Powerhorse M792220B User manual

1
M792220B
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 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: 792220
Serial Number: _____________

Hazard Signal Word Definitions
2

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..........................................................................................15
Installation / Initial Set-Up:
1. Unpacking & Delivery Inspection.......................................................................................... 19
2. Planning the Power Load........................................................................................................ 19
3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source ............................ 20
4. Selecting a Suitable Site......................................................................................................... 23
5. Grounding the Generator........................................................................................................ 25
Operation:
1. General Safety Rules for Operation ....................................................................................... 26
2. Preparing for Operation.......................................................................................................... 29
3. Starting the Generator............................................................................................................. 34
4. Checking Generator Output.................................................................................................... 36
5. Connecting Loads................................................................................................................... 37
6. Stopping the Engine ............................................................................................................... 37
7. AC Parallel Operation ............................................................................................................ 38
8. Storage & Exercise................................................................................................................. 40
Maintenance & Repair.................................................................................................................. 41
Troubleshooting............................................................................................................................. 49
Summary of Important Safety Information for Operation....................................................... 50
Generator Exploded View ............................................................................................................ 54
Generator Kit Exploded View...................................................................................................... 57
Engine Kit Exploded View ........................................................................................................... 67
Limited Warranty ......................................................................................................................... 73

About Your Generator
4
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. 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 4 & 5 of this manual.
Contact Powerhorse Product Support at 1-866-443-2576 with questions about optional accessories
or to order.
Read this Manual
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.
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.

About Your Generator
5
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.
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.

Specifications
6
Item Number
#792220
Maximum Output
3500 Watts (W)
Continuous Output
3000 Watts AC (W)
96Watts DC (W)
Voltage
120 Volt AC (V)
12 Volt DC (V)
Phase
Single phase
Frequency
60 Hertz (Hz)
Power Factor
1.0 p.f.
Engine Size
212cc
Engine Speed
2600 –3600 RPM (with ESC button OFF)
Fuel Type
Non-leaded automobile gasoline
Fuel Capacity
2.6 US gallons (10L)
Oil Type
10W-30 (API Service SE type or higher)
Oil Capacity
0.63 US quarts (0.6L)
Noise Level
57 dBA @ 7 meters with ¼ load
Starting Method
Recoil/Electric Start
Dimensions
Length
22.75" (578 mm)
Width
17.32" (440 mm)
Height
20.07" (510 mm)
Dry Weight
99 lbs. (45 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. No.
Part #
Description
Qty
1
790858
Overfill & Spark Decal
1
2
790855
Exhaust Decal
1
3
793583
Name Plate
1
4
793584
EPA Decal
1
5
790908
Oil Fill Decal
1
6
790852
Burn Hazard Decal
1
7
790853
CPSC Decal
1
8
790856
Improper Connection Decal
1
9
794515
Wheel Latch/Lock
1
N/A
790933
Small Powerhorse Decal (recoil side)
1
N/A
790859
Large Powerhorse Decal
1

Safety Label Locations
8
2
3
4
5
1
6
7
8
9

Machine Component Identification
9
Ref.
Description
Ref.
Description
1
Fuel Tank Cap
9
Oil Drain Bolt
2
Handles
10
Oil Filler Cap
3
Control Panel
11
Air Cleaner
4
Inverter Location
12
Carburetor
5
Battery Location
13
Spark Plug
6
Brake
14
Left Side Cover
7
Recoil Starter Grip
15
Oil Fill Cover with Screw
8
Muffler

Machine Component Identification
10
REFERENCE GUIDE
Reference 1 –Fuel Tank Cap
The fuel tank cap seals the fuel in the tank.
Reference 2 –Handles
Provides a means for moving and lifting the generator. Grasp
the handle firmly when pulling the recoil starter grip so the
generator does not fall over.
Reference 3 –Control Panel
An electrical device that contains receptacles, switches and
other electrical devices.
Reference 4 –Inverter Location
Storage location for inverter.
Reference 5 –Battery Location
Storage location for battery (battery not included)
Reference 6 –Brake
Lever used to eliminate movement of generator during
operation.
Reference 7 –Recoil Starter Grip
Grasp firmly when starting engine to engage engine
cranking.
Reference 8 –Muffler
An acoustic device installed onto the exhaust system that is
designed to reduce noise. The outlet includes a spark
arrestor.
Reference 9 –Oil Drain Bolt
Bolt that allows oil to be drained from crankcase.
Reference 10 –Oil Filler Cap
Cap with dipstick for checking oil level. Also allows access
to the oil fill port.
Reference 11 –Air Cleaner
Foam element that removes particles from incoming air.
Reference 12 –Carburetor
A device that mixes fuel with air to produce a combustible
mixture.
Reference 13 –Spark Plug
A device that produces a spark for ignition.
Reference 14 –Left Side Cover
Allows access to the maintenance components of the
generator.
Reference 15 –Oil Fill Cover
with Screw
Access window to the oil filler cap to easily check the oil
level.

Machine Component Identification
11
Ref.
Description
Ref.
Description
1
120V 30 Amp Locking Receptacle (NEMA L5-30R)
7
Grounding Post
2
AC Circuit Breaker
8
ESC Switch (Engine Smart Control)
3
120V 20 Amp Duplex Receptacles (NEMA 5-20R)
9
Electric Start Switch
4
Parallel Operation Outlets
10
12V DC Receptacle
5
Digital Display Meter
11
12V DC Circuit Protector
6
Engine OFF/ON/CHOKE control
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.
Engine
OFF/ON/CHOKE
Switch
A switch used to start and stop the generator.
1. “OFF” position. The ignition circuit is switch off. Fuel is switched off.
The engine will not start or run.
2. “ON” position. The ignition circuit is switched on. Fuel is switched on.
Choke is switched off. A warm engine will start and stay running in
this position.
3. “CHOKE” position. The ignition circuit is switched on. Fuel is switched
on. Choke is switched on. A cold engine will start in this position but
should be switched to “ON” when the engine is warm and running
smoothly.
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(9)
(10)
(11)
(7)

Machine Component Identification
12
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.
Note: The ESC switch must be turned to “OFF” when using electrical
devices that require a large starting current, like a submersible pump.
12V DC Outlet and
Protector
The 12V DC outlet allows for a connection of DC cables to power a 12 Volt
DC product.
The 12V DC protector turns “OFF” and stops power when a connected
device is trying to operate at a power level this generator cannot power.
1. “ON” position. When the button is in a semi-flush position. Direct
current is available.
2. “OFF” position. When the button is in a raised position. Direct current
is not available. Press the button to reset to the “ON” position.
Note: If the protector turns “OFF” try reducing the load of the connected
electrical device so it is below the rated flow of the DC outlet, if it still turns
“OFF” then stop using and take to an authorized service center.
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.

Machine Component Identification
13
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.
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.
Parallel Operation
Outlets
Outlets for connecting a special cable for parallel running of two
generators.
Parallel running requires the following:
(2)item# 792220 generators and (1) parallel cable kit# 51123 for 6000W
or
(1)item# 792220 generator and (1)item# 42411 generator and (1) parallel
kit # 51122 for 4600W
Digital Display
Meter
Electrical device with a LCD screen 2, Operation key 3 which is displayed
as M and three lights: Low oil warning light 4, Overload indicator light 5
and Output indicator light 6. The operating conditions of the generator will
determine which lights are illuminated.

Machine Component Identification
14
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.
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.
Over heat 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.
Maintenance time is displayed when the generator reaches 200 hours of
running time. It cannot be reset.
Output short circuit
Over heat
Over voltage
Under voltage
Output over current
Maintenance time

Machine Component Identification
15
Low Oil Warning
Light
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.
Overload Indicator
Light (Red)
The overload indicator light 1 comes on when an overload of a connected
electrical device is detected, the inverter control unit overheats, or the AC
output voltage rises. The AC protector will trip, stopping power generation
in order to protect the generator and any connected electric devices. The
output indicator light (green) will go off and the overload 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 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 Light 1 comes on when the engine starts and
produces power.

Power Load Planning & Management
16
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
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
-

Power Load Planning & Management
17
Device
Running Watts
(Continuous)
Starting Watts
(Surge)
Clothes Dryer (electric)
1800
5750
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

Power Load Planning & Management
18
(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:
Device to be Powered
Greater of
Starting/Running Wattage
Light Bulbs (10 –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 in order to
power all of the devices simultaneously.
The overload indicator light 1 comes on 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

Installation / Initial Set-Up
19
There are a number of important steps required to set up your generator for initial use. These
steps are:
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.
Each of these steps is discussed in detail below:
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.
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.
Generator
Funnel
Part # 791453
Flat Head
Screw Driver
Part # 791455
Spark Plug Wrench
and Handle Bar
Part # 791454
12V DC Cord
Part # 794974

Installation / Initial Set-Up
20
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. 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 an UL-listed 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-listed 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, its 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