Powerhorse 74006 User manual

1
M74006A.3
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).
WARNING –READ THIS MANUAL
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. Generator has been shipped WITHOUT engine oil, Check the oil level using the dipstick and add
oil as needed. 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-listed 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.
Any Questions, Comments, Problems, or Parts Orders
Call Powerhorse Product Support 1-866-443-2576
Item Number: 74006
Serial Number: _____________

Hazard Signal Word Definitions
2
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.
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.
CAUTION without the safety alert symbol, is used to address practices not related to
personal injury.
NOTICE is used to address practices not related to personal injury.
DANGER
WARNING
CAUTION
CAUTION
NOTICE

Table of Contents
3
Hazard Signal Word Definitions..................................................................................................................2
About Your Generator..................................................................................................................................4
Specifications...............................................................................................................................................6
Safety Label Locations ................................................................................................................................7
Machine Component Identification.............................................................................................................9
Power Load Planning & Management ......................................................................................................18
Installation / Initial Set-Up:
1. Unpacking & Delivery Inspection.........................................................................................................21
2. Assembly.............................................................................................................................................22
3. Planning the Power Load ....................................................................................................................24
4. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source .............................................24
5. Selecting a Suitable Site......................................................................................................................27
6. Grounding the Generator.....................................................................................................................29
Operation:
1. General Safety Rules for Operation ....................................................................................................30
2. Preparing for Operation.......................................................................................................................33
3. Starting the Generator ........................................................................................................................38
4. Checking Generator Output ................................................................................................................39
5. Connecting Loads ..............................................................................................................................40
6. Stopping the Generator .......................................................................................................................40
7. AC Parallel Operation..........................................................................................................................41
8. Storage & Exercise..............................................................................................................................43
Maintenance & Repair................................................................................................................................45
Troubleshooting.........................................................................................................................................53
Summary of Important Safety Information for Operation .......................................................................54
Generator Exploded View..........................................................................................................................58
Generator Kit Exploded View ....................................................................................................................62
Engine Exploded View...............................................................................................................................64
Engine Kit Exploded View and Parts List.................................................................................................66
Limited Warranty........................................................................................................................................67
California Proposition 65 Information ......................................................................................................68

About Your Generator
4
Thank you for purchasing a Powerhorse portable generator!
About Your Generator
This engine-driven, portable generator is designed to provide up to its rated amount of electrical power.
(See the 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: 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 and 6 of this manual.
Contact Powerhorse Product Support at 1-866-443-2576 to order or for questions regarding optional
accessories.
Read this Manual
DANGER
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.
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.
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, refer to the “Operation” and
“Maintenance & Repair” sections within this generator manual.
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.

About Your Generator
5
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.
ATTENTION:
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 set-up and operate the generator and remain available to
answer any questions a renter/borrower might have.

Specifications
6
Item Number
#74006
Maximum Output
7500 Watts (W)
Continuous Output
6500 Watts AC (W)
3 Amp DC (A)
Voltage
120/240 Volt AC (V)
5 Volt DC (V)
Phase
Single phase
Frequency
60 Hertz (Hz)
Power Factor
1.0 p.f.
Engine Size
420cc
Engine Speed
3100 –3600 RPM (with ESC button OFF)
Fuel Type
Unleaded gasoline
Fuel Capacity
6.6 US gallons (25L)
Oil Type
10W-30 (API Service SE type or higher)
Oil Capacity
1.53 US quarts (1.45L)
Noise Level (dB) @ 7 meters
55 at 1/4 load; 63.9 at rated load
Starting Method
Recoil/Electric Start
Spark Plug
BPR6ES/BP6ES (NGK)
or
F7RTC/F7TC (Torch)
Battery Specs
12 Volt DC - 11.2 Ah (10 hour) - 230 CCA
5.94” (L) x 3.46” (W) x 4.33“(H)
SLA (Sealed Lead Acid)
Terminal Type - K
DC Fuse Specifications
(Automotive Style)
5A is BK-ATC-5J (Orange)
20A is BK-ATC-20J (Yellow)
Unit Dimensions Length
37.4" (950 mm)
Width
30.1" (765 mm)
Height
30.4" (773 mm)
Dry Weight
322 lbs. (146 kg)
Any Questions, Comments, Problems, or Parts Orders
Call Powerhorse Product Support 1-866-443-2576

Safety Label Locations
7
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.
Ref.
Part #
Description
Qty.
1
790858
Overfill & Spark Decal
1
2
790856
Improper Connection Decal
1
3
790855
Exhaust Decal
1
4
790853
CPSC Decal
1
5
800579
Name Plate
1
6
N/A
Emissions Decal
1
7
790908
Oil Fill Decal
1
8
790852
Burn Hazard Decal
1

Safety Label Locations
8
2
4
5
1
6
6
7
6
3
8

Machine Component Identification
9
Ref.
Description
Ref.
Description
1
Fuel Tank Cap
8
Muffler
2
Control Panel
9
Carbon Canister
3
Handles
10
Air Cleaner
4
Battery Location
11
Carburetor
5
Inverter Location
12
Left Side Cover
6
Right Side Cover
13
Spark Plug
7
Rear Handle
14
Spark Plug Cover

Machine Component Identification
10
REFERENCE GUIDE
Reference 1 –Fuel Tank Cap
The fuel tank cap seals the fuel in the tank.
Reference 2 –Control Panel
An electrical device that contains receptacles, switches and other
electrical devices.
Reference 3 –Handles
Provides a means for moving the generator.
Reference 4 –Battery Location
Storage location for battery (battery included).
Reference 5 –Inverter Location
Location for inverter.
Reference 6 –Left Side Cover
Allows access for inspection/replacement of maintenance
components like the spark plug and air filter. It is also used to
access the carburetor for inspection and draining.
Reference 7 –Rear Handle
Provides a means for lifting the generator.
Reference 8 –Muffler
An acoustic device installed onto the exhaust system that is
designed to reduce noise. The outlet includes a spark arrester.
Reference 9 –Carbon Canister
An evaporative control system that captures vapor emissions from
the fuel tank to reduce emissions into the atmosphere.
Reference 10 –Air Cleaner
Foam element that removes particles from incoming air.
Reference 11 –Carburetor
A device that mixes fuel with air to produce a combustible mixture.
Reference 12 –Right Side Cover
Allows access for inspection/replacement of the engine oil. It is
also used to access the recoil start cord for manually starting the
engine of the generator.
Reference 13 –Spark Plug
A device that produces a spark for ignition.
Reference 14 –Spark Plug Cover
Covers the spark plug and engine to optimize air flow for cooling.

Machine Component Identification
11
Ref.
Description
Ref.
Description
1
Digital Display Meter
9
Grounding Post
2
Voltage Selector Switch
10
120V/240V 30 Amp Locking Receptacle (NEMA L14-30R)
3
USB Receptacle (Type A)
11
120V 20 Amp Duplex Receptacles (NEMA 5-20R) GFCI
4
AC Circuit Breakers
12
ESC Switch (Engine Smart Control)
5
AC 120V/240V 30A Circuit Breaker
13
Main Switch
6
AC 120V/240V 50A Circuit Breaker
14
Engine Switch
7
Parallel Operation Outlets
15
120V 30 Amp Locking Receptacle (NEMA L5-30R)
8
120V/240V 50 Amp Receptacle (NEMA 14-50R)
Control Panel Function
There are different kinds of electrical features on the generator control panel. Always ensure the generator is
properly grounded to prevent electrical shock.
Main Switch (Power
OFF/ON and Fuel
OFF/ON)
A switch used to start and stop the generator when rotated between “OFF and “ON”.
1. When the switch is rotated to the “OFF” position the fuel is turned off and the
engine will not start or run.
2. When the switch is rotated to the “ON” position the fuel is turned on and the
engine will start and stay running.

Machine Component Identification
12
ESC Throttle/ Engine
Control
Switch
A switch used to reduce fuel consumption and noise.
1. STANDARD position: When the ESC switch is on STANDARD, the engine runs
at the rated (3100 RPM) when the electrical load is less than 4.5kW.
2. ECONOMY position: When the ESC switch is on ECONOMY, the economy
control unit controls the engine speed according to the connected load.
3. MAX position: When the ESC switch is on MAX, the engine runs at rated (3600
RPM).
Note: The ESC Throttle switch must be turned to MAX when using electrical devices
that require a large starting current, like a submersible pump or air compressor.
USB Outlet
The USB outlet allows for a connection of USB cables to power a USB 5V device.
The USB outlet has a 1A port and a 2.1A port with a total 3A max. from USB outlet.
Ground (Earth) Post
Allows the generator to be connected to the earth to prevent electric shock.
1. Location to connect the wire for grounding the generator to a copper pipe.
Loosen nut and wrap wire around threads of post and tighten nut.
Note: See the Installation / Initial Set-up section of this manual, Step 6. Grounding
the Generator for detailed instructions.

Machine Component Identification
13
Engine Switch
(Electric Start/Stop
Button)
Button used to start the generator without pulling on the recoil starter grip.
Press the engine switch to electric start the generator.
CAUTION: 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.
This will also help extend the battery life.
Parallel Operation
Outlets
Outlets for connecting a special parallel cable (not included) for parallel running of
two generators. Parallel cable kit item # 157247 is available to purchase from
Northern Tool & Equipment.
Voltage Selector
Switch
Before starting the engine, select either the 120V/240V dual voltage or the 120V full
power voltage.
Digital Display Meter
The digital display meter is an electrical device found on the control panel that
provides the operating status, maintenance status and fault status of the generator.
1Digital display meter
2Liquid crystal display (LCD)
3Oil warning light
4Overload indicator light
5Output indicator light
6Operating key

Machine Component Identification
14
Liquid Crystal
Display (LCD) Screen
The main section of the LCD screen shows the operating status of the generator.
Pushing the operation key Mwill toggle through the status of the generator
including: voltage, amperage, power, frequency, rpm, run time, cumulative time,
remaining run time, and battery voltage. The LCD screen will turn on when the main
switch is turned to on.

Machine Component Identification
15
Liquid Crystal
Display (LCD) Screen
(21) Battery (Voltage greater than 12V)
(25) Battery (More than 8V and less than 12V)

Machine Component Identification
16
Liquid Crystal
Display (LCD) Screen
When the main switch is in the “ON” position, the LCD screen will display
maintenance tips only if the engine is not started or when the engine is running
normally. Press the operating key Mto clear and reset. The maintenance symbol
located to the left of the fuel quantity symbol will not be displayed until the operating
key Mis cleared and reset.
The following symbols will display across the LCD screen when a failure occurs.
Over voltage occurs when the AC voltage is > greater than 133V and DC
voltage is > greater than 275V for more than 1 second.
Under voltage occurs when the AC voltage is < less than 108V and DC
voltage is < less than 36V for more than 5 seconds.
Output over current occurs when the amps are > greater than 1.2 the
rated amps.
Output short circuit occurs when an abnormal problem is encountered
with electrical power. The short circuit protection happens within 4 seconds to
protect the generator and stop further damage.
Overheat condition occurs when the internal temperature of the inverter is
higher than 285 degrees Fahrenheit (285°F). Check for adequate air flow and any
blockages.
(27) Fault code symbol
(28) Fault identification

Machine Component Identification
17
Low Oil Warning
Light
When the oil level falls below the lower level, the oil warning indicator 1lights up
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.
Overload/Fault
Indicator Light (Red)
The overload (fault) indicator light 1comes on when an overload of a connected
electrical device is detected, the inverter control unit overheats, or the AC output
voltage rises. The AC circuit breaker will trip, stopping power generation to protect
the generator and any connected electric devices. The output indicator light (green)
will go off and the overload (fault) indicator light (red) will stay on but the engine
does not stop running. When the overload indicator light comes on and power
generation stops, proceed as follows:
1) Turn off any connected electric devices and stop the engine.
2) Reduce the total wattage of connected electric devices within the rated
output.
3) Check for blockages in the cooling air inlet and around the control unit. If any
blockages are found, remove.
4) After checking, restart the engine.
Note: The overload (fault) indicator light may come on for a few seconds at first when using
electric devices that require a large starting current, such as a compressor or a submersible
pump. However, this is not a malfunction.
Output Indicator
Light (Green)
The Output Indicator 1lights up when the engine starts and produces power.

Power Load Planning & Management
18
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. 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:
120 Volts X 5 Amps = 600 Watts
240 Volts X 5 Amps = 1200 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
Device
Running Watts
(Continuous)
Starting Watts
(Surge)
10in. Table Saw
1800
4500
7-1/4in. Circular Saw
1400
2300
8in. Bench Grinder
1400
2500
Air Conditioner - Central (24,000 BTU)
3800
4950
Air Conditioner - RV (13,500 BTU)
1500
3000
Air Conditioner - Window (10,000 BTU)
1200
2200
Battery Charger: 100 Amp with 300 Amp Boost
2400
7800
Battery Charger: 15 Amp
380
-
Battery Charger: 60 Amp with 250 Amp Boost
1500
5750
Belt Sander
1200
2400
Ceiling Fan
800
1200
Clock Radio
100
-
Clothes Dryer (electric)
1800
5750

Power Load Planning & Management
19
Device
Running Watts
(Continuous)
Starting Watts
(Surge)
Clothes Dryer (gas)
700
1200
Clothes Washer
1150
2300
Coffee Maker
1750
-
Deep Freezer
700
1000
Desktop Computer w/ 17" monitor
800
-
Dishwasher (hot dry)
1500
1500
Drill: 1/2in., 5.4 Amps
600
900
Drill: 3/8in., 4 Amps
440
600
DVD/CD Player
100
-
Electric Fence: 25 Miles
2500
-
Electric Fry Pan
1300
-
Electric Range: 8in. Element
2100
-
Furnace Fan (gas or fuel oil): 1/2 HP
875
2350
Furnace Fan (gas or fuel oil): 1/4 HP
600
1000
Furnace Fan (gas or fuel oil): 1/8 HP
300
500
Garage Door Opener
750
1200
Hair Dryer
1250
-
Hot Plate
2100
-
Inkjet Printer
80
-
Iron
1200
-
Laser Printer
950
-
Lights (ten 75-Watt light bulbs)
750
-
Microwave Oven 1000W
1000
-
Milk Cooler
1100
1800
Milker (Vacuum Pump): 2 HP
1000
2300
Miter Saw - 10"
1650
2400
Oscillating Fan
200
400
Portable Heater (kerosene, diesel: 150,000 BTU)
625
1000
Pressure Washer: 1 HP
1200
3600
Quartz Halogen Work light
1000
-
Reciprocating Saw
1200
2000
Refrigerator Freezer
700
1500
Security System
500
-
Space Heater
1800
-
Stereo Receiver
450
-
Sump Pump: 1/2 HP
1050
2150
Sump Pump: 1/3 HP
800
1300
Television 27"
500
-
VCR
100
-
Water Heater (electric 40gal)
4000
-
Water Well Pump (1/3hp 220v)
1000
2000
(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.

Power Load Planning & Management
20
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:
Device to be Powered
Greater of Starting/Running
Wattage
Light Bulbs (ten –75 watt)
750 W
Refrigerator Freezer
1500 W
Microwave Oven 1000W
1000 W
Air Conditioner, Window (10,000 BTU)
2200 W
Sump Pump (1/3 hp)
1300 W
Total
6750W
In this example, the generator must have a continuous output of at least 6750 watts to power all the
devices simultaneously.
The overload (fault) indicator 1lights up when the total wattage exceeds the generators capability, if that
happens, proceed as follows:
1. Turn off any connected electric devices and stop the generator.
2. Reduce the total wattage of connected electric devices within the rated output.
3. Check for blockages in the cool air intake (louver) and around the control unit. If any blockages
are found, remove.
4. After checking, restart the generator.
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.
STAGGERING LOADS