CHICAGO 66604 Set Up, Operating, And Servicing Instructions

Portable generator 6500 rated watts/7000 maximum watts

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6500 RATED wATTs/7000 MAXIMUM wATTs

poRTAblE GENERAToR

sET Up, opERATING, AND sERvIcING INsTRUcTIoNs

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.

2007 by Harbor Freight Tools

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

66604

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.

DANGER

only use oUTsIDE and

far away from windows,

doors, and vents.

Table of Contents

Summary of Contents for CHICAGO 66604

Page 1 6500 RATED wATTs/7000 MAXIMUM wATTs poRTAblE GENERAToR 66604 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...
Page 2: Specifications
Keep this manual and invoice in a safe and dry place for future reference. REV 09l SKU 66604 For technical questions, please call 1-800-444-3353. Page 2...
Page 3: General Safety Rules
Do not force the tool and do not use the tool for a purpose for which it is not intended. SKU 66604 For technical questions, please call 1-800-444-3353.
Page 4 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. SKU 66604 For technical questions, please call 1-800-444-3353. Page 4...
Page 5: Specific Safety Rules
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. SKU 66604 For technical questions, please call 1-800-444-3353. Page 5...
Page 6 Do not refill the Fuel Tank while the Engine is running or hot. Do not operate the Generator with known leaks in the Engine’s fuel system. Use only oil and fuel recommended in the “Product Specifications” section of this manual. SKU 66604 For technical questions, please call 1-800-444-3353. Page 6...
Page 7: Mechanical Precautions
The Generator must be earth-grounded in accordance with all relevant electrical codes and standards before operation. SKU 66604 For technical questions, please call 1-800-444-3353. Page 7...
Page 8 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. SKU 66604 For technical questions, please call 1-800-444-3353. Page 8...
Page 9: Control Panel Features
(8, 10, 10b): The Generator features three Outlet Sockets with which to power tools and equipment. The type and voltage of the Outlet Sockets are as follows: REV 09l SKU 66604 For technical questions, please call 1-800-444-3353. Page 9...
Page 10: Battery Installation
Control Panel of the Generator. (see Figure b.) Slide the Battery into the Battery Guard Plate (44) with the Battery’s terminals facing outward and with the Battery’s negative (--) terminal facing left. (see Figure b.) REV 09l SKU 66604 For technical questions, please call 1-800-444-3353. Page 10...
Page 11: Installation Instructions
Locate the Generator (outdoors only) where cooling air is readily available. Locate the Generator so that the air inlets and outlets are not blocked by obstructions such as bushes, trees, walls, snow drifts, etc. Locating the Generator in the path SKU 66604 For technical questions, please call 1-800-444-3353. Page 11...
Page 12: Pre-Start Instructions
The Engine MUST be filled with a high quality engine oil. If the Engine will be run in temperatures above 32 degrees Fahrenheit, use sAE 30 weight oil. If the Engine will be run in temperatures below 32 degrees Fahrenheit, use sAE 5w-30 weight oil. SKU 66604 For technical questions, please call 1-800-444-3353. Page 12...
Page 13 Periodically, check the Fuel Filter (32) for excessive dirt and debris. If necessary, remove the Fuel Filter and clean with compressed air. (see Figure E.) FUEl vAlvE (41) choKE lEvER (21A) FIGURE F SKU 66604 For technical questions, please call 1-800-444-3353. Page 13...
Page 14: This Unit Can Power The Following Items
When the Engine starts, slowly move the Choke Lever (21A) to its “RUN” position. (see Figure F.) IMpoRTANT: Allow the Generator to run at no load for five minutes after each start-up so that the Engine and Generator can stabilize. SKU 66604 For technical questions, please call 1-800-444-3353. Page 14...
Page 15: To Connect Electrical Loads
240 VAC Outlet Socket (10B). (see Figure A.) NoTE: If Engine speed or voltage fluctuates with a load below 250 watts, move the En- gine Choke Lever (21A) to the “HALF-CHOKE” position. (see Figure F.) REV 09l SKU 66604 For technical questions, please call 1-800-444-3353. Page 15...
Page 16: Inspection, Maintenance, And Cleaning
(59A) To change the oil, remove the Plug (59A) and allow the old oil to drain in a proper container. Once drained, replace the Plug. (see Figure G.) REV 10e SKU 66604 For technical questions, please call 1-800-444-3353. Page 16...
Page 17 (see Figure h.) Clean more often under dusty conditions or when airborne debris is present. Replace Air Cleaner parts if necessary. (see Figure h.) 0.028” - 0.031” spARK plUG (28A) FIGURE I SKU 66604 For technical questions, please call 1-800-444-3353. Page 17...
Page 18: Please Read The Following
HE OR SHE IS qUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS qUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR SKU 66604 For technical questions, please call 1-800-444-3353. Page 18...
Page 19: Troubleshooting
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. TRoUblEshooTING SKU 66604 For technical questions, please call 1-800-444-3353. Page 19...
Page 20 Fuel Filter Seal Ring Fuel Tank Cap Lock Washer Bolt (M6x30) NoTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 66604 For technical questions, please call 1-800-444-3353. Page 20...
Page 21 AssEMblY DIAGRAM - GENERAToR REV 09l SKU 66604 For technical questions, please call 1-800-444-3353. Page 21...
Page 22: Parts List - Engine
Anti-Wear Valve Stem Protector Locating Pin Cylinder Head Cover Packing Oil Seal Governor Spring Connecting Rod Bolt Bolt Connecting Rod Cap High Tension Line Connecting Rod Ignition Coil Piston Nut (Special 14mm) SKU 66604 For technical questions, please call 1-800-444-3353. Page 22...
Page 23 NoTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Record product’s serial Number here: Note: If product has no serial number, record month and year of purchase instead. SKU 66604 For technical questions, please call 1-800-444-3353. Page 23...
Page 24: Assembly Diagram -Engine
AssEMblY DIAGRAM -ENGINE SKU 66604 For technical questions, please call 1-800-444-3353. Page 24...
Page 25: Wiring Diagram
DIAGRAM SKU 66604 For technical questions, please call 1-800-444-3353. Page 25...
Page 26: Emission Control System Warranty
Manufacturer’s warranty coverage The 1997 and later engines are warranted for two (2) years. If any emission-related part on your engine is defective, the part will be repaired or replaced by HFT. SKU 66604 For technical questions, please call 1-800-444-3353. Page 26...
Page 27 Any replacement part, provided it is equivalent in durability and performance, may be used in performance of maintenance or repairs. The owner is responsible for commissioning a qualified technician/mechanic to perform all required maintenance, as outlined in the Inspection, Cleaning, and Maintenance section in this manual. SKU 66604 For technical questions, please call 1-800-444-3353. Page 27...
Page 28 (if so equipped) Exhaust pipe stud. Muffler. Catalytic converter (if so equipped). iii) Miscellaneous Items Used in Above systems Vacuum, temperature and time sensitive valves and switches. Hoses, belts, connectors, and assemblies. SKU 66604 For technical questions, please call 1-800-444-3353. Page 28...