keys, if available) before leaving the
work area.
Use only accessories that are recom-6.
mended 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 atmo-7.
spheres, 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.
Do not overreach. Keep proper foot-9.
ing 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.
Parts, especially exhaust system 11.
components, get very hot during use.
Stay clear of hot parts.
Page 4For technical questions, please call 1-800-444-3353.SKU 65414
Do not cover the engine or equipment 12.
during operation.
Keep the equipment, engine, and sur-13.
rounding area clean at all times.
Use the equipment, accessories, etc., 14.
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.
Do not operate the equipment with 15.
known leaks in the engine’s fuel system.
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 17.
must 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 bottom-ventilated, covered, metal
container.
Keep hands and feet away from 18.
moving 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 ac-
cidents are caused by poorly maintained equipment.
Use the correct equipment for the 20.
application. Do not modify the equipment and do not use the equipment
for a purpose for which it is not intended.
SERVICE PRECAUTIONS
Before service, maintenance, or 1.
cleaning:
Turn the engine switch to its a.
“OFF” position.
Allow the engine to completely b.
cool.
Then, remove the spark plug c.
wire(s) 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 alter or adjust any part of 3.
the equipment or its engine that is
sealed by the manufacturer or dis-
tributor. Only a qualied service
technician may adjust parts that
may increase or decrease governed engine speed.
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
Page 5For technical questions, please call 1-800-444-3353.SKU 65414
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 equip-8.
ment maintenance.
Refueling Precautions:9.
Do not smoke, or allow sparks, a.
ames, 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 6For 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 outlet 2.
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 exten-4.
sion 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 prop-7.
erly 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
Fuel
Type
Capacity 4 Gallons
Type
Engine Oil
Capacity
Spark Plug Gap 0.030”
Run Time @ 50%
Load
Engine Type
Electrical Plugs
Note: Additional specications 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.
87+ octane 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
Dula NEMA
120V~receptacle
One NEMA 120/240V
4 prong twist lock
receptacle
One T-Type 12V outlet
shown on the cover of this manual 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.
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.
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 the number
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.
REV 09a; 09f
Page 8For technical questions, please call 1-800-444-3353.SKU 65414
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.
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.
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 xed properly.
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
low engine oil WILL permanently
damage the engine. Check the oil
level with the engine stopped and
in a level position.
Remove the dipstick and wipe it off 1.
with a clean rag.
Reinsert the dipstick into the oil ller 2.
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).
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
shutdown 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
bottom edge of the oil ll hole before
each start-up.
CAUTION! DO NOT run the engine with
low oil or no oil; the engine will be
permanently damaged.
Checking and Filling Fuel
Visually check the fuel level. A fuel 1.
level from about 1 inch under the ll
neck or higher is full.
WARNING! TO PREVENT
SERIOUS INJURY FROM
FIRE:
Fill the fuel tank in a well-venti-
lated area away from ignition sources. Do not smoke.
To ll the Fuel Tank, rst wipe off the 2.
Fuel Tank Cap and the surrounding
area.
REV 09a
Page 9For technical questions, please call 1-800-444-3353.SKU 65414
Unscrew, and remove the Fuel Tank 3.
Cap.
Mix fuel stabilizer (not included) with 4.
87 octane (or better) unleaded gasoline according to fuel stabilizer directions.
Fill the Fuel Tank to about 1 inch un-5.
der the ll neck of the gasoline tank
with the stabilized unleaded gasoline
mixture.
Then replace the Fuel Tank Cap.6.
Start Procedure
stroke. Once again while holding
the handle, allow the rope to rewind
slowly. Repeat as necessary, until
the engine starts.
After the engine starts and warms 6.
up, slowly move the choke lever to its
“RUN” position.
IMPORTANT: Allow the engine to run 7.
at no load until warm (1-5 minutes)
with no load after each start-up to allow the engine to stabilize.
Move the AC circuit breaker switch to 8.
its ON or RUN position.
Before starting the engine:
Inspect the equipment and a.
engine.
Fill the engine with the prop-b.
er amount and type of fuel
and oil.
Read the Equipment Opera-c.
tion section that follows.
Unplug loads from the Generator 1.
and make sure the AC circuit breaker
switch is in the OFF position before
starting to prevent permanent generator damage.
Turn the engine fuel valve to its ON 2.
or OPEN position.
Turn the engine power switch to its 3.
ON or RUN position.
Then, turn the engine choke lever to 4.
its “CHOKE” position. Set the choke
lever in the “RUN” position when
starting a warm engine.
Break-in Period
Breaking-in the engine will help to 1.
ensure proper equipment and engine
operation, and will extend the engine’s lifespan. The warranty is void
if the engine is not broken in properly.
The rst 20 hours of operation is the
break-in period.
During the rst 3 hours of use:2.
Do not apply a heavy load to the •
equipment.
Do not operate the engine at its •
maximum speed.
After the rst 20 hours of use:3.
Change the engine oil.•
Under normal operating conditions
subsequent maintenance follows the
schedule explained in the MAINTENANCE AND SERVICING section.
Grasp the starter handle, and pull 5.
slowly until resistance is felt. While
holding the handle, allow the starter
rope to rewind slowly. Then, pull the
starter handle with a rapid, full arm
Page 10For technical questions, please call 1-800-444-3353.SKU 65414
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