Harbor Freight Tools 68526 User Manual
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.
6500 WAT T
PORTABLE
GENERATOR
5500 RATED WATTS
6500 MAX WATTS
• 420ccAirCooledOHVGasEngine
• 12HourRunTimeat50%Capacity
• LowOilIndicator/LowOilShutdown
• HeavyDuty1-1/4"SteelRollCage
• ULListedCircuitBreaker
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.
Only use OUTSIDE
and far away from
windows, doors,
and vents.
ITEM 68526 / 68529
Visit our website at: http://www.harborfreight.com
Email our technical support at: tech@harborfreight.com
Email our Engine support at: predator@harborfreight.com
When unpacking, make sure that the product is intact and undamaged.
If any generator parts are missing or broken, please call 1-800-444-
3353 as soon as possible. If any engine parts are missing or broken,
please call 1-800-520-0882 as soon as possible.
Copyright© 2011 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
Safety ......................................................... 2
Setup .......................................................... 6
Specications ............................................. 6
SAFETY OPERATION MAINTENANCESETUP
Operation .................................................... 9
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Maintenance .............................................. 15
Parts List and Diagram .............................. 20
Warranty .................................................... 23
WARNING SYMBOLS AND DEFINITIONS
Obey all safety messages that follow this symbol to avoid possible injury or death.
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.
IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS PERTAINING TO A RISK OF FIRE,
ELECTRIC SHOCK, OR INJURY TO PERSONS
WARNING – When using tools, basic precautions should always be followed, including the following:
Set up Precautions
1. Gasoline fuel and fumes are ammable, and
potentially explosive. Use proper fuel storage
and handling procedures. Do not store fuel
or other ammable materials nearby.
2. Have multiple ABC class re extinguishers nearby.
3. 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.
4. Set up and use only on a at, level,
well-ventilated surface.
5. All connections and conduits from the Generator
to the load must only be installed by trained and
licensed electricians, and in compliance with all
relevant local, state, and federal electrical codes and
standards, and other regulations where applicable.
6. 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.
7. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during set up.
8. Use only lubricants and fuel
recommended in this manual.
Page 2
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Set up Precautions (cont.)
9. 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 and a qualied electrician
if intending to use the generator for back up power.
Operating Precautions
1. CARBON MONOXIDE HAZARD
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.
10. Do not operate the Generator before grounding.
The Generator must be earth-grounded
in accordance with all relevant electrical
codes and standards before operation.
SAFETYOPERATIONMAINTENANCE SETUP
7. Fire Hazard! Do not ll 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 ame.
8. Do not touch engine during use. Let
engine cool down after use.
9. Never store fuel or other ammable
materials near the engine.
10. 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.
Only use OUTSIDE and far away from windows,
doors, and vents.
2. Never use a generator indoors, including in
garages, basements, crawlspaces and sheds.
Opening doors and windows or using fans will NOT
prevent carbon monoxide build up in the home.
3. When using generators, keep them outdoors
and far away from open doors, windows,
and vents to avoid toxic levels of carbon
monoxide from building up indoors.
4. If you start to feel sick, dizzy, or weak while
using a generator, get to fresh air right away.
The carbon monoxide from generators can
quickly lead to full incapacitation and death.
5. Keep children away from the equipment,
especially while it is operating.
6. Keep all spectators at least six feet
from the Engine during operation.
11. 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.
12. Do not exceed the maximum power rating of the
generator. Make sure that the total electrical rating
of the all of the tools or appliances plugged into
the generator at the same time does not exceed
that of the generator. Check that the startup surge
will not be beyond the limit of the Generator.
Power levels between rated and maximum
may be used for no more than 30 minutes.
13. Avoid substantially overloading which will trip 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.
14. Do not attempt to connect or disconnect
load connections while standing in
water, or on wet or soggy ground.
15. Do not touch electrically energized parts of
the Generator and interconnecting cables or
conductors with any part of the body, or with
any non-insulated conductive object.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 3
Operating Precautions (cont.)
16. Connect the Generator only to a load or
electrical system (120 volt or 240 volt) that is
compatible with the electrical characteristics
SAFETY OPERATION MAINTENANCESETUP
and rated capacities of the Generator.
17. Insulate all connections and disconnected wires.
18. Guard against electric shock. Prevent body
contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerators.
19. Only use a suitable means of transport and
lifting devices with sufcient weight bearing
capacity when transporting the generator.
20. Secure the Generator on transport vehicles to
prevent the tool from rolling, slipping, and tilting.
21. Industrial applications must follow
OSHA requirements.
22. Do not leave the Generator unattended when it is
running. Turn off the Generator (and remove safety
keys, if available) before leaving the work area.
23. The Generator 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.
24. Wear ANSI-approved safety glasses,
hearing protection, and NIOSH-approved
dust mask/respirator during use.
29. 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 inuence
of drugs, alcohol or medication.
30. 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.
31. Parts, especially exhaust system components,
get very hot during use. Stay clear of hot parts.
32. Do not cover the generator or its
engine during operation.
33. Keep the generator, its engine, and
surrounding area clean at all times.
34. Use the generator, 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.
35. Do not operate the generator with known
leaks in the engine’s fuel system.
36. 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.)
25. People with pacemakers should 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.
26. 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.
27. Do not operate in explosive atmospheres,
such as in the presence of ammable
liquids, gases, or dust. Gasoline-powered
engines may ignite the dust or fumes.
28. Keep grounded conductive objects, such as
tools, away from exposed, live electrical parts
and connections to avoid sparking or arcing.
These events could ignite fumes or vapors.
37. When spills of fuel or oil occur, they 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.
38. Keep hands and feet away from moving parts. Do
not reach over or across generator while operating.
39. Before use, check for misalignment or binding
of moving parts, breakage of parts, and any
other condition that may affect the generator’s
operation. If damaged, have the generator
serviced before using. Many accidents are
caused by poorly maintained equipment.
40. Use the correct generator for the application. Do not
modify the generator or its engine, and do not use the
generator for a purpose for which it is not intended.
Page 4
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Service Precautions
1. Before service, maintenance, or cleaning:
a. Unplug all devices from the generator.
b. Turn the engine switch to its “OFF” position.
c. Allow the engine to completely cool.
d. 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
mufer, air cleaner, mechanical guards,
and heat shields, among other guards.
3. Make sure the Engine Switch is in its “OFF”
position before moving the Generator and
before performing any service, maintenance,
or cleaning procedures on the unit.
4. Keep all electrical equipment clean and dry.
Replace any wiring where the insulation is
cracked, cut, abraded, or otherwise degraded.
Replace terminals that are worn, discolored, or
corroded. Keep terminals clean and tight.
5. Do not alter or adjust any part of the
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.
6. Wear ANSI-approved safety goggles, heavy-duty
work gloves, and dust mask/respirator during service.
7. Maintain labels and nameplates on the
equipment. These carry important information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
8. Have the equipment serviced by a 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.
9. Store equipment out of the reach of children.
10. Follow scheduled engine and
equipment maintenance.
Refueling:
1. Do not smoke, or allow sparks, ames,
or other sources of ignition around the
equipment, especially when refuelling.
2. Do not rell the fuel tank while the
engine is running or hot.
3. TO PREVENT FUEL LEAKAGE AND FIRE
HAZARD, Do not overll with fuel. Fill with
fuel according to the Fuel Level information
below the Specication chart for your model.
4. Do not ll fuel tank to the top. Leave a little
room for the fuel to expand as needed.
5. Refuel in a well-ventilated area only.
6. 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.
SAVE THESE
SAFETYOPERATIONMAINTENANCE SETUP
Item 68526 / 68529
INSTRUCTIONS.
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 5
Functional Description
Specications
SAFETY OPERATION MAINTENANCESETUP
Rated Output
Generator
Electrical Receptacle
Displacement 420cc
Engine Type Horizontal Single Cylinder 4 stroke OHV
Cooling System Forced air cooled
Fuel
Engine
Engine Oil
Run Time @ 50% load 12 hr.
Operational Volume 74 dB
Available accessories Wheel kit (sold separately)
Item 68526 - 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.
Item 68529 - 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.
Type 87+ octane unleaded gasoline
Capacity 6.6 Gallons (25L)
Type SAE
Capacity 1.16 Quart (1.1L)
120/240V~, 60Hz
5,500 Watts (6,500 max)
Two 3-Prong, duplex NEMA #5-15 120V
One 4-Prong, NEMA #L14-30 twistlock 120V/240V
One DC Outlet 12VDC
10W-30 above 32° F
5W-30 at 32° F or below
Components and Controls
Fuel Cap
Fuel Valve
Choke
Air Filter
Frame
Starter
Handle
DC Receptacle
DC Circuit Breaker
AC Circuit Breakers
AC Receptacles
Ground Terminal
Power Switch
Low Oil Indicator
Page 6
Wheel Kit sold separately
(Item 68531)
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
Components and Controls (cont.)
The following are descriptions of the controls
on the power panel. Your generator has
sockets to power your products with circuit
breakers to protect the voltage ow.
I
O
1.
Engine Switch: Used to start and stop the Engine.
2. AC Receptacles: The Generator contains several
AC receptacles to power tools and equipment.
a.
3-Prong, duplex
120 volt receptacle
(NEMA #5-15)
ON
OFF
Circuit Breakers: The circuit breaker protects the
3.
Generator from overloading. The rating of the breaker
and the load it protects are marked near the breaker.
Should any of the Circuit Breakers trip, the Generator
will stop the electricity output. If this happens, unplug
all loads from the Generator. Allow the Generator to
cool down. Then, press the tripped Circuit Breaker,
restart the Engine, and re-attach loads.
DC Receptacle: 12 VDC Receptacle set provides a
4.
power source for 12 volt DC items.
5.
Grounding Terminal: Prior to each use, set
up the ground wire (not included) connection
to the Grounding Terminal to properly ground
the Generator. See Set up instructions
to properly ground the Generator.
SAFETYOPERATIONMAINTENANCE SETUP
4-Prong, twistlock,
120/240 volt receptacle
(NEMA #L14-30)
WARNING! Connect tools and equipment
only to the Receptacle (120 volt or 240 volt)
that is compatible with the electrical
characteristics and rated capacities of the
tools and equipment being used.
Item 68526 / 68529
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Page 7
Initial Tool Set Up/Assembly
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 OPERATION MAINTENANCESETUP
Note: For additional information regarding the parts listed in the following pages,
refer to the Assembly Diagram near the end of this manual.
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.
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 includes,
but is not limited to, audio/video equipment, some television sets, computers, and printers. Sensitive
electronic equipment should be operated on approved inverter type generators or pure sine wave generators.
Note: Wheel Kit, item # 68531 (sold separately) can be used with this generator.
Grounding
The Generator must be properly grounded before
use. Have the unit grounded by a qualied
electrician if you are not qualied to do so.
To ground the Generator, connect a #6 AWG
grounding wire (not included) from the Grounding
High Altitude Operation
The fuel system on this generator may be inuenced
by operation at higher altitudes. Proper operation
can be ensured by installing an altitude kit when
required. See the table at right to determine when
an altitude kit is required. Operating this generator
without the proper altitude kit installed may increase
the engine’s emissions and decrease fuel economy
and performance. Kits should be installed by a
qualied mechanic. The kits may be requested
from Customer service. See parts list for details.
Terminal on the Control Panel to a grounding rod
(not included) that has been driven at least 24
inches deep into the earth. The grounding rod must
be an earth-driven copper or brass rod (electrode)
which can adequately ground the Generator.
Altitude Range* Kit Part Number
Up to 3000 ft No modication needed
3000-6000 ft #174
6000-8000 ft** #175
* Elevation above sea level
** At elevations above 8000 ft, the engine
may experience decreased performance
Page 8
For Pump technical questions, please call 1-800-444-3353.
For Engine technical questions, please call 1-800-520-0882.
Item 68526 / 68529
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