M792220G.7 Item Number: 792220 Serial Number: _____________ Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up connection to a building’s power supply (via a professionally installed UL-listed transfer switch).
Hazard Signal Word Definitions 2
Table of Contents Hazard Signal Word Definitions ................................................................................................... 2 About Your Generator ................................................................................................................... 4 Specifications ................................................................................................................................... 6 Safety Label Locations ..................................................
About Your Generator Thank you for purchasing your Powerhorse portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to its rated amount of electrical power. (See specifications section of this manual for model specific ratings) It can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. 2. As a back-up, standby power source for a building.
About Your Generator Before using, the user shall determine the suitability of this product for its intended use and assumes liability therein. Contact Powerhorse Product Support at 1-866-443-2576 for any questions about the appropriate use of this generator. Warranty Registration Please fill in the warranty registration information in the back of this manual and have it on hand when you call in on a warranty claim or replacement parts.
Specifications Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Size Engine Speed Fuel Type Fuel Capacity Oil Type Oil Capacity Noise Level Starting Method Dimensions Length Width Height Dry Weight #792220 3500 Watts (W) 3000 Watts AC (W) 96Watts DC (W) 120 Volt AC (V) 12 Volt DC (V) Single phase 60 Hertz (Hz) 1.0 p.f. 212cc 2600 – 3600 RPM (with ESC button OFF) Non-leaded automobile gasoline 2.6 US gallons (10L) 10W-30 (API Service SE type or higher) 0.
Safety Label Locations Ref. No. 1 2 3 4 5 6 7 8 9 N/A N/A N/A Part # Description 790858 Overfill & Spark Decal 790855 Exhaust Decal 793583 Name Plate 793584 EPA Decal 790908 Oil Fill Decal 790852 Burn Hazard Decal 790853 CPSC Decal 790856 Improper Connection Decal 794515 Wheel Latch/Lock 790933 Small Powerhorse Decal (recoil side) 790859 Large Powerhorse Decal 796449 Powerhorse Decal (front) Qty 1 1 1 1 1 1 1 1 1 1 1 1 Always make sure safety labels are in place and in good condition.
Safety Label Locations 1 2 3 4 5 6 7 8 9 8
Machine Component Identification Ref. 1 2 3 4 5 6 7 8 Description Fuel Tank Cap Handles Control Panel Inverter Location Battery Location Brake Recoil Starter Grip Muffler Ref.
Machine Component Identification REFERENCE GUIDE Reference 1 – Fuel Tank Cap Reference 2 – Handles Reference 3 – Control Panel Reference 4 – Inverter Location Reference 5 – Battery Location Reference 6 – Brake Reference 7 – Recoil Starter Grip Reference 8 – Muffler Reference 9 – Oil Drain Bolt Reference 10 – Oil Filler Cap Reference 11 – Air Cleaner Reference 12 – Carburetor Reference 13 – Spark Plug Reference 14 – Left Side Cover Reference 15 – Oil Fill Cover with Screw The fuel tank cap seals the fuel i
Machine Component Identification (1) (2) (3) (4) (5) (7) Ref. 1 2 3 4 5 6 (8) Description Ref.
Machine Component Identification ESC Throttle/ Engine Control Switch A switch used to reduce fuel consumption and noise. 1. “ON” position. When the ESC switch is “ON”, the economy control unit controls the engine speed according to the connected load. 2. “OFF” position. When the ESC switch is turned to “OFF”, the engine runs at the rated (3100 RPM) regardless if a load is connected or not.
Machine Component Identification Electric Start Switch Switch used to start the generator without pulling on the recoil starter grip. Press the electric start switch no more than 3 seconds to start the generator. Parallel Operation Outlets Note: Make sure the intervals between pressing the switch is longer than 10 seconds. The engine electric start motor requires 10 seconds to cool between uses. Outlets for connecting a special cable for parallel running of two generators.
Machine Component Identification Liquid Crystal Display (LCD) Screen The main section of the LCD screen 2 shows the operating status of the generator. Pushing the Operation key 3 will toggle through the status of (V) volts, (A) amps, (VA) volt amps/watts and (Hour) current run time and accumulated run time. In addition, the following symbols will display across the top of the LCD screen when a failure occurs or maintenance time is indicated.
Machine Component Identification Low Oil Warning Light Overload Indicator Light (Red) Output Indicator Light (Green) When the oil level falls below the lower level, the oil warning light 1 comes on and the engine stops automatically. The engine will not start again until oil has been added. Note: If the engine stalls or does not start, turn the engine switch to “ON” and then pull the recoil starter. If the oil warning light flickers for a few seconds, the engine oil is insufficient. Add oil and restart.
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously.
Power Load Planning & Management Device Clothes Dryer (electric) Clothes Dryer (gas) Clothes Washer Coffee Maker Deep Freezer Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles Electric Fry Pan Electric Range: 8in.
Power Load Planning & Management (b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to determine maximum wattage To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps: 1. Make a list of all electrical devices you will be powering at the same time with the generator. 2.
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: 1. 2. 3. 4. 5. Steps for Installation / Initial Set-Up Unpacking & delivery inspection. Planning the power load to stay within the generator’s rated capacity. Setting up generator for the type of power generation you need: a. portable power source, or b. connected to a building as a back-up power source. Selecting a site for using the generator. Grounding.
Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to its rated amount of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch.
Installation / Initial Set-Up normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated line could be electrocuted. If your generator is connected (running or not) when utility power is restored, your generator will be destroyed. It could also explode or cause fire.
Installation / Initial Set-Up WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices. 5. All extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise damaged. WARNING: Use of damaged electric cords can cause electric shock or fire. Note: If an extension cord becomes hot to the touch, it is overloaded or damaged and must be replaced.
Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet all of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. Choose a site that meets all of the criteria specified.
Installation / Initial Set-Up Adequate cooling ventilation The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. No wet conditions Hot exhaust clearance • Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.
Installation / Initial Set-Up 5. Grounding the Generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a 3/4" or 1" copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth – the depth required will be dictated by local soil conditions. Consult with an electrician.
Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. 1. 2. 3. 4. 5. 6. 7. 8.
Operation • Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o o o o o o o o o Excessive change in engine speed, slow or fast Overheating in load connecting devices Sparking or arcs from generator Loss of electrical output Receptacle damage Engine misfire Excessive vibration Flame or smoke Abnormal noise • Adjusting / repairing.
Operation Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
Operation 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from air intakes.
Operation 4) Fill with the recommended amount and type of engine oil (See Specification section). Check oil level then install and tighten the oil filler cap 4 . Max oil level Min oil level 5) Install the oil fill cover 2 and tighten the screw 1. (See specification section for oil type and capacity.) WARNING: Burn hazard Never open oil port while engine is running. Hot oil can spray over face and body. ˙ Notes: o Low oil shutdown feature prevents the generator from starting without sufficient oil.
Operation Use extreme care when handling gasoline.
Operation avoiding static electric sparking. - Do NOT overfill the gasoline tank. WARNING: Static electric spark hazard A static electric spark can explosively ignite gasoline vapor, resulting in a flash fire that could cause serious injury or death.
Operation Personal Protection Battery Connection Inspect the entire fuel system. Look for: • signs of leaks or deterioration, • chafed or spongy fuel hose, • loose connections, • loose or missing fuel hose clamps, • a damaged gasoline tank, or • a defective gasoline shut-off valve. 1) Hearing can be damaged from prolonged, close-range exposure to the type of noise produced by this generator.
Operation 3. Starting the Generator After you have completed the pre-start checklist procedures, you are ready to start the generator. To start the engine: 1) Turn the ESC throttle switch 1 to “OFF”. 2) Turn the Engine OFF/ON/CHOKE control 2 to: A. CHOKE (cold engine) a. Ignition circuit is switched on. b. Fuel is switched on. c. Choke is switched on. B. ON (warm engine) a. Ignition circuit is switched on. b. Fuel is switched on. c. Choke is switched off.
Operation 4) Recoil Start - Pull slowly on the recoil starter until it is engaged, then pull it briskly. NOTE: Grasp the generator handle firmly to prevent the generator from falling over when pulling the recoil starter. 5) After a cold engine is started, allow time to warm up so when the knob is turned to the ON position 3 the generator will stay running. 6) Under long, continuous-run operating conditions, be prepared to: a. Check and refuel the engine on a regular basis.
Operation 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. Output voltage should be checked with a portable voltage meter: 1. Start engine and allow to warm up for five minutes. Do not connect any loads. 2.
Operation 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING: Do not overload generator. Make sure that combined starting and running loads do not exceed rated capacity of generator.
Operation 3. Turn the Engine OFF/ON/CHOKE control to “OFF” 2. a) Ignition circuit is switched off. b) Fuel is switch off. 7. AC Parallel Operation AC parallel operation allows the connection between two generators to increase available power. Before connecting an appliance to the 50A receptacle on the parallel kit, you must: o o o o o Make sure that the appliance is in good working order. Verify the appliance electrical rating does not exceed that of the receptacle.
Operation Connect Parallel Cables 1. Secure the parallel kit to the 3kw generator handles as shown below. 2. Connect the red parallel operation cable to the parallel operation outlets designated with the red O-ring on each of the generators. 3. Connect the black parallel operation cable to the remaining parallel operation outlets on each of the generators. 4. Connect the green/yellow parallel operation cable to the grounding post on each of the generators.
Operation 8. Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Allow generator to completely cool down o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below.
Operation Prepare engine for 1 to 2 month storage Prepare engine for 2 months to 1 year storage Prepare engine for 1 year or more storage Add fuel stabilizer: 1. Ensure gasoline tank is full. 2. Add fuel stabilizer to fuel tank. 3. Run engine at least 10 minutes after adding stabilizer to allow it to enter the fuel system. 4. Shut off engine. 5. Disconnect spark plug wire and remove spark plug. 6. Add one teaspoon oil through spark plug hole. 7.
Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using. Note: The generator head is brushless and maintenance free.
Maintenance & Repair (cont’d) d) Remove the oil filler cap 4. Inspect the O-ring 5. e) Place an oil pan under the engine. Remove the oil drain bolt 6 and inspect the oil filler cap packing 7. Tilt the generator to drain the oil completely. f) Reinstall the oil drain bolt 6. g) Reinstall the end cap to bottom of the generator. h) Place generator on a level surface.
Maintenance & Repair (cont’d) Air filter check/replacement a) Place the generator on a level surface. b) Remove the screws 1, and then remove the side cover 2. c) Remove the air filter cover and foam element 3. d) Wash the foam element in a solution of household detergent and warm water, rinse thoroughly and let air dry. e) Soak the foam element in oil and squeeze out excess oil.
Maintenance & Repair (cont’d) foam element should be wet but not dripping. Note: DO NOT twist or wring out the foam element when squeezing, this could cause it to tear. f) Install the foam element. g) Install the air filter case cover in its original position and tighten the screw. h) Install the side over and tighten the screws. Spark plug cleaning and replacement a) Remove the cover screws 1 and take off the left side cover 2. b) Remove spark plug cap 3.
Maintenance & Repair (cont’d) e) Install the spark plug. Torque specification is 14.8 ft. lbs. If a torque wrench is not available, a good estimate of the correct torque is 1/4-1/2 turn past finger tight. f) Install the spark plug cap and left side cover and screws. Fuel tank filter check/replacement a) Remove the fuel tank cap and filter. b) Clean the filter with gasoline. c) Wipe the filter and install it. d) Install the fuel tank cap.
Maintenance & Repair (cont’d) Check receptacles Inspect fuel system / check for leaks Clean & inspect spark arrester Check receptacles before each use to make sure they are not cracked or broken. If a receptacle is cracked or otherwise damaged, do not use until replaced with an authorized factory part. Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment. Inspect the fuel system and check for leaks on a regular basis.
Maintenance & Repair (cont’d) Keep generator clean High Altitude Operation 4. Reinstall the spark arrester, muffler screen and sparker arrester bracket. 5. Secure the spark arrester bracket with securing bolts. 6. Install the end cover and tighten the screws. Keep generator clean. If dust or debris accumulates on the generator, clean the generator with a damp cloth or soft bristle brush. Do not allow air intakes to become blocked. Note: Do not spray generator with a garden hose or pressure washer.
Troubleshooting Problem Possible Causes Possible Remedies Engine will not start. a) b) c) d) e) f) a) a) b) c) d) e) f) a) Voltage too low. Low oil level. Fouled spark plug. Out of fuel. Switch in OFF position. Clogged fuel filter. Bad fuel. Defective invertor board. Fill crankcase to proper oil level. Clean or replace spark plug. Fill fuel tank. Place switch in Run or Choke position. Clean fuel filter. Drain tank and carburetor. Refuel. Bring generator to a qualified technician for inspection.
Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator.
Summary of Important Safety Information for Operation Installation / Initial Set-up Safety • Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. • Operate OUTSIDE only – dangerous carbon monoxide exhaust! Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from building air intakes.
Summary of Important Safety Information for Operation • Fuel outdoors. Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. • Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel. Use an UL listed fuel container to transfer gas to the engine. • Running / hot engine. A running engine is hot enough to ignite fuel.
Summary of Important Safety Information for Operation • Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never remove any drive belt or fan guard while the unit is operating. • Refueling. DO NOT refuel the engine until it has cooled at least two minutes. • Malfunction during operation.
Generator Exploded View - Rev G.
Generator Exploded View - Rev G.
Generator Exploded View - Rev G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Generator Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Engine Kit Exploded View Rev – G.
Limited Warranty Dear Valued Customer: The Powerhorse Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a Powerhorse product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
WARNING: This product can expose you to chemicals including gasoline engine exhaust, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. Distributed by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.
