Powerhorse M166112G Owners Manual

WARNING

READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up,

operate, and maintain this generator could result in serious injury or death from carbon monoxide poisoning, electric shock, fire/explosion, or burns. In particular, be aware of the following hazards:

CO Poisoning

Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.  ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or

semi-enclosed spaces, including homes, basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.

 Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).

Electric shock / Electrocution

 High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly

grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.

 NEVER plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST

ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.

Fire / Explosion

 DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so

engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7 feet from all combustible objects.

 All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use

approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.

 ALWAYS keep a fire extinguisher rated “ABC” nearby.

STOP!

CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power load Planning & Management” section

of this manual to determine your power load requirements and then compare to the generator’s rated capacity.

INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking

& Delivery Inspection” section for instructions on whom to contact to report missing or damaged parts.

ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to

your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this requirement.

M166112G

ITEM NUMBER: 166112 SERIAL NUMBER:

Owner’s Manual

Instructions for Installation/Set-up, Operation, Servicing, & Storage

Portable, Outdoor Use-Only, Gasoline Generator

166112 - 3100 Watt Continuous (4000 Watt Surge) Capacity

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-approved transfer switch.

Any Questions, Comments, Problems, or Parts Orders

Call Powerhorse Product Support 1-866-443-2576

Hazard Signal Word Definitions

Table of Contents

Hazard Signal Word Definitions ................................................................................................. .2

About Your Generator ................................................................................................................. .4

Specifications ................................................................................................................................. .6

Safety Label Locations .................................................................................................................. .7

Machine Component Identification ............................................................................................. 10

Power Load Planning & Management ....................................................................................... 12

Installation / Initial Set-Up:

1. Unpacking & Delivery Inspection .......................................................................................... 14

2. Planning the Power Load ........................................................................................................ 14

3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ...................................... 15

4. Selecting a Suitable Site ......................................................................................................... 18

5. Grounding the Generator ........................................................................................................ 20

Operation:

1. General Safety Rules for Operation ....................................................................................... 21

2. Preparing for Operation .......................................................................................................... 24

3. Starting the Engine ................................................................................................................. 27

4. Checking Generator Output .................................................................................................... 28

5. Connecting Loads ................................................................................................................... 29

6. Stopping the Engine ............................................................................................................... 29

7. Storage & Exercise ................................................................................................................. 30

Maintenance & Repair .................................................................................................................. 32

Troubleshooting ............................................................................................................................. 34

Summary of Important Safety Information for Operation ....................................................... 35

Engine Operation .......................................................................................................................... 39

Engine Troubleshooting ................................................................................................................ 46

Engine Specifications .................................................................................................................... 47

Engine Electrical Diagram ........................................................................................................... 48

Exploded Views ............................................................................................................................. 49

Wheel Kit Assembly ...................................................................................................................... 55

About Your Generator

WARNING

Improper use or maintenance of this generator can result in serious injury or death from carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.

Read this manual completely before using the generator and follow all instructions and safety rules.

Thank you for purchasing your Powerhorse portable generator!

About Your Generator

This engine-driven, portable generator is designed to provide up to 4000Watts of electrical power (3100 watts continuous, 4000 watts surge).

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. A licensed electrician can connect

the generator to your building’s electrical system via the installation of an UL-approved transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn

more about specific requirements and precautions relating to wiring the generator to your building’s electrical system.)

You must select a generator adequately sized for your power needs. You need to determine the power needs of all the appliances/tools you wish to power at the same time and

choose a generator rated to provide at least that power level. See the “Power Load Planning & Management” section of this manual to determine your specific power load requirements and then compare them to this generator’s rated capacity. You must not overload the generator.

Overloading will cause damage to the generator and attached electrical devices, and may also result in fire.

Be sure to read about site selection and grounding requirements for running this generator. More detailed information can be found in the “Installation & Initial Set-up, Steps

5 & 6” of this manual.

Contact Powerhorse Product Support at 1-866-443-2576 with questions about optional accessories or to order.

Read this Manual

You must follow all instructions and safety precautions presented throughout this manual. A summary of important safety information can be found at the end of the manual. Keep this manual for reference and review.

About Your Generator (cont’d)

ATTENTION:

All Rental Companies and Private Owners who loan this

equipment to others!

All persons to whom you rent/loan this generator must have access to and read this manual.

Keep this owner’s manual with the generator at all times and advise all persons who will

operate the machine to read it. You must also provide personal instruction on how to safely operate the generator and remain available to answer any questions a renter/borrower might have.

Proper preparation, operation, and maintenance will result in operator safety, as well as best performance and long life of the generator. For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator.

Powerhorse is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture.

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 and have it on hand when you call in on a warranty claim or replacement parts.

Specifications

Item Number

#166112

Maximum Output

4000 Watts (W)

Continuous Output

3100 Watts (W)

Voltage

120/240 Volt (V)

Phase

Single phase (4-wire)

Frequency

56.5 - 63.3 Hertz (Hz)

Power Factor

1.0 p.f.

Total Harmonic Distortion

less than 5%

Engine

208cc

Engine Speed

3750 RPM

Fuel Type

Unleaded gasoline

Fuel Capacity

3.9 gallons ( 15 L)

Oil Capacity

.53 US quarts (.5 L)

Starting Method

Recoil

120 V Receptacles

4 - 20 Amp (A) duplex

(NEMA 5-20R)

1 – 30 Amp 120/240V locking

(NEMA L14-30R)

Circuit Breakers

1-8 Amp (A) thermal, push to reset

2-13.5 Amp (A) thermal, push to reset

Dimensions

Length

28” ( cm)

Width

20” ( cm)

Height

23” ( cm)

Dry Weight

140 lb. ( kg)

Safety Label Locations

Part # 782411

Part # 782554

Part # 782635

Part # 782629

Part # 782415 Qty 2

Part # 782631

Part # 782627

Part # 782632

Part # 782931

Part # 782628

Safety Labels Locations

Part # 782633

Part # 782930

Part # 782630 (1 of 2)

Part # 782630 (2 of 2)

Safety Label Locations

Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result.

To order replacement safety labels, call Powerhorse Product Support at 1-866-443-2576.

Machine Component Identification

Ref.

Description

Ref.

Description

Vibration Isolation Mount

Engine Switch

Oil Drain Plug

Circuit Breaker

Recoil

12VDC Supply

Handle

Circuit Breaker

Air Cleaner

Voltmeter

Gas Cap

120V, 20A Duplex Receptacle

3.9 Gallon Gas Tank

120/240V, 30A Locking Receptacle

Generator Head

Grounding Post

Muffler

Fuel Shut Off

Low Oil Warning

Machine Component Identification

REFERENCE GUIDE

Reference 1 – Vibration Isolation Mount

The engine and generator head are mounted on rubber cylinders that absorb most of the engine vibration. This feature eliminates the tendency of the machine to “walk” which is common in enginepowered equipment.

Reference 2 –Oil Drain Plug

Refer to your engine manual for oil change recommendations.

Reference 3 – Recoil

Grasp firmly when starting engine.

Reference 4 – Handle

Pivot to move the generator.

Reference 5 – Air Cleaner

Refer to your engine manual for air cleaner care.

Reference 6 –Gas Cap

The gas cap is extra large, creating a large hole for refilling and a comfortable grip.

Reference 7 - Gas Tank

Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely.

Reference 8 - Generator Head

The electricity producing part of the generator.

Reference 9 - Muffler

This generator is equipped with a quiet style muffler. The muffler is designed to allow moisture (condensation) to drain from the bottom of the canister. Always check for loose fasteners

Reference 10 – Low Oil Warning

Lamp turns on if oil is low.

Reference 11 – Engine Switch

On / Off for power to engine for starting.

Reference 12 - Circuit Breaker

Circuit breakers protect against electrical overloads.

Reference 13 – 12VDC Supply

12 volts for charging battery and operating other 12 volt devices.

Reference 14 – Circuit Breaker

Circuit breakers protect against electrical overloads.

Reference 15 – Voltmeter

Voltmeter needle should be in appropriate voltage range during all generator load conditions.

Reference 16 - 120V, 20A Duplex Receptacle

The generator has a control panel with four duplex (two receptacles in a common housing) receptacles. Each duplex is a 120 volt (V) 20 amp (A) straight blade receptacle, National Electrical Manufacturer’s Association (NEMA) number 5-20R. This receptacle accepts NEMA plug numbers 5-15P and 5-20P.

Reference 17 – 120/240V, 30 A Locking Receptacle

The generator has a control panel with a 120/240 volt (V) 30 amp (A) locking receptacle, National Electrical Manufacturer’s Association (NEMA) number L14-30R.

Reference 18 – Grounding Post

Used to prevent electrical shock.

Reference 19 – Fuel Shut Off

The engine is equipped with an ON-OFF valve located on the left side of the recoil. ALWAYS keep this valve closed when the generator is not in use.

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.

Device

Running

Watts

Device

Running

Watts

Air conditioner (12.000 BTU)

1700 (a,b)

Jet pump

800 (a)

Battery charger (20 Amp)

500

Lawn mower

1200

Belt sander (3”)

1000

Light bulb (100 Watt)

100

Chain saw

1200

Microwave oven

700

Circular saw (6½”)

2000 (a,b)

Milk cooler

1100 (a)

Coffee maker

1800 (a,b)

Oil burner on furnace

300

Compressor (1 HP)

1400 (a,b)

Oil-fired space heater (140,000 Btu)

400

Compressor (3/4 HP)

1800 (a)

Oil-fired space heater (85,000 Btu)

225

Compressor (1/2 HP)

1400 (a)

Oil-fired space heater (30,000 Btu)

150

Curling iron

700

Oven

4500

Dishwasher

1200

Paint sprayer, Airless (1/3 HP)

600 (a)

Edge trimmer

500

Paint sprayer, Airless (handheld)

150

Electric nail gun

1200

Radio

200

Electric range (1 element)

1500

Refrigerator

600 (b)

Electric skillet

1250

Slow cooker

200

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. The sum of the running and starting wattages of the devices being powered must not exceed the continuous output rating of your generator. (The continuous output rating of your generator is listed in the “Specifications” section of this manual.) Note that:

 Devices without electric motors such as light bulbs, radios, and televisions have the same

running and starting wattage.

 Devices with electric motors such as refrigerators, compressors, and hand tools typically

require a starting wattage that is 3 to 5 times greater than the running wattage.

The running and starting wattage requirements are often listed on a device’s nameplate. If wattage

is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate

voltage by nameplate amperage, Watts = Volts X Amps.

Example conversion to watts:

If only the running voltage is given on the nameplate for a device with an electric motor, the starting wattage can be approximated to be three to five times the running wattage.

Estimates for the running wattage requirements for common devices are listed in Table 1 below. Guidance for starting wattages is provided in the table’s footnotes.

Table 1

120 Volts X 5 Amps = 600 Watts

Power Load Planning & Management (cont’d)

Device

Running

Watts

Device

Running

Watts

Furnace fan (1/3 HP)

1200 (a)

Submersible pump (1-1/2 HP)

2800 (a)

Freezer

800 (b)

Submersible pump (1 HP)

2000 (a)

Hair dryer

1200

Submersible pump (1/2 HP)

1500 (a)

Hand drill (1”)

1100

Sump pump

600 (a)

Hand drill (1/2”)

875

Table saw

2000 (a)

Hand drill (3/8”)

500

Television

500

Hand drill (1/4”)

250

Toaster

1000

Hedge trimmer

450

Vacuum cleaner

250

Home computer

150

VCR

Impact wrench

500

Water Heater

3000

Weed trimmer

500

Device to be Powered

Greater of

Starting/Running Wattage

Light Bulb

75 W

Refrigerator – 18 Cu. Ft.

1600 W

Microwave

700 W

Window AC

1800 W

Sump pump (1/3 hp)

2100 W

Total

6275W

STAGGERING LOADS

(a) Hard-starting motors require 3-5 times the rated running watts (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. List the greater of the running or starting wattage next to each device as obtained from the

devices’ nameplate or Table 1. If only the running wattage for a device with an electric motor is known, the starting wattage can be estimated to be at least 3 times the running wattage.

3. Add the wattages for all devices on your list. This total must be lower than the continuous

output rating of your generator.

Example:

In this example, the generator must have a continuous output of at least 6275 W in order to power all of the devices simultaneously.

You can increase the number of devices your generator can power by staggering the load on the generator. For example, you could alternately power your refrigerator and air conditioner for limited periods of time -- powering only one of the devices at a time and never powering both at the same time.

Installation/Initial & Set-Up

Steps for Installation / Initial Set-Up

1. Unpacking & delivery inspection.

2. Planning the power load to stay within the generator’s rated

capacity.

3. 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.

4. Selecting a site for using the generator.

5. Grounding.

6. Battery installation (electric start models only).

1. Unpacking & Delivery Inspection

You should inspect the generator immediately after you receive delivery.

See the “Machine Component Identification” section of this manual for a

diagram of the generator and its components.

 If you have missing components, contact Product Support at 1-866-443-2576.  If you have damaged components, contact the freight company that delivered the unit and file a

claim.

2. Planning the Power Load

Plan your power load so that you do not exceed the generator’s rated capacity.

See the “Power Load Planning & Management” section of this manual to review how to plan and

manage power loads for the generator.

There are a number of important steps required to set up your generator for initial use. These steps are:

Each of these steps is discussed in detail below:

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 4000 watts of electrical power. It can supply electricity in two ways:

1. As a backup, 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. The transfer switch must be installed in accordance with building electrical code and guidelines supplied by your power company.

2. As a portable power source. You can plug appliances or tools directly into the generator’s

electrical outlets.

Specific requirements for each are given below.

Note: Regardless of whether you use your generator as a back-up power source connected to a

building or as a portable power source, you must not overload the generator. Overloading may cause serious damage to the generator and attached electrical devices.

Using as a Back-up Power Source for a Building

Contact a licensed electrician to install a UL-approved transfer switch if

you want to use your generator as a back-up power source for a building. What does a transfer switch do? It:

a) Safely connects the generator to your building’s electrical system by

isolating your generator from your utility company’s power lines,

AND

b) Connects your generator to a critical subset of your building’s circuits

that are needed for emergency power needs.

If your generator will be connected to your building’s electrical system, it MUST ALWAYS be isolated from the utility power grid with a UL-approved transfer switch installed by a licensed electrician in compliance with all applicable building and electrical codes, and in accordance with guidelines supplied by your power company.

DANGER:

A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise:  When your generator is running, it’s output will back feed into

the utility power line and transformer that are normally used to provide you with power. The transformer will step up the current to the 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.

In addition to isolating your generator from the utility system, the transfer switch connects your generator to a limited set of circuits in your building that have been chosen as critical to operate during a power outage.

Installation/Initial Set-Up

The generator cannot power your entire home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator.

(See the previous section of this manual entitled “Power Load Planning &

Management” for more information on load application and selection.)

Using as a Portable Power Source

When using the generator as a portable power source, you can plug electric devices and appliances directly into the generator’s electrical outlets.

There are two different kinds of electrical outlets on the generator:

1. Two 120 Volt, 20 Amp duplex straight-blade receptacles (NEMA 5-

20R duplex receptacles compatible with NEMA 5-20P or 5-15P mating plugs).

2. One 120/240 Volt, 30 Amp Locking receptacle (NEMA L14-30R)

compatible with NEMA L14-30P mating plugs).

(See more technical detail about these receptacles and their associated

circuit breakers in the “Machine Component Identification” section of this

manual.)

 Make sure you plug each electrical device/appliance into the correct

generator outlet based on the device’s plug configuration and

voltage/amperage rating. Never exceed the amperage rating of an outlet.

5-20R

L14-30R

Installation/Initial Set-Up

 Extension cords may be used to power devices that are located at a

distance from the generator. However, use only UL-listed, outdoor-rated, grounded extension cords of the proper size. Use Table 2 below to choose an adequately sized extension cord according to the amperage of the device being used and the length of the cord.

Table 2

Current/Power

Maximum Extension Cord Length

Amps at

240V

Load

(watts)

#10 Ga.

Cord

#12 Ga.

Cord

#14 Ga.

Cord

#16 Ga.

Cord

2400

250’

150’

100’

75’

4800

125’

75’

50’

25’

7200

60’

35’

25’

10’

9600

30’

15’

10’ * 50

12000

15’ * *

WARNING:

Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.

 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.

Northern Tool is NOT responsible for damage or injury resulting from customer use of inadequate extension cords.

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.

Dry, level surface

The generator should be positioned on a dry, firm, level surface.

Ensure that the generator sits level and will not slide or shift during operation. If applicable, block the generator’s wheels to prevent sliding and shifting.

Outdoors only – dangerous carbon monoxide exhaust

WARNING: Carbon monoxide poisoning hazard

The exhaust from your generator contains carbon monoxide (CO), a poisonous gas that can kill. You cannot smell it, see it, or taste it.

Carbon monoxide exhaust is given off whether you are using gasoline, natural gas, or propane as the fuel source to power the generator.

Follow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning.

The location you choose to operate the generator must be OUTDOORS and away from all air intakes:

 Never run the generator inside any closed or semi-enclosed spaces (even if

outdoors), including homes, garages, basements, sheds, or boxes. These spaces can trap poisonous gases, even if you run a fan or open windows.

 Place the generator so that the exhaust fumes will not be directed towards

people or building air intakes.

 Ensure that working, battery-operated or battery back-up carbon monoxide

alarms are used in any dwelling/structure that is in close proximity to the running generator.

 Note that this generator is NOT designed or approved for use in vehicles or

marine applications. Never run the generator inside RVs or other vehicles, on boats, or on pick-up truck beds.

WARNING:

Never attempt to attach ductwork to the muffler system to allow for installation inside an enclosure. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator.

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.

 Situate so there is adequate clearance around generator to allow for cooling

airflow so that heat does not build up.

+ 40 hidden pages

Powerhorse M166112G Owners Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Specifications